Roomo Village, Manyar DistrictRoomo Village, Manyar DistrictGresik, East Java,Gresik, East Java,

IndonesiaIndonesia

PROSES PRODUKSI PROSES PRODUKSI TEMBAGA DI PT TEMBAGA DI PT

SMELTINGSMELTING

PROSES PRODUKSI PROSES PRODUKSI TEMBAGA DI PT TEMBAGA DI PT

SMELTINGSMELTING

METAL EXPO 2012 TEKNIK METAL EXPO 2012 TEKNIK METALURGI METALURGI

FT UNTIRTA CILEGON 26 MARET FT UNTIRTA CILEGON 26 MARET 20122012

BOUMAN TIROI SITUMORANG

TOPIKTOPIK

• PENDAHULUAN

• PROSES PENANGANAN BAHAN BAKU

• PROSES PELEBURAN

• PROSES PERMURNIAN

Word Mine Production and Reserves (*1000 MT)

(data minerals.usgs)Country 2008 2009 Reserves

USA 3 1,310 1,190 35,000

Australia 6 886 900 24,000

Canada 607 520 8,000

Chile 1 5,330 5,320 160,000

China 4 950 960 30,000

Indonesia 5 651 950 31,000

Kazakhstan 420 410 18,000

Mexico 247 250 38,000

Peru 2 1,270 1,260 63,000

Poland 430 440 26,000

Russia 750 750 20,000

Zambia 546 655 19,000

Other country 2,030 2,180 70,000

World Total 15,400 15,800 540,000

World Cathode production (MT)(source: minerals.usgs)

2005 2006 2007

1 China 2,615,000 3,020,000 3,500,000 960,000 30,000,000

2 Chile 2,824,000 2,811,300 2,936,500 5,320,000 160,000,000

3 Japan 1,395,284 1,532,055 1,576,818

4 United States 1,260,000 1,250,000 1,310,000 1,190,000 35,000,000

5 Russia 933,000 947,000 939,000 750,000 20,000,000

6 India 497,000 629,000 729,000

7 Germany: 638,258 662,338 665,517

8 Korea, Republic 526,566 575,492 581,467

9 Poland 560,000 556,600 533,000 440,000 26,000,000

10 Zambia 399,000 418,000 480,000 655,000 19,000,000

11 Canada 515,223 500,463 453,453 520,000

12 Australia 469,000 439,400 441,000 900,000 24,000,000

13 Peru 511,736 507,710 413,907 1,260,000 63,000,000

14 Kazakhstan 418,356 427,723 406,091 410,000 18,000,000

15 Belgium 382,900 391,000 394,100

16 Mexico 416,375 379,376 388,000 250,000 38,000,000

17 Spain 308,700 299,300 308,000

18 Indonesia 262,900 217,600 277,000 950,000 31,000,000

19 Brazil 199,043 219,700 220,000

20 Sweden 222,000 229,000 214,000

21 Iran 173,100 194,000 208,000

22 Philippines 172,000 181,000 180,000

23 Finland 134,000 134,000 120,000

No Country Cathode Production Mine Prod

2009Reserves

“Truly a Plant for the 21st Century...”“Truly a Plant for the 21st Century...”

Prof. Herbert H. KelloggColumbia University

PT. Smelting LayoutPT. Smelting LayoutPT. Smelting LayoutPT. Smelting Layout

SmelterSmelter

RefineryRefineryRefineryRefinery

AcidAcidPlantPlant

OfficeOfficeOxygenOxygenPowerPower

Water Water ReservoReservo

irir

LaboratoryLaboratory

ConcentrateConcentrate YardsYards

WWTPWWTP

PROPONENT PROPONENT of Gresik Copper Smelter & of Gresik Copper Smelter &

RefineryRefinery

PROPONENT PROPONENT of Gresik Copper Smelter & of Gresik Copper Smelter &

RefineryRefinery

Nippon Mining and Metals Corporation

.Co.Ltd5%

MitsubishiCorporation

9.5%

PT FreeportIndonesia

25%

Mitsubishi Materials

Corporation60.5%

Flow Sheet of Gresik PlantFlow Sheet of Gresik PlantFlow Sheet of Gresik PlantFlow Sheet of Gresik Plant

PROSESPROSES PELEBURANPELEBURAN

• Batch Type– Smelting furnace

• Electric furnace, Reverberatory furnace, Outokumpu flash furnace, Inco flash furnace,

Noranda reactor, Isasmelt/Ausmelt

– Converting furnace• Peirce-Smith converter

• Continuous Type– Mitsubishi furnace

Copper Smelting Copper Smelting ProcessProcess

Copper Smelting Technology in Copper Smelting Technology in the World the World

(survey data in 2002)(survey data in 2002)

Technology Quantity

Reverberatory 41

Blast Furnace 21

Electric Furnace 9

Noranda Furnace 3

Flash Furnace 3

Outokumpu 25

Mitsubishi Furnace * 5

Isasmelt 6

Ausmelt 1* The newest data

MITSUBISHI PROSESMITSUBISHI PROSES

Mitsubishi ProcessMitsubishi Process

• Pilot plant of Mitsubishi process by 72T/D in 1968

• Basic idea– Smelting and converting in separate furnace

(Two steps)– Transportation through launders– Top blow lances blowing and feeding

MITSUBISHI MITSUBISHI PROCESSPROCESS

NAOSHIMA

1974 ～

NAOSHIMA

1974 ～ONSAN

1998 ～

ONSAN

1998 ～

GRESIK

1999 ～

GRESIK

1999 ～

PORT KEMBLA

1997 ～ 2003

PORT KEMBLA

1997 ～ 2003

Dahej

2005 ～

Dahej

2005 ～

KIDD CREEK

1981 ～ 2010

KIDD CREEK

1981 ～ 2010

ONAHAMA

2008 ～

ONAHAMA

2008 ～

KEUNTUNGAN PROSES MITSUBISHI

Reaksi leburan berlangsung sangat cepat

Transfer panas selama proses lebih cepat dan efisiensi dibanding metode lain

Dpt meningkatkan produksi dengan meningkatkan kadar O2 dalam udara blowing

Sedikit tenaga kerja

Pengambilan SO2 lebih mudah

Tempat yang dibutuhkan tidak terlalu luas

PROSES PROSES PENANGANAN BAHAN PENANGANAN BAHAN

BAKUBAKU

Raw Material HandlingRaw Material Handling

• Raw MaterialRaw Material

– Copper ConcentrateCopper Concentrate

• CoalCoal

– CrushingCrushing

• FluksFluks

– Silica SandSilica Sand

– Lime stoneLime stone

• Recylce Material (Revert)Recylce Material (Revert)

– CrushingCrushing

Source of Concentrate & Copper Source of Concentrate & Copper Cathode DestinationCathode Destination

Source of Concentrate & Copper Source of Concentrate & Copper Cathode DestinationCathode Destination

Newmont Batu Hijau

Sumbawa BaratNusa Tenggara Barat

Grasberg MineIrian

Jaya/PapuaPT SMELTINGPT SMELTING

Jakarta

Singapore

Source of Concentrate• PT Freeport Indonesia-Grasberg• PT Newmont Nusa Tenggara-Batu Hijau

Copper Cathode Destination• Domestic• Asian Countries

COPPER CONCENTRATECOPPER CONCENTRATE

• PEMBAYARAN – Cu, Au, Ag– Harga Logam sesuai LME

• TC / RC

• RECOVERY

Jetty & WharfJetty & Wharf

Concentrate Bed PreparationConcentrate Bed Preparation

• Chemical Analysis of ConcentrateChemical Analysis of Concentrate

– Cu , S , FeCu , S , Fe

• Material & Heat Balance CalculationMaterial & Heat Balance Calculation

• Coal Blending RatioCoal Blending Ratio

• Concentrate BedConcentrate Bed

Furnace Furnace arrangement and arrangement and

melt flowmelt flow

Concentrate Concentrate DryerDryer

• Moisture content : 8~10% 0.5%

• Rotary dryer & flash dryer

• Drying media :

Natural gas burner

Hot air from Acid Plant

Anode Furnace Off gas

• Bag filter for dryer off gas to catch the dust

Feeding System

• Dried concentrate

• Flux (Silica sand)

• Coal

• Recycled converting slag

• Recycled dust

Charged into Smelting Furnace by pneumatic conveying system

• Flux (limestone)

• Recycled converting slag

Charged into Converting Furnace by pneumatic conveying system

Dried concentrate

Flux, Coal, C-Slag, Dust

S Furnace schematic concept

Reaction in Smelting Furnace

3FeO + 1/2O2 Fe3O4

concentrate Air + O2

CuFeS2 + O2 Cu-Fe-S + FeO + SO2

Molten matte

Cu2S, FeS

gas

FeO + SiO2 FeO.SiO2

flux Molten slag

Cu2O + FeS Cu2S + FeO

In slag In slagIn matteIn matte

Behavior of gas/solid jet

in Smelting Furnace

Behavior of gas/solid jet

in Smelting Furnace

Characteristics a Good Slag

• Low dissolution of Copper

• Low melting temperatur

• Small Density

• Low viscosity

Actual Copper Loss

FeO-SiO2 Phase Diagram

C furnace Concept

Main Reaction at

C furnace

Main Reaction at

C furnace

Phase Diagram of CaO-FeO-Fe2O

AF & Casting

Anode Furnace : Fire Refining

• Oxidation : air & oxygen blowingTo reduce Sulfur content

0.7% 0.05%

• Reduction : reducing agent blowing (fuel)

To reduce Oxygen content

0.7% 0.15%

Anode Furnace Operation Steps Schedule

AF-1

AF-2

Receiving Blister

Receiving Blister

Oxidation

Reduction

Casting

Oxidation

Reduction

Casting

Receiving Blister

Anode Casting Process

Anode Furnace

Holding Furnace

CastingMachine Shear Cooling

TunnelAnodeStacking

To TankHouse

Hazelett Caster

AnodeAnode

Copper Refining Process

SS-blank Cathode (-)

Fresh Anode (+)

Cuo = Cu++ + 2e-

Power supply

Cu++ + 2e- = Cuo

CuSO4 + H2SO4 + H2O

Electrorefining Process

• Electrochemically dissolving copper from impure copper anode to electrolyte

Cuoanode Cu++ + 2e- Eo = +0.34V

• Selectively electroplating pure copper without anode impurities from electrolyte onto cathodes

Cu++ + 2e- Cuocathode Eo = -0.34V

Standard Electrochemical (Reduction) Potentials

Au3+ + 3e- ---> Auo 1.50 voltsAg+ + e- ---> Ago 0.80 voltsCu2+ + 2e- ---> Cuo 0.34 voltsBiO+ + 2H+ + 3e- ---> Bio + H2O 0.32 voltsHAsO2 + 3H+ + 3e- ---> Aso

+ H2O 0.25 voltsSbO+ + 2H+ + 3e- ---> Sbo

+ H2O 0.21 volts2H+

+ 2e- ---> H2 0 (pH=0; pH2=1atm)Pb2+ + 2e- ---> Pbo -0.13 voltsNi2+ + 2e- ---> Nio -0.26 voltsCo2+ + 2e- ---> Coo -0.28 voltsFe2+ + 2e- ---> Feo -0.45 volts

Refining Target

• Production of pure copper, free from impurities (<65ppm)

• Separation of valuable impurities - precious metals Ag, Au, Pt - as slime (by-product)

Operation Control

• Electrodes flatness and alignment.

• Anode composition (Lead, Arsenic).

• Electrolyte parameter (Cu, FA, Cl-, Impurities, reagent, temperature, flow rate, and clarity).

• Cell monitoring (shorts inspection and breaking).

SS-blank Cathode

Fresh Anode

7th dayFinish19th day

50kgCathode 100kgCathode

Anode Scrap

Start0 day

Anode life

REFINERY SIMPLIFIED DIAGRAMREFINERY SIMPLIFIED DIAGRAM

Anode

• Cu : 99.2~99.5%

• Continuous casting:

Hazelett Contilanod

• 400 kg/plate, 47 mm thick

• 19 Days anode life

Anode Preparation Machine

• Spacing 103.5 mm• Lug brushing• Anode verticality

measurement, 5 mm • 59 Anodes per cell

Cathode Mother Plate

• ISA Process Permanent Cathode

• SUS 316L

• 1 x 1 m deposit face

• 58 Cathodes per cell

Commercial Cells

• 798 cells• Polymer concrete• V-notch weir • Cell voltage 0.3 V/cell

Electrode Alignment

• Gap between anode and cathode must be uniform.

• One side lays on busbar and another side lays on insulator.

• Touching = short

Inside Tankhouse

Electrolyte

• Cu : 48-50 g/l• H2SO4 : 170-180 g/l• Cl- : 50-60 mg/l• Temp : 58-62oC• Flowrate : 35-40 l/m• Steam-heated by plate

heat exchanger

Reagents

• Glue: leveling agent

• Thiourea: grain refiner

• HCl: grain refiner

Some ER tankhouse add AVITON

Cropping activity

Cathode Washing & Stripping Machine

• Washing by hot water 86oC to melt wax

• Flexing to open• Chiseling to peel-off• Apply bottom waxing• Spacing 103.5 mm

Product Cathode

• 1st-crop = 50 kg/sheet• 2nd-crop = 100

kg/sheet• Size 1 x 1 m• LME Grade-A• Capa. 300,000 t/y

Current Efficiency

• Ratio between actual cathode deposited and theoretical deposition by Faraday’s law

• Simplified formula for theoretical deposit:

W (kg) = 1.185 x set kA x hour x cell

• Target CE = 98.0 %

Why CE drops?• Mainly by short circuit

between anode-cathode

• Checked by infra-red camera, or gaussmeter

• Short must be broken to avoid current loss

SHORT

Anode Scrap Washing Machine

• Washing anode scrap by hot water

• Anode scrap ratio 11~14%

Electrolyte Purification

• Dissolved Cu in electrolyte: 14 kg per ton Cathode.

• Soluble anode impurities build-up: Bi, Co, Fe, and Ni.

• Partially dissolved As and Sb.

• Dissolved Se and Te from slime leaching process.

Liberator Cells

• Electrowinning cell

– Anode: H2O 2H+ + 1/2O2 + 2e-

– Cathode: Cu++ + 2e- Cu

• Using lead anode

• Cell voltage = 2.4 volt

• Used for stabilizing Cu in electrolyte as anode dissolve is ~1.4% and reducing some impurities.

Primary Liberator

• ISA blank cathode• Pb-Sn-Ca anode, cold

rolled• Reducing Cu from 50

40 g/l in the electrolyte

• Saleable liberator cathode product

Secondary Liberator

• Anode scrap as cathode

• Reducing Cu from 40 20 g/l in electrolyte

• Deposited cathode recycled in smelter

Tertiary Liberator

• Anode scrap as cathode

• Reducing Cu from 20 1 g/l , then deposited As, Sb and Bi.

• Sludge to be recycled to smelter

Anode Slime

• Insoluble elements in anode is accumulated at cell bottom (slime).

• Au, Pt, As, and Sb• Ag2Se, Ag2Te, Cu2Se,

Cu2S, PbSO4, Sn(OH)2SO4.• Cu in slime must be

controlled lower than 1%

Slime Leaching

• Using autoclave

• High temperature

• High pressure

• Oxygen blowing

• Cu + H2SO4 + 1/2 O2 CuSO4 + H2O

• Cu2O + 2H2SO4 + 1/2 O2 2CuSO4 + 2H2O

• Decopperized slime : tankhouse by-product