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HOT METAL PRODUCTION HOT METAL PRODUCTION FROM A TITANIUM CONTAINING FROM A TITANIUM CONTAINING
IRON SANDIRON SAND
Adil Jamali, Eng., M.Sc.Adil Jamali, Eng., M.Sc.
WAITRO-CMRDI WORKSHOP ON NEW TRENDS IN MINERAL PROCESSING 22-25 JANUARY 2006, Cairo, Egypt. -
Introduction Introduction
Indonesian SteelIndonesian Steel
Production (2005)Production (2005) : 4.4 M.Ton : 4.4 M.Ton
Consumption (2004) : 22 kg/cap-yearConsumption (2004) : 22 kg/cap-year
Raw MaterialRaw Material
Hemato MagnetiteHemato Magnetite :small and :small andscattered 15 M.Tonscattered 15 M.Ton
Iron Sand containing TiOIron Sand containing TiO22 165 M.Ton 165 M.Ton
Lateritic Iron Ore 974 M.Ton Lateritic Iron Ore 974 M.Ton
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Iron Sand Raw Material Raw Material Conc.Conc.
FeFe 12.5 % 12.5 % 58 %58 %
MnOMnO22 0.6 %0.6 %
AlAl22OO33 7.6 % 7.6 % 3.6 %3.6 %
CaOCaO 13.2 % 13.2 % 1.5 %1.5 %
MgOMgO 7.7 % 7.7 % 2.4 %2.4 %
NaNa22OO 0.03 %0.03 %
KK22OO 0.18 %0.18 %
SiOSiO22 34.4 % 34.4 % 2.5 %2.5 %
TiOTiO22 1.9 % 1.9 % 8.5 %8.5 %
PP 0.3 % 0.3 % 0.13 %0.13 %
SS 0.04 % 0.04 % 0.06 %0.06 %BackBack
ProblemsProblems
How to produce iron from iron sandHow to produce iron from iron sand
TiOTiO22 : 7 – 12 %: 7 – 12 %
Vanadium Vanadium
Use the available technology / Use the available technology / equipment equipment
HYL – EAFHYL – EAF
Induction FurnaceInduction Furnace
Small – medium scaleSmall – medium scale
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Hot MetalHot Metal
ExperimentExperiment
SpongSpongee
Pellet Pellet CompositeComposite
PelletizerPelletizer
MixerMixer
Reduction Reduction in Shaft Kilnin Shaft Kiln
Melting Shaft Melting Shaft FurnaceFurnaceSlagSlag
Hot MetalHot Metal
SlagSlag
BentoniteBentoniteCoalCoal Iron SandIron Sand
Melting in InductionMelting in InductionFurnaceFurnace
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Separation of TiOSeparation of TiO22
TiOTiO22 SlagSlag
MMTT = 1400 = 1400 ˚̊CC
Slag composition adjustmentSlag composition adjustment
TiOTiO22 ::
SiOSiO22 ::
CaOCaO ::
to satisfy the TiOto satisfy the TiO22 – SiO – CaO liquid at – SiO – CaO liquid at
T = 1400 T = 1400 ˚̊C in the phase diagramC in the phase diagram
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TiOTiO22 – SiO – SiO22 – CaO Phase Diagram – CaO Phase Diagram
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Experiment Result (I)Experiment Result (I)I. Sponge iron from shaft furnaceI. Sponge iron from shaft furnace = 400 mm= 400 mm h = 1500 cmh = 1500 cm
Fe %Fe % Wt %Wt %Pellet spongePellet sponge : 80 % : 80 % 45 %45 %Fine SpongeFine Sponge : 86 % : 86 % 35 %35 %Sintered Sponge Sintered Sponge : 67 %: 67 % 20 %20 %
II. Slag can be tapped at T II. Slag can be tapped at T 1400 1400 ˚̊C C from shaft furnace and induction from shaft furnace and induction furnace furnace
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Experiment Result (II)Experiment Result (II)
III. Hot Metal composition III. Hot Metal composition from induction furnacefrom induction furnace
FeFe = 93.9 %= 93.9 %
SiSi = 1.81 %= 1.81 %
Mn Mn = 0.8 %= 0.8 %
PP = 0.027 %= 0.027 %
SS = 0.08 %= 0.08 %
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Why Induction Furnace ?Why Induction Furnace ?
FamiliarityFamiliarity
Lower power consumption Lower power consumption
Easy to adjust metal Easy to adjust metal composition composition
Small scale Small scale
End product from ore is End product from ore is possiblepossible
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ConclusionConclusion1.1. Hot metal can be produced from iron Hot metal can be produced from iron
sand containing sand containing 8 % Titanium Dioxide 8 % Titanium Dioxide by three processing steps :by three processing steps :
Production of composite pelletProduction of composite pelletReduction in shaft furnace Reduction in shaft furnace Melting in induction furnaceMelting in induction furnace
2.2. Titanium can be separated into slag that Titanium can be separated into slag that flow at flow at T = 1400 T = 1400 ˚̊CC
3.3. The prospect of producing “end product” The prospect of producing “end product” is now open directly from iron sand is now open directly from iron sand
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Thanks to :Thanks to :
WAITROWAITRO
CMRDICMRDI
Workshop ParticipantsWorkshop Participants
Organization Organization committeecommittee
HOT METAL PRODUCTION HOT METAL PRODUCTION FROM A TITANIUM CONTAINING FROM A TITANIUM CONTAINING
IRON SANDIRON SAND
• Introduction Introduction • Iron Sand
• ProblemsProblems
• ExperimentExperiment
• Separation of Separation of TiO2TiO2
• TiO2 – SiO2 – CaO TiO2 – SiO2 – CaO Phase Diagram Phase Diagram • Experiment Result Experiment Result (I)(I)• Experiment Result Experiment Result (II)(II)• Why Induction Furnace ?Why Induction Furnace ?• ConclusionConclusion
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