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Metallurgy and Materials Engineering DepartmentUniversity of Indonesia2009

Tanur Tinggi (Blast Furnace)

Prof. Dr.-Ing. Bambang Suharno

University of Indonesia

Metallurgy and Materials Engineering Department UI

Steel Making Flowlines

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University of Indonesia

Metallurgy and Materials Engineering Department UI

Blast furnace with host blast stove, cast-house, and conveyor charging system.Courtesy of Mannesmann-Demag

University of Indonesia

Metallurgy and Materials Engineering Department UI

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University of Indonesia

Metallurgy and Materials Engineering Department UI

Blast Furnace Plant

University of Indonesia

Metallurgy and Materials Engineering Department UI

Blast Furnace Facilities

Baca:http://www.jfe-21st-cf.or.jp/chapter_2/2d_1.html

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University of Indonesia

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Perlengkapan lain tanur tinggi

Couper: berfungsi untuk mensupply angin panas ketempat sekitar 1350 oCInjection Pembersih debu

kantong debu diameter 15 mkadar debu pada top gas < 10 mg/m3

Hot blast ring Diameter luar 20 mDiameter pipa 2,7 m± 28 tuyure

University of Indonesia

Metallurgy and Materials Engineering Department UI

Input Output Blast Furnace

INPUT TANUR TINGGIIron ore (bijih besi)Lime StoneKokas / CoalAngin

OUTPUTPig Iron SlagTop gas / Dust

Iron Ore + Coke + Limestone + Air (1.93) (0.96) (0.48) (3.93)

Pig Iron + Slag + Gases + Flue Dust(1.0) (0.55) (5.68) (0.09)

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University of Indonesia

Metallurgy and Materials Engineering Department UI

University of Indonesia

Metallurgy and Materials Engineering Department UI

Blast Furnace Operation

Baca:http://www.jfe-21st-cf.or.jp/chapter_2/2d_2.html

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University of Indonesia

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Kokas (Cokes)Kokas dihasilkan dari batubara kualitas tinggi yang dipanaskan dalam suatu retorte yang kedap udara

agar tak terbakarhanya terjadi penguapan & sublimasi dari bahan bahanyang terkandung misal : air (degassing)

degassing

Kokas disiram air , agar tak terbakar

Kadar air dalam kokas : 3 – 6 %

Memiliki persyaratan

Cokes metallurgy

standard harga

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Cokes dan Charcoal

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University of Indonesia

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Kokas (Cokes)

University of Indonesia

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Range of Coal and Cokes

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University of Indonesia

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Kokas (Cokes)Persyaratan kokas

Ash :max 9,8 – 10,2 %S :max 0,9 – 1,2 % kualitas rendahAir :max 3,5 – 6 % energi penguapan tinggi

Ash tinggi kualitas kokas rendah , sebab :Menurunkan nilai kaloriMengandung SiO2 , slag baik harus ditambah CaO

SiO2 + CaO CaSiO3Perlu energi untuk reaksi tinggiMengandung alkali Na , K beban bahan sirkulasi diTT meningkat

Contoh komposisi kokas% C : 96 – 97 %, - % N2 : 1,2 %% H2 : 0,5 %, - % O2 : 0,5 %,

University of Indonesia

Metallurgy and Materials Engineering Department UI

Kokas (Cokes)

Sifat lain kokasTitik nyala : 640 oCTitik lebur abu kokas : 1300 oCKuat tekan : 120 – 175 kg/cm2Ukuran kokas : 2 – 4 kali ukuran bijih besiVisual : pori-pori banyakMicum test : 80 % > 40 mm

1 m

1 m

diputar 1 menit 50 putaran

screening 80% > 40 mm

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University of Indonesia

Metallurgy and Materials Engineering Department UI

Baca : http://www.jfe-21st-cf.or.jp/chapter_2/2c_2.html

University of Indonesia

Metallurgy and Materials Engineering Department UI

Perkembangan Profil Blast Furnace

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University of Indonesia

Metallurgy and Materials Engineering Department UI

Konstruksi Tanur Tinggi

O2Slag

Iron

2,25 m

4 m

1,2 m

17 m

86 o

80 o

mengurangi abrasi

Peleburan bijih besi

Pembakaran kokas

Diameter kecilagar angin panas

masuk ke hearth

Profil tanur tinggi

Metallurgy and Materials Engineering DepartmentUniversity of Indonesia2009

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University of Indonesia

Metallurgy and Materials Engineering Department UI

Konstruksi Tanur Tinggi

Secara umum perkembangan tanur tinggi

Pengecilan diameter top furnace Pengecilan sudut shaftPengecilan sudut boshPembesaran Hearth

University of Indonesia

Metallurgy and Materials Engineering Department UI

Konstruksi Shaft

Pemilihan umpan yang baik kapasitaspengumpanan tinggiJika tidak baik

t contact solid-gas rendahAkibatnya : penggunaan gas tak efisien

Perlu shaft lebih panjangShaft tinggi untuk bijih besi yang sulit direduksi

Kemiringan shaft diperlukanadanya pemanasan umpan (bijih besi , kokas , additiv)< 90 derajat , agar pembentukan jembatan (umpan-dinding) dihindari, umumnya derajat kemiringandisarankan < 84 derajat

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University of Indonesia

Metallurgy and Materials Engineering Department UI

Konstruksi Bosh & Bosh Paralel

Diameter bosh paralel kecil Diameter Bosh kecil

Bosh & Bosh paralel yang tinggi diperlukan untuk :waktu smelting untuk slag / besi cair tinggijumlah slag tinggiinternal smelting tinggi

Parameter lain f (tinggi/rendahnya bosh dan bosh paralel)Temperatur gas hearthBesarnya tekananKualitas kokas (reaktifitas kokas)

University of Indonesia

Metallurgy and Materials Engineering Department UI

Konstruksi Bosh & Bosh Paralel

Bosh ParalelKemiringan tak diperlukan karena :

Penyusutan Fe – Carrier (reduksi)Kebutuhan kokas untuk RL

• FeO + CO Fe + CO2• CO2 + C 2 CO

Kemiringan BoshDaerah ini Volume umpan menyusut

Smelting Fe-Carrier yang intensifPembakaran kokas yang intensif

Harus tetap dijaga kemiringan < 80o

Agar umpan tak jatuh ke hearthGangguan jalannya gas reduktor dihindari

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University of Indonesia

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Diameter Hearth vs Kap. ProduksiDiameter Hearth tolok ukur tingginya produksi besi mentah1970 Diameter hearth 15 m impian

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Top Closing (Sistem Lonceng)

2 loncengTanur Tinggi untuk tekanan normalMc-kee closing

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Top Closing (Sistem Lonceng)

Dengan adanya kebutuhan

akan tanur tinggi bertekanan

Dibuat penutup 4 lonceng

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Efisiensi Kemampuan Tanur Tinggi

Faktor-faktor yang dapat mempertinggi kemampuanproduksi Tanur Tinggi :

Umpan sinter / pellet yang telah di treatmentAliran gas reduktor yang optimalTemperatur top gas dibuat serendah mungkinKonsentrasi O2 pada angin tinggi (Oxygen enrichment)Penambahan bahan bakar tambahan

oil-injectioncoal-injectionCH4-injection

Meninggikan temperatur anginMeninggikan tekanan pada TT top furnace = 2,5 atm

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University of Indonesia

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Mini Blast Furnace di Shanxi, China

University of Indonesia

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Mini Blast Furnace (80m3) diLian Yun Gang

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University of Indonesia

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Produk Pig Iron

University of Indonesia

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Mini Blast Furnace Brazil

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University of Indonesia

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Mini Blast Furnace Brazil (Renewable Energy : Arang Kayu)

University of Indonesia

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Penebangan dan PenanamanKembali Pohon: Sumber Arang Kayu

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University of Indonesia

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Penebangan Pohon dan PembuatanArang Kayu

University of Indonesia

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Pig Iron Production

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University of Indonesia

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“Mini Blast Furnace”/ Mini Cupola