TK 4046 Dasar-Dasar Metalurgi Proses - Week I

TK 4046 Dasar-dasar Metalurgi Proses TK 5035 Teknologi Proses Metalurgi Dr. Tjokorde Walmiki Samadhi & Dr. Winny Wulandari Teknik Kimia ITB

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Source: reuters.com TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Perkuliahan 

Jadwal kuliah: 

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Student evaluation:  

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Rabu 15.00-17.00 316 Kamis 15.00-16.00 316 UTS UAS Tugas Quiz Tugas Akhir

Referensi:  

Hayes, Process Principles in Minerals & Materials Production Treaties on Process Metallurgy, Elsevier TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Outline  

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Sumberdaya mineral Teknologi Pemrosesan mineral secara Fisik Pyrometallurgy Hydrometallurgy Electrometallurgy

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Definition 

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Metallurgical engineering is a discipline concerned with extracting metals from their ores, and the development, production and use of metallic materials. Metallurgical engineering is based on the principles of science and engineering, and may be divided into process metallurgy, which is concerned with extracting metals from their ores to make refined alloys, and physical metallurgy, which involves the shaping, alloying, heat treatment, joining, corrosion protection and testing of metals. (sources: UNSW) TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Process Metallurgy 

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The science and technology of winning metals from their ores and purifying metals; sometimes referred to as chemical metallurgy. Its two chief branches are extractive metallurgy and refining. Extractive metallurgy is the study of the processes used in the separation and concentration of raw materials. The field is an applied science, covering all aspects of the physical and chemical processes used to produce mineral-containing and metallic materials, sometimes for direct use as a finished product, but more often in a form that requires further physical processing . Physical metallurgy is the science of making useful products out of metals. Metal parts can be made in a variety of ways, depending on the shape, properties, and cost desired in the finished product. The desired properties may be electrical, mechanical, magnetic, or chemical in nature; all of them can be enhanced by alloying and heat treatment. TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Sumberdaya Mineral 

Karakteristik sumberdaya mineral:    

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Mineral dan bijih Bahan organik Bahan daur ulang Bahan setengah jadi

Karakteristik produk:  

Macam-macam produk akhir Jenis dan bentuk produk dan nilainya

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Hierarchy of process aims in minerals, metals, and materials production

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Sources Ores Partially Processed Materials Recycled Material

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

I. Ores 

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A mixture of materials one or more of which can be economically exploited to become a source of supply of a particular material. The differences between ore body and mineral deposit?

Ores

Examples

Sulphides

Cu2S, PbS, S, ZnS, NiS

Oxides & Hydroxides

Fe2O3, TiO2, Al2O3.nH2O

Halides

NaCl, KCl, CaF2

Carbonates, nitrates, borates

MgCO3

Sulphates, chromates, molybdates, tungstates

CaWO4

Phospates, vanadates

(La,Ce,Nd)PO4

Silicates

ZrSiO4

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Summary of Major sources of metal Element

Abundanc Principal Sources e (%)

Commercial Product

Application

Magnesium

1,3

Seawater, dolomite (CaMg(CO3)2

Mg MgO

Alloy, metallothermic

Aluminium

8

Bauxite, Al2O3.xH2O

Fe-Al, Al, Al2O3, Steel additive, Al2(SO4)3, alloy, chem. equipments

Nickel

0,016

Pentlandite, Laterite

Ni NiO

Alloy, stainless steel

Copper

0,007

Chalcopyrite, bornite

Cu CuO, CuSO4

Electrical & thermal conductor

Zinc

0.01

Zinc blende ,ZnS Calamine, ZnCO3

Zn, ZnO, ZnSO4.H2O

Galvanizing, alloys

Iron/steel

5,1

Hematite, magnetite, Fe, FeSO4 limonite

2 x 10-4

TK4046PbS Dasar-dasar Metalurgi Proses Galena, Pb, PbO 2

Lead

TK5035 Teknologi Proses Metalurgi

Iron and steel, alloys solders SemesterAlloys, II 2013/2014

Iron Ore

Hematite (Fe2O3) at Brazilian mining

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Copper Ore

Chalcocite (Cu2S)

Cuprite (Cu2O)

Chalcopyrite (CuFeS2) TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Bauxite

Alumina

Bauxite conveyor and stockpile (Alcoa)

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Gold

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Macro-characteristics of Ores  

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Size and depth of the ore body below the surface Orientation relative to the surface Integrity/presence of geological faults Geographical location

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

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The macro-characteristic of the ore body largely influence the methods which are required to remove the valuable material from the ground The design of the mine, is principally the responsibility of the mining engineer, as important factor to determine the mining cost.

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Micro-characteristic of Ores  

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Phase present & their chemical composition Volume or mass fraction of each mineral Grain size and size distribution Shape of the grains Microstructure of mineral grains Distribution of grains within the ore

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

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Micro-characteristic influence the methods which can be used for the physical and chemical processing of the ore The grain size of mineral phases can have a significant bearing on the choice of processes which may be used. The microstructure of the grain defines the distribution of the phase within grains. It is important to define the continuous and isolated phases in a structure. This can explain particular physical & chemical characteristics of the minerals and can influence the choice of mineral separation technique.

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Tugas #1

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Cari jenis-jenis bahan baku logam yang ada di Indonesia, jenis-jenis mineral & karakteristiknya.

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Cari data-data mengenai persebaran mineral di Indonesia, terutama bauksit, nikel laterit, bijih besi, timah, dan tembaga.

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

II. Organic Materials  

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Crude oil Coal Natural gas

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

III. Partially processed materials 

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Many ores contain more than one metal or mineral which may be recovered economically. These metals may be present in the ore as separate phases or may be dissolved in the major ore minerals. As a result of physical or chemical processing of the ore to remove the major phases these other elements may then become available as by-products

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Partially processed materials  

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Fine particulate matter Aqueous solution Precipitates or residues Melts or solidified melts Metallic or intermetallic compounds Gases or fumes

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

IV. Recycled Materials 

Battery Recycling

Source: Umicore TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Recycled Materials 

Aluminium Recycling     

One hundred percent of a recycled aluminum can ends up as another aluminum can in as little as 60 days An aluminum can has no limit to the number of times it can be recycled Aluminum is the most recyclable of all materials: it is four times more valuable than other recycled consumer materials Throwing away a single aluminum can is like pouring out six ounces of gasoline Sources: the Aluminium Association

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Energy Consumption for production of primary and secondary metals Metal

Magnesium Aluminium Nickel Copper Zinc Steel Lead

Energy expended Energy expended from production from recovery (Primary) [GJ/t] from scrap (Secondary) [GJ/t] 372 253 150 116 68 33 28

10 13 16 19 19 14 10

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Net Energy Saving on recycling [GJ/t metal] 362 340 134 97 49 19 18

Semester II 2013/2014

Recycled Materials 

Difficulties: 

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Collection and sorting the scrap Labor intensive Metallurgical factors Contamination of recycled materials

Recyclability of materials and manufactured components can be increased through:  

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Selection/replacement of materials to avoid contamination Improved design for disassembly of obsolete products Reduction in number of different materials used in manufactured products TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Summary of Source Characteristics 

Ores and ore bodies are complex association of mineral grains. To enable the selection of suitable processing routes, important characteristics should be defined:      

The mineral phases The proportions of each of the mineral phase present The sizes and shapes of the mineral grains The physical and chemical characteristics in the ore & ore body Variation of characteristics The cost of removing the ore from the ore body, i.e. mining

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Products Product Form & Value Standard & Specification Marketing

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

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Common metal products: ingot, bar, slab, nodule, sheet, strip, foil, granule Aluminium products: alumina, alloys, castings, electricals, extrusions, foil, forging, impacts, ingot, billet, molten metal, powder, wire, rod, bar

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Further reading  

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Kirk Othmer Encyclopedia of Technology Ullman’s Encyclopedia of Industrial Chemistry US Geological Survey: www.pubs.usgs.gov

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Intoduction to Metallurgical Processing

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Process Metallurgy

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The science and technology of winning metals from their ores and purifying metals; sometimes referred to as chemical metallurgy. Its two chief branches are extractive metallurgy and refining. Extractive metallurgy is the study of the processes used in the separation and concentration of raw materials. The field is an applied science, covering all aspects of the physical and chemical processes used to produce mineral-containing and metallic materials.

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Introduction to Metallurgical Processing

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TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Recent Development Trends   

Metallurgical industry is well established However, there have been significant changes to the technologies The principle driving force for change  the need to:    

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Improve financial performance Respond to market supply/demand for products Adapt to changing sources of raw materials supply Address environmental issues: energy efficiency, hazardous emission, and discard material Improve OHS of operation

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Examples of major improvement  

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Halving the coke rate in the iron blast furnace Improving refractory technology Extending furnace lining and campaign life

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Thermodynamic Aspects  

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Multiphase thermodynamics (solids, liquids, gas) First, second, and third laws of thermochemistry Phase Rule Ellingham diagram Solution thermochemistry Thermodynamics of slag Thermodynamics of aqueous phases Thermodynamic basis of electrolysis and electrochemistry Computational thermodynamics

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Process Mass & Energy Balances 

Well understood by chemical engineers

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Transport processes & reaction kinetics 

Well understood by chemical engineer; problems adapted to metallurgical process:   

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Packed bed reactor Continuous casting Rotary dryer

Chemical kinetics: mostly heterogeneous reaction, involving transfers of species between gas, liquid, and solid phases, include chemical reaction occuring at interfaces Importance of interfacial phenomena in high temperature metallurgy Importance of bubbles in process metallurgy TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Principles of Metallurgical Thermodynamics Ellingham Diagram

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Thermodynamics  

∆𝐺 = ∆𝐻 − 𝑇∆𝑆 ∆𝐺 = 𝑅𝑇𝑙𝑛

𝑝 𝑝°

= 𝑅𝑇𝑙𝑛 𝑎

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Gibbs Energy Minimisation

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Thermodynamic Principles   

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Ellingham Diagram: plot of G versus temperature Three main uses of Ellingham diagram: Determine the relative ease of reducing a given metallic oxide to metal Determine PO2 that is in equilibrium with MO Determine PCO/PCO2 that will be able to reduce the oxide to metal at a given temperature TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

Problems Why MgO requires high energy to reduce its oxide to metal compared to Fe2O3? What is the temperature required to reduce

1. 2.

a) b) 3.

4.

Cr2O3 NiO by using carbon as reducing agent? Most Al production in the commercial process ulitize Al2O3 electrolysis instead of reduction with carbon. Why? Which one is more stable: TiO2 or MgO? Can Mg reduces TiO2? TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014

5. Using the Ellingham diagram, calculate the following: a) What is the partial pressures of CO to CO2 for equilibrium of Cr and Cr2O3 in a CO-CO2 atmosphere at 1300 oC b) What is G (kJ/mol) at 650 oC for the reaction: c) Ti + SiO2 = TiO2 + Si d) Why there is no discontinuity in the Ellingham diagram at the point where phase transformations take place?

TK4046 Dasar-dasar Metalurgi Proses TK5035 Teknologi Proses Metalurgi

Semester II 2013/2014