tk 4046 dasar-dasar metalurgi proses - week i

8/13/2019 TK 4046 Dasar-Dasar Metalurgi Proses - Week I

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TK 4046 Dasar-dasar Metalurgi Proses

TK 5035 Teknologi Proses Metalurgi

Dr. Tjokorde Walmiki Samadhi & Dr. Winny Wulandari

Teknik Kimia ITB

Semester II 2013/2014TK4046 Dasar-dasar Metalurgi Proses

TK5035 Teknologi Proses Metalurgi



Semester II 2013/2014TK4046 Dasar-dasar Metalurgi ProsesTK5035 Teknologi Proses Metalurgi




Source: reuters.com



Perkuliahan


Jadwal kuliah: Rabu 15.00-17.00 316

Kamis 15.00-16.00 316

Student evaluation:

UTS

UAS

Tugas

Quiz

Tugas Akhir

Referensi:

Hayes, Process Principles in Minerals & Materials Production

Treaties on Process Metallurgy, Elsevier



Outline

Sumberdaya mineral Teknologi Pemrosesan mineral secara Fisik

Pyrometallurgy

Hydrometallurgy

Electrometallurgy




Definition


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 processmetallurgy, 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)



Process Metallurgy


The science and technology of winning metals from their ores andpurifying metals; sometimes referred to as chemical metallurgy. Itstwo chief branches are extractive metallurgy and refining.

Extractive metallurgy is the study of the processes used in theseparation and concentration of raw materials. The field is an appliedscience, 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 aform that requires further physical processing .

Physical metallurgy is the science of making useful products outof 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, orchemical in nature; all of them can be enhanced by alloying and heattreatment.



Sumberdaya Mineral

Karakteristik sumberdaya mineral: Mineral dan bijih

Bahan organik

Bahan daur ulang

Bahan setengah jadi

Karakteristik produk:

Macam-macam produk akhir

Jenis dan bentuk produk dan nilainya




Hierarchy of process aims in minerals,

metals, and materials production




Sources

Ores

Partially Processed MaterialsRecycled Material

Semester II 2013/2014TK4046 Dasar-dasar Metalurgi Proses

TK5035 Teknologi Proses Metalurgi



I. Ores

A mixture of materialsone or more of which can

be economically exploited

to become a source of

supply of a particularmaterial.

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




Summary of Major sources of metal


Element Abundanc

e (%)

Principal Sources Commercial

Product

Application

Magnesium 1,3 Seawater, dolomite

(CaMg(CO3)2

Mg

MgO

Alloy,

metallothermic

Aluminium 8 Bauxite,

Al2O3.xH2O

Fe-Al, Al, Al2O3,

Al2(SO4)3,

Steel additive,

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,

limonite

Fe, FeSO4 Iron and steel,

alloys

Lead 2 x 10-4 Galena, PbS Pb, PbO2 Alloys, solders



Iron Ore


Hematite (Fe2O3) at Brazilian mining



Copper Ore


Cuprite (Cu2O)

Chalcopyrite (CuFeS2)

Chalcocite (Cu2S)



Bauxite


Bauxite conveyor and stockpile(Alcoa)

Alumina



Gold




Macro-characteristics of Ores


Size and depth of the ore body below the surface Orientation relative to the surface

Integrity/presence of geological faults

Geographical location




The macro-characteristic of the ore body largelyinfluence 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 determinethe mining cost.



Micro-characteristic of Ores


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




Micro-characteristic influence the methods which can beused 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 distributionof 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 mineralseparation technique.




Cari jenis-jenis bahan baku

logam yang ada di

Indonesia, jenis-jenismineral & karakteristiknya.

Cari data-data mengenai

persebaran mineral di

Indonesia, terutamabauksit, nikel laterit, bijih

besi, timah, dan tembaga.

Tugas #1



II. Organic Materials


Crude oil Coal

Natural gas



III. Partially processed materials

Many ores contain more than one metal or mineral whichmay 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 oreto remove the major phases these other elements may

then become available as by-products




Partially processed materials

Fine particulate matter Aqueous solution

Precipitates or residues

Melts or solidified melts

Metallic or intermetallic compounds

Gases or fumes




IV. Recycled Materials


Battery Recycling

Source: Umicore



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



Energy Consumption for production of

primary and secondary metals


Metal Energy expended

from production(Primary) [GJ/t]

Energy expended

from recoveryfrom scrap

(Secondary)

[GJ/t]

Net Energy

Saving onrecycling [GJ/t

metal]

Magnesium

AluminiumNickel

Copper

Zinc

Steel

Lead

372

253150

116

68

33

28

10

1316

19

19

14

10

362

340134

97

49

19

18



Recycled Materials


Difficulties: Collection and sorting the scrap

Labor intensive

Metallurgical factors

Contamination of recycled materials Recyclability of materials and manufactured components

can be increased through:

Selection/replacement of materials to avoid contamination

Improved design for disassembly of obsolete products Reduction in number of different materials used in

manufactured products



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



Products

Product Form & Value

Standard & SpecificationMarketing





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



Further reading


Kirk Othmer Encyclopedia of Technology

Ullman’s Encyclopedia of Industrial Chemistry

US Geological Survey: www.pubs.usgs.gov



Intoduction to MetallurgicalProcessing




Process Metallurgy


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 processesused 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.

Introduction to Metallurgical Processing

http://localhost/var/www/apps/conversion/tmp/scratch_7/Chapter%201.1%20Introduction%20to%20Metallurgical%20Processing.pdf

http://localhost/var/www/apps/conversion/tmp/scratch_7/Chapter%201.1%20Introduction%20to%20Metallurgical%20Processing.pdf



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:

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



Examples of major improvement


Halving the coke rate in the iron blast furnace

Improving refractory technology

Extending furnace lining and campaign life



Thermodynamic Aspects


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



Process Mass & Energy Balances


Well understood by chemical engineers



Transport processes & reaction kinetics


Well understood by chemical engineer; problems adapted

to metallurgical process:

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 temperaturemetallurgy

Importance of bubbles in process metallurgy



Principles of Metallurgical Thermodynamics

Ellingham Diagram




Thermodynamics


∆ = ∆ − ∆

∆ =

° =



Gibbs Energy Minimisation




Thermodynamic Principles


Ellingham Diagram: plot of

G versus temperature

Three main uses ofEllingham diagram:

Determine the relative ease

of reducing a given metallicoxide to metal

Determine PO2 that is inequilibrium with MO

Determine PCO

/PCO2

thatwill be able to reduce theoxide to metal at a giventemperature



Problems


1. Why MgO requires high energy to reduce its oxide to

metal compared to Fe2O3?

2. What is the temperature required to reduce

a) Cr2O3

b)

NiOby using carbon as reducing agent?

3. Most Al production in the commercial process ulitizeAl2O3 electrolysis instead of reduction with carbon.Why?

4. Which one is more stable: TiO2 or MgO? Can Mgreduces TiO2?



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?

tk 4046 dasar-dasar metalurgi proses - week i

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