PROSES PRODUKSI TEMBAGA DI PT SMELTING

METAL EXPO 2012 TEKNIK METALURGI FT UNTIRTA CILEGON 26 MARET 2012

BOUMAN TIROI SITUMORANG

Roomo Village, Manyar District Gresik, East Java,

Indonesia

TOPIK
PENDAHULUAN PROSES PENANGANAN BAHAN BAKU

PROSES PELEBURAN PROSES PERMURNIAN

Word Mine Production and Reserves (*1000 MT) (data minerals.usgs)

Country USA
3 6

2008 1,310 886 607 5,330 950 651 1,190 900 520 5,320 960 950

2009

Reserves 35,000 24,000 8,000 160,000 30,000 31,000

Australia Canada Chile

1

China 4 Indonesia 5

Kazakhstan
Mexico Peru
2

420
247 1,270 430

410
250 1,260 440

18,000
38,000 63,000 26,000

Poland

Russia
Zambia Other country World Total

750
546 2,030 15,400

750
655 2,180 15,800

20,000
19,000 70,000 540,000

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

No

Country

Cathode Production
2005
2,615,000 2,824,000 1,395,284 1,260,000 933,000 497,000 638,258 526,566 560,000 399,000 515,223 469,000 511,736 418,356 382,900 416,375 308,700 262,900 199,043 222,000 173,100 172,000 134,000

2006
3,020,000 2,811,300 1,532,055 1,250,000 947,000 629,000 662,338 575,492 556,600 418,000 500,463 439,400 507,710 427,723 391,000 379,376 299,300 217,600 219,700 229,000 194,000 181,000 134,000

2007
3,500,000 2,936,500 1,576,818 1,310,000 939,000 729,000 665,517 581,467 533,000 480,000 453,453 441,000 413,907 406,091 394,100 388,000 308,000 277,000 220,000 214,000 208,000 180,000 120,000

Mine Prod Reserves 2009

960,000 30,000,000 5,320,000 160,000,000 1,190,000 750,000 35,000,000 20,000,000

1 China 2 Chile 3 Japan 4 United States 5 Russia 6 India 7 Germany: 8 Korea, Republic 9 Poland 10 Zambia 11 Canada 12 Australia 13 Peru 14 Kazakhstan 15 Belgium 16 Mexico 17 Spain 18 Indonesia 19 Brazil 20 Sweden 21 Iran 22 Philippines 23 Finland

440,000 655,000 520,000 900,000 1,260,000 410,000 250,000 950,000

26,000,000 19,000,000 24,000,000 63,000,000 18,000,000 38,000,000 31,000,000

Truly a Plant for the 21st Century...

Prof. Herbert H. Kellogg Columbia University

PT. Smelting Layout

Concentrate Yards Acid Plant

WWTP

Refinery

Smelter

Laboratory Office Oxygen Power

PROPONENT of Gresik Copper Smelter & Refinery

PT Freeport Indonesia 25% Mitsubishi Corporation 9.5%

Mitsubishi Materials Corporation 60.5%

Nippon Mining and Metals Corporation .Co.Ltd 5%

Flow Sheet of Gresik Plant

PROSES PELEBURAN

Copper Smelting Process

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 Technology in the World

(survey data in 2002)
Technology Reverberatory Blast Furnace Electric Furnace Noranda Furnace Flash Furnace Outokumpu Quantity 41 21 9 3 3 25

* The newest data

Mitsubishi Furnace * Isasmelt Ausmelt

5 6 1

MITSUBISHI PROSES

Mitsubishi 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 PROCESS
NAOSHIMA 1974 ONSAN

1998

KIDD CREEK Dahej 2005 ONAHAMA 19812010

GRESIK
1999

2008 PORT KEMBLA 19972003

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 PENANGANAN BAHAN BAKU

Raw Material Handling

Raw Material Copper Concentrate Coal

Crushing
Fluks Silica Sand

Lime stone
Recylce Material (Revert) Crushing

Source of Concentrate & Copper Cathode Destination

Source of Concentrate PT Freeport Indonesia-Grasberg PT Newmont Nusa Tenggara-Batu Hijau Copper Cathode Destination Domestic Asian Countries

Singapore

Jakarta

Grasberg Mine Irian Jaya/Papua Newmont Batu Hijau Sumbawa Barat Nusa Tenggara Barat

PT SMELTING

COPPER CONCENTRATE
PEMBAYARAN
Cu, Au, Ag Harga Logam sesuai LME

TC / RC RECOVERY

Jetty & Wharf

Concentrate Bed Preparation

Chemical Analysis of Concentrate
Cu , S , Fe

Material & Heat Balance Calculation Coal Blending Ratio

Concentrate Bed

Furnace arrangement and melt flow

Concentrate Dryer
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

CuFeS2 + O2
concentrate
Air + O2

Cu-Fe-S + FeO + SO2

Molten matte Cu2S, FeS gas

FeO + SiO2
flux

FeO.SiO2
Molten slag

3FeO + 1/2O2

Fe3O4

Cu2O + FeS
In slag In matte

Cu2S + FeO
In matte In slag

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

Phase Diagram of CaO-FeO-Fe2O

AF & Casting

Anode Furnace : Fire Refining

Oxidation : air & oxygen blowing

To 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

Receiving Blister AF-1 Oxidation

Reduction Casting

Receiving Blister

AF-2

Receiving Blister Oxidation

Reduction Casting

Anode Casting Process

Anode Furnace

Holding Furnace

Casting Machine

To Tank House Shear Cooling Anode Tunnel Stacking

Hazelett Caster

Anode

Copper Refining Process

Power supply Fresh Anode (+) SS-blank Cathode (-)

Cu++ + 2e- = Cuo

Cuo = Cu++ + 2e-

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+ Ag+ Cu2+ BiO+ + + + + + + + + + + + 3e- ---> Auo e- ---> Ago 2e- ---> Cuo 3e- ---> Bio o 3e- ---> As o 3e- ---> Sb 2e2e2e2e2e---> ---> ---> ---> ---> H2 Pbo Nio Coo Feo 1.50 0.80 0.34 + H2O 0.32 + H2O 0.25 + H2O 0.21 0 -0.13 -0.26 -0.28 -0.45 volts volts volts volts volts volts (pH=0; pH2=1atm) volts volts volts volts

+ 2H+ + HAsO2 + 3H + + SbO + 2H 2H+ Pb2+ Ni2+ Co2+ Fe2+

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).

Anode life
Fresh Anode Anode Scrap

SS-blank Cathode

50kgCathode

100kgCathode

Start 0 day

7th day

Finish 19th day

REFINERY 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 Faradays 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