5 Reduksi Langsung
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Transcript of 5 Reduksi Langsung
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Metallurgy and Materials Engineering DepartmentUniversity of Indonesia2009
PROSES REDUKSI LANGSUNG
Prof. Dr.-Ing. Bambang Suharno
University of Indonesia
Metallurgy and Materials Engineering Department UI
PROSES REDUKSI LANGSUNG
DEFINISIReduksi bijih besi dengan menghindarifasa cair
REDUKTORPadat (batubara / coal)Cairan (minyak bumi)Gas (CH4)
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Ciri-Ciri Reduksi Langsung (RL)
Menggunakan batubara/gas bumi sebagai penggantikokasProduk kualitas tinggi
Bersaing dengan harga besi tuangMengandung sedikit elemen Cu, Sn, Zn
Pada beberapa proses , dengan menggunakan ‘fine gas’ (fluidized bed)
Tidak memerlukan aglomerasi mengurangi costKapasitas produksi bisa rendah , sesuai permintaan
pasarInvestasi dapat kecil
Lingkungan hidup lebih baikEmisi CO2 rendah
University of Indonesia
Metallurgy and Materials Engineering Department UI
Prinsip Reduksi Langsung (RL)
Berbeda dengan tanur tinggi , pada RL terdapat sisaoksida dalam bijih besi pada akhir proses reduksi
Pada tanur tinggi , sebagian besar oksida yang adaakan tereduksi , bahkan terjadi karburisasi(peningkatan C) dalam besi mentah
ini akan dikeluarkan dalam proses oksidasi (di BOF)
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University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Metallurgy and Materials Engineering Department UI
Produk Akhir Reduksi Langsung
BESI SPONS Fetotal : 91-97 %C : 1-2,5 %P & S : 0,01 %Sisa : 2 % gangue di oksida besi
Bahaya reoksidasi dari besi sponsBiasanya dibriketasi atau secara langsung (dalamkeadaan panas) di charge ke agregat peleburan(mis:EAF)
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University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Metallurgy and Materials Engineering Department UI
5
University of Indonesia
Metallurgy and Materials Engineering Department UI
Hot Briquette Iron
University of Indonesia
Metallurgy and Materials Engineering Department UI
Jenis Reduksi Langsung
Dibagi berdasarkanJenis reduktor : padat , cair , gasJenis produk : padat , cair ,plastisJenis reaktor :
shaft rotary kilnFluidized bed
Retorte : HYL IShaft : Midrex , HYL IIIFluidized bed : Fior,Iron Carbide,CircoferRotary kiln : SL/RNRotary Hearth : Inmetco
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University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Metallurgy and Materials Engineering Department UI
2008 DRI Production = 68.5 Juta Ton2008 Steel Production = 1.326 Juta Ton
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Produksi DRI
2004 = 50 Jt Ton
2005 = 60 Jt Ton
University of Indonesia
Metallurgy and Materials Engineering Department UI
67.22 million tonnes (2007)
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University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Metallurgy and Materials Engineering Department UI
9
University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Metallurgy and Materials Engineering Department UI
10
University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Midrex
Dikembangkan oleh Midrex – Corporation (USA)Prinsip
Reaktor
gas reduksi
CH4 + CO2 2 CO + 2 H2
Umpan
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Midrex
University of Indonesia
Metallurgy and Materials Engineering Department UI
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses MidrexOre feed
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Midrex
Reduksi berdasarkan prinsip berlawananarahTop gas direcycling
untuk mengcracking CH4
pemanasanReforming CH4 & CO2 berlangsung kontinuproduk didinginkan sampai temperatur kamar
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Midrex
Pada zona reduksiDiameter shaft = 6 meter Umpan turun dari atas ke bawah
Fe2O3 + 3 H2/CO 2 Fe + 3 H2O/CO2
Di bawah zona reduksi terdapat zonapendinginan
sponge iron akan didinginkanBekerja pada tekanan normal
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Midrex
Gas PenghalangAgar udara tak masuk ke reduktorberasal dari top gas
Gas reduksicracking CH4 dan CO2 atau H2O yang berasal dari top gascrakcing terjadi di reformergas reduksi (after reduksi) = 900 OCGas reduksi di shaft = 800 OCsetelah melalui reduksi keluar dari reaktor dalambentuk top gas
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Midrex
0,6 bar0,9 barTekanan400 oC800 oCTemp2 %2 %N2
2 %2 %CH4
16 %2 %CO2
22 %5 %H2O20 %34 %CO38 %55 %H2
Top gasGas reduksi
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Midrex
Kegunaan top gas :pemanasan awal gas bumi untuk reformeruntuk mengcracking gas metan
Proses reduksi T = 800 OCjika sponge iron langsung dikeluarkan
reoksidasiperlu pasivasi cara : mendinginkan dengan gas
pendingingas pendingin naik ke atas panas keluarreaktor dicuci & didinginkan diinjeksikankembali
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Midrex
metalisasi : 92 – 96 %C : 0,7 – 2 %Produk Akhir Berupa :
besi spons (Direct Reduced Iron)briket (Hot Briquet Iron)
untuk briket(ada hot briquetting unit)
Keuntungan bentuk briket :tahan terhadap reoksidasi & tahan terhadapsifat fisik (tidak mudah pecah)mudah dihandling & aman untuk dikapalkan
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses HYLSA
Hojalaya Y Lamina SA (HYLSA)Plant pertama : di Monterrey 1957
1994 HYL I : 11 modul(dunia) HYL III : 6 modul
Peralatanfix bed reaktor : umpan tidak bergerak utamaterdiri dari:
gas reforming unit4 buah reaktor vessel
PT Krakatau Steel2 modul HYL I + 10 EAF2 modul HYL III
produksi 1995 = 2.600.000 ton / tahun
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Pembuatan Besi Baja di PTKS
0.450 jt T Wire Rod
0.950 jt TCold Rolled
Reformer
Pelet
Hyl-III, 1.350 jt T DRI
CO, H2
EAF:6x120T
Skrap
LF
Vac Degasser
CCM
RHF
Slab
Reheating F’ce.
Hot Strip Mill
Slab Caster
EAF4x60T
Skrap
LF
CCM
Billet: Caster
Wire Rod Mill
Cold Rolling Milll2 jt T Hot Strip
1.8 jt T Slab
0.650 jt T Billet:
Gas Alam
Shipment
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses HYLSA I
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses HYLSA I
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses HYLSA I
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa I
Gas reforming unittube Ni-Cr alloykatalis Ni
Reaksi :CH4 + H2O CO + 3 H2
Bahan bakulump ore and ore pelletukuran optimal
terlalu kecil penyumbatan timbul kanalterlalu besar reduksi belum sempurna , terutamabagian dalam pellet metalisasi rendah
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa I
Cara kerjaterdapat 4 reaktor @ 3 jam operasi total 12 jam
reaktor pendinginanreaktor reduksi akhir (primary reduction)reaktor reduksi awal (secondary reduction)reaktor pengeluaran / pengisian umpan
Tahap pendinginangas yang terbentuk dari reformer dialirkan ke atasreaktor pendinginan
komposisi gas :H2 : 75 % CO : 14 %CO2 : 7 % CH4 : 4 %
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa I
proses ini berlangsung di reaktor reduksi akhirgas yang telah dipergunakan pada reaktor pendingin , selanjutnya didinginkan dalam quencher (dehumidifier)Tujuan :
memisahkan uap air (H2O) yang tak bereaksi selama direformer , dengan metanagar gas reduktor yang masuk lebih baik kualitasnya
gas lalu dipanaskan s/d 850 OC di heat exchanger dan 1000-1300 OC pada combustion chamber gas reduktor tersebut lalu masuk ke atas reaktor reduksi akhirFe2O3 + 3 H2 = 2 Fe + 3 H2O H : 858 MJ/ton FeFe2O3 + 3 CO = 2 Fe + 3 CO2 H : -246 MJ/ton Fe
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa I
disebut ‘secondary reduction’ , karena menggunakan gas reduksi yang telah digubakan pada tahap reduksi akhir .
(gas yang telah kehilangan “reduction powernya”)gas buang pada tahap reduksi akhir diquench uap air rendah
dipanaskan pada heat exchanger s/d 800-850 OC dibakar sampai 1050-1150 OC di combustion chamber masuk ke atas reaktor reduksi awal
pada tahap ini 40 % proses reduksi terjaditop gas pada reduksi awal di quench sebagai fuel gas untuk :
generator uap/steammemanaskan heat exchanger
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa I
merupakan proses RL pertama berbasis gas alamkebutuhan energi spesifik tinggi
17-19 GJ/ton DRIkarenanya banyak dimodifikasi menjadi HYL IIIHYL II : pengembangan HYL Ipemanasan gas reduktor lebih tinggi reduksibaik
digunakan high temperatur alloy tube pada reaktor4 unit reaktor 2 reaktor
kurang berkembang
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa I
Persamaan HYL I & IIIPembuatan gas reduktor di reformergas H2 : CO tinggi (lebih banyak H2)temperatur proses tinggi (850-930 OC)tekanan tinggi (5,5 bar)
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa III
digunakan single shaft furnace (moving bed) pengganti four fixed bed reaktordikembangkan oleh : Hojalaya Y Lamina SA Monterrey,Mexico)merupakan pengembangan HYL Iumpan : pellet atau lump ore direduksimenjadi sponge iron
University of Indonesia
Metallurgy and Materials Engineering Department UI
22
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa III
University of Indonesia
Metallurgy and Materials Engineering Department UI
23
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa III
sama seperti Midrex
umpan bergerak dari atas ke bawahterdapat 2 zona zona reduksi
zona pendingingas reduksi panas masuk ke reaktor & mengalir berlawanan ke arah atas
shaft
gas reformer
gas reheater
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa III
TOP GAS (400-450 OC)masuk ke reformer untuk mengcracking gas bumi(kebanyakan dengan H2O = uap air)CH4 + H2O CO + 3 H2dan untuk pemanasan gas reduktordirecycling dan dicampur dengan gas reduktoryang baru diproduksi
GAS REDUKTOR (850 – 930 OC)dimasukkan ke reaktor dengan tekanan ± 5,5 barada special pressure lock system pada charging (top) & discharging (bottom)
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Komposisi Gas Reduktor Hylsa III
5,5 barTek930 oCTemp1,2 %N2
7,0 %CH4
3,3 %CO2
1,4 %H2O (uap)13,0 %CO74,1 %H2
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa III
ReduksiFe2O3 dengan H2 endotermFe2O3 dengan CO sedikit endoterm
Fe2O3 + 3 H2 2 Fe + 3 H2O ∆ H = -858 MJ/ton FeFe2O3 + 3 CO 2 Fe + 3 CO2 ∆ H = -246 MJ/ton Fe
pada HYL III dibanding midrexratio H2/CO tinggikarenanya temp masuk reaktor boleh tinggi
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa III
ZONA PENDINGINANgas yang terjadi (500-550 OC) didinginkan
dibersihkan alirkan kembali ke reaktorTemperatur sponge iron yang dikeluarkan ± 40 OCPT KS
terdapat 2 HYL III-reaktorkapasitas masing-masing 675.000 ton DRI/tahun
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses Hylsa III
HYL juga mengembangkan Hytem-Prosestanur digabungkan dengan “sistemtransport” , dimana besi spons panas (650 OC) langsung di charging ke EAFtransport gas = digunakan gas hasilproseskebutuhan energi :
HYL I : 17-19 GJ/ton DRIHYL III : 11,65 GJ/ton DRI
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University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Metallurgy and Materials Engineering Department UI
Main constraints in using local raw materials (iron ore of lateritic type and coal):
Uninvented technology process benefitting lateritic iron ore which is so efficient and economical that Fe content can be increased.
Moreover, most Indonesia coal reserves are “non coaking coal” type not suitable for Blast Furnace route.
Indonesia Iron Ore resource (Table 7) , especially lateritic iron type is abundant. Nevertheless due to technical and economical reasons, the utilization of this type for domestic steel industry is still low, more for export commodity.
Common challenge faced by Indonesia steel industry nowadays is seeking for the right tachnology process which is technically and economically able to :
•Use local Indonesia coal for reductor/energy source.•Optimally use local ores (especially lateritic type – Indonesia biggest deposit ) as Fe source
Iron SandPrimary IronLateritic Iron
Source : BP Statistical Review 2008
1.565.195.899,30 368.493.173,95 165.108.793,97
Tabel 7. Iron Ore Resources of Indonesia (Status 2007)
Type of Mineral Millions Tons
Halaman 12 dari 18
Bijih Besi di Indonesia
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Masalah Penggunaan Bijih Besi LateritUntuk Bahan Baku Pembuatan Baja
Kadar Fe relatif rendah (<67%)Kandungan Nikel dan Chrom relatiftinggiKandungan Al2O3 dan SiO2 relatiftinggi
University of Indonesia
Metallurgy and Materials Engineering Department UI
TipikalTipikal KomposisiKomposisi KimiaKimia BijihBijih BesiBesi LateritLaterit
LOKASI
GERONGGANGKALSEL
(GRAVEL)
GERONGGANGKALSEL
(SUPER FINE)
SEBUKU(KALSEL)GRAVEL
SEBUKUKALSEL
(SUPER FINE)
PARAMETER%
0.1430.1820.0820.18Ni
0.0520.1530.060.141S
0.4050.0120.0350.071P
0.1160.560.330.82MnO
1.0250.711.401.01Cr2O3
0.0400.0560.048-V2O5
0.160.480.2530.19TiO2
4.1713.683.588.90Al2O3
0.230.250.111.20MgO
0.110.130.0760.50CaO
2.303.920.783.35SiO2
56.9143.1257.0550.50Fe Total
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Komposisi Kimia Besi Spons Ex Bijih Besi Laterit
0,034S0,34MgO
0,031P0,34CaO
0,46Ni1,18SiO2
0,02C11,38Fe Oksida
4,64Cr2O373,59Fe metal
4,36Al2O384,97Fe total
% BeratUnsur% BeratUnsur
University of Indonesia
Metallurgy and Materials Engineering Department UI
Lump Ore
Fe (total) 52-53 %Fe2O3 81.0 % (min)SiO2 3.5 % (max)Al2O3 5.0 % (max)Ca O 1.0 % (max)Mg O 1.0 % (max)Ni 0.5 % Cr 1.5 %P 0.06 % (max)S 0.08 % (max)LOI 8 – 12 %Size distribution 10 – 35 mm (90% min)
10 mm minus, 35 mm plus (10% Max)
TYPICAL PRODUCT IRON SPECIFICATION
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University of Indonesia
Metallurgy and Materials Engineering Department UI
LUMP ORELUMP ORELUMP ORE
University of Indonesia
Metallurgy and Materials Engineering Department UI
TYPICAL PRODUCT IRON SPECIFICATION
Coarse Fine
Fe (total) 52.0 % (min)Fe2O3 80.0 % (min)SiO2 3.0 % (max)Al2O3 5.5 % (max)Ca O 1.0 % (max)Mg O 1.0 % (max)Ni 0.5 % Cr 1.5 %P 0.06 % (max)S 0.08 % (max)LOI 8 – 15 %Size distribution 10 mm minus (90% Min)
10 mm plus (10% Max)100 mesh minus (30% Max)
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University of Indonesia
Metallurgy and Materials Engineering Department UI
COARSE FINECOARSE FINE
University of Indonesia
Metallurgy and Materials Engineering Department UI
Flowchart of SL/RN DRI Production Process Flowchart of SL/RN DRI Production Process
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses SL-RN (Rotary Kiln)
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses SL-RN (Rotary Kiln)
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses SL-RN (Rotary Kiln)
University of Indonesia
Metallurgy and Materials Engineering Department UI
Rotary Kiln PT. Krakatau Stell
pilot plant 5 ton/hari Agustus 200650 ton/ hariMei 2007150 ton/ hari di Kalimantan
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University of Indonesia
Metallurgy and Materials Engineering Department UI
TRANS-SHIPMENT BIJIH BESI LOKAL UNTUK DI EKSPOR KE CHINA
Batu besi1.jpg
University of Indonesia
Metallurgy and Materials Engineering Department UI
Lump Ore Laterit Batu Bara Lokal
Reduksi di Rotary Kiln
Peleburan di Dapur Listrik
PengecoranBaja Cair
Slab / BiletBaja
Hot Rolling / Cold Rolling
Baja Siku, Baja betonBaja KawatBaja HRCBaja tipis CRC
TRIAL BIJIH LATERIT SKALA PABRIK DI PTKS
Besi spons / DRI
34
University of Indonesia
Metallurgy and Materials Engineering Department UI
Bahan Baku & Produk Rotary Kiln PT Krakatau Steel
-3 mmFines
+3 mmSize Lump
Physical
0.10 maxCarbon
0.05 maxPhosphorus
0.03 maxSulphur
90 (±2)Metallisation
81-84Fe, Metallic
90-92Fe, Total
Chemical
ProsentaseUnsur Pokok1. CoalReduktor = batu bara, mulai jenisantrasit sampai lignite. Untukkandungan kalori rendah, diperlukan tambahan bahan bakarseperti gas alam atau bahanbakar cair, untuk menjaga profiltemperatur yang dibutuhkan
2. Iron Oreberupa iron ore pellet, lump ore, atau pasir besi. Kandungan Fe minimum 53% dan kandungangangue maksimum 5%.
3. DolomiteBatu kapur berfungsi sebagaipenyerap belerang dari campuranbahan baku selama prosesreduksi.
University of Indonesia
Metallurgy and Materials Engineering Department UI
Iron Ore Low Grade High Grade
Beneficiation
Concentrate (Fe>65%)
Grinding
Rotary Kiln
Binder
Pelletizer Pellet
Coal
Coal
Grate-Rotary Kiln Indurator
FASTMET
Lump 6-25mm
Screen
Coke
Sintering
<6mm
Blast Furnace
Binder
Mixer
Pelletizer
Iron Nugget DRI Pig Iron
Crushing
Crushing
ITmk3
Briquette Machine
Dryer
DRI
Rotary Hearth
35
University of Indonesia
Metallurgy and Materials Engineering Department UI
Iron Ore
Low Grade High Grade
Beneficiation
Concentrate (Fe>65%)
Grinding
TEKNOLOGI PENGOLAHAN BIJIH BESI MENGGUNAKAN ITmk3®
Size: 0.08-0.17mm
Coal
RHF
Lump 6-25mm
Screen
<6mm
BinderMixer
Pelletizer
Iron Nugget
Crushing Crushing
Slag
University of Indonesia
Metallurgy and Materials Engineering Department UI
Third Generation of Iron Making Technology (ITmk3®)
Slag dan Fe terpisah dalam satu tahapBatubara sebagai reduktorKapasitas dapat disesuaikanHigh Grade Iron Ore dan Low Grade dapatdigunakan (Pasir Besi dan Laterit)Biaya investasi setengah dari Investasi Blast Furnace untuk kapasitas yang sama (US$90-100 juta)
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Rotary Hearth
University of Indonesia
Metallurgy and Materials Engineering Department UI
Briquetting Machine
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Perbandingan Antara Pellet Sebelum dan Sesudah DiProses di Dalam RHF
University of Indonesia
Metallurgy and Materials Engineering Department UI
Produk RHF dikeluarkan olehRotary Screw
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University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses FIOR (Fluidized Bed) Venezuela
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses FIOR
39
University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Metallurgy and Materials Engineering Department UI
40
University of Indonesia
Metallurgy and Materials Engineering Department UI
University of Indonesia
Metallurgy and Materials Engineering Department UI
41
University of Indonesia
Metallurgy and Materials Engineering Department UI
Proses COREX (Smelting Reduction)