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PROPOSED ECONOMIC SMELTER FOR THE PRODUCTION OF NICKEL PIG IRON FOR PT GEMA RIPAH PRATAMA
CONCEPT Nickel Smelter Working Principle Using Blast Furnace with specially designed half noble and noble metal with Coal as reductant The working principle of Blast Furnace for production of Nickel Pig Iron is almost similar to the working principle of Blast Furnace for production of pig iron. The difference is in the design of the blast (combustion), air flow rate, the type of fuel used, the composition of the input materials, and the tapping-off technique. The combustion process is similar to the process of burning iron. The main difference is, in the Blast Furnace for pig iron, iron will lose very little, while in the Blast Furnace for nickel, the composition will lose a lot of iron, so that the finished product of FeNi will have obtained a high Ni content (18% - 22%). And if we want to further increase Ni levels again, this can be done using the oxygen reduction process of iron during tapping. The Gas chamber serves as a briquette dryer, semi sintering, and also functions as a reducing agent in this exhaust gas Mini Blast Furnace. Inside the gas chamber, methane gas will be produced and this will be flue off in the chimney exhaust
ECOSMELT BF150
Twin Blast Furnace 100 MT/Day
GENERAL SPECIFICATION COMPONENTS
BLAST FURNACE
SUB
SPECIFICATION
Furnace Set
D:3m, H:7.5m (50m3), Double wall coated Bosch,SiC Brick for Bosh, coated 600C Outer Steel, Water jacket system with 2 Thermocouple set Full boundary, Bucket convey Reservoir system, Gate control, Control unit, Stair Mild steel, Coated 600C Stainless at Upper set Trowelling Alumina wall Trowelling Alumina Oxy intake SK32 set, Thermocouple K type 1200C, hor ver option L:18m, D:2.5m, Coated 600C Cyclone type, SS 304, Water Rotation set 2.5ton/hour, Double roll with Single Mould plus Conveyor to Raw Silo plus Speed Control for both 3mx3m.1.8m plus Screen Srew conveyor to Roller crusher 2.5ton/hour, Double Crusher Four Roller with Distance setting Conveyor to Roller press plus Speed control for both capp 2.8m3. with Gate control Wiring set & Electrical with Lance water jacket with Compressor 145L for Coal and Dolomite with Screen and Hopper with conveyor to bucket Genset 150kva Silent type plus Pumping part, Hose Work part (weld, cut, drill etc) for Refining, High Pressure Blow SiC Brick for Bosh, Operator set Moulding, Water jacket, for 2 month Shoes, Gloves, Helm, Mask Face shield, Fireproof shirt
Operator Set
Piping
GAS HANDLING
Gas Chamber Briq Dryer Lime Kiln Chimney Water Scrubber Roller press
Hopper BRIQUETTING Roller crusher
Material Silo Supports
Roller Crusher
Electrical SUPPORTINGS Workshop Small Cupola
Spare Parts Safety
FEATURES
Bosh Design
PROCESS FLOW DIAGRAM
Laterite Nikel
Coal / Cokes
Dolomite/Limestone Raw Material Flow
Jaw Crusher
Exhaust Gas Flow Hot Liquid Flow
Roller Crusher
Air Flow Roller Briquette
Gas Chamber
Water Scrubber
Exhaust Hood
Finish Product Flow
Blast Furnace Water injection
Laddle
FeNi Granulator
Water inject
Air Injection
Oxygen Injection (optional) FeNi Granule
SELLING
COMPARISON ECOSMELT BF150
STANDARD BLAST FURNACE
Using coal as a reductant and fuel, resulting in lower production costs
Using coke, so the cost of production is higher
Drying process, using fuel derived from methane gas coming from the exhaust gases
Drying process using independent fuel in the form of gas, oil, or pulverized coal
Drying process by using a gas chamber, so no need to make a rotary dryer
Drying process using rotary dryer, so the manufacturing cost becomes very high
The results of a FeNi production with much higher levels (20% Ni), in a single process
The results of a FeNi production with lower levels (5% 8% Ni), in a single process
Using the air flow rate is very high, so that the fluid flow rate becomes higher. With the same size, higher production speeds
Using low air flow rate
With the use of coal, the slag becomes more
By using coke, then the slag becomes less
Shorter time period for fabrication, installation, up to production (approx. 3 months) because ifabrication is made locally Maintenance process to be faster, because the expert teams are always standby during the production process
Longer time period required before the plant is ready for production (approx. 10 to 12 months) Maintenance process takes a long time, because they have to wait for a technician
COST ESTIMATES MECHANICAL & ENGINEERING COMPONENTS
BLAST FURNACE
GAS HANDLING
SUB
QTY
UNIT
Furnace Set
2
set
UNIT PRICE Rp1,750,000,000
SUB TOTAL Rp3,500,000,000
Operator Set
1
set
Rp650,000,000
Rp650,000,000
Piping
2
set
Rp350,000,000
Rp700,000,000
Gas Chamber Briq Dryer Lime Kiln Chimney
2
set
Rp875,000,000
Rp1,750,000,000
2
set
Rp150,000,000
Rp300,000,000
Water Scrubber
2
set
Rp250,000,000
Rp500,000,000
Roller press
2
set
Rp350,000,000
Rp700,000,000
Hopper
2
set
Rp250,000,000
Rp500,000,000
Roller crusher
2
set
Rp300,000,000
Rp600,000,000
Material Silo Supports
2 2
set set
Rp250,000,000 Rp250,000,000
Rp500,000,000 Rp500,000,000
Roller Crusher
2
set
Rp350,000,000
Rp700,000,000
TOTAL Rp4,850,000,000
Rp2,550,000,000
Rp2,300,000,000
BRIQUETTING
Electrical
2
set
Rp375,000,000
Rp750,000,000
Workshop Small Cupola
2 2
set set
Rp150,000,000 Rp450,000,000
Rp300,000,000 Rp900,000,000
Spare Parts Safety
2 20
set set
Rp175,000,000 Rp10,000,000
Rp350,000,000 Rp200,000,000
Fabrication Testing Commissioning
1
set
Rp3,700,000,000
SUPPORTINGS
EPC
Rp1,500,000,000
Rp1,500,000,000
Rp14,900,000,000 NOTES: All Parts are disassembled to ease transportation Plant Capacity: 100 MT per day Laterite Nickel (Input)
COST ESTIMATES… CIVIL WORK SEGMENT
SITE
SUPPORTING FACILITY
QTY
UNIT
UNIT PRICE
Site Preparation / Steel Frames Construction / Roofing / Concrete Foundation / Security Post etc.
1
set
Rp3,000,000,000
Rp3,000,000,000
Land drilling for Clean Water Supply / Staff Lodging / Site Office / Furniture & Fixtures / AC / Electrical / IT / CCTV / Small Genset / Water Tank / Operational Vehicle
1
set
Rp1,500,000,000
Rp1,500,000,000
DETAIL
TOTAL
Rp4,500,000,000 NOTES: The above is only estimation based on assumption that the site has been cleared and levelled. The client has the right to appoint third party contractor for the work.
START-UP COST START-UP PROJECT COST ITEM Mechanical & Engineering Civil Work Laterite Nickel Stock - 2 months Coal Stock (55up kcal) - 3 months Dolomite Stock Operational Cost - 2 months
DESC. 100ton/day 1.60% HGI