PROPOSAL Nickel Smelter [PDF]

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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