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    Smelter Analysis

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    David Budi Saputra
    The document discusses the different technologies (RKEF and BF) used to produce ferronickel in Indonesia. It provides details on the requirements for each technology, including ore type needs, products produced, power requirements, and costs. For a 10,000 tonne per year nickel capacity, it estimates that RKEF production would cost $7,400/tonne while BF production would cost $10,200/tonne. It also lists several current and planned ferronickel smelting projects in Indonesia.

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    Smelter Analysis

    Uploaded by

    David Budi Saputra
    341 views8 pages
    The document discusses the different technologies (RKEF and BF) used to produce ferronickel in Indonesia. It provides details on the requirements for each technology, including ore type needs, products produced, power requirements, and costs. For a 10,000 tonne per year nickel capacity, it estimates that RKEF production would cost $7,400/tonne while BF production would cost $10,200/tonne. It also lists several current and planned ferronickel smelting projects in Indonesia.

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    Describe smelter cost benefit

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    The document discusses the different technologies (RKEF and BF) used to produce ferronickel in Indonesia. It provides details on the requirements for each technology, including ore type needs, products produced, power requirements, and costs. For a 10,000 tonne per year nickel capacity, it estimates that RKEF production would cost $7,400/tonne while BF production would cost $10,200/tonne. It also lists several current and planned ferronickel smelting projects in Indonesia.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    341 views8 pages

    Smelter Analysis

    Uploaded by

    David Budi Saputra
    The document discusses the different technologies (RKEF and BF) used to produce ferronickel in Indonesia. It provides details on the requirements for each technology, including ore type needs, products produced, power requirements, and costs. For a 10,000 tonne per year nickel capacity, it estimates that RKEF production would cost $7,400/tonne while BF production would cost $10,200/tonne. It also lists several current and planned ferronickel smelting projects in Indonesia.

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    © All Rights Reserved
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    You are on page 1of 8

    SinceJan

    .,2014,partscompaniesrushtoIndonesiatobuilduptheferronickelsmelteraccordingtotheGovernmentRegulationNo.1/2014.Untilnowseveral
    companieslikePTSMIandPTCahayaModernNickel,investedbyChinesecompaniesalreadyputintoproduction.However,therestrainingpowerandother
    deficiencyinfrastructuremakesthecosttobedifferentbyRKEFandBF.ThebasicdemandsforthesetwodifferenttechnologyinRKEFandBFistheoretypes
    andpoweraswellasthefuel.Ifwewanttoproduce10,000t/aNickelCapacityinNPI,itshouldbefeededof1.8%NiSaproliteOre.Detailsasbelow.

    RKEF BLASTFURNACE DIRECT

    REDUCTION/MAGSEP

    ORETYPE Saprolite(Ni>1.8%,,Fe<20%, BestforlimoniteSmallBFfor BestforhighFe,lowMgO


    S/M>1.5) saproliteduetoslagremoval

    PRODUCT NPIwith1012%Ni HighCarbonNPI(about8%Ni) HighslagNPI

    POWER Substantialpowerneeded Cogenerationofpowerfromoff Moderateasonlyneededforequipment


    gas
    Integrationofpowerplantwith
    furnaceanissue

    COAL/COKE Reductantcoalavailablelocally Operatingcostsdependon Mainenergysourceiscoal


    importedcoke

    Cokepricesincreasing
    OTHER Dustingissuesseverewithsmall Notwellestablishedtechnology
    plants
    Accretionissuesinreductionasclosetomeltingpoint
    Offgashandlingamajorcostarea

    Andifweproduce10000tonsnickelpigirononeyearwhichneeds88200tonsinRKEFand917000TONSinBlastFurnace.

    AndtakingthenickelorepriceasUSD25/tfor1.8%,soitmaytakeaboutUSD7400/tforoneyearbyRKEFandUSD10200/tforBF.

    Item Cost/Unit RKEF BLASTFURNACE


    Quantity/a USD/a Quantity/a USD/a

    MiningandTransport

    Ore 25 882,000 22,050,000 917,000 22,925,000

    ReagentsandConsumables

    Coal 65 69,600 4,524,000

    Anthracite 100 39,150 3,915,000

    Coke 170 286,000 48,620,000

    Limestone 15 30,000 450,000

    Lime 85 98,000 8,330,000


    Fluorite 150 5,300 795,000

    Refractory 1,914,000 355,000

    ElectrodePaste 910 1,500 1,365,000

    Electrodecasing 348,000

    NitrogenandOxygen 313,000 360,000

    Tappingclayanddrill 1,280,000

    Refiningadditives 1,160,000

    Labcosts 450,000 450,000

    MobileFleet 1,914,000 1,440,000

    Power 40 480,000 19,200,000 6,440,000


    Personell 550 5,500,000 700 6,000,000

    Maintenance 5,000,000 4,700,000

    Administration 957,000 1,100,000

    Product 30 87,000 2,610,000 130,000 3,900,000

    Slag 2 485,000 970,000 455,000 910,000

    TOTAL(USD) $73,920,000 $106,325,000

    TOTAL(USD/tonne) $7,400 $10,200

    ItisreportedthatrightnowonlyseveralcompanieshavecompletedtheconstructionforsmelterinIndonesia.NewsmeltersincludedTsingshanRKEF
    (Morowali)inStage2development,Antam(FeNi4),PTKaryatamaKonaweUtaraandBlackspace(Kabaena)partiallycompleted.AsidefromPTIndoferra,
    somesmallblastfurnaces(CahayaModernGroup,PTGebeSentra)arestillunderconstruction.However,asthelackoftechnologyaswellasfunds,someother
    projectshavealsobeensuspendedsuchasthesmelterinvestedbyFujianFuxingIndustryImportandExportCompany.Besides,theslowferronickelmarketin
    Chinaalsopullsdowntheinvestmentsinsmelting.

    However,asofnowPhilippinegovernmentAuditonnickeloreminingmakesthenickeloreimportbehardwhichalsostimulatestheferronickelproducersin
    Chinatoraisetheprice.Besides,Indonesiagovernmentalsotriestoreleasetheexportbanonnickelorein2017amongthecompanieswhohavebuildup
    smelters.Underthiscondition,Ferroalloynetforecaststheferronickelsmelterconstructionmaybeflourishinnearfuture.

    PROJECT LOCATION OWNER TECHNOLOG PRODUCT NiPRODN CAPITAL CAPEX NOTES

    Y FORM (t/a) COST(US$ (USD/tNi)

    million)

    CurrentIndonesianProjects

    PTIndoFerra KrakatauSteel Indonesian BlastFurnace NPI 10,000 230 23,000 450m3Blastfurnace


    Growth

    Steelgroup

    PTCahayaModern SESulawesi ModernGroup BlastFurnace NPI 1,750 20 11,000


    Nickel

    ZhenshiGebe FajarBhakti, BlastFurnace NPI 5,000 56 11,000


    Gebe

    Sentra,Zhenshi
    Hdgs

    Macika PTKaryatama BlastFurnace NPI 4,000 45 10,000

    KonaweUtama

    Harita ObiIs HaritaGroup RKEF(Chinese) FeNi 15,000 320 21,000 Basedon8%Ni,includes120

    MWpowerplant

    PTSulawesiMining Morowali Tsingshan/PT RKEF(Chinese) FeNi 30,000 656 22,000 Includes2x65MWCoal


    (Stage1) Bintang Power

    Delapan Plants

    PTSulawesiMining Morowali Tsingshan/PT RKEF(Chinese) FeNi 60,000 1030 17,000 Includes2x150MWCoal


    (Stage2) Bintang Power

    Delapan Plants

    PTSulawesiMining Morowali Tsingshan/PT RKEF(Chinese) FeNI 60,000 1000 17,000 Includespowersupply


    (Stage3)
    Bintang

    Delapan

    MakmurNickelsmelt ChinaHanking RKEF(Chinese) FeNi 10,000 245 25,000

    Holdings

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