The Simulation Model of Iron Sponge Plant Layout for the Defense Industry Based on Industry 4.0 Model

The Industry 4.0 is a change in the perspective of how to view an industry based on the resources owned, to operate according to needs. The sponge iron industry is a raw material industry to support the steel industry which is intended as material for shipbuilding and combat vehicles used by the Indonesian National Millitary. It is necessary to plan and design a sponge iron plant with an Industrial 4.0 model. The implementation of the Industry 4.0 model aims to optimize the operational needs of the plant, especially the sponge iron plant, which is relatively rare in Indonesia. The concept of a factory layout (cellular layout, modular layout), the concept of lean manufacturing, as well as the concepts and principles of the smart factory (Cyber-Physical Systems) are concepts that will be applied in the planning and design of the Industrial 4.0 sponge iron plant layout. In order to produce an optimal layout, a simulation model using FlexSim 2018 Software and layout optimization is used the Computerized Relative Allocation of Facilities Technique (CRAFT) algorithm with the help of CRAFT Software Integrated Microsoft Excel 2019.

Iron Recovery from Bauxite Tailings Red Mud by Thermal Reduction with Blast Furnace Sludge

More than 100 million tons of red mud were produced annually in the world over the short time range from 2011 to 2018. Red mud represents one of the metallurgical by-products more difficult to dispose of due to the high alkalinity (pH 10–13) and storage techniques issues. Up to now, economically viable commercial processes for the recovery and the reuse of these waste were not available. Due to the high content of iron oxide (30–60% wt.) red mud ranks as a potential raw material for the production of iron through a direct route. In this work, a novel process at the laboratory scale to produce iron sponge (≤ 1300 °C) or cast iron (> 1300 °C) using blast furnace sludge as a reducing agent is presented. Red mud-reducing agent mixes were reduced in a muffle furnace at 1200, 1300, and 1500 °C for 15 min. Pure graphite and blast furnace sludges were used as reducing agents with different equivalent carbon concentrations. The results confirmed the blast furnace sludge as a suitable reducing agent to recover the iron fraction contained in the red mud. For all the conditions tested, the metallization degree was higher than 70%, and the best condition to reduce red mud through blast furnace sludge was identified at 1:1 red mud/blast furnace (B.F.) sludges equal to 0.85 C/Fe2O3.

ANALYSIS OF THE PROCESS OF IRON SAND PROCESSING INTO SPONGE IRON IN ORDER TO SUPPORT THE DEFENSE INDUSTRY OF STEEL RAW MATERIALS

<p>The number of iron sand reserves is mostly spread in the coastal waters of Indonesia, from the coast of Sumatra, the southern of Java to Bali, the beaches of Sulawesi, beaches in East Nusa Tenggara (NTT), and the northern coast of Papua. Total reserves for ore are 173,810,612 tons and metal as much as 25,412,652.62 tons. But its utilization was not optimal because PT. Krakatau Steel, and PT. Krakatau Posco has produced steel plates only 24,000 to 36,000 tons per year. While the need for steel plates for the shipping industry each year requires 900,000 tons per year. With the need for raw material for steel plates in the form of iron sponges with Fe ≥ 60%, PT. Krakatau Steel is still imported from abroad. The proof is PT. Krakatau Steel before and during the year 2000 still imported Iron Ore Pellets from the countries of Sweden, Chille and Brazil for 3,500,000 tons per year. This condition is the cause of the national steel industry unable to compete with the foreign steel industry because imported raw materials are subject to import duties. This is an opportunity to build a steel raw material company because all this time the steel raw material industry in Indonesia has only two companies. This condition encourages the manufacture of iron sponges, with the process of making iron sponges with technology adapted to installed production capacity. This study analysed the manufacture of iron sponges using Cipatujah iron sand, as raw material for the manufacture of iron sponges, with the results obtained in the form of iron sponges with the highest levels of Fe ≥60.44%. This can be used for the purposes of raw materials for steel making PT. Krakatau Steel (PT. KS), because so far PT. KS claims that Fe &lt;60% local sponge iron products. This can encourage the independence of steel raw materials, which impacts on the independence of the defence industry. But the government must also protect and prioritize steel raw materials for national production for national steel production. With the national government steel industry, the consortium of vendors supplying raw material (iron sponge) to maintain the quality and supply of continuous sponge iron.</p><p><strong>Keywords</strong>: iron sand, iron pellet, iron sponge</p>

Research Concerning Reducing the Polluation Degrees in the Sectors of Production of Metal Materials

This paper contains the results of researches and experimentations on the reduction of the concentration of gaseous emissions and powders in the manufacture of ferrous alloys in aggregates of electric arc furnaces (EBT) coupled with a treatment plant (LF) located at Mechel Targoviste using new technology. Experiments have shown that using the new technology one achieves a reduction in pollutant gaseous emissions by about 30% and in dust content by about 25% compared to the use of classical technology, with particularly beneficial effects on the environment. The results have confirmed the validity of the new technology that used iron sponge in the loading phase, foamed slag in the melting phase and long electric arc in the production phase. The paper presents the results of the experiments using both technologies, as well as the equipment established and used in the experiments for the measurement and recording of the gaseous emissions and powders content, which ensured an accurate evaluation of the obtained results.