Hamdi, Muhammad Hisyam Maulana (2025) Pengaruh Penambahan ZrO₂ dan Parameter q-Value Particle Size Distribution (PSD) dengan Pendekatan Modified Andreassen Equation Al₂O₃ terhadap Sifat Mekanik, Fisik, dan Ketahanan Alkali Pada High Alumina Refractory. Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Salah satu permasalahan krusial adalah rendahnya ketahanan refractory brick terhadap serangan alkali di rotary kiln, yang mengakibatkan downtime secara berkala, kerusakan lapisan tahan api, hingga menyebabkan kerugian operasional signifikan. Penelitian ini bertujuan mengkaji peningkatan performa high alumina refractory brick melalui rekayasa distribusi ukuran partikel Al₂O₃ menggunakan Modified Andreassen Equation (q = 0,25 dan 0,30) dan penambahan zirkonia (ZrO₂) sebesar 0%, 1%, dan 2% berat, dengan fly ash sebagai sumber silika dari limbah PLTU. Pengujian mekanik dan ketahanan alkali dilakukan melalui uji bulk density, cold crushing strength (CCS), ketahanan abrasi, apparent porosity, water absroption, dan uji ketahanan alkali menggunakan metode static cup test, serta identifikasi fasa (XRD) dan mikrostruktur (SEM-EDX). Formulasi A2.5Z2 (q = 0,25; 2% ZrO₂) memberikan hasil terbaik dengan bulk density 2,75 g/cm³, porositas 12,21%, absorpsi air 7,07%, CCS 26,02 MPa, dan abrasi 32,75 cm³. Uji ketahanan alkali menunjukkan zona reaksi hanya 5,31 mm, menandakan peningkatan signifikan dibanding formulasi lain. Meskipun nilai CCS, ketahanan abrasi, apparent porosity, water absroption, dan ketahanan alkali tersebut masih berada di bawah target desain, hasil ini menunjukkan peningkatan nyata dibanding refraktori konvensional. Kehadiran fasa m-ZrO₂ terbukti memperkuat struktur melalui mekanisme toughening, sedangkan kontrol distribusi partikel meningkatkan densifikasi dan homogenitas mikrostruktur. Meskipun belum seluruh parameter memenuhi target desain industri, peningkatan signifikan terhadap refraktori konvensional telah dicapai.
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One of the critical challenges is the low alkali resistance of refractory bricks in rotary kilns, which results in periodic downtime, degradation of thermal linings, and significant operational losses. This study aims to improve the performance of high alumina refractory bricks through microstructural engineering by varying the particle size distribution (PSD) of Al₂O₃ using the Modified Andreassen Equation (q = 0.25 and 0.30) and incorporating zirconia (ZrO₂) at 0%, 1%, and 2% by weight, with fly ash from coal-fired power plant waste serving as a silica source. Mechanical and chemical resistance testing includes bulk density, cold crushing strength (CCS), abrasion resistance, apparent porosity, water absorption, and alkali resistance, as determined using the static cup test method. Additionally, phase identification (XRD) and microstructural analysis (SEM-EDX) are employed. The A2.5Z2 formulation (q = 0.25; 2% ZrO₂) demonstrated the best performance, with a bulk density of 2.75 g/cm³, porosity of 12.21%, water absorption of 7.07%, CCS of 26.02 MPa, and an abrasion volume of 32.75 cm³. Alkali resistance testing showed a reaction zone depth of only 5.31 mm, indicating significant improvement over other formulations. Although the values of CCS, abrasion resistance, porosity, water absorption, and alkali resistance remain below the industrial target thresholds, these results represent a substantial enhancement compared to conventional refractory bricks. The presence of monoclinic ZrO₂ (m-ZrO₂) contributed to structural reinforcement through transformation toughening mechanisms, while optimized particle distribution enhanced densification and microstructural homogeneity.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Alkali Attack, High Alumina Refraktory Brick, Particle Size Distribution, Rotary Kiln, ZrO2, Alkali Attack, High Alumina Refraktory Brick, Particle Size Distribution, Rotary Kiln, ZrO2 |
| Subjects: | T Technology > TA Engineering (General). Civil engineering (General) > TA418.16 Materials--Testing. T Technology > TN Mining engineering. Metallurgy > TN295 Fly ash T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning) |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Material & Metallurgical Engineering > 28201-(S1) Undergraduate Thesis |
| Depositing User: | Muhammad Hisyam Maulana Hamdi |
| Date Deposited: | 30 Jul 2025 10:22 |
| Last Modified: | 30 Jul 2025 10:22 |
| URI: | http://repository.its.ac.id/id/eprint/122974 |
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