Wardani, Zahra (2025) Analisis Pengaruh Komposisi Agregat Pada Refractory Brick Alumina Silika Terhadap Packing Density Menggunakan Discrete Element Method (DEM). Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Refractory brick (batu bata tahan api) merupakan komponen krusial dalam proses industri yang melibatkan temperatur tinggi salah satunya proses produksi klinker semen didalam alat cement rotary kiln. Didalam alat tersebut, refractory brick berfungsi melindungi dinding cement rotary kilm dari paparan temperatur tinggi. Salah satu tantangan utama dalam produksi refractory brick adalah mencapai packing density yang tinggi pada tahap pembentukan greenbody. Penelitian ini bertujuan untuk menganalisis pengaruh komposisi agregat yang dipengaruhi oleh distribusi ukuran partikel ”q” dalam perhitungan Modified Andreassen Packing Model terhadap packing density refractory brick. Metodologi penelitian menggunakan simulasi Discrete Element Method (DEM) dengan software ANSYS Rocky R1 2022 dengan memodelkan pembuatan greenbody dalam proses powder compaction. Simulasi dilakukan dengan memvariasikan nilai modulus distribusi ”q” (0,21, 0,24, 0,28, 0,31 dan 0,35) pada campuran 78 wt% alumina silika, 7 wt% andalusite, dan 15 wt% clay. Gaya tekan (punch) juga divariasikan pada nilai 98000 N, 110250 N, dan 122500 N. Kondisi kuat tekan dan variasi agregat pada material yang digunakan dalam penelitian ini disesuaikan dengan kondisi yang digunakan dalam industri pembuatan refractory brick Alumina-Silika pada PT X. Dikarenakan keterbatasan software simulasi, maka ukuran agregat paling halus (0 – 0,044 mm) dengan presentase 19,01% - 37,01% tergantung dari nilai q yang diteliti tidak dapat dimasukkan kedalam proses simulasi.
Hasil simulasi menunjukkan bahwa nilai q terbaik untuk mencapai packing density tertinggi adalah 0,28 pada kondisi gaya tekan sebesar 122.500 N, dengan nilai packing denisty 70,42%. Pada kondisi ini terdapat 25,67% partikel halus sehingga jika ditambahkan maka akan diperoleh packing density sebesar 98%. Pada kondisi q dibawah 0,28 terdapat kenaikan packing density secara gradual dari 0,21. Sebaliknya pada kondisi nilai q setelah 0,28 terjadi penurunan packing density secara signifikan dengan nilai penurunan tertinggi pada q=0,35 yang memberikan packing denisty sebesar 68,69%.Validasi dilakukan menggunakan pendekatan numerik dan EMMA Mix Analyzer, yang memperlihatkan kecocokan tren data antara simulasi dan data teoritis.
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Refractory bricks are crucial components in industrial processes involving high temperatures, such as the production of cement clinker in rotary kilns. Inside the rotary kiln, refractory bricks serve to protect the kiln walls from extreme thermal exposure. One of the main challenges in producing refractory bricks lies in achieving a high packing density during the greenbody formation stage. This study aims to analyze the influence of aggregate composition affected by particle size distribution "q" using the Modified Andreassen Packing Model on the packing density of refractory bricks. The research methodology involved Discrete Element Method (DEM) simulations using ANSYS Rocky R1 2022 software, modeling the greenbody formation process during powder compaction. The simulations were conducted by varying the distribution modulus "q" values (0.21, 0.24, 0.28, 0.31, and 0.35) for a mixture composed of 78 wt% alumina-silica, 7 wt% andalusite, and 15 wt% clay. Punch force was also varied at 98,000 N, 110,250 N, and 122,500 N. The compressive strength and aggregate variation used in this study were aligned with the conditions applied in the alumina-silica refractory brick manufacturing process at PT X.Due to limitations in the simulation software, the finest aggregate size (0–0.044 mm), which comprised between 19.01% and 37.01% depending on the q value, could not be included in the simulation process.
Simulation results showed that the optimal q value for achieving the highest packing density was 0.28 under a compaction force of 122,500 N, yielding a packing density of 70.42%. Under this condition, the mixture contained 25.67% fine particles, indicating that the addition of these fines could potentially raise the packing density to 98%. At q values below 0.28, the packing density increased gradually from 0.21, while beyond 0.28, a significant decrease in packing density was observed, with the lowest result at q = 0.35, yielding a packing density of 68.69%. Validation was conducted through both numerical approximation and the EMMA Mix Analyzer, which demonstrated a strong correlation between the simulation data and theoretical trends.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Refractory Bricks, Alumina-Silikat, Discrete Element Methode (DEM), Powder Compaction, q (Modulus Distribusi), Refractory Bricks, Alumina-Silikat, Discrete Element Methode (DEM), Powder Compaction, q (Modulus Distribution) |
| Subjects: | T Technology > T Technology (General) T Technology > T Technology (General) > T57.62 Simulation T Technology > TJ Mechanical engineering and machinery T Technology > TJ Mechanical engineering and machinery > TJ174 Maintenance and repair of machinery T Technology > TN Mining engineering. Metallurgy T Technology > TS Manufactures > TS167 Costs, Industrial |
| Divisions: | Faculty of Industrial Technology > Mechanical Engineering > 21201-(S1) Undergraduate Thesis |
| Depositing User: | Zahra Wardani |
| Date Deposited: | 04 Aug 2025 03:46 |
| Last Modified: | 04 Aug 2025 03:46 |
| URI: | http://repository.its.ac.id/id/eprint/126577 |
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