Rohadi, Anggoro (2025) Investigasi Dan Strategi Peningkatan Kinerja Refraktori Alumina 70% Terhadap Korosi Termal Dan Temperatur Ekstrem Pada Atap Tanur Listrik Eaf Untuk Produksi Nickel Matte. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Penelitian ini menginvestigasi kinerja refraktori alumina 70% pada atap Electric Arc Furnace (EAF) dalam proses peleburan nickel matte. Metode yang digunakan mencakup karakterisasi material melalui X-Ray Fluorescence (XRF), X-Ray Diffraction (XRD), dan Scanning Electron Microscopy-Energy Dispersive X-ray (SEM-EDX), simulasi termodinamika menggunakan FactSage, serta simulasi tegangan termal berbasis Finite Element Analysis (FEA). Hasil penelitian menunjukkan penurunan signifikan kandungan Al₂O₃ hingga di bawah 16% pada zona korosi, serta peningkatan Fe₂O₃ yang memicu pembentukan fasa korosif hercynite (FeAl₂O₄) dan magnesium spinel (MgAl₂O₄). Simulasi FactSage mengonfirmasi kestabilan fasa-fasa ini pada temperatur 1200–1400 °C. Hasil FEA mengidentifikasi konsentrasi tegangan maksimum di zona tengah atap, mendekati batas kekuatan material refraktori. Berdasarkan temuan ini, strategi mitigasi yang diusulkan mencakup: optimasi desain geometri bata untuk mereduksi tegangan (paling realistis dalam jangka pendek), peningkatan kadar alumina serta penurunan Fe₂O₃ pada material refraktori (berpotensi efektif, namun perlu evaluasi ekonomi), serta pengendalian distribusi temperatur furnace (paling menantang secara teknis). Studi ini memberikan pendekatan komprehensif untuk perancangan refraktori EAF yang lebih andal dan tahan lama.
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This study investigates the performance of 70% alumina roof refractories in Electric Arc Furnace (EAF) for nickel matte smelting. The methodology involves material characterization via X-Ray Fluorescence (XRF), X-Ray Diffraction (XRD), and Scanning Electron Microscopy-Energy Dispersive X-ray (SEM-EDX), thermodynamic simulation using FactSage, and thermal stress analysis through Finite Element Analysis (FEA). The results reveal a significant reduction of Al₂O₃ content to below 16% in the corrosion zone, accompanied by an increase in Fe₂O₃ that leads to the formation of corrosive phases such as hercynite (FeAl₂O₄) and magnesium spinel (MgAl₂O₄). FactSage simulations confirm the stability of these phases within the 1200–1400 °C temperature range. FEA identifies peak stress concentrations near the roof’s midsection, approaching the refractory’s mechanical limits. Based on these findings, proposed mitigation strategies include: optimizing brick geometry to minimize stress (the most practical short-term solution), increasing alumina content and reducing Fe₂O₃ in refractory formulations (potentially effective but requiring cost evaluation), and improving furnace heat distribution control (technically challenging). This study offers a comprehensive framework for developing more durable and reliable EAF refractory designs.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | alumina 70 %, XRF, XRD, SEM-EDX, FactSage, FEA, atap EAF |
| Subjects: | T Technology > TN Mining engineering. Metallurgy > TN687 Electric furnaces. |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Material & Metallurgical Engineering > 27101-(S2) Master Thesis |
| Depositing User: | Anggoro Rohadi |
| Date Deposited: | 08 Aug 2025 06:37 |
| Last Modified: | 08 Aug 2025 06:37 |
| URI: | http://repository.its.ac.id/id/eprint/127982 |
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