Analisa Perbaikan Proses Dengan Pengukuran Pencapaian Temperatur Anoda Aktual Pada Proses Pemanggangan Anoda Di PT Indonesia Asahan Aluminium

Rahmadi, Ananto Dwi (2024) Analisa Perbaikan Proses Dengan Pengukuran Pencapaian Temperatur Anoda Aktual Pada Proses Pemanggangan Anoda Di PT Indonesia Asahan Aluminium. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT Indonesia Asahan Aluminium atau “INALUM” adalah perusahaan yang bergerak di bidang peleburan aluminium. INALUM terdiri dari power plant dan smelting plant. Smelting Plant terdiri dari tiga pabrik utama yaitu pabrik karbon, pabrik reduksi dan pabrik pencetakan. Pabrik Karbon memproduksi anoda karbon yang digunakan pada proses elektrolisis di pabrik reduksi. Dalam proses reduksi alumunium menggunakan proses Hall-Héroult, anoda karbon digunakan untuk mereduksi alumina (Al2O3) menjadi aluminium cair. Hal ini menjadikan anoda karbon sebagai komponen utama dalam produksi aluminium. Salah satu tahapan proses produksi anoda yaitu proses pemanggangan dimana anoda mentah (green block) dipanggang dalam tungku pemanggangan anoda hingga temperatur 1250 ˚C dengan tujuan untuk meningkatkan kekuatan parameter secara kimia maupun fisika. Parameter proses yang dimonitor pihak operasi pabrik anoda panggang adalah tekananan draught dan kurva temperatur dari flue gas yang telah diatur dalam recipe (resep pemanggangan). Kurva temperatur dari flue gas adalah representasi dan mencerminkan kualitas anoda, apabila kurva temperatur tidak tercapai atau berlebih dari yang telah ditargetkan maka dapat berdampak pada kualitas anoda panggang. Implementasi analisa perbaikan proses dengan pengukuran pencapaian temperatur anoda aktual pada proses pemanggangan yang sudah dilakukan mendapatkan hasil rata-rata temperature akhir pada pit #5 di lapisan bawah sebesar 1110,5°C dan pada lapisan atas sesebesar 1132°C sehingga terdapat distribusi temperatur sebesar 21°C. Sedangkan rata-rata temperatur akhir pada pit #4 di lapisan bawah sebesar 1157°C dan pada lapisan atas sebesar 1187°C sehingga terdapat distribusi temperatur sebesar 30°C. Gradien temperatur pemanggangan anoda pada pit #5 sebesar 12 – 16°C/jam yang ditunjukkan saat 24 jam setelah fase pambakaran. Sedangkan pada pit #4 sebesar 17 – 20°C/jam yang ditunjukkan saat 20 jam setelah fase pembakaran. Dari hasil pengukuran temperatur anoda aktual sudah tercapai sesuai dengan standar minimal temperatur anoda, yaitu 1100 - 1150°C. Namun gradien temperatur pada pit #4 dan pit #5 memiliki perbedaan yang cukup signifikan dan untuk pit #4 melebihi standar maksimum 17°C/jam, maka setting burner nomor 3, 4 dan 5 diberikan offset agar didapatkan temperatur anoda aktualnya memiliki nilai gradien temperatur/laju kenaikan temperatur yang sama. Selain dapat mengurangi deviasi temperatur pada masing-masing pit, offset pada pengaturan burner juga dapat mengurangi konsumsi bahan bakar.
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PT Indonesia Asahan Aluminum or "INALUM" is a company engaged in aluminum smelting. INALUM consists of a power plant and a smelting plant. The Smelting Plant consists of three main factories, namely the carbon factory, reduction factory and molding factory. The Carbon Factory produces carbon anodes which are used in the electrolysis process in the reduction plant. In the aluminum reduction process using the Hall-Héroult process, a carbon anode is used to reduce alumina (Al2O3) into liquid aluminum. This makes carbon anodes the main component in aluminum production. One of the stages of the anode production process is the roasting process where the raw anode (green block) is baked in an anode roasting furnace to a temperature of 1250 ˚C with the aim of increasing the strength of chemical and physical parameters. The process parameters monitored by the roasted anode factory operations are the draft pressure and temperature curve of the flue gas which have been set in the roasting recipe. The temperature curve of the flue gas is a representation and reflects the quality of the anode. If the temperature curve is not achieved or exceeds the target, it can have an impact on the quality of the baked anode. Implementation of process improvement analysis by measuring the actual anode temperature achieved in the roasting process that has been carried out results in an average final temperature in pit #5 in the bottom layer of 1110.5°C and in the top layer of 1132°C so that there is a temperature distribution of 21 °C. Meanwhile, the average final temperature in pit #4 in the lower layer was 1157°C and in the upper layer was 1187°C, so there was a temperature distribution of 30°C. The anode roasting temperature gradient in pit #5 is 12 – 16°C/h which is shown 24 hours after the burning phase. Meanwhile in pit #4 it was 17 – 20°C/h which was shown 20 hours after the combustion phase. From the measurement results, the actual anode temperature has been achieved in accordance with the minimum anode temperature standard, namely 1100 - 1150°C. However, the temperature gradient in pit #4 and pit #5 has quite a significant difference and for pit #4 it exceeds the maximum standard of 17°C/hour, so the burner settings number 3, 4 and 5 are offset so that the actual anode temperature has a temperature gradient value. /the same rate of temperature increase. Apart from reducing temperature deviations in each pit, offsets in the burner settings can also reduce fuel consumption.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	aluminium, pabrik karbon, anoda panggang, kurva pemanggangan, aluminum, carbon plant, baked anode, baking curve
Subjects:	T Technology > TS Manufactures > TS155 Production control. Production planning. Production management T Technology > TS Manufactures > TS156 Quality Control. QFD. Taguchi methods (Quality control)
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 23902-Engineer Professional Program
Depositing User:	Ananto Dwi Rahmadi
Date Deposited:	09 Aug 2024 03:35
Last Modified:	09 Aug 2024 03:35
URI:	http://repository.its.ac.id/id/eprint/115186

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