Pengaruh Formulasi dan Packing Density pada Refractory Magnesia-Spinel Brick untuk Cement Rotary Kiln

Ghifari, Febrian Rizky (2025) Pengaruh Formulasi dan Packing Density pada Refractory Magnesia-Spinel Brick untuk Cement Rotary Kiln. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Rotary kiln merupakan komponen utama dalam produksi semen yang mengubah bahan baku menjadi klinker melalui pemanasan tinggi. Refractory brick berperan sebagai isolasi termal dan pelindung rotary drum dari lingkungan ekstrem. Magnesia-spinel brick adalah salah satu jenis refraktori yang digunakan di upper transition zone karena ketahanannya terhadap suhu tinggi dan stabilitas termal yang baik. Komposisi MgO dan MgAl₂O₄ yang tepat dapat meningkatkan sifat fisik, kimia, dan mekanik refraktori. Packing density yang tinggi juga dapat meningkatkan kekuatan mekanik, menurunkan porositas, dan meningkatkan ketahanan terhadap infiltrasi gas serta cairan agresif. Pada penelitian ini, variasi formulasi berupa komposisi MgAl₂O₄ sebesar 11, 13, 15 wt% dan pengaruh aggregate penyusun berupa variasi modulus distribusi q = 0,18, q = 0,23, dan q = 0,28 yang dihitung menggunakan Modified Andersen Andreasen (MAA) Model pada packing density akan diteliti. Sampel refraktori kemudian diuji dengan pengujian bulk density untuk menentukan kerapatan material, permanent linear change untuk mengukur perubahan dimensi setelah pemanasan, cold crushing strength untuk mengetahui ketahanan terhadap beban tekan, serta modulus of rupture untuk menilai kekuatan lentur. Selain itu, analisis SEM (Scanning Electron Microscopy) digunakan untuk mengamati mikrostruktur, dan XRD (X-ray Diffraction) untuk mengidentifikasi fasa kristal yang terbentuk setelah sintering. Hasil menunjukkan sampel Mg1B3 dengan penambahan MgAl₂O₄ 15% dan q = 0,28 yang menghasilkan nilai pengujian bulk density 2,731 g/cm³, CCS 14,666 MPa, MOR 2,555 MPa, dan PLC 0,045%. Penambahan 15% spinel (MgAl₂O₄) dari percobaan yang dilakukan terbukti sebagai formulasi yang paling optimal karena meningkatkan densitas, meningkatan kekuatan tekan dan lentur dalam material berbasis MgO. Pengaruh variasi agregat terhadap modulus distribusi (q) menunjukkan bahwa q = 0,28 merupakan yang optimal dalam mengisi celah antar partikel sehingga meningkatkan sifat mekanik dan fisik magnesia-spinel refractory bricks.
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The rotary kiln is the main component in cement production, converting raw materials into clinker through high-temperature heating. Refractory bricks serve as thermal insulation and protect the rotary drum from extreme environments. Magnesia-spinel bricks are one type of refractory used in the upper transition zone due to their high-temperature resistance and excellent thermal stability. The appropriate composition of MgO and MgAl₂O₄ can enhance the physical, chemical, and mechanical properties of the refractory. A high packing density can also improve mechanical strength, reduce porosity, and increase resistance to gas and aggressive liquid infiltration. In this study, variations in formulation, specifically the MgAl₂O₄ composition of 11, 13, and 15 wt%, as well as the influence of aggregate composition through variations in distribution modulus q = 0.18, q = 0.23, and q = 0.28, calculated using the Modified Andersen-Andreasen (MAA) Model for packing density, will be investigated. The refractory samples were then tested using bulk density testing to determine material density, PLC testing to measure dimensional changes after heating, CCS testing to determine resistance to compressive loads, and MOR testing to evaluate flexural strength. Additionally, SEM analysis was used to observe the microstructure, and XRD was employed to identify the crystalline phases formed after sintering. The results show that the Mg₁B₃ sample with the addition of 15% MgAl₂O₄ and q = 0.28 produced bulk density test results of 2.731 g/cm³, CCS of 14.666 MPa, MOR of 2.555 MPa, and PLC of 0.045%. The addition of 15% spinel (MgAl₂O₄) in the experiment proved to be the most optimal formulation as it increased density, improved compressive and flexural strength in MgO-based materials. The effect of aggregate variation on the distribution modulus (q) indicates that q = 0.28 is the optimal value for filling the gaps between particles, thereby enhancing the mechanical and physical properties of magnesia-spinel refractory bricks.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Refraktori, magnesia, magnesia-spinel, packing density, rotary kiln, Refractory brick, magnesia, magnesia-spinel, packing density, rotary kiln
Subjects:	T Technology > TA Engineering (General). Civil engineering (General) > TA418.16 Materials--Testing. T Technology > TJ Mechanical engineering and machinery T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning)
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21101-(S2) Master Thesis
Depositing User:	Febrian Rizky Ghifari
Date Deposited:	05 Feb 2025 13:51
Last Modified:	05 Feb 2025 13:51
URI:	http://repository.its.ac.id/id/eprint/118300

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