Analisis Interaksi Fe-Silicate Calcine Dan Dampaknya Terhadap Degradasi Magnesia-Chrome Refractory Brick Pada Electric Arc Furnace Di Industri Nikel

Pradana, Faisal Ridho Pradana (2026) Analisis Interaksi Fe-Silicate Calcine Dan Dampaknya Terhadap Degradasi Magnesia-Chrome Refractory Brick Pada Electric Arc Furnace Di Industri Nikel. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Material refraktori magnesia-kromit merupakan salah satu komponen penting pada Electric Arc Furnace (EAF) di industri nikel karena berfungsi menahan temperatur tinggi serta interaksi dengan media korosif selama proses peleburan. Salah satu faktor yang dapat memicu degradasi refraktori adalah interaksi dengan Fe-silicate calcine yang berpotensi masuk ke dalam mikrostruktur refraktori dan membentuk daerah reaksi lokal. Penelitian ini bertujuan untuk menentukan mekanisme interaksi Fe-silicate calcine terhadap refraktori magnesia-kromit serta menganalisis pengaruh interaksi tersebut terhadap proses degradasi refraktori. Sampel yang digunakan adalah refraktori B-MAG 64 CR dan B-MAG 55 CR yang diberi perlakuan uji imersi statis dengan Fe-silicate calcine pada temperatur 1200 ℃ selama 60, 120, dan 180 menit. Hasil perlakuan kemudian dianalisis menggunakan SEM-EDX untuk mengamati morfologi dan distribusi unsur, ImageJ untuk mengukur ketebalan reaction layer, XRD untuk mengidentifikasi fasa kristalin, XRF untuk mengevaluasi perubahan komposisi kimia, serta simulasi COMSOL untuk memodelkan transport massa pada media berpori. Hasil penelitian menunjukkan bahwa interaksi Fe-silicate calcine terhadap refraktori diawali oleh pembasahan dan penempelan calcine pada permukaan, kemudian diikuti transport komponen Fe-silicate secara lokal melalui pori, celah antarbutir, dan batas butir. SEM-EDX dan ImageJ menunjukkan bahwa interaksi dominan terjadi pada daerah antarmuka, dengan ketebalan reaction layer sebesar 12.87–24.73 µm pada B-MAG 64 CR dan 4.84–27.42 µm pada B-MAG 55 CR, sehingga tidak menunjukkan infiltrasi homogen ke seluruh bulk refraktori. Hasil XRF menunjukkan kandungan MgO refraktori yaitu 77.824 wt%, 70.831 wt%,78.099 wt% dan 69.021 wt%. Selain itu, kandungan Fe2O3 pada refraktori adalah 0.723 wt% dan 0.700 wt%. Hasil XRD menunjukkan bahwa fasa utama didominasi MgO sebesar 73.7–83.0% dan 66.8–85.6%, disertai spinel kompleks. Simulasi COMSOL menunjukkan profil konsentrasi menurun dari permukaan ke bagian dalam refraktori, dengan difusivitas efektif rata-rata 9.14 × 10⁻¹⁵ m²/s pada B-MAG 64 CR dan 5.87 × 10⁻¹⁵ m²/s pada B-MAG 55 CR. Secara keseluruhan, degradasi refraktori masih berada pada tahap awal serangan kimia, ditandai oleh reaction layer lokal dan perubahan komposisi antarmuka, bukan kerusakan bulk secara menyeluruh.
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Magnesia-chromite refractory is an important component in Electric Arc Furnace (EAF) applications in the nickel industry due to its ability to withstand high temperatures and corrosive media during the smelting process. One factor that may initiate refractory degradation is the interaction with Fe-silicate calcine, which can infiltrate the refractory microstructure and form a localized reaction region. This study aims to determine the interaction mechanism between Fe-silicate calcine and magnesia-chromite refractory and to analyse its effect on refractory degradation. The materials used in this study were B-MAG 64 CR and B-MAG 55 CR refractories, which were subjected to static immersion with Fe-silicate calcine at 1200 ℃ for 60, 120, and 180 minutes. The treated samples were then characterized using SEM-EDX to observe morphology and elemental distribution, ImageJ to determine the reaction layer thickness, XRD to identify crystalline phases, XRF to evaluate chemical composition changes, and COMSOL simulation to model mass transport in porous media. The results show that the interaction between Fe-silicate calcine and the refractory begins with wetting and adhesion of calcine on the refractory surface, followed by localized transport of Fe-silicate components through pores, intergranular gaps, and grain boundaries. SEM-EDX and ImageJ results show that the interaction predominantly occurred at the interfacial region, with reaction layer thicknesses of 12.87–24.73 µm for B-MAG 64 CR and 4.84–27.42 µm for B-MAG 55 CR. This indicates that homogeneous infiltration throughout the refractory bulk did not occur. XRF results show that the MgO contents in the refractories were 77.824 wt%, 70.831 wt%, 78.099 wt%, and 69.021 wt%. In addition, the Fe₂O₃ contents in the refractories were 0.723 wt% and 0.700 wt%. XRD results show that the main phases were dominated by MgO at 73.7–83.0% and 66.8–85.6%, accompanied by complex spinel phases. COMSOL simulation shows that the concentration profile decreased from the surface toward the interior of the refractory, with average effective diffusivity values of 9.14 × 10⁻¹⁵ m²/s for B-MAG 64 CR and 5.87 × 10⁻¹⁵ m²/s for B-MAG 55 CR. Overall, the refractory degradation was still in the early stage of chemical attack, characterized by a local reaction layer and compositional changes at the interface, rather than overall bulk damage.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Degradasi, Difusi Efektif, Fe-Silicate Calcine, Magnesia-Kromit, Reaction Layer, Refraktori, Degradation, Effective Diffusion, Fe-Silicate Calcine, Magnesia-Chromite, Reaction Layer, Refractory
Subjects:	Q Science > QC Physics > QC151 Fluid dynamics Q Science > QC Physics > QC 611.97.T46 Temperature effects. Including transition temperature
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Material & Metallurgical Engineering > 28201-(S1) Undergraduate Thesis
Depositing User:	Faisal Ridho Pradana
Date Deposited:	21 Jul 2026 09:10
Last Modified:	21 Jul 2026 09:10
URI:	http://repository.its.ac.id/id/eprint/135549

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