Analisis Post-Mortem Material Refractory Brick Magnesia Chrome Pada Electric Arc Furnace di Industri Smelter Nikel

Fauzan, Hafidh Nur (2026) Analisis Post-Mortem Material Refractory Brick Magnesia Chrome Pada Electric Arc Furnace di Industri Smelter Nikel. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Refraktori magnesia-chrome pada Electric Arc Furnace (EAF) industri smelter nikel bekerja pada temperatur tinggi dan berkontak dengan media proses peleburan calcine yang dapat memicu penetrasi unsur eksternal serta penurunan performa material. Penelitian ini bertujuan menganalisis pengaruh interaksi hasil peleburan calcine terhadap perubahan komposisi kimia, fase, dan mikrostruktur refraktori magnesia-chrome. Selain itu, menganalisis hubungan penetrasi unsur eksternal dengan sifat mekanik serta menentukan mekanisme degradasi dan akar penyebab kegagalan refraktori. Sampel yang digunakan terdiri atas refraktori pasca pemakaian RMS Afrika A, RMS Afrika B, RMS Afrika C, dan sampel hasil immersion test RMS Afrika I. Variabel bebas meliputi perbedaan sampel post-mortem dan perlakuan imersi, variabel terikat yaitu komposisi oksida, distribusi unsur lokal, mikrostruktur, fase kristalin, kedalaman penetrasi, dan nilai Cold Crushing Strength. Karakterisasi material menggunakan XRF, XRD, SEM-EDX, uji CCS, analisis kedalaman penetrasi, dan pendekatan Fault Tree Analysis. Hasil XRF menunjukkan penurunan MgO serta peningkatan Fe2O3 dan NiO pada Afrika A dan Afrika B dibandingkan Afrika C. Hasil XRD menunjukkan fase periclase dominan yang disertai pembentukan fase sekunder magnesiowustite, magnetite, magnesioferrite, nickel chromite, chromium oxide, dan fase silikat. SEM-EDX menunjukkan mikrostruktur heterogen, pori, area intergranular, dan area kaya unsur eksternal. Nilai CCS Afrika B terendah 8,94 MPa, sedangkan penetrasi lokal terbesar pada immersion test terjadi di Afrika I3 sebesar 693,53 ± 28,43 µm. Degradasi refraktori terjadi akibat kombinasi serangan kimia, pembentukan fase sekunder, degradasi mikrostruktur, pengaruh termal, dan penurunan integritas mekanik.
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Magnesia-chrome refractories used in Electric Arc Furnace (EAF) of nickel smelter operate at high temperatures and exposed to process media that generated from calcine smelting. The process may promote external element penetration to reduce material performance. This study aims to analyze the effect of calcine smelting interaction on the chemical composition, phase formation, and microstructure of magnesia-chrome refractories. In addition, this study evaluates the relationship between external element penetration and mechanical properties, as well as determines the degradation mechanism and root causes of refractory failure. The samples used in this study consisted of used refractory samples RMS Afrika A, RMS Afrika B, RMS Afrika C, and immersion test sample RMS Afrika I. The independent variables included different post-mortem samples and immersion treatment conditions, while the dependent variables included oxide composition, local elemental distribution, microstructure, crystalline phases, penetration depth, and Cold Crushing Strength (CCS). Material characterization conducted using XRF, XRD, SEM-EDX, CCS testing, penetration depth analysis, and the Fault Tree Analysis approach. The XRF results showed a decrease in MgO and an increase in Fe₂O₃ and NiO in Afrika A and Afrika B compared with Afrika C. The XRD results indicated that periclase remained the dominant phase, accompanied by the formation of secondary phases such as magnesiowustite, magnetite, magnesioferrite, Nickel Chromite, chromium oxide, and silicate phases. SEM-EDX results revealed heterogeneous microstructures, pores, intergranular areas, and regions enriched with external elements. Afrika B exhibited the lowest CCS value of 8.94 MPa, while the greatest local penetration in the immersion test occurred in Afrika I3, reaching 693.53 ± 28.43 µm. Refractory degradation occurred due to a combination of chemical attack, secondary phase formation, microstructural degradation, thermal effects, and decreased mechanical integrity.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Refraktori, Magnesia-chrome, Analisis Post-Mortem, Calcine, Electric Arc Furnace, Refractory, Magnesia-chrome, Post-Mortem Analysis, Calcine, Electric Arc Furnace
Subjects:	Q Science > QD Chemistry > QD481 Chemical structure. Q Science > QD Chemistry > QD96F56 Fluorescence spectroscopy Q Science > QE Geology > QE604 Deformation
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Material & Metallurgical Engineering > 28201-(S1) Undergraduate Thesis
Depositing User:	Hafidh Nur Fauzan
Date Deposited:	23 Jul 2026 03:34
Last Modified:	23 Jul 2026 03:50
URI:	http://repository.its.ac.id/id/eprint/136364

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