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All Journal Eduvest - Journal of Universal Studies
Rohadi, Anggoro
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Innovative Investigation and Strategy for Improving the Performance of 70% Alumina Refractory Roofs Against Thermal-Slag Corrosion and Extreme Temperatures in Electric Arc Furnaces (EAF) in the Nickel Matte Production Process Rohadi, Anggoro; Sulistijono, Sulistijono; Noerochim, Lukman; Sutarsis, Sutarsis; Purwaningsih, Hariyati
Eduvest - Journal of Universal Studies Vol. 5 No. 12 (2025): Eduvest - Journal of Universal Studies
Publisher : Green Publisher Indonesia

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.59188/eduvest.v5i12.52513

Abstract

This study investigates the performance of 70% alumina refractories on the roof of an Electric Arc Furnace (EAF) in the nickel matte smelting process. The methods used include material characterization through 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 simulation based on Finite Element Analysis (FEA). The results of the study show a significant decrease in Al₂O₃ content to below 16% in the corrosion zone, as well as an increase in Fe₂O₃ which triggers the formation of corrosive hercynite (FeAl₂O₄) and magnesium spinel (MgAl₂O₄) phases. FactSage simulations confirmed the stability of these phases at temperatures of 1200–1400 °C. FEA results identified maximum stress concentrations in the central zone of the roof, approaching the strength limit of the refractory material. Based on these findings, the proposed mitigation strategies include: optimizing the brick geometry design to reduce stress (most realistic in the short term), increasing the alumina content and decreasing Fe₂O₃ in the refractory material (potentially effective, but requires economic evaluation), and controlling the furnace temperature distribution (most technically challenging). This study provides a comprehensive approach to designing more reliable and durable EAF refractories.
Co-Authors Hariyati Purwaningsih Lukman Noerochim Sulistijono Sulistijono Sutarsis Sutarsis