ABSTRACT

Andani Achmad, A Miniature of the Solid Material Industrial Process Plant (supervised by Dadang A. Suriamiharja,  Rhiza S. Sadjad and Josaphat Tetuko Sri Sumantyo)

	This is a design project to develop a prototype of the solid material industrial process plant, miniaturized from the real size as a replica to represent the industrial world in the eastern region of Indonesia. Four kinds of industry have been considered as references, namely the flour industry, cement, nickel and the copper industry. 
	The main goals of this research are (1) to build an accurate replica of the solid material industrial process plant as the miniaturization of the real industrial world, (2) to develop a numerical model of the replica and to verify it with the replica, and (3) to conduct experimental procedures using both the numerical model and the replica for the industrial training activities and/or for the research and development purposes.
	The miniature is designed to consist of 7 (seven) components: 2 (two) silos, 2 (two) kilns (heaters), a cooler and 2 (two) belt-conveyors. Those components are assembled to allow the solid material to move from one silo to another, through the moisturizing process at the first silo, the drying process at the two kilns, the cooling process at the cooler and finally stored at the second silo. It is also possible to put the whole process in repeated cycles by opening the valve at the bottom of the second silo and carrying the material back to the first silo. There are 3 (three) controllable physical parameters available at the 2 (two) silos, namely the level, ranging from 0 mm to ....... mm at the first silo and to ...... mm at the other silo, the moisture of the solid material and its temperature, ranging from ...... % to ...... % and from ......oC to........ oC respectively.
	The experimental procedures are conducted in 3 (three) scenarios, namely (1) moving materials from the first silo to the other, (2) moving materials from the first silo to the other, then back to the first silo in cycles, and (3) varying the moisture and temperature using the two kilns and cooler. A statistical validation has shown that the results of the simulation using the numerical model are similar to the results of the measurement at the replica. However, there are discrepancies between the results of the simulation and the results of physical measurement of the replica. For scenario (1), the numerical model computes that the system moves 5 liter of material from the first silo to the other one in ...... minutes and ...... seconds, while the physical experiment measures ........... minutes and ............ seconds. In scenario (2), the material is returned back to the first silo using the second conveyor so the process is put into repeated cycles. The model shows that the time for one cycle is ........ minutes and ...... seconds with only 0.127 liter of material is outside the silos, while the physical measurement gives the time for one cycle is ......... minutes and ...... seconds with 1 liter of material is outside the silos. The moisture and temperature variation of the numerical model in scenario (3) provides insignificantly different results from the physical experiments. The differences are only 0.06% and 0.2oC in average for the moisture and temperature respectively.