Redesign Combustion Air Shelter of the furnace to improve the performance in melting bronze for manufacturing gamelan.

Recent Decisions in
Technologies for
Sustainable Development

Edited by
A. Ghurri
N.P.G. Suardana
N.N. Pujianiki
I.N. Arya Thanaya
A.A. Diah Parami Dewi
I.N. Budiarsa
I.W. Widhiada
I.P. Agung Bayupati
I.N. Satya Kumara

Recent Decisions in
Technologies for Sustainable
Development

Selected, peer reviewed papers from the
3rd International Conference on

Sustainable Technology Development
(ICSTD 2014),
October 30-31, 2014, Bali, Indonesia

Edited by

A. Ghurri, N.P.G. Suardana, N. N. Pujianiki,
I. N. Arya Thanaya, A.A. Diah Parami Dewi,
I. N. Budiarsa, I. W. Widhiada,
I. P. Agung Bayupati and I.N. Satya Kumara

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Volume 776 of
Applied Mechanics and Materials
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Preface
This volume was selected from papers presented at the 3rd International Conference on

Sustainable Technology Development (ICSTD Bali 2014), which have been held in Udayana

University Bali during October 30-31, 2014. The conference was organized by Faculty of Engineering,

University of Udayana Bali Indonesia. This conference covered wide range of engineering issues
toward the achievement of sustainablility.

In order to meet high standard of Applied Mechanics and Materials, the organization committee


has made their efforts to do the following things. Firstly, all submitted papers have been reviewed by 2
anonymous expert reviewers, poor quality papers have been rejected after reviewing. Secondly,

periodically review meetings have been held around the reviewers about three times for exchanging
reviewing suggestions. Finally, the conference organization had several preliminary sessions before the

conference. Through efforts of the scientific committee and Editors team, the volume will be the best
collected papers.

We would like to thank the Faculty of Engineering, University of Udayana, the member of

organizing and scientific committees, and also to TTP publisher.

Editors
Ainul Ghurri

N.P.G. Suardana

Ni Nyoman Pujianiki


I Nyoman Arya Thanaya
A.A. Diah Parami Dewi
I Nyoman Budiarsa
I Wayan Widhiada

I Putu Agung Bayupati
I.N. Satya Kumara

Table of Contents
Preface

Chapter 1: Technologies of Sustainable Development in Civil
Engineering, Transportation and Urban Planning
Sustainable Development of Concrete Using GGBS: Effect of Curing Temperatures on the
Strength Development of Concrete
G. Turu'allo
Properties of Sand Sheet Asphalt Mixture Incorporating Waste Plastic
I.N.A. Thanaya, I.G.R. Purbanto and I.G. Wikarga
Asphalt Pavement Temperature Profile for Tropical Climate in Indonesia
I.M.A. Ariawan, B.S. Subagio and B.H. Setiadji

The Development of Slurry Seal Design with Ordinary Portland Cement Replacement by
Low Calcium Fly Ash
A. Setyawan, D. Sarwono and M.S. Adnan
The Structural Properties Assessment of Thin Hot Mixture Asphalt for Pavement
Preservation
A. Setyawan, A.H. Mustafa Elshawesh and S. As'ad
Mechanical Strength of Hydraulic Binder Made by Blending Type I Portland Cement and
Pozzolan
I.M.A.K. Salain
Laboratory Tests on Failure of Retaining Walls Caused by Sinusoidal Load
A.M. Hidayati, R.W. Sri Prabandiyani and I.W. Redana
Deformation Behavior of Concrete due to the Influence of the Steel Ring Width Variations
as the External Confinement
E. Safitri, I. Imran, Nuroji and S. Asa'ad
Evaluation of High Grade Recycled Coarse Aggregate Concrete Quality Using NonDestructive Testing Technique
N.N. Kencanawati, J. Fajrin, B. Anshari, Akmaluddin and M. Shigeishi
Experimental and Theoretical Investigation of Bolted Bamboo Joints without Void Filled
Material
G.M. Oka, A. Triwiyono, A. Awaludin and S. Siswosukarto
The Significant Importance to Measure Road Safety

S.A. Caroline
Accessibility to Location of Activities in Denpasar City, Bali-Indonesia
P.A. Suthanaya
Travel Time Estimation Based on Spot Speed with Instantaneous and Time Slice Model
A.M.H. Mahmudah, A. Budiarto and S.J. Legowo
Port Location Selection Model: Case Study of Tourism Sector in Bali
R.M.N. Budiartha, T. Achmadi and D. Manfaat
Determining Passenger Car Equivalent for Motorcycle at Mid-Block of Sesetan Road
I.G.R. Purbanto
Readiness Criteria: Indonesias New Initiative to Ensure Sustainable Development Program
A. Merthayasa
Conceptual Framework of Bidding Strategy in Order to Improve Construction Project
Performance
I.N.Y. Astana, H.A. Rusdi and M.A. Wibowo
The Conceptual Framework of Design Change Effects in Some Project Delivery Systems
A.A.G.A. Yana, H.A. Rusdi and M.A. Wibowo
An Identification of Construction Project Overheads for Sustainable Cost Management and
Controlling Practices (CMCPs)
N.M. Jaya and A. Frederika
Risk Analyses for Riau Regional Water Supply Projects (SPAM), Indonesia

A. Sandhyavitri

3
9
17
24
30
36
41
47
53
59
66
74
80
87
95
101
108
114

121
127

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Recent Decisions in Technologies for Sustainable Development

Modeling Discharge of the Bangga Watershed under Climate Change
I.W. Sutapa, M. Bisri, Rispiningtati and L. Montarcih
Water Resources Management of Subak Irrigation System in Bali
I.N. Norken, I.K. Suputra and I.G.N.K. Arsana
Study of the Evolution of Sanur Beach Nourishment Project for Beach Enhancement
I.G.B.S. Dharma and S.S. Efendi
Numerical Simulation of Breaking Waves in a Wave Group by SPH
N.N. Pujianiki
The Study on Bore Piles Foundation of the Reinforced Concrete Arch Bridge Beams of
Tukad Pekerisan and Tukad Penet
I.N. Sutarja and I.W. Wayan Redana
The Importance of the Physical Boundary Line onBali Coastal Tourist Resorts
A. Rajendra, N. Temple and R. Nicholls

Comparative Analysis of Traditional House at Taman Mini Indonesia Indah with Modern
House
S. Purnawan, I.W. Sukania and L. Widodo

133
139
145
151
157
163
169

Chapter 2: Materials and Technologies for a Sustainable Development
The Property and Applicability to Auto Industry of Natural Fiber Reinforced Composites
R.H. Hu, Z.G. Ma, S. Zheng, C.L. Zheng and A.J. Jiang
Fracture Parameters of Short Carbon Fiber Reinforced Polycarbonate Composite
Fabricated by Injection Molding Process
M.G. Hwang, G.H. Kim, H.J. Park, Y.G. Lee, C.M. Yang, J.K. Lim and H.Y. Kang
Effect of Polar Extract of Cocoa Peels Inhibitor on Mechanical Properties and
Microstructure of Mild Steel Exposed in Hydrocloric Acid

Gunawarman, Y. Yetri, Emriadi, N. Jamarun, Ken-Cho, M. Nakai and M. Niinomi
Hardness Distribution and Effective Case Depth of Low Carbon Steel after Pack
Carburizing Process under Different Carburizer
D.N.K.P. Negara, I.D.M.K. Muku, I.K.G. Sugita, I.M. Astika, I.W. Mustika and D.G.R. Prasetya
The Effect of Solidification on Acoustical of Tin Bronze 20Sn Alloy
I.K.G. Sugita and I.G.N. Priambadi
Morphological Analyses and Crystalline Structures of Anodic TiO2 Thin Film on Ti6Al4V
Alloy Using Phosphate and Calcium Containing Electrolyte under Different Voltage and
Calcium Molarity
I.N.G. Antara, K.I.M. Gatot, I.M. Budiana and D.K. Choi
Determination of Optimal Clinker Factor in Cement Production by Chemical Grinding
Aids Addition
T. Eryanto and E. Amrina
Wear of Carbon Steel (0.65%C) in Rolling-Sliding Contact with Creep Ratio
M. Widiyarta, T.G.T. Nindhia and H. Mudiastrawan
Hardness Prediction Based on P-h Curves and Inverse Material Parameters Estimation
I.N. Budiarsa
The Influence of Austenisation Temperature and Holding Time on Mechanical Properties,
Scale Thickness, and Microstructure in Alloy Steel
A. Aziz, M. Hidayat and I. Hardiyanti
Hardness, Density and Porosity of Al/(SiCw+Al2O3p) Composite by Powder Metallurgy
Process without and with Sintering
K. Suarsana and R. Soenoko
Development of Fiberglass Woven Roving Composite as an Alternative Material for the
Hull of Fishing Boat
Winarto, W. Eddy, R. Liza and H. Syamsul
Tensile Strength of Banana Fiber Reinforced Epoxy Composites Materials
A.P. Irawan and I.W. Sukania
Green Composites Based on Recycled Plastic Reinforced Local Sisal Fibers
N.P.G. Suardana, N.M. Suaniti and I.P. Lokantara
Cement Bonded Sol-Gel TiO2 Powder Photocatalysis for Phenol Removal
N. Hafizah and I. Sopyan

179
186
193
201
208
215
223
229
233
239
246
253
260
264
271

Applied Mechanics and Materials Vol. 776
Review on Zn-Based Alloys as Potential Biodegradable Medical Devices Materials
M.S. Dambatta, D. Kurniawan, S. Izman, B. Yahaya and H. Hermawan
Bone Implant Materials from Eggshell Waste
I. Sopyan
Boiling Phenomenon of Tabulate Biomaterial Wick Heat Pipe
W.N. Septiadi and N. Putra
Fluidization Characteristic of Sewage Sludge Particles
I.N.S. Winaya, R.S. Hartati and I.N.G. Sujana
Design of Fluidized Bed Co-Gasifier of Coal and Wastes Fuels
I.N.S. Winaya, R.S. Hartati, I.P. Lokantara, I.G. Subawa and I.M.A. Putrawan

c

277
282
289
294
300

Chapter 3: Advanced Decisions in Mechanical Engineering
Magnetic Camera and its Applications in Aging Aircraft, Express Train and Pipelines for
Green Technology
J.Y. Lee and J.M. Kim
Buckling Analysis on Pechiko Field of Fixed Offshore Platform in Makassar Strait
M.Z.M. Alie, Y.R. Palentek and D.G. Sesa
Simulation of a Differential-Drive Wheeled Mobile Lego Robot Mindstorms NXT
I.W. Widhiada, C.G.I. Partha and Y.A.P. Wayan Reza
Design and Simulation of Five Fingers Gripper for Dexterous Pick-Up Various of
Components
I.W. Widhiada, E. Pitowarno, C.G.I. Partha and Y.A.P. Wayan Reza
Tar Balls Collector for Mechanical Recovery in Combating Oil Spill on the Marine
Environment
C.P. Mahandari, M. Yamin and D.S.A. Asandi
Three Wheel Bike as Physical Therapy Equipment for Post-Stroke Patient
I.M.L. Batan, Rodika and M. Riva'i
Geometric Progression Application in Design Transmission Gear Ratio
A.A.I.A.S. Komaladewi, I.G.A.K. Suriadi and I.K.A. Atmika
Role of Risk Management in Effective Maintenance
H.A. Yuniarto and P.F. Paristiawati
Redesign Combustion Air Shelter of the Furnace to Improve the Performance in Melting
Bronze for Manufacturing Gamelan
I.G.N. Priambadi, I.K.G. Sugita, A.A.I.A.S. Komaladewi, K. Astawa and I.W.B. Adnyana
Model of Carbon Dioxide (CO2) Emission from Motorcycle to the Manufactures, Engine
Displacement, Service Life and Travel Speed
A.M. Mulyadi and S. Gunarta
Experimental Study of Heat Transfer Characteristics of Condensed Flow on the Vertical
Wave Plates
W.H. Piarah and Z. Djafar
Forces Analysis on a Spherical Shaped Delivery Valve of Hydram Pump
M. Suarda
The Influence of Distance Variation between Rings with Sloping Position on the Cylinder
Surface to Drag Coefficient
S.P.G.G. Tista, A. Ghurri and H. Wijaksana
Auto PID Tuning of Speed Control of DC Motor Using Particle Swarm Optimization Based
on FPGA
H. Tayara, D.J. Lee and K.T. Chong
Mobile Robot Motion Planning to Avoid Obstacle Using Modified Ant Colony Optimization
N. Habib, A. Soeprijanto, D. Purwanto and M.H. Purnomo
Mobile Robot Motion Control Using Laguerre-Based Model Predictive Control
M. Chipofya, D.J. Lee and K.T. Chong

Chapter 4: Application of Alternative Energy and Information
Technologies

309
313
319
325
331
337
343
349
355
361
371
377
384
390
396
403

d

Recent Decisions in Technologies for Sustainable Development

Experimental Investigation of Micro-Hydro Waterwheel Models to Determine Optimal
Efficiency
L. Jasa, A. Priyadi and M.H. Purnomo
Understanding Peak Average Power Ratio in VFFT-OFDM Systems
N.M.A.E.D. Wirastuti
Fusing Multiple Inexpensive GPS Heading Data via Fuzzified Ad-Hoc Weighing
F.P. Vista IV, D.J. Lee and K.T. Chong
Tree Data Structure Implementation in Android Base System of E-Ulambebantenan
A.A.K.O. Sudana and A.A.G. Brampramana Putra
Design and Implementation of Web-Based Geographic Information Systems on Mapping
Hindu s Temple
N. Piarsa and K. Adi Purnawan
Improving Biogas Quality through Circulated Water Scrubbing Method
H.S. Tira, Y.A. Padang, Mirmanto and Hendriono
Study on Solar Generating Apparatus for Solving Problem of Shadow
J.W. Chang, S.S. Kim, J.K. Lim and J.J. Lee
An Experimental Study on the Thickness of Stainless Steel as an Electrode in Alkaline Fuel
Cell
M. Sucipta, I.M. Suardamana, I.K.G. Sugita, M. Suarda and K. Astawa
Transient Thermal Efficiency of Natural Hybrid Dryer System on Chimney Height
Variation of Exhaust Moist Air
M.R. Murti and C.W. Park

413
419
425
431
437
443
449
455
461

Applied Mechanics and Materials Vol 776 (2015) pp 355-360
© (2015) Trans Tech Publications, Switzerland
doi:10.4028/www.scientific.net/AMM.776.355

Submitted: 2015-02-19
Accepted: 2015-04-10

Redesign combustion air shelter of the furnace to improve the
performance in melting bronze for manufacturing gamelan
I.G.N. Priambadi1,a, I Ketut Gede Sugita2,b, AAIA.Sri Komaladewi3,c,
Ketut Astawa4,d, I Wayan Bandem Adnyana5,e
Department of Mechanical Engineering Faculty of Engineering Udayana University
priambadi.ngurah@yahoo.com, bsgita_03@yahoo.com, ckomaladewijegeg@yahoo.co.id,
d
awatsa@yahoo.com,ebandem.aiwa@yahoo.com5

1,2,3,4,5

a

Keywords: Gamelan, furnace, pollutants, injectors

Abstract. Gamelan Bali is a set of Balinese traditional musical instruments used to accompany a
series of cultural and religious ceremonies or performances. The existence of gamelan has been
famous to foreign countries. Therefore, gamelan is not only produced for national orders but also
for international orders. Almost 75% of gamelan production process is done using traditional
method, namely: smelting, forging, grinding (Sruti) to get the basic tone, and assembly. Smelting
process uses traditional furnace, where combustion air is blown from the blower through the
injector into the combustion chamber of melting furnace. Open model furnace is used so that the
heat generated in the combustion of the fuel is not perfect and it consumes more fuel. This
condition, of course, impacts on pollutant factors produced in the combustion process and
production cost that is relatively high. To minimize that problem, a change in the combustion air
shelters form is done. The use of this method in the smelting process is expected to reduce the
production cost, especially in fuel use and to reduce pollutants produced in the combustion process.
Studies have shown that the application of the above method reduces the fuel consumption up to
20%. The decrease in the fuel consumption due to the fuel (charcoal) is wrapped by more air, thus it
makes the fuel combustion process work better.
Introduction
Bronze alloy smelting process in the manufacture of gamelan is an activity that determines
the quality of the resulting gamelan. This activity starts by manufacturing a composition consists of
copper (Cu) and tin (Sn). Gamelan craftsmen in this study usually make the alloy composition of
80% Cu and 20% Sn. Based on that composition the surface hardness was VHN 29.33 [1]. Bronze
material that has been smelted will be printed using an open mold according to the shape of the
gamelan instruments that is intended to be made. Wrought aims to condense the microstructure of
the bronze material. After the forging process, then the grinding process is performed to obtain the
basic tone. In the smelting process many obstacles were faced by artisans, such as smelting process
that takes a long time, the high consumption of fuel, and the dust flying in the workplace that is
quite disturbing. The research was done by redesigning the air reservoir so that the constraints
faced by the artisans can be reduced. Of course, redesign is not done to reduce the mechanical
strength of the alloy material that is being melted. This research shows that the melting time did not
significantly alter the mechanical properties of the material [2,3].
Research Methodology
Form of Furnace Design
Furnace design indirectly impacts on the smelting process. Conventional furnace design
which is commonly used by craftsmen is shown in Figure 1a, while the redesign is shown in Figure
1b. Part A is the position of the bowl (a bronze) at the mouth of the furnace at ground level. Part B

356

Recent Decisions in Technologies for Sustainable Development

is a shelter of the combustion air that flows through the air blower that is located under the ground
surface. The volume of combustion air shelter, a bronze alloy capacity, fuel capacity before and
after having the same volume. The fuel is wood charcoal (biomass). The capacity of the alloy
bronze bowl is 1.25 kg / bowl, the study used the 6 fruit bowl.

a. Before the redesign

a. After the redesign
Figure 1 Shape furnace

Specification:
1
= cup holder in the furnace mouth
2
= injector combustion air from the blower
3
= shelter combustion air
Red dots are the placement of the thermocouple probes to measure air temperature in the
air storage space. 4 channel thermocouples which were used in this study were equipped with a data
acquisition that has the capability of data collection at intervals of 70 milliseconds, the brand
National Instrument NI USB-9211 / 9211A. Combustion air flows through the blower with the
following specifications :
Table 1. Spesifications Blower

Spesification
Merk Elektrical Blower
made in China
The diameter of the output
(do)
The diameter of blade (ds)
Motor rotation (n)
Voltage (V)
Power (P)
Current flow (i)

size

Dimention

2
5,5
3000/3600
220
30
1,5

inch
inch
rpm
volt
Watt
Ampere

Data collection was conducted three times in different time and day. The data obtained in the form
of temperature data, the capacity of the fuel (biomass) consumption and the resulting production.
Design of air Shelter
The basis of calculation of the air reservoir design was done using the following equation:
The volume of the combustion air shelters is shown in Figure 2

Applied Mechanics and Materials Vol. 776

357

Figure 2 Shape of air reservoirs
Calculation is done using the following equation:

V airshelter

= V1

1
. l1 . t 1
3
1
=
. l2 . t 2
3

V2

V1 =
V2
so
V air

shelter

=

1
[( l1 . t1 )
3

(1)

(l 2

t 2 )]

where
l1 = surface area 1 (m2)
l2 = surface area 2 (m2)
t1 = great pyramid height 1 (m)
t2 = small pyramid height 2 (m)
Combustion Air Flow
The air that flows into the combustion chamber follows the ideal gas equation:
p . V = n . R .T

(2)

where
p = air pressure (N / m2)
V = volume of air (m3)
n = number of mole gas
R = general gas constan 8314 J/kmol K (0,082 L atm/mol K)
T = temperature (K)
Models as in Figure 1, where the flow of combustion air into the combustion chamber with the
pressure that is generated by the blower. Combustion air flows directly into the combustion
chamber and partly to the shelter to the air. The combustion air that flows into the shelter space will
receive energy in the form of heat transfer from the walls of the furnace so that the temperature
increasing. Hot air in the shelter flows into the combustion chamber together with the air from the
blower. Combustion air temperature is high enough to accelerate the melting process as well as to

358

Recent Decisions in Technologies for Sustainable Development

reduce fuel consumption [4]. Provision of adequate combustion air in the combustion process of
fuel can reduce emissions levels [5].
A number of Energy Transfer
Transfer of an amount of energy in the form of heat is caused by the heat of combustion of
the fuel in the furnace mouth into the air shelter. This energy transfer occurs by conduction,
convection and radiation.
The transfer of energy by conduction
The energy that will flow by conduction through the walls of the furnace which has a high
temperature to the wall air shelter is counted with the following equation [6]:
(3)
Qcon = K. A (T1 T2 ) / L
where
Qcon
= conduction heat flows from the mouth of the furnace into the air shelter walls made of
refractory bricks (W / m-2K-1)
K
= thermal conductivity of refractory bricks (Wm-1K-1)
A
= area of heat area (m2)
T1- T2 = temperature difference (K)
L
= height of the air space shelter, according the location of the thermocouple probe (m)
Transfer of a number of energy by convection
The amount of energy transfer by convection occurs on the walls of the shelter space to air
is calculated by using the following equation [7]:
Qconv = hch A(T1 T2 )
where
hch
= convection coefficient (W/m2K)
A
= area of contact with the walls of the shelter air space (m2)
T1
= temperature at the wall of the shelter room air (K)
T2
= temperature of the air storage space (K)

(4)

Transfer the amount of radiation energy
The amount of energy radiation transfer occurs because of the heat that occurred from the
mouth of the furnace into the air storage space is calculated with the following equation [8]:
Qrad =
where

T

( T ) 4 (kW )

(5)

= emission factor for material
= constan Bolzman (5,72.10-5 kWm-2K)
= difference in temperature (K)

Results and Discussion
Measurements on teperature distribution during the fuel burning were conducted by using
thermocouples. The measurements were recorded every 5 minutes from 7:00 until 12:00 Am. The
results can be seen on the following graphs:

Applied Mechanics and Materials Vol. 776

Figure 3 Temperature of the air shelter

359

Figure 4 Melting temperature

Figure 3 shows that the air that is in the air shelter receives a transfer of energy in the form
of heat from the furnace during the process of fuel combustion. This condition causes the
temperature of the air in the air shelter increased after the redesign. The results of the research that
has been conducted in which the temperature rise to give effect to the perfection of the process of
fuel burning charcoal. Existing air in the air shelter is functioning to increase the combustion air
requirements. Previous research states that the addition of combustion air temperature affects the
burning process [9].
Figure 4 shows the melting temperature increases significantly after redesign. This is
because the combustion air used in the combustion process already has a high temperature based on
Figure 1. Previous studies also suggested that the high temperature of combustion air causes the fuel
combustion process more quickly and produces high temperatures [10].

Figure 5 The use of wood charcool

Figure 6 Production

Figure 5 shows that the redesign gives significant effect to the reduction of fuel consumption
in the combustion process by 20%. This condition has an impact on the effectiveness of the
consumption of the fuel in the process melting of bronze alloy. The effectiveness of the fuel
consumption in the combustion process will have a significant influence on the thermal efficiency
of the furnace used [11].
Figure 6 shows the amount of increase in production generated in the smelting process
before and after redesign The graph shows a constant line which indicates that the span of the
melting process is underway, the rising line indicates the time of production. This research shows
that the development of technology-based redesign can increase production compare to the
conventional way [4].

360

Recent Decisions in Technologies for Sustainable Development

Conclusion
Based on the research that has been done, the redesign of the combustion air shelters provides
enough benefit to the performance of the furnace. That performance is significantly measured
during the process of fuel combustion that causes higher combustion temperatures. Fuel
consumption in the design has shown a decrease to 20%. In addition, smelting process of gamelan
production shows an increase.
References
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Sugita IKG., Priambadi, IGN dan Kusuma K. 2006. Experimental Study of Mixed
Composition Bronze Variations and Variation Charges Against Forging Close Fracture
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