30 2 > Material balances in metallurgical processe: of the total vessel volume. The charging operation is begun with the addition ol lime. The hot metal is transferred to the vessel, and then the scrap isadded. After charging, the vessel is moved into an upright position, and the lance is lowered into the vessel. The lance nozzle is 1 to 2 m above the bath level. Oxygen gas is blown onto the surface of the liquid at a very high velocity, The oxygen jet penetrates the slag layer and interacts with the liquid metal. The high-speed action and the general agitation of the bath result in the formation of a metal-slag emulsion that in turn causes rapid refining. The operation, or the blow, as it is called, lasts about 20 min. The removal of the impurities during the blow is -howr in Figure 2-3, The principal reactions are as follows: C + 40g) = CO(g) Si + Oxlg) = SiO2 ‘Mn + %O,(g) = MnO 2P + $0x(g) = P»Os CO(g) + 401g) = CO+(g) Fei) + 2OAg) = FeO ‘The italicized species are in a dissolved state; the elements are part of the liqui¢ metal, and the oxides are part of the slag. Not much sulfur is removed from the ixample 2-1, Pyrite, FeS:, is a naturally occurring mineral of iron and sulfur. If | ryrite is 93.6 wt% pure, with the remainder an inert clay, how many kilcgrams of sulfur: resent per ton of pyrite? If the pyrite is completely oxidized to Fe,O, and SO, what : fe amounts of these products per ton of pyrite? Consider 1 ton of impure pyrite as the basis. nass of FeS; mineral = 936 kg g-mole of FeS: contains 2 gatoms of sulfur nolecular weight of FeS = 119.85 19.85 kg of FeS; contains 2 x 32 kg of sulfur ow much sulfur is in 936 kg of FeS;? The amount of S present in the pyrite ore is 5001 The oxidation of pyrite can be represented as follows: FeS + 5.502 = FesO, + 450; * 119.85 159.7 159.7 x 936 imount of FeO, produced = ———— = 623.6 kg 2 x 119.85 256 x 936 amount of SO; produced = ————~ = 999.6 kg 2% 119.85 Example 2-2. [ron can be produced by the reduction of wustite, Feo sO, with cart nonoxide: Feq oO) + COlg) = 0.94Fe(s) + CO2(g)rrurncu cAurnpice on Caleulate the weight of wustite required and the volume of CO gas consumed to produce 1 ton of iron. From the foregoing chemical equation it is clear that to produce 0.94 x $5.85 kg of Fe, 68.499 kg of wustite and 1 kg-mole of CO gas are required. 68.499 1000 wustite required =~ = 1304.84; reduc’ 94 x 55.85 * One kilogram-mole of CO gas occupies 22.415 m* at STP. 22.415 x 1000 CO consumed = ————_—~ = 427 m* at STP 0.94 x 55.85 Example2-3. An iron blast furnace produced 2400 tons of pig iron per day. The analysis of the pig iron was 92.9% Fe, 4% C, 1.38% Si, 0.9% P, 0.8% Mn, and 0.02% S. The iron ore charged into the furnace contained 72.2% FeO}, 9.6% SiOz, 7.8% AlO;, 6.29% HO, 3.1% MnO, and 1.1% POs. The coke used contained 89% C, 8% SiO, 2% AlO3, and 1% FeS. The limestone flux was 96.5% CaCO) and 3.5% SiO,. The input rates of coke and limestone were 1800 and 1200 tons per day, respectively. Furthermore, 98.5% of all the iron entering the furnace was accounted for by pig iron. Determine (1) the input rate of ore and (2) the output rate and composition of the slag. Assume steady-state operation. For steady-state operation, the conservation of mass yields For iron, (ijn) (0.722)(111.7/159.7) + 18(55.85/87.85) ~ 2400(0.929/0.985) 50 (Wig), = input rate of fron ore = 4462 tonsiday a “The slag-forming constituents are Al,Os. CaO, CaS. FeO, MnO, POs, and SiO:. Al units are tons per day. total ALO; input to the furnace = 4462(0.078) + 18(2) = 384 All of this AlsOs is accounted for by the slag. total sulfur input to the furnace = 18(32/87.85) = 6.55 sulfur in the pig iron = 24(0.02) = 0.48 sulfur going into the slag = 6.07 CaS in the slag = 6.07(72/32) = 13.7 total CaO input to the furnace = 1200(0,965)(0.56) = 648.5 amount of CaO converted to CaS = 13.7(56/72) = 10.6 amount of CaO going into the slag = 637.9 amount of iron slagged off = 24(92.9)(1.5/98.5) — 34 amount of FeO going into the slag = 34(71.85/55.85) = 43.7 total Mn input to the furnace = 4462(0,031)(54.94/70.94) = 107.2 amount of Mn in the pig iron = 24(0.8) = 19.2 amount of MnO going into the slag ~ $8(70-94/54.94) = 113.6 total P:Os input to the furnace = 44.6201.1) = 49.1 total phosphorus input to the furnace = 49,1(62/142) = 21.6 Phosphorus output as a constituent of pigiron = 21.6 ‘Thus. no phosphorus enters the slag. total SiO; input to the furnace = 44.62(9.6) + 18(8) + 12(3.5) = 614.4 Si in the pig iron = 24(1.38) = 33.1* Example 2-4, The daily charge to an iron blast fumace consists of 3600 tons of hematite ore, 2000 tons of coke, and limestone flux sufficient to produce a slag containing35% SiO;. Ore: 74.4% Fe0s, 9.8% Si», 0.9% P2Os, 3.4% MnO2, 4.3% AlOs, and 7.2% H.0. Coke: 88% C, 8.5% SiO, 1.6% FeS, and 1.9% H,0. Limestone: 97.6% CaCOy, 0.8% lO. 1% SiO, and 0.6% HO. Pig iron contains 3.8% carbon. All of the phosphorus in the charge enters the pig iron, and so do. 40% of the manganese and 15% of the silicon in the charge. All of the sulfur and 1.2% of the iron in the charge are slagged off. The amount of blast per ton of coke charged is 3600 m? measured at 17°C and | atm. The blast is preheated to a final temperature of 771°C, and its steam content amounts to 5 pim?. Assuming steady-state operation, (1) prepare a charge balance, and (2) find the ‘compositions of pig iron, slag, and the top gas. In the following calculations, all weights are in tons, and all percentages are by weight, except where noted otherwise. For steady-state operation, equation (2-7) applies. In other words, input rate of Fe = output rate of Fe Fe in the hematite ore = 3600(0.744)(111.7/159.7) 2678(111.7/159.7) = 1872 32(55.85/87.85) = 20.3, 1872 + 20,3 = 19923 Fe as FeS in coke total Feinput to the furnace Of the total Fe, 1.2% is slagged off as FeO. amount of Fe slagged off = 1.2(18.923) = 22.7 amount of FeO in the slag = 22.7(71.85/55.85) = 29.2 amountof Fe entering pig iron = 1869.6 total P input to the furnace = 32.4(62/142) = 14.2 No phosphorus enters the slag. amount of P entering pig iron = 14.2 {otal Mn input to the furnace = 122.4(54.94/86.98) = 77.4 ‘OF this total amount, 40% enters pig iron. amount of Mn entering pig iron = 77.4(0.4) = 31 amount of Mn going intothe slag = 46.4 amount of MnO iin the slag = 46.4(70.9954.94) = 59.9 ‘The amount of flux used is computed as follows. Gy, in tons per day, denotes the input rate of flux to the furnace. total SiO, input to the furnace = 525 + 0.016, total Si input to the furnace = (523 + 0.01G;)(28.1/60.1) OF this silicon, 85% enters slag as SiO amount of SiO; going into the slag = 444.5 + 0.0085C, ‘The other components in the slag, besides SiO, are Al;Os, CaO, CaS, FeO, and MnO. total CaO input to the furnace = G,(0.976)(0.56) = 0.54666,Worked examples 33 OF this CaO, # small portion is converted to CaS. total $ input to the furnace ~ 32(32/87.85) = 11.7 None of this sulfur enters pig iron and all of itis converted to CaS. amount of CaS going into the slag = 11.7(72/32) = 26.3, amount of CaO converted to CaS = 26.3(56/72) = 20.5 amount of CaO going into stag = 0.54666, ~ 20.5 amount of AlzO; going into slag = 154.8 + 0.0086, amount of slag formed = Al,0; + CaO + CaS + FeO + MnO + SiO; total amount of slag ~ 694.2 + 0.5631G, Because SiO; constitutes 35% of the slag, we have 444.5 + 0.00856, = 0.35(694.2 + 0.56316) input rate of the flux = 1070 amount of CaO going into slag = 564.0 amount of SiO, going into slag = 453.6 amount of SiO, reduced to Si = 80. amount of Si entering pig iron ~ 80.1(28.160.1) = 37.4 163.4 ‘We now calculate the amount of carbon entering pig iron; denote this quantity by q. total massof pigiron = 19522 +4 q = 0.038(1952.2 + q) Solving for q, we find q ~ amount of carbon entering pig iron = 77.1 Blast calculations total amount of blast = 3600(2000) = 7.2 x 10° m? volume of preheated blast = (7.2 x 10°)(1044/290) = 25.92 x 10° m? ‘steam content = (25.92 x 10°\(5 x 10°*) = 129.6 tons In 1 m' of prebeated blast: mass of H;O = 5 g, mio = (5/18) g-mole,V = 1000 liters For ideally behaving water vapor, Py,oV = my,oRT, where T = 1044°K Pu,o = (5/18)(0.08206)(1044/1000) = 0.0238 atm = 18.1 mm Dry air contains 21 mol% Q,, 78 mol% No, and 1 mol% Ar. Therefore, Po, = (760 ~ 18.10.21) = 155.8 mm; Py, = 578.7 mm; Pa, = 7.4mm Using the ideal-gas law, we can find no, = 2.392 g-moles, nx, = 8.884 g-moles, a, = 0.114 g-mole In the preheated blast: kilogram-moles of O2 = (25.92 x 10°)(2.392 x 10") = 62.07 x 10°kilogram-moles of Np = (25.92 10°)(8.884 x 107%) = 23.04 x 10* kilogram-moles of Ar = (25.92 x 10°)(0.114 x 10") = 2.954 x 10? mass of oxygen in the blast = (62.07 x 32) = 1986 tons ‘mass of nitrogen and argon’ in the blast = 6571 tons mass of moist blast (inclusive of steam) = 8686.6 tons Oxygen from the solids in the charge oxygen entering the furnace as Fe,Os = 2678(48/159.7) = 804.6 ‘oxygen ticd up in the FeO of slag — 29.2(16/71.85) ~ 6.5 oxygen of Fe;Os going into gases = 798.1 oxygen of P:0s going into gases = 32.4(80/142) = 18.3, ‘oxygen entering the furnace as MnO. = 122.4(32/86.94) = 45.1 ‘oxygen tied up with MnO of slag = 59.9(16/70.94) = 13.5 oxygen of MnO; going into gases = 49.1 - 13.5 = 31.6 amount of SiO» reduced to metal = 80.1 otygen of reduced SiO: going into gases = 80.1(32/60.1) = 42.6 conygen from CaQ-rCeS conversion going into gases — 5.8 Oxygen from the gases fed 10 the furnace ‘onygen from the water vapor in the blast 129.6(16/18) = 115.2 tons Combustion of carbon at the tuyeres amount ofcarbon charged into the furnace = 1760 amount of carbon going into pig iron = 77.1 mass of carbon bumed at the tuyeres = 1682.9 mass of oxygen available for combustion = 2997.6 The combustion of coke produces CO gas, a portion of which is subsequently oxidizedmass of oxygen required by C-+CO conversion = 1682.9(16/12) ‘mass of oxygen in excessof that required for CO formation ~ 753.7 tons mass of CO formed at tuyeres = 3926.8 tons mass of CO oxidized to CO> gas = 753.7(28/16) = 1319 net amount of CO gas formed = 3926.8 ~ 1319 = 2607.8 amount of CO; gas formed by oxidation of CO gas = 2072.7 amount of CO: gas released by calcination of limestone = 1048.3(44/100) = 460.1 net amount of CO gas formed = 2532.8 ‘net amount of hydrogen formed = 129.6 ~ 115.2 = 14.4 net amount of water vapor in top gas = 303.6 net amount of nitrogen in top gas = 6571 2283.9 Conversion of these masses into kilogram-moles is carried out: kilogram-moles of CO gas 93.13 x 10° kilogram-moles of CO, gas . 57.55 x 10° kilogram-moles of Hz gas = (14.472)(10") = 7.20 x 10° kilogram-moles of H:O gas = (3(3.6/18)(10") = 16.87 x 10° kilogram-moles of Nz gas = (6571/28)(10") = 234.7 x 10° ‘The complete charge balance is given in Table 2~3. The compositions of pig iron, slag, and the top (blast-furnace) gas are computed as follows: Table 2-3. Charge balance (in tonsiday)* Liquids output Input Pig iron Slag Gases output Solids Ore: 3600 FeO; 2678 Fe 1849.3 FeO 29.2 0 798.1 SiO, 353 Si 37.4 SiO, 272.9 0426 P05 324 142 = 0183 MnO; 122.4 Mn 31.0 MnO 59.9 O16 ‘Aly 154.8 = AL, 154.8 H,0 2592, - - 1,0 259.2 Coke: 2000 C1760 cm - C 1682.9 SiO; 170 = SiO, 170 FeS 32 Fe 20.3 SU7 H,O 38 - - HO 38 Flux: 1070 CaCO, 1044.3 - CaO 564.0; )> 460.1; CaasCaS 14.6 O fromCa05.8 ALO5 86 - ALO; 86 SiO, 10.7 - SiO, 10.7 H,064 - - 1,0 64Gases Blast: 8686.6 “The charge balance developed here follows the approach of Butts (reference 10). fon (wt. %) Slag (wt.%) Top gas (vol.%) Fe 1869.6(92.15%) AlsOs 163.4 (12.61%) CO (22.74%) C 77.1 (3.80%) CaO 564.0 (43.51%) CO(14.06%) Mn 31.0 (1.51%) CaS_——-26.3 (2.03%) Hy (1.76%) P= 14.2 (0.70%) FeO 29.2 (2.25%) “HO (4.12%) Si 37.4 (1.84%) — MnO 59.9 (4.62%) Nz (57.32%) SiO, 453.6 (35.00%) ‘*Example 2-5. The daily charge to an iron blast furnace consisted of the following. Alll percentages are by weight. Pellets: 2400 tons 86% Fe;0}, 9% SiO2, 0.6% CaO, 0.5% AhOs, 0.4% FeO, 0.4% MgO, 0.25% MnO, 0.04% POs, 0.01% FeS, 2.8% H,0 Sinter: 2400 tons 66% Fe,Oy, 14% FeO, 85% SiO;, 6% CaO, 2% AlO,, 1% MgO, 0.75% MnO, 0.1% P2Os, 0.05% FeS, 1.6% H,O Flaxes Limestone: 315 tons 96.5% CaCOs, 1.8% MgCOs, 0.7% Fez0s, 0.5% AlLOs, 0.5% SiO, Dolomite: 375 tons 54.6% CaCOs, 43.8% MgCOy, 0.6% Fez0s, 0.5% SiOz, 0.5% Al0s Fuel Coke: 1875 tons 87% C, 3.5% SiOz, 2.5% AlzOs, 1.5% FeS, 0.4% CaO, 0.1% MgO, 5% H,0 ‘The amount of blast supplied to the tuyeres was 5.85 x 10° m'/day measured at 37°C and atm. The moisture content was 30 g/m? of nonpreheated blast. The solid particles carried away by the upward-moving gases were collected in the dust catchers. This flue dust amounted to 65 tons/day and contained the following: 60% Fe,Os, 18.5% C, 8.5% CaCOs, 8% SiOz, 3.5% MgCOs, 1.5% ALOs lithe phosphorus charged, one-half of the Mn, one-seventhof the Si, andone-tenth of the sulfur entered the pig iron, which also contained 93.5% Fe. Assume that no iron was lost in the slag. The blast-furnace operation was at steady state. (1) Prepare a charge balance. (2) Find the amounts and compositions of pig iron, slag, and top gases. (3) Find the fraction of carbon in the coke burned at the tuyeres. ‘Mass balance for tron (tons/day) input as pellets = 2064(111.7/159.7) + 9.6(55.85/71.85) + 0.24(55.85/87.85) = 1450.9input as sinter = 1584(111.7/159.7) + 336(55.85/71.85) + 1.2(55.85/87.85) = 1369.9 input with fluxes = 4.9(111.7159.7) = 3.4 input with coke = 28.2(55.85/87.85) = 17.9 output with fluedust = 39(111.7/159.7) = 27.3 output with pig iron = 2814.8 amount of pig iron = 2814.80.935 = 3010 Mass balance for phosphorus (tonsiday) input with pellets = 0.96(62/142) = 0.42 input with sinter = 2.4(62/142) = 1.10 output with pig iron = 1.52 Mass balance for manganese (tonsiday) input with pellets = 6(54.94/70.94) = 4.6 input with sinter = 18(54.94710.94) = 14 total input of Mn = 18.6 amount of Mn entering pig iron = 9.3 amount of MnO going into the slag = 9.3(70.94/54.94) = 12 ‘Mass balance for silicon (tons/day) SiO; input with pette ‘SiO; input with sinter 2400(9/100) = 216 2400(8.5/100) = 204 vorkea examples ‘SiO, input with fluxes = 375(1/100) = 3.7 SiOz input with coke = 1875(3.5/100) = 65.7 total input of SiQ; to the furnace = 489.4 amount of Si entering pig iron = (1/7)(489.4)(28.1/60.1) = 32.9 amount of SiO. going into flue dust = 65(8/100) = 5.2 amount of SiO; going into slag = 413.7 Mass balance for sulfur (sonsiday) input with pellets = 0.24(32/87.85) = 0.09 input with sinter = 1.20(32/87.85) = 0.44 input with coke = 28.2(32/87.85) = 10.25 ‘output with pig iron = 1.08 sulfur entering theslagasCaS = 9.7 Mass balance for carbon (tons/day) input of carbon with coke = 1631 output of carbon with flue dust = 65(18.5/100) = 12 ‘output with pig iron = 3010 — (Fe + P + Mn + Si + S) = 150.5 output of carbon with gases = 1468.5,input of oxygen with Fe.0, of pellets = (2064 - 39)(48/159.7) = 609 input of oxygen with FeO of pellets = 9.6(16/71.85) = 2.1 input of oxygen with FeyO, of sinter = 1584(48/159.7) = 476 input of oxygen with FeO of sinter = 336(16/71.85) = 75 iput of oxygen from the SiO» reduction = 32.9(32/28.1) = 37.5 rput of oxygen from the MnO reduction = 9.3(16/54.94) = 2.8 iput of oxygen from the PQs reduction = 1.52(80/62) = 1.8 iput of oxygenfrom CaO» CaS conversion = 9.7(1632) = 4.8 total input of oxygen from solids = 1210.5 tons/day last calculations on a daily basis volume of moist blast = 5.85 x 10° m’day mass of moisture in the blast = (5.85 x 10°)(30 x 10™*) = 175.5 tom nlume of | kg-mole of H,O(e) at STP = 22.4 m* plume of 1 kg-mole of Hz0(g) at 37°C = 22.4(310/273) = 25.43 m* slume of 175.5tonsof moisture at 37°C = (175.5 x 10°)(25.43/18) 0.248 x 10° mivday olume of dry blast at 37°C and 1 atm = 5.602 x 108 m'iday volume of dry blast at STP = (5.602 x 10°)(273/310) = 4.934 x 10 STP, 1m? of dry air weighs 1.293 kg. mass of the dry blast = 1.293(4934) = 6380 tons ass of oxygen in the dry blast = 0.232(6380) = 1480 tons vase of nitrogen in the dry blast = 0.768(6380) = 4900 rons mass of the moist blast = 6380 + 175.5 = 6555.5 tons Joke reacts with the HO(g) of the wet blast. ‘oxygen from the H;O(g) in the blast = 175.5(16/18) = 156 tons hydrogen from the H;O(g) in the blast = 175.5(2/18) = 19.5 tonswe 6 areeeec tuk UMMSArHLES ene rrctuaeeND eCuE pre LEE: oxygen input with the moist blast = 1480 + 156 = 1636 tons total input of oxygen = 1636 + 1210.5 = 2846.5 tons oxygen required by C--CO combustion = 1468.5(16/12) = 1958 tons oxygen in excess of combustion requirements = 888.5 tons amount of CO formed by combustion at the tuyeres = 3426.5 tons The excess oxygen oxidizes some af this CO to CO; amount of CO oxidized to CO; = 888.5(28/16) = 1555 tons ‘amount of CO remaining = /871.5 tons amount of COs produced by oxidation amount of CO; released by decomposing solids total amount of CO, produced ‘The charge balance is shown in Table 2-4. The following are the amounts and com ‘positions of pig iron, slag, and top gases (see p. 39): Solids Pigeleontap put output Pig iron Slag Gases out Aids ets: 2400 Flue dust: 65 Fe.Q, 2064 F039 Fe 1416 - 0 609 SiO, 216 SiO,52 $132.9 SiO; 140.4 os Cad 14.4 = - CaO 14.4 — AlzOy 12 ALO, 10 — Aly 1 ~ FeO 9.6 - Fes - out MgO 9.6 - = Mz09.6 _ MnO 6.0 - Mn 4:6 - O14 20s 0.96 = Po.42 = Oost Fes 0.24 - Fe0.15;$0.09 — = H,0 67.2 - - - H,0 67.2 nter: 2400 Fe:03 1584 — Fe 1108. = 0476 FeO 336 = Fe 261 = O75 SiO, 204 - - SiO; 204 = C20 144 - - Ca as CaS 12.1; OfromCa a0 127.1 AlO3 48 - = AlO, 48 - MgO 24 - - ‘MgO 24 - MnO 18 = Mn 4.7 MnO 12 ola P05 2.4 = PL = 013 FeS 1.2 - .76;S0.44 — H,0 384 = — = H,0 38.4 waxes mestone: 375 CaCO; 362 CACO. — CaO 199.6 CO; 156.5 MgCO; 6.8 — MgCO32.3 MgO 2.2 CO; 2.3 Fe,0, 2.6 = Fe 18 O08Worked examples 39 Table 2-4. (Continued) Soli Liquids output _ Input output Slag Gases output ‘AL Os 1.8 - = ALO; 18 - SiOz 1.8 = = SiO; 18 - Dolomite: 375 CaCO; 204.7 — - CaO 114.7 CO, 90 MgCO, 164.4 — Mg0 78.5 CO, 85.9 Fe,05 2.3 - Fe 1.6 = 007 SiOz 1.8 = SiOp 1.8 - ‘AbOs 1.8 - ALO, 18 - Coke: 1875 C1631 cr C1505 = 1468.5 SiO, 65.7 - = SiO, 65.7 = AlO3 46.9 - - A203 46.9 = Fes 28.2 - Fe 17.90.55 SasCas97 0 — C20 7.5 - - Ca0 7.5 = MgO 1.9 - MgO 1.9 — H,0 93.8 = = H,0 93.8 Gases Blast: 6555.5 0 1480 - - - 0 1480 N 4900 - - - N 4900 H,0 175.5, = = = 0156; H 19.5 iron (3010 tons/day) Slag (1136.5 tons/day) Fe 2814.8 93.50% ‘ALO, 109.5 9.63% C 150.5 5.00% CxO 463.3 40.76% Si 32.9 1.09% CoS 21.8 1.92% Mn 9.3 030% MgO 116.2 10.23% P 152 005% MnO 12.0 1.06% S 1.08 0.035% SiO, 413.7 36.40% Top gases (9769 tons/day) kilogram-moles___volume-percent CO 18715 19.16% 66.84 x 10° 20.52 CO, 2778.6 28.44% 63.15 x 10° 19.38 Hy; 195 0.20% 9.75 x 10° 3.00 HO 194 2.04% 11.08 x 10° 3.40 N; 49000 50.16% 175.00 x 10" 93.70 To determine the fraction of carbon in the coke burned at the tuyeres we note that the consumption of carbon at the tuyere level proceeds in accordance with the following, chemical equations:C +050; = CO 2 6 C+H,O =CO+H 2B 40 2. Material balances in metallurgical processes carbon reacting with the oxygen of the blast = 1480(12/16) = 1110 tons/day carbon reacting with the water vaporof the blast = 175.5(12/18) = 117.0 tons/day total carbon in the coke = 1631 tons/day fraction of carbon burned at the tuyeres = 1227.0'1631 = 0.7520 4 2 Matertat balances in metallurgical processe. ample 2-7. The conversion of copper matte into blister copper is carried out in 2 Fee-Smith converter by blowing air through tuycres submerged in the molten matte. Determine the theoretical air requirements for conversion as a function of matte de, (2) Assuming 265% blowing efficiency, find the percentage of SO: in the off-gases, 2 as a function of matte grade. The matte grade is the weight-percent of Cu in the matte adjusted for silica, lime, mina, and magnetite. As an illustration, we can evaluate the matte grade.in the previous imple: Quin the matte unadjusted = 41 ‘@SiQ) in the matte = 1,01 CaO in the mate = 0.51 %A1,0) in the matie = 0.43 2 as FesO, in the matte = 1.05 Fe as Fe,O, in the matte = 1.05(167.55/64) = 2.75 adjustment to be made = 5.75% matte grade = 41/0.9425 = 43.50 wt.% Cu = blowing efficiency is the ratio of the oxygen that combines with the iran and sulfur the matte to the total oxygen supplied to the converter. 1) Let q in weight-percent Cu denote the matte grade. The matte is composed of Fes 1 Cus. ight-percent ofS present as CusS = 9(32/127.08) = 0.25189 ‘weight-percent of FeS = 100 — g — 0.25189 = 100 ~ 1.2518q weight-percent of Cuz8 = 1,2518q 100 tons of matte, there are 3: 100 ~ 1.25184 tons = 1138.4 ~ 14.25q kg-moles CHS 1 981k tone = 7 87a ke-maleeAap: 1.c98ng tons = 1.e4g KE MOIS The oxidation of iron and sulfur can be represented as follows: Fe§ + 1.50; = FeO + 80, CuyS + 0; = 2Cu + $0, amount of O; required by FeS = 1707.6 - 21.38q kg-moles amount of ©; required by Cu,8 = 7.87q kg-moles total amount of O; required = 1707.6 ~ 13.51y kg:moles. tntal amount aie ranuinad = WY A hd Me bemola theoretical requirement of air = (182,143 ~ 1441q)/q ‘The units are cubic meters per metric ton of Cu at STP. The result is shown graphic in Figure 2-6. (2) The basis of calculations is 100 tons of matte. The amounts of all gases are expre: in kilogram-moles. blowing efficiency = 65% amount of air supplied = (8131.4 ~ 64.334)/0.65 = 12.510 — 99 excess air = 4378.6 ~ 34.67q amount of N3 in the off-gases = (12,510 ~ 999)(0.79) = 9882.9 - 78.2g amount of O; in the off-gases = (4378.6 ~ 34.679)(0.21) = 919.5 — 7.287‘orked examples gure 2-6. Theoretical air ‘quirement as a function matte grade, gure 27. Percentage Oy off-gascs as a function of atte grade 5 S = & E 2 36 a 36 cs) Mote grade —» 50: ne Ot1-Gases —» co 30 20 3 wo Marte Grade ——s+ charge was blown with oxygen (98 wt.% pure) that was metered in at the rate of ton/min. The blow oxidized all of the C. Si, Mn, and P. as well as Fe amounting 1 wt.% Of the hot metal. All of the FeO thus formed was reported in the slag. The escontained CO and CQ; in the proportion of 9:1. Assume that enough lime (CaQ) was led to form a stag analyzing 38 wt.% CaO. Calculate (a) the amount of oxygen used, the time of blowing, and (c) the weight and composition of the slag made. The terial streams are indicated below: ut Output tmetal ‘Refined metal ap Slag veen Gases “he reactions occurring in the furnace can be represented as follows: idation of carbow + XQ, = XCO + X,CO; cause the COCO; proportion in the product gases is given as being equal to 9/1, have = OX, ap sm balance with respect to carbon yields Xp +X 2 om balance with respect to oxygen yields =X, + 2Xy @ uations (1), (2), and (3) are solved by the conventional Gauss method: = 0.1, ¥2=0.9, X= 0.55 2 carbon oxidation reaction thus becomes + 0.550; = 0.9C0 + 0.160; ) Fun = amy wr idation of manganese + 40; = MnO (6) idation of phosphorus + 520, = PO, qa) idation of tron +40; = FeO @) ‘ss of carbon present in the change = 8.44 tons amount of pure O; requited = (8.64/12.01)(0.55} = 0.3865 ton-moles nass of silicon present in the charge = 3.0 amount of pure Oy required = (3/28.09)(1) 10682 Matertat balances in metauurgucat processe. amount of pure Oz required = (1.6/54,94)(0.5) = 0.01456 mass of phosphorus removed = 0.8 amount of pure QO; consumed = (0.8/62)(2.5) = 0.03226 mass of Fe oxidized = 8 amount of pure Oz consumed = (8'55.85)(0.5) = 0.07162 total O> (pure) required = 0.61175 wmmercial oxygen used in this case had 98 wt.% purity, This is equivalent to 97.7; ale Or, tount of oxygen needed = 0.6260 ton-male ‘we assume that the commercially pure oxygen contained 2% by adily calculate its molecular weight. Wt Nz, we cat lecular weight of commercialoxygen = 31.92 ‘mass of commercial O; supplied = 19.982 tons @ ve oxygen was blown in at the rate of 1.0 ton/min. Thus. ae of blowing = 19.982 min cy ve slag consists of CaO, SiO. MnO, P:Os, and FeO. We can calculate the masses 0 ese by means of the stoichiometric equations (5) through (8): 15 of SiOz produced = (3/28.09)(60.09) = 6.4176 ss ofMnO produced = (1.6/54.94)(70.94) = 2.0660 sss of POs produced = (0,8/62)(142) = 1.8323 185 of FeO produced = (8/55,85)(71.85) = 10,2919 Ly denote the mass of linie (CaO) added. reentage of lime in the slag = 38 = (yislag)100 ass of slag = 20.6078 + y once, = 0.38(20.6078 + y) andy = ass of slag = 33.2384 tons « ‘omponent —_mass(tons)__weight-percent, 320 12.6306 38.00 iO; 6.4176 19.31 in 2.0660 6.22 20s 1.8323 20 10,2919 ‘oral 33,2384 100.00 ROBLEMS =: Wustite (FeO) is directly reduced to metallic iron by solid carbon, The stiochiometr [the reaction is 20 + ZC = Fe + (22 - 1)CO + (1 - 2)CO; he product gases analyze 75 val.% CO and 25 vol.% COs. Compute (a) the value of 5 ad (b) the amount of carbon required to produce 1 ton of iron,