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DRI Processmass Balance
DRI Processmass Balance
7.0. Introduction
Heat and mass balance plays a very important role to increase the
industry. In sponge iron production through coal based rotary kiln process
raw materials used are iron ore, coal and flux (lime stone or dolomite). In
i) . Given the composition of the charge put in the furnace, including their
weight what will be the amount and compositions of the resulting products
these products are mainly the metals, the slag and the gases.
ii) . Given the composition of various ores, fluxes and reducing agents
Finally third important step is the heat balance of the system i.e.
iii) . With given charge undergoing known reactions and yielding certain
products, what are the heat requirements, or how much heat is supplied or
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furnaces and processes for the purpose of estimating fuel requirements and
of the process.
lost, or distributed, the sum of the first set of items being equal to the sum
of the second set. In practice it is not possible to evaluate all items. In most
cases the heat lost by radiation, convection and conduction to the ground or
supports cannot be determined, and the difference between the total heat
supplied and the determined amount of heat distributed is then called heat
lost by radiation, convection and conduction, the two sides thus being
different processes. In general the source of heat entering may include the
following:
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i) . Heat of combustion of the fuel (or electric energy in case of electric
furnace)
viii) .Heat lost by convection to air in contact with furnace directly; but all
7.1 Calculation
7.1.1.Data used.
1) . Sponge iron produced : 12.54 TPH
2) . Iron ore used : 18.45 TPH
3) . Coal used
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a) . Feed end (F.E.) : 6.31 TPH
b) . Discharge end (D.E.) 6.51 TPH
c) . Back Spill 0.267 TPH
4). Dolomite 0.38 TPH
5). Char out 1.96 TPH
6). Fly ash going out with flue gas 2.23 TPH
n8
).
Temp, of the bed inside the kiln
Temp, of the solid discharged from
1067°C(1340K)
Heat values used for heat balance calculation (As per Janaf Table)
7.1.3.Mass Balance
""Unaccounted loss is
i) . In magnetic separation
ii) . In dust extraction system
iii) . In accretion inside the reactor.
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7.I.3.2. Carbon balance
Total: - = 1995.74
From ore = 18450 x .04251 = 784.43 Gangue in sponge iron = 12540 x .0462
= 579.35
Lost in flue dust = 205.08
Total: - = 784.43
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7.I.3.4. Coal ash balance
?oal ash in F.E. Coal = 6043 x . 178 Ash in char = 1960 x 0.7032 = 1378.3
= 1075.654. Ash flying dust = (2230x0.3392)-205.08
^oal ash in D.E. Coal = 6510 x .1596 = 551.336
= 1038.996 Ash to cooler free gangue loss and other
losses =(2114.65-1929.636)
= 185.014
7.1.4. L Reaction-1
Total FeiOa input = 1B450 x 0.6702.x 160/112 = 17664.557 Kg./hr
Fe203 lost in flying dust =2230x0.2898x160/112 = 923.22 Kg./hr
7.I.4.2. Reaction-2
FeO undergone reduction = 15048.72-FeO in sponge iron
= 15048 - 1468.4
= 13580.32 Kg./hr.
FeO + CO = Fe +C02
188.6 188.6 188.6 188.6
(moles) (moles) (moles) (moles)
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AH2—> 12174077.86 + 5145241.864 = 0 + 17800217.07
= 17319319.7- 17800217.07
=(-) 480897.346 k. Cal.
7.I.4.3. Reaction-3
Total C02 formed due to the reduction of iron oxides =
8298.4 + 4598 = 12896.4
(Ri) (R2)
This CO2 will combine with carbon to generate CO
co2 + C = 2CO
293.1 293.1 586.2
(moles) (moles) (moles)
7.1.4.4. Reaction-4
Excess CO for combustion
R3 - (Ri + R2)
16413.6 - (2926 + 5280.8) = 8206.8 Kg..
7.I.4.5. Reaction-5
Excess fixed carbon burnt = Net fixed Carbon input - Carbon consumed in
reduction reaction i.e. CO formation. — Carbon
lost in various ways
= 6137.978 - 3728.4 - (553.896 + 316.66 + 21.32 = 891.876)
= 1517.7 Kg.
C +O2 = C02
126.47 126.47 126.47
(moles) (moles) (moles)
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A H5 -► 5564.68 x (-) 2146.54 = (-) 11944975.15 k. Cal
7.I.4.6. Assumption:
the kiln
7.1.4.7.CaIculatiori
For C from discharge end (983.66 - 16.70) x 0.67 = 647.863 Kg.
Char
H2 from V.M of D.E. Coal (223.94 - 5.57) x 0.67 = 146.30 Kg.
Char
42% V.M.C burnt to C02 = (983.66 - 16.70) x 0.42 = 406.123 Kg.
25% V.M.C burnt to CO = (580.18 - 406.123) x 0.25 = 241.74 Kg.
7.1.4.8. Reaction-6,
a). C + 02 = C02
33.84 3.84 33.84
(moles) (moles) (moles)
406.12 1082.88 1488.96
(Kg.) (Kg.) (Kg.)
b). 2C + 02 = 2CO
20.145 10.07 20.145
(moles) (moles) (moles)
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A H6 (b) —> 0 + 0 - (564.06 x 974.33) =(-) 549580.6 k. Cal
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7.1.4.11. (b). Sensible heat lost in char and ash at 1325 K.
i) . Sensible heat lost through C in char
= 558.6 x 380.9 = 212770.74 k. Cal.
ii) . Sensible heat lost through V.M. in char
= 1960 x 0.0190 x 380.9 = 14184.72 k.cal
iii) . Sensible heat lost through Ash in char
= 1960x0.6960x271.875 = 370881.0 k. Cal
iv) . Sensible heat lost through free coal ash going to cooler
= (2114.65 - 1378.27 - 551.334) x 271.875
= 50309.38 k. Cal
C + 2H2 = CH4
(ix203.83) ofH2 = 67.943 Kg. ofH2 = 67.943x^ = 271.77Kg. of
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Table-7.1. Composition of Flue gas and its sensible heat
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7.4. Overall heat balance.
Heat input
a) . F.E. Coal = 6309.733 x 5325.80 = 33.6044 G.Cal
b) . D.E. Coal = 6510.000 x 5497.54 = 35.7890 G.Cal
HEAT BALANCE
Heat input in G.Cal Heat utilized in G.Cal
69.394 i). Heat utilized in kiln
= 36.1349
ii). Heat out in char
= 5.88
iii). Unaccounted loss
= 4.155
iv). Heat out by Unburnt
VMC + VMH2
= 19.9611
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v). Heat out by flue dust and
sponge iron
= 3.26043
40 526
Kiln efficiency = —1---- = 100 » 58%
69.394
7.5. Conclusion
The thermal efficiency of the of the rotary kiln used for the
fraction at the kiln discharge end and in the kiln waste gas. However in JSPL
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