MME449Fer

rousPr
oduct
ionMet
all
urgy
Mat
eri
alsBal
ancei
ntheBessemerSt
eel
maki
ngPr
ocesses

Pr
obl
em 1
AnacidBessemerconv ert
erblows20met ri
ctonsoft hefol
lowingpigiron:C=4.0,Mn=1. 2,Si
=1.4,Fe=93. 4%.Besi destheimpur i
ti
esthereisoxidisedi
ronequivalentto1.5%ofthepi
g;
assumet hei
ronoxidisedatauni formrate.Three-
fourthsofthecarbongoest oCOandone-
3
fourt
htoCO2.Thebl astsuppliedataconst antrat
eof600m permi nute,measur
edatthe
standar
dconditi
ons( 1atm, 273K) .
Requi
red:
1.Thet ot
alvolumeofairused
2.Thet i
meofeachoft hetwoperi
odsofbl
ow
3.Thewei ghtandper
centagecomposi
ti
onofthesl
ag

Sol
uti
on

Basi
s:20,
000kgpi
gir
on

Si =280kg Si+O2=Si
O2 O=280x( 32/28)=320kg
Mn =240 Mn+O=MnO O=240x( 16/55)=70
C CO =600 C+O=CO O=600x( 16/12)=800
C CO2 =200 C+O2=CO2 O=200x( 32/12)=534
Fe =300 Fe+O=FeO O=300x( 16/56)=86
-
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
-
TotalOrequir
ed=1810kg

Vol
umeofai
rrequi
red=(
1810kgO)x( 4m3/32kg)x(
22. 21)=6040m3atSTP [
100/ 1]

Osuppl
i
edpermi
nut 600m3ai
e=( r)x(
1. m3)x(
293kg/ 23.
2/100)=180kg

I
naci
dBessemerprocess,t
woper i
odsofblowcanbeident
if
ied.Dur
ingt
hef
ir
stper
iod,
Siand
Mnar
eoxidi
sedandduringthesecondperi
od,al
lcar
bonisoxidi
sed.

Ti
mef
or1stper
iod(
wit
houtFe)=(320+70)
/180=2.
17min
Ti
mef
or2ndperi
od(wi
thoutFe)=(
800+534)/
180=7.41min
Ti
meforFe=86/
180=0.48min,
tobedi
vi
dedbet
weent
hef
ir
standt
hesecondper
iodsi
n
pr
opor
ti
ontot
het
imeabove.
Tot
alt
imef
or1stper
iod=2.
17+0.48x2.
17/(
2.17+7.
41)=2.28mi
n
Tot
alt
imef
or2ndperi
od=7.41+0.
48x7.41/
(2.
17+7.41)=7.
78min [
2]

Slagcomposi ti
on:
SiO2=280+320=600kg =46. 3%
MnO=240+70=310 =23.9
FeO=300+86=386 =29.8
--
---
--
--
--
---
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
Totalsl
ag=1296kg =100% [
3]

Page1of4
Pr
obl
em 2

AnacidlinedBessemerconvert
erbl
ows15t onsofpigi
ronin12min.Thefoll
owingimpuri
ti
es
areoxidi
sed:C=4. 0,
Si=1.8,Mn=0.8%.Al so,3%oftheir
onisoxi
dised.Assumethatir
onis
oxidi
sedatauniformrat
eandt hatt
hree-
fourthsofthecar
bongoestoCO, one-
fourt
htoCO2.
Requi
red:
1.Vol
umeofairr
equi
red
2.Thel
engt
hofthetwoper
iodsoft
hebl
ow.
3.Thewei
ghtoft
heslagmade.

Pr
obl
em 3

ABessemerconvert
erischar
gedwi t
h18metri
ctonsofpigi
ronfrom whichthefoll
owi
ng
i
mpurit
iesar
eoxidi
sed:C=4. 2,Si=1.5,
Mn=0.7%.Enoughironisalsooxidi
sedtomake24%
FeOi
nt hesl
ag.Assumethatir
onisoxidi
sedatauni
for
mr at
e.Ther at
ioofCOt oCO2is3:
1.The
bl
owingengi
nessupplyperminute510m3ofair,
measuredatstandardcondit
ions.
Requi
red:
1.Theti
meofeachoft het
woper i
odsofthebl
ow
2.Theweightoft
heslag
3.Thepercent
agecomposi
tionofthegasesi
neachper
iod.

Pr
obl
em 4

Achargeof10,
000kgpigir
onisbl
owninaBessemerconvert
er,
giv
ing527kgofsl
agofthe
fol
l
owingcomposi
ti
on:SiO2=65.
5,MnO=13.5,FeO=21%.Thegasesf r
om t
heconver
ter
amountsto2760m3andcarryCO2=6.
0,CO=18.1,N2=75.9%.
Requi
red:
1.Thecomposi t
ionofthepigir
onused
2.Theyieldofpureir
onleftaf
terthebl ow
3.Thecubicmet reofai
rrequi
redf ortheent
ir
eblow
4 Therelati
veti
meoccupi edbythet woperi
ods.

Pr
obl
em 5

ABessemerconv ert
erblowslow- sil
i
conhi ghmanganesepi gi
ronunti
lthesteel
remaincert
ain
C,SiandMni nit:
Pigiron: C=4. 36,Si =0.95,Mn=2. 98,P=0. 02,Fe=91. 69%
Steel: C=0. 74,Si =0.04,Mn=0. 25%
Slag: SiO2=47. 25,MnO=37. 80,FeO=9. 45,Al 2O3=4.22,MgO=0. 40,
P2O5=None,CaO=0. 88%
Thechar gei
s20met ri
ctonsandt heweightoft hesteelis18,
400kg.Nof l
uxisadded,butt
here
i
scorr osi
onfr
om t heconvert
erlining.Thel i
ningcontainsnomanganese.
Requi
red:
1.Theper
cent
ager
emov
alofeachoft
hei
mpur
it
ies

Page2of4
2.Theper
cent
agecomposi
ti
onoft
hel
i
ning
Pr
obl
em 6

ABessemerconv ert
er,l
inedwi t
hbasicmat er
ial
, i
schargedwith20t onsofpigir
onoft he
foll
owi ngcomposi t
ion:Fe=91. 2%,C=3. 6%,Si=1. 7%,
Mn=1. 1%,P=2. 4%.Theblowoxidises
alltheC, Si
,Mn, andPandal soFeamount i
ngt o5.6%oft hepigi
ron.Assumet hattheFe
oxidisesatauni for
mr atet hr
oughouttheblow.EnoughCaOi saddedt omake35%CaOi nthe
slag.Two- t
hir
dsoft hecar bongoestoCO, one-thi
rdtoCO2.Thebl owingenginesfur sh580m3
ni
ofai rperminute.
Requi
red:
1.Thevol
umeofairnecessar
ytoblowthecharge.
2.Thel
engthofeachperi
odoftheblow.
3.Thewei
ghtofCaOtobeadded, andtheper
centagecomposi
ti
onoft
hesl
ag.

Sol
uti
on

Basi
s:20,
000kgpi
gir
on

Si=340kg Si+O2=Si
O2 Orequir
ed=340x( 32/28)=338. 57kg
Mn=220kg Mn+O=MnO Orequir
ed=220x( 16/55)=64kg
CCO2=240kg C+O2=CO2 Orequir
ed=240x( 32/12)=640kg
CCO=480kg C+O=CO Orequir
ed=480x( 16/12)=640kg
P=480kg 2P+5O=P2O5 Orequir
ed=480x( 80/62)=619. 35kg
Fe=1120kg Fe+O=FeO Orequir
ed=1120x( 16/56)=320kg
-
--
--
--
--
--
--
--
--
--
--
--
--
---
--
--
--
--
--
--
----
--
--
--
--
--
--
--
TotalOrequired=2621. 92kg

Vol
umeofai
rrequi
red=(
2621.
92kg)x( 4m3/32kg)x(
22. 100/ 73m3atSTP [
21)=8739. 1]

Osuppl
i
edpermi
nut 580m3)x(
e=( 1. m3)x(
293kg/ 23.
2/100)=173.
99kg

InbasicBessemerprocess,t
hreeperi
odsofblowcanbeidenti
fi
ed.Duri
ngthefi
rstper
iod,
Si
andMnar eoxidi
sed.Duringthesecondper
iod,al
lcar
bonisoxi
dised.I
nthethi
rdperi
od,Pis
oxi
dised.

Ti
mef
or1stper
iod(
wit
houtFe)=(338.57+64)kg/173.
99kg/min=2.
31min
Ti
mef
or2ndperi
od(wi
thoutFe)=(
640+640)kg/173.99kg/min=7.
36min
Ti
mef
or3rdper
iod(
wit
houtFe)=619.35kg/173.99kg/min=3.56mi
n

Ti
mef
orFeoxi
dat
ion=320kg/173.
99kg/
min=1.
84mi
n

Tot
alt
imef
or1stper
iod=2.
31+1.84x2.
31/(2.
31+7.36+3.
56)=2.63mi
n
Tot
alt
imef
or2ndperi
od=7.36+1.
84x7.36/(
2.31+7.
36+3.56)=8.
38min
Tot
alt
imef
or3rdper
iod=3.
56+1.84x3.
56/(2.
31+7.36+3.
56)=4.06mi
n [
2]

SiO2i
nslag=340+338. 57=678.
57kg
MnOi nslag=220+64=284kg
P2O5i
nsl ag=480+619.
35=1099.
35kg
FeOinslag=720+320=1040kg
Total
slagwithoutCaO=3101.
92kg,whi
chi
s(100-
35)or65%oft
het
otal
slag

Page3of4
Tot
alsl
agfor
med=3101.92kg/0.
65=4772.
18kg
Wei
ghtofCaOtobeadded=4772.
18–3101.
92kg=1670.
26kg [
3]

Slaganalysis:
SiO2=678. 57kg =14.22%
MnO=284kg =5.95%
P2O5=1099. 35kg =23.04%
FeO=1040kg =21.79%
CaO=1670. 26kg =35.00% [
3]
--
---
--
--
--
---
--
--
----
--
--
--
--
--
--
--
--
--
--
--
--
Totalslag=4772. 18kg=100%

Pr
obl
em 7

AbasicBessemerconvert
eri
schargedwith20met r
ict
onofpi
giron,t
ogetherwit
haf l
uxof
CaO,andisblownunti
li
thas17.0tonsofFeand5720kgofsl aganaly
sing13%Si O2,5MnO,19
P2O5,
27FeO, 36CaO.Assumethatthei
roni soxi
disedatauni
for
mr at
et hr
oughoutthebl
ow.
Thecarbongoestwo-t
hir
dstoCOandone- thir
dtoCO2.Thetot
alblowi
ngt i
meis28mi n.
Requi
red:
1.Thet
otal
vol
umeofairrequi
redf
ort
hebl
ow
2.Thet
imeofeachper
iod.

Page4of4