[1]

Upper furnace/thought/preheating area

T: up to 800 ˚C
Indirect reduction of iron oxides
3Fe2O3+CO2 Fe3O4+CO2
Fe3O4+CO3FeO+CO2

Middle furnace/shaft/belly area

T: 800 – 1000 ˚C
Main rxn – indirect reduction
FeO+COFe+CO2
Reduction of hematite and magnetite:
3Fe2O3+COFe+CO2
Fe3O4+CO3FeO+CO2

Lower furnace/bosh/tuyeres area

T: 1200 – 1900 ˚C
Direct & Indirect Reduction and melting zone:
CO2+C2CO
FeO+COFe+CO2
FeO+CFe+CO
Other reactions:
MnO+CMn+CO
SiO2+2CSi+2CO
P2O5+5C2P+5CO
FeS+CaO+CCaS+Fe+CO

b.
Major Components of Slag Major Components of iron liquid product
SiO2, Cao, Al2O3, MgO, MnO, S, FeO Fe, ~4 % C, ~0.4 % Si, ~0.3 % Mn, ~0.1 % P,
~0.03 % S

c.
It is possible by adding C up to 4.27% based on
the diagram. The liquidus temperature of the
pig iron product with 3-4 % C is ~1200 ˚C. by
adding C, the liquidus temperature decreases.
 SiO 2 75 wt %
[2] a. =3=
A l2 O3 25 wt %

Point 2

Point 1

Possible slag compositions:

Point 1 composition: Point 2 composition:
CaO: 51 % CaO: 9.8 %
Al2O3: 12 % Al2O3: 22.5 %
SiO2: 37 % SiO2: 67.7 %

Point 1
Since the viscosity of point 1 is ~0.55 Pa-s and for point 2 is 400 – 1000 Pa-s, the proposed slag
composition is 51 % CaO, 12 % Al2O3 and 37 % SiO2.
b.

2.05
wt % flux= =46.07 %
4.45
46.07 flux
wt flux= =85.43 g g slag
100−46.07 100
Composition:
11.71
wt % CaO= =87.26 %
13.42
wt % Si O2=100−87.26=12.74 %

c.
Assuming the same proportions of other components:
wt % CaO=51 ( 100−wt % MgO )=51 ( 100−5 )=4 8 . 45 %
wt % Al 2O 3=12 ( 100−wt % MgO ) =12 ( 100−5 )=11 . 40 %
wt % Si O 2=37 ( 100−wt % MgO )=37 (100−5 )=35 . 15 %

Liquidus T: 1500 ˚C
Primary phase field: C2S (dicalcium silicate)

[3]
R1: Mn + 0.5S2  MnS
R2: MnS(s)  MnS(l)
R3: Mn(s)  Mn(l)
R4: Mn(l)  1wt% Mn (in Fe)
R5: 0.5S2(g)  1wt% S (in Fe)
ΔR1Go= -296520 - 76.735T
ΔR2Go= 26083 + 4.463T
ΔR3Go= 12122 + 7.942T
ΔR4Go= -4084 + 38.158T
ΔR5Go= -135060 -23.430T

R6: Mn (in Fe) + S (in Fe)  MnS(l)

R 6=R 1+ R 2+ R 3+ R 4 + R 5
∆ R 6 G o= (−296520+26083−12122+ 4084+135060 ) +T (−76.735−4.46 +7.942+ 38.158−23.43 )
J
∆ R 6 Go=−321261
mol

a MnS
∆ ❑R 6 G=∆R 6 Go + RTln =0
( wt % S Fe ) ( wt %M n Fe )
o
−∆ R 6 G
a MnS=( wt % S Fe ) ( wt %M n Fe ) exp
RT
321261
a MnS=0.025 ( 0.76 ) exp
8.314 ( 1873.15 )
 a MnS=17317105.82
 Inclusions will form since the activity of MnS (l) is greater than 1.

b.
wt % S slag
=250
wt % Smetal

wt % S ∈slag=wt % Smetal ( 250 )

wt % S ∈slag=0.002 ( 250 )=0.5 %

75 tons ( initial wt %S−final wt % S ) 75 ( 0.25 %−0.002 )

S ¿ be removed = = =0.01725tons
100 100
X ( initial wt % Sslag −final wt % slag ) X ( 0.5−0.1 )
S ¿ be absorbed ∈ slag=0.01725 tons= =
100 100
X =4.31 tons refining slag