Term Report Topics.

Subject : Industrial calculations.

Sub. Code: ChT-303.
Semester : 5th.
Session : 2k21-2k25.
Group-1:
Names: Roll No:
Shabaz Ali 2k21-ChET-01
Attiq-ur-Rehman 2k21-ChET-03
Mohammad Okasha 2k21-ChET-04
Shehroz Yaseen 2k21-ChET-08
Zeshan Yaseen 2k21-ChET-09
Daniyal Amjad 2k21-ChET-11
Topic:
THE MATERIAL AND ENERGY BALANCES OF A Chamber Sulfuric
Add Plant.

Pyrites, containing 85.3% FeSj, 2% H2O, and 12.7% inert gangue, is burned in a
shelf furnace yielding a gas containing 8.5% SO2, 10.0% O2, and 81.5% N2 by
volume. The pyrites is charged at 18°C and the air is supplied at the same
temperature with a percentage humidity of 49% and at a pressure of 750 mm of
Hg. The cinder leaves the burner at 400°C containing 0.42% sulfur as unburned
pyrites. The pyrites burned forms Fe203 and SO2 and the gangue passes into the
cinder unchanged. The mean specific heat of the cinder is 0.18. The gases from
the burner, after passing through the dust chamber, enter the Glover tower at
450°C and leave at 91°C.
In the Glover tower 16% of the SO2 in the gas is converted to H2SO4. There are
sprayed into the top of the Glover tower, per 100 kg of moisture-free pyrites
charged:
 182 kg of aqueous sulfuric acid at 25°C from the chambers, containing
 64.0% H2SO4 and 36% H2O.
 680 kg of mixed acid at 25°C from the Gay-Lussac tower, containing 77%
H2SO4, 22.1% H2O, and 0.885% N2O3.
 1.31 kg of aqueous nitric acid at 25°C, containing 36% HNO3 and 64% H2O.
Acid leaves the bottom of the Glover tower, free from oxides of nitrogen, at a
tem1perature of 125°C, and containing 78.0% H2SO4 and 22%, H2O. This acid is
cooled to 25°C, part of it is returned to the top of the Gay-Lussac tower, and the
remainder is withdrawn as the final product of the plant. The gases leaving the
Glover tower are passed through a series of four chambers and finally enter the
Gay-Lussac tower, at 40°C. Spray water is introduced at the tops of the various
chambers at 18°C. The acid formed in the chambers is withdrawn from the first
chamber at 68°C, con1taining 64.0% H2SO4. This acid is cooled to 25°C and all fed
into the top of the Glover tower. Part of the Glover acid after cooling to 25°C is
returned to the top of the Gay-Lussac tower. The Gay-Lussac acid leaves the
bottom of the tower at 27°C and is all fed to the top of the Glover tower at 25°C.
The spent gases leave the top of the Gay-Lussac tower at 30°C.
Calculate material and energy balances of the entire plant and of each of the
follow1ing units, all based on 100 kg of moisture-free pyrites charged:
 The burner
 The Glover tower.
 The four chambers as a single unit.
 The Gay-Lussac tower.
Group-2:
Names: Roll No:
M. Muzamil Riaz 2k21-ChET-12
Muhannad Hassan 2k20-ChET-21
Hafiz M. Naveed 2k20-ChET-26
Muhammad Younas 2k2 -ChET-
Mubashar Jameel 2k2 -ChET-

Topic :
THE MATERIAL AND ENERGY BALANCES OF A BLAST FURNACE:

A blast furnace is essentially a huge gas producer were, in conjunction

with the partial combustion and distillation of a carbonaceous fuel, the reduction
of ore and the formation of slag occur simultaneously.
The charge, consisting of iron ore, coke, and limestone in proper proportions, is
fed into the top of the blast furnace. Preheated air, preferably free from
watervvapor, is blown through the tuyeres near the bottom of the furnace into
the descending stream of solids. This results in combustion of the coke to carbon
dioxide. The carbon dioxide gas in the presence of excess coke is reduced at the
high prevailing temperature to carbon monoxide. A great many chemical
reactions occur within the furnace. As the charge descends the shaft and as its
temperature is gradually increased, dehydration of the ore, coke, and limestone
takes place, followed by distillation of the remaining volatile matter of the coke,
calcination of magnesium and calcium carbonates present in the limestone or ore,
and reduction of the higher oxides of manganese and iron to manganous and
ferrous oxides by the rising stream of reducing gases.
The carbon dioxide formed by reduction of the ore with carbon monoxide is
reduced in the presence of excess coke. As the temperature of the descending
charge becomes still higher the lower oxides of iron and manganese are reduced
to a metallic state.
At the highest temperature of the tuyeres (a tube, nozzle or pipe through which
air is blown into a furnace or hearth.), part of the silica present is reduced to the
metallic state and is dissolved in the molten iron. The excess silica and alumina of
the charge are fluxed by reaction with the metallic bases present resulting in the
formation of a fusible slag consisting of complex silicates and aluminates of
calcium, magnesium, and iron. The high temperature at the tuyeres produces a
fluid slag and molten metal which readily flow through the solid reacting charge,
separate into two layers at the bottom of the furnace, and are periodically run out
in two separate streams as molten pig iron and as molten slag.
A high temperature at the tuyeres favors a ready separation of the slag and
removal, as CaS in the slag, of much sulfur which was originally present in the
coke.The temperature of the blast furnace is too low and insufficient coke is
present to reduce the oxides of calcium, magnesium, aluminum and silicates.
Hence, these compounds pass into the slag. Silica is used as a flux in a few
exceptional cases where the alkaline earths and alumina predominate in the
gangue present in the ore. The purpose of preheating the air used in combustion
of the coke is to permit the attainment of the high temperatures necessary for
the final reduction of the ore and the fusion of the pig iron and slag. Any water
vapor present in the incoming air will lower the temperature in the fusion zone on
account of the heat
absorbed in its reduction to hydrogen and carbon monoxide. For this reason, it is
desirable to use a blast of dried air.
The products of the blast furnace consist of molten pig iron, slag, and
blast1furnace gas. The outgoing gas consists essentially of nitrogen, carbon
monoxide, carbon dioxide, and water vapor, with small amounts of hydrogen and
methane, and also carries in suspension a considerable amount of dust. The
heating value of this gas is very low because of its high nitrogen content and the
small amount of volatile matter in the coke which is used for reduction. The free
moisture in the incoming charge is distilled off near the top of the furnace and
escapes into the blast furnace gas without reduction.
The slag contains all the lime, magnesia, alumina, and alkalies originally present in
the ore and flux, together with most of the silica and some ferrous and
manganous oxides. The exact mineralogical compositions of ore, flux, and slag are
usually not known completely, so that some uncertainty exists concerning the
exact thermal energy involved in reduction and chemical transformations. The
molten pig iron contains, in addition to iron, some carbon present as cementite
and lesser amounts of silicon and manganese, cooling, the cementite partly
decomposes into graphite and iron.
In order to establish the energy balance of a blast furnace it is necessary to know
the masses and chemical compositions of the ore, flux, dust, and pig iron, and the
analysis of the dry blast-furnace gas. The masses of slag, air, and water vapor can
then be calculated.
The material balance includes:

Input
 Iron ore.
 Flux.
 Coke.
 Air Dust.
 Water vapor.

Output
 Dry gases.
 Water vapor in gases.
 Pig iron.
 Dust.
 Slag.

As an illustration of the calculations involved in the material and energy balance of

a blast furnace, the data for the reduction of a basic iron ore with charcoal and acid
flux will be given. An example of the more usual operation with a limestone flux is
given in the problems at the end of this chapter. The balances are worked out on a
basis of 100 kilograms (about 220.46 lb.) of pig iron produced.