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Iron Blast Furnace Analysis and Calculations

- The document analyzes the inputs and outputs of an iron blast furnace producing 1,000 kg of pig iron. It determines that 931 kg of coke and 3,083.5 m3 of air are required per ton of pig iron produced. - Carbon, nitrogen, iron oxide, silicon oxide, manganese, aluminum oxide, and calcium oxide balances are performed to calculate the composition of the slag produced. The slag is estimated to contain 60 kg of Fe2O3, 297.4 kg of SiO2, 4.6 kg of MnO, 52.5 kg of Al2O3, and 266 kg of CaO.

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620 views3 pages

Iron Blast Furnace Analysis and Calculations

- The document analyzes the inputs and outputs of an iron blast furnace producing 1,000 kg of pig iron. It determines that 931 kg of coke and 3,083.5 m3 of air are required per ton of pig iron produced. - Carbon, nitrogen, iron oxide, silicon oxide, manganese, aluminum oxide, and calcium oxide balances are performed to calculate the composition of the slag produced. The slag is estimated to contain 60 kg of Fe2O3, 297.4 kg of SiO2, 4.6 kg of MnO, 52.5 kg of Al2O3, and 266 kg of CaO.

Uploaded by

naveena
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd

Iron blast furnace analysis

Consider an iron blast furnace charged with iron ore, limestone and coke of following analyses:
Rational Analysis wt%
Material Fe2O3 SiO2 MnO Al2O3 H2 O C CaCO3
Ore 80 12 1 3 4
Limestone 4 1 95
Coke 10 90

The ultimate analysis of the pig iron gives 93.8% Fe, 4% C, 1.2% Si, 1% Mn
For every ton of pig iron produced, 1750 kg of iron ore and 500 kg limestone are used and 4200
m3 of flue gas is produced
The rational analysis of flue gases gives 58% N2, 26% CO, 12% CO2, 4% H2O
Basis 1000 kg of pig iron
Blast furnace gas 4200m3
Ore 1750 kg
Limestone 500 kg Slag
Coke

Air Pig iron 1000 kg


Reactions
Fe2O3 + 3CO = 2Fe + 3CO2 SiO2 + 2C = Si + 2CO
CaCO3 = CaO + CO2 MnO + C = Mn + CO
C + 1/2O2 = CO CO2 + C = 2CO
Basis 1000 kg of pig iron
Ore 1750 kg Blast furnace gas 4200m3
80% Fe2O3, 12% SiO2, 1% MnO,
58% N2, 26% CO, 12% CO2, 4% H2O
3% Al2O3, 4% H2O
Limestone 500 kg Slag
95% CaCO3, 1% H2O, 4% SiO2
Coke
10% SiO2, 90% C
Air Pig iron 1000 kg
Reactions 93.8% Fe,4% C, 1.2% Si, 1% Mn

Fe2O3 + 3CO = 2Fe + 3CO2 SiO2 + 2C = Si + 2CO


CaCO3 = CaO + CO2 MnO + C = Mn + CO
C + 1/2O2 = CO CO2 + C = 2CO

Calculate the quantity of coke used per ton of pig iron


Carbon balance:
Ccoke + Climestone = C pig iron + Cflue gas let x be the weight of coke

0.9𝑥 0.95 ∗ 500 ∗ 12/100 0.04 ∗ 1000 4200 ∗ 0.26 4200 ∗ 0.12
+ = + +
12 12 12 22.4 22.4

0.075x + 4.75 = 3.333 + 71.25, x= 69.833/0.075=931 kg coke per ton of pig iron

Calculate the air consumption per ton of pig iron


N2 balance:
N2(air) = N2(flue gas) = 4200*0.58 = 2436 m3, Air consumption = 2436*(100/79) = 3083.5m3
Basis 1000 kg of pig iron
Ore 1750 kg Blast furnace gas 4200m3
80% Fe2O3, 12% SiO2, 1% MnO,
58% N2, 26% CO, 12% CO2, 4% H2O
3% Al2O3, 4% H2O
Limestone 500 kg Slag
95% CaCO3, 1% H2O, 4% SiO2
Fe2O3, SiO2, MnO, Al2O3, CaO
Coke
10% SiO2, 90% C
Air Pig iron 1000 kg
93.8% Fe,4% C, 1.2% Si, 1% Mn

Calculate the composition of the slag


Fe2O3 balance:
Fe2O3(ore) = Fe2O3(pig iron) + Fe2O3(slag)
1750*0.8 = 0.938*1000*(160/112) + Fe2O3(slag), Fe2O3(slag)=1400-1340= 60 kg
SiO2 balance:
SiO2(ore) + SiO2(limestone) + SiO2(coke) = SiO2(pig iron) + SiO2(slag)
1750*0.12 + 500*0.04 + 931*0.1 = 0.012*1000*(60/28) + SiO2(slag), SiO2(slag)=210+20+93.1-25.7
MnO balance: =297.4 kg
MnO(ore) = MnO(pig iron) + MnO(slag)
Total slag composition:
1750*0.01 + 0.01*1000*(71/55) + MnO(slag)
Fe2O3 60 kg 8.82%
MnO(slag) = 17.5 – 12.9 = 4.6 kg
SiO2 297.4 kg 43.70%
Al2O3 balance:
MnO 4.6 kg 0.67%
Al2O3(ore) = Al2O3(slag) = 1750*0.03 = 52.5 kg
Al2O3 52.5 kg 7.71%
CaO balance:
CaO 266 kg 39.10%
CaO(limestone) = CaO(slag) = 500*(56/100)*0.95 = 266 kg
Total 680.5 kg

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