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Modeling and Simulation for S.S. Re-Rolling Mills Waste Treatment

Modeling and Simulation for S.S. Re-Rolling Mills Waste Treatment

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Published by Bharadwaj Santhosh
Modeling and Simulation for S.S. Re-Rolling Mills Waste Treatment
Modeling and Simulation for S.S. Re-Rolling Mills Waste Treatment

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Published by: Bharadwaj Santhosh on Nov 04, 2011
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02/05/2013

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Modeling and Simulation for S.S. Re-Rolling Mills Waste Treatment
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Abstract:
The S.S. Re-Rolling mills use mixture of acids to wash the plates during process. This acidmixture becomes waste and is currently treated by lime which generates lot of solid sludge. A treatment process of commercial importance has been developed to convert this effluent into a useful product. TheS.S. Re-Rolling mills are of different size and hence effluent generated are of varying magnitude rangingfrom 4000 liters / day to 15,000 liters / day. The process developed therefore needs to be simplified to treatdifferent quantity of waste liquor. This paper offers computer program for the sizing of various equipments,important components and certain important features of lay-out of the treatment plant. The treatment process is briefly discussed first with flow diagram. With the help of equipment occupancy chart, the needof various size of equipment is worked out and finally the model is presented. The simulation of the modelis done using C programming language.
Keywords:
S.S. Re-Rolling Mill Waste, Waste Treatment, Algorithm, Mathematicalmodel, Simulation
Introduction
The industrial process for the treatment of the waste from S.S. Re-rolling mill has beendeveloped (1).The paper briefly describes the process with flow diagram. The details of the process on industrial scale have been worked out during the exercise performed to
 
submit the report to Department of Science and Technology (DST) under ‘TechnologyTransfer Scheme’. The industries generate effluent of different magnitude and hence thetreatment plant required is also of different size. Since the cost of treatment may not beaffordable by a single unit, number of units can come together, form a cluster to generateand treat the larger quantity of effluent. Thus the need for the size of the effluenttreatment plant will vary. Looking at the need the paper describes the modeling andsimulation for the above case. In the last segment of this paper the application of thissimulation is explained.
Process Description
The industrial process for said treatment is shown along with the flow diagram. Pl. refer fig.1. The pickling liquor is treated for a day with the Mild Steel Scrap. The clear supernatant liquor is then neutralized to pH 7 by adding pickling liquor to theAmmonium hydroxide solution. This is done in a neutralizing tank. Neutralization takes40 minutes. The slurry is then circulated through the spray reactor, three-phase separator and then is returned to the neutralizing tank. Slurry gets sprayed in the reactor and there itgets oxidized with air. The time for oxidation ranges from 20 to 45 minutes, judged bythe color change of the slurry to reddish brown. The mass then is separated in the three phase separator into liquid and solid phase. The wet precipitates are collected, dried andcalcined in furnace to obtain red iron oxide.
Mathematical Model
 
The problem involves treatment of waste pickling liquor generated by industry. Normallythe quantity remains between 4000 and 15000 liters/day. The material flow is alreadydescribed. Now the problem remains to design the equipment used at various stages.The liquor is available continuously and total collection in a day is, say, Q liters. Thesegment of the process which involves circulation of pickling liquor from storage tank of  pickling liquor to oxidizer, to separator and then back to neutralizer; 1
st
segment of the process, takes 2.5 hr. The steps of filtration, moulding, drying and calcinations thenfollows. The quantity of the material to be handled changes from ‘1
st
segment of the process’ to different subsequent steps of the process. Hence selection of the size of theequipment for ‘1
st
segment of the process’ is done separately and selection of theequipment for each stage is done separately.For ‘1
st
segment of the process’, per 8 hours three cycles can be conveniently completedwithout any hassle. Therefore, in 24 hours, 9 cycles can be completed. Hence, thecapacity of the equipment in ‘1
st
segment of the process’ is chosen as compatible to 9
th
 part of the total pickling liquor production.As said before, in the subsequent operations, there are filtration, moulding, drying andcalcination. The rate of filtration, rate of drying and rate of calcination are all establishedin the laboratory, providing necessary design data. Further, equipments for operation likefiltration, drying and calcination are available in standard sizes. Hence, equipment sizingfor all these operations are done depending upon batch size and commercially availableequipment size. Help of Equipment occupancy chart is taken. Pl refer fig. 2. From theequipment occupancy chart also, it becomes clear that sizing of the set of equipment for 

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