NATIONAL INSTITUTE OF TECHNOLOGY, ROURKELA ~ 769 008 METALLURGICAL & MATERIALS ENGINEERING DEPARTMENT B.Tech., End-Semester(AUTUMN) Examination, 2012 SUBJECT: IRONMAKING (MM-321) FULL MARKS : 50 Time : 3 Hours ‘Answer Question No.1, which is compulsory, and any three questions from the rest. Alll parts of a question should be answered at one place. ‘GQNo Q1 a) A. b) Q.1.0) Q2 a) b) Suppose a blast furnace of volume 1200m® and blast rate of 2400Nm*/m*.h is working with top pressure of 1.1ata and tuyere pressure of 2.5ata. Calculate the bottom (tuyere) and top pressure necessary to achieve 30 percent increase in coke buming rate (by blowing more blast) without changing the linear gas velocity. Justify or correct the following statements with proper explanation: i) Charging of fine ores in the Channel removes Channelling, ii) From a chemical stand point the blast furnace coke should be of high reactivity. ii) Bosh slag is much more acidic than the final slag. iv) The water content of the pelletisation feed is quite critical for obtaining strong green balls. v) The ore size is always 3-4 times larger than the coke size vi) In rich sinters slag bond is of minor importance A blast furnace stove burns blast furnace gas at the rate of 760m° /minute with 15% excess air. Blast furnace gas analysis is CO=26%, CO2=14%, Ho = 2%, N2=58%. Waste gas leaves the stove at 150°C. The net calorific value of the gas is 798 kcal/m®*. Cold air blast at 180°C is preheated to 1000°C in a Period equal to the heating time of the stove at a rate of 1980m‘/minute. The specific heats of both air and gas may be taken as 0.320 kcal/m*°C. Calculate the thermal efficiency of the stove using an ambient temperature of 15°C With the help of a schematic diagram, enumerate the salient features of "COREX" process. With the help of a schematic diagram, enumerate the salient features of “Midrex Process”. Critically compare between the followi i) Direct and indirect reduction of 'Fe,O5' ii) Coal and Gas based DR Process. Marks @) (2x6) (5) (3) (3) (2x2) PTO.Q3 a) ») Q4 a) b) °) Q.5 a) » How the configuration of cohesive zone in blast furnace affect the following: i) Gas permeability ii) Extent of indirect reduction of Wustite il) Sizicon content of the liquid Pig Iron. With the help of a schematic diagram explain the mechanism of gj reaction in Blast Furnace. Discuss the strategy for production of low sulphur hot metal in Blast Furnace Describe the chief causes of failure of the blast furnace lining. Enumerate the various important measures which can be taken to decrease the coke rate of the blast furnace. With the help of a schematic diagram, explain the temperature distribution of gas and solids along the height of the blast furnace What do you mean by CO-utilisation factor? Briefly explain why CQ.utiisation factor at 900°C is critical for blast furnace performance. Briefly explain how the following factors affect the burden distribution inside the blast furnace. i)Angle of repose and i) Size distribution of charge materials List the various physical properties of the iron ore which affect the rate of reduction (4) (3) (3) (4) (3) (3) 4) (3) (3)