Example 12 An iron blast furnace smelting a magnetite ore uses per day 912 short tons of ore, 510 tons of coke, and enough limestone to yield a slag of 40 per cent SiO, Assume that all the phosphorus, one-half the manganese, and one-fifth the silicon charged 110 METALLURGICAL PROBLEMS are reduced and go into the pig iron, which also contains by analysis 4 per cent carbon. Assume all the sulphur slagged as CaS. 1 per cent of the iron charged is lost in the slag, The blast amounts to 112,000 cu. ft. (measured at 60°F., 30 in. pressure) con- taining 9 grains of moisture per cubic foot, per ton of coke charged. The analyses of the ore, flux, and coke are as follows: Ore, per cent Flux, per cent | Coke, per cent Fes0, 70.3 CaCO, 95.4 C 87.2 FeO; 4.8 | MgCO, 2.5 | SO, 90 SiO, 10.2 AIO, 0.5 FeS 20 P:0, 0.9 810. 0.9 HO 1.8 Mn0;, 3.6 HO 07 ALO, 2.6 HO 7.6 } A complete charge balance sheet of the furnace, in pounds per day. centage composition of the pig iron, the slug, and the gases. Solution: Enter the weights of the components of the ore and coke in the charge columan of the balanee sheet, below. Fe in FesO. = 168432 X 1,281 = 928 (thousand pounds) Fe in Fe$ of coke = 5% 3 X20= 13 Fe in FeO: = 11359 X88 = _—62 Total Fe charged = 1,003 (thousand pounds) 0.01 X 1,003 = 10 Fe lost in slag (as FeO). 725 X 10 = 13 FeO. Assume this taken from the-Fe:0;, 62 — 10 = 52 Fe enters the pig from Fes0s. Mn in MnO; = 557 X 66 = 42.. Mn in pig = 21 MnO in slag = 7445 x 2L =27. Before calculating the SiO, it will be necessary to determine the weight of the flux, since the flux contains SiO. If the weight of the flux be taken as x, the SiOs in it will be 0,009z and the total S10; charged 186 + 92 + 0.0092, four-fifths of whichenters the slag and constitutes 40 per cent theroof. ‘The other components of the slag are as follows: From the ore: FeO + MnO + Al:Os = 13 + 27 + 47 = 87. From the flux: CaO + MgO + Al.O, = 0.5342 + 0.0122 + 0.0052 = 0.5512. From the coke: CaS, formed from FeS by using some of the CaO of the flux (FeS + CaO + C = Fe + CaS + CO), = 7245 X20 = 16. CaO used = 555 X 20 = 13. * Total weight of slag, including SiO: = 87 + (16 — 13) + O.551z + $6 (278 + 0.009z) = 312 + 0.558r. Then: : 222 + 0.007z = 0.40(312 + 0.5582), whence z= 449, ‘This may now be entered in the balance sheet. ‘The totul S10, charged is 278 + 0.0092 = 282. Si in pig iron = 2549 X 7834 = 26. CaO in flux = 56{99 X 429 = 240, CaOnceded to form (aS = 5$%— X 20 = 13 Ca = 4% X13 = 9. Total weight of pig iron without carbon = 1047. Weight of C = $64 x 1,047 = 44. Total blast, = 510 X 112,000 = 57,100,000 cu. ft. at 60°, 30 in. HO in this = 9 X 57,100,000 = 514,000,000 grains = 73,400 Ib, One pound-molecular weight of a gas occupies 859 eu, ft. wt 0°C., 760mm. oF 350 x 27 ISS x TO) arg cu.ft. at 60°F, 30 in, 78,400 Ib. of 1.0 = 781400 x 579 = 1,540,000 cu. ft. Volume of dry air = 57,100,000 — 1,540,000 = 55,560,000 cu. ft. 1 cu. ft. of air at O°C. 760 mm., weighs 0.0807 Ib., or 1 cu. ft at 60°F., 30 in., weighs 0.0807 x pa x is 0.07737 cu. ft. 55,560,000 X 0.07737 = 4,300,000 Ib. of dry air. 0.232 X 4,300,000 = 997,600 Ib. of oxygen.Cuarce Binance Suenr (In pounds per day divided by 1,000) Charge Pig iron Slag Cases Ore (1,824): | | | FeO. = 1,281 Fe = 928 | O = 3 FeO: = 88 2 | FO = 18 | O 23 S10; = 186 2% | Si, -130 | 0 30 PO, = 16 T / 0 9 Mn: = 66 | 21 Mn0= 27 | 0 = 18 MLO; = 47 ALO. = 47 | HO = 138 (HO = 138 Flux (449): . CaCO, = 429 CaO = 227 CO: = 189 Ca = 9 O = 4 MgO, = MgO = 5 CO.= 6 ALO, = 2 ALO. = 2 $0: = 4 Si: = 4 HO = 3 | HO= 3 Coke (1,020): | | c = 890 C = tk | Co = 86 S10: = 92 | S02 = 92 | FS = 20 Feo=B | 8S = 7 | HO = 18 | WO0=- 18 i Blast (4,378): | Oo a 998 e | oO = 998 N = 3,302 N = 3,302 HO = 78 Ho= 8 | 0 = 65 Totals 7,664 1,00 | 563 | 6,010 The balance sheet may now readily be completed. It is of interest 6 note that the gases weigh over five times as much as the pig iron, while the slag weighs about half as much as the pig iron.‘The percentage compositions of the pig iron and the slag are obtained from the figures in the balance shect, as follows: Pig Iron Slag Fe = 993 = 91 0 per cent SiO, = 226 = 40.2 per cent Si = %= 24 CaO = 227 = 404 Mn= 21= 19 MgO = 5= 09 Po = 7= 06 ALO; = 49 = 8.7 G = 4= 40 FeO = 13 = 23 MnO = 27= 48 CaS = 16= 28 The percentage composition of the gases should be caleulated hy volume. The total weight of carbon burned from the coke is 346,000 Ib. ‘The total weight of oxygen to combine with this is 1,500,000 Ib. (obtasned by adding all the oxygen items in the gases column), This will convert all the carbon to CO and some of this CO to CO. 846,000 X 18%» = 1,128,000 Ib. of oxygen required for CO, forming 1,974,000 Ib. of CO and leaving 372,000 Ib. of oxygen for CO — COs. ‘This will oxidize 28/4 X 372,000 = 651,000 Ib. of CO, formmg 1,023,000 Ib. of CO; and leaving 1,323,000 Ib. of COQ, Adding the CO: from the flux gives 1,218,000 Ib. of COs total. Blast-furnace gas: CO = 1,823,000 X 25955 Oz = 1,218,000 X 25944 16, 960,000 cu. ft. = 23 0 per cent 9, 940,000 = 135 H,0 = ‘159,000 x #5975 = 3,170,000 43 H = — 8,000 x 959) = 1,430,000 ee 19 N = 8,302,000 X 25945 = 42,340,000 = 573 Total = 73,840,000 cu. ft. = 100 0 per cont The thermal balance sheet of the iron blast furnace is taken up on page 169.