Rist Diagram For Pulverized Coal Injection

Introduction:-
Modified Rist Diagram is graphical representation of (O+H2)/Fe Vs
(O+H2)/(C+H2), which helps to understand the application of blast furnace
theory . Most important characteristics of blast furnace operation can be
solved by steady state mass and heat-balance equations which was developed
by Paul et al. Rist operating diagram is also heat and mass balance of blast
furnace operation represented in the graph.
The chemical reserve zone where both thermal and chemical equilbria prevail,
effectively separates the heat and oxygen exchange process into two stage.
Heat balance at thermal reserve zone gives thermal pinch point called P
whereas wustite point,W in thermal reserve zone depends upon fraction of
hydrogenaceous gas and carbonaceous gas.
From two point P and W , Rist Diagram is plotted.The slope of operating
diagram of Rist gives Fuel Rate . It has been found from Rist Diagram , “
Thermal point P goes down with increase in PCI level whereas W point shifts
right , but shift is very small ” .

1.1 Equation for the operating Line

Steady state oxygen balance for infinitesimal volume between two
horizontal planes in a shaft which describes counter current reaction is written
as
VFedY = VgdXJCO2+H2O .............................................................…. [1]
Where,
VFe = Solid feed rate
Vg = Gas flow rate
Y = Oxygen level of the burden during reduction
O+ H 2
XJCO2+H2O = Gas composition { ( C+ H 2 ) J = 1+ XJCO2+H2O }

In turn
Vg
V Fe
= ncT+nH2I+nH2OBl =FR ………….................................................... [2]
Where fuel rate , FR is constant for the process at steady state.
Integration of Eq [1] gives
Y = FR XJCO2+H2O +b …………............................................................... [3]
or
Y=FR*¿) J – FR +b ..……….......................................................... [4]
Overall oxygen balance for the process is expressed as
O (blast) + O (fuel injection) + O (metalloids) + O (burden) = O (top gas) ….. [5]
{Note:- No calcinations are considered . Blast Furnace is running on
superfulxed sinter }
Or,
noBl+nH2OBl+noI+noM+noB=nCOTG+2nCO2TG+nH2OTG ………………...............................[5 a]
Eq [5] can be written as ,
O O
noBl+nH2OBl+noI+noM+noB = nCT( C )TG +nH2OT( H 2 ¿TG …………...................................[6]

The above equation can be rewritten as

noBl+nH2OBl+noI+noM+noB = FR*¿) TG – nH2T …………..................................[7]

noBl+2nH2OBl+nH2I+noI+noM+noB = FR*¿) TG ……………..................................[8]

At the top of the shaft
Y n oB
XJ XT.G
Putting above condition in Eq [4] and comparing with Eq [8]
b = FR- noBl-2nH2OBl-nH2I -noM-noI ……………......................................................[9]
or in the notation
b=FR-yb-yf ……………...................................................................................[10]
where,
yb = noBl+2nH2OBl ………….................................................................................[11]
and,
yf =noM+noI+nH2I …………................................................................................[12]
Thus the equation of the operating line in the Rist Diagram is :
Y= FR*¿) J –nOBl-2nH2OBl-nH2I-nOM-nOI .…………........................................[13]
1.2 Plotting of Rist Diagram
Rist Diagram is plotted by using two co-ordinate naming thermal point (P) and
wustite point (W) .
1.2 (a) Heat Balance for determination of thermal point
Heat balance is expressed by the following standard equation
HEAT IN = HEAT OUT+REACTION HEAT ……………........................................[14]
HEAT IN=QSB+QSBl+QSI ……………................................................................[15]
Where
QSB = ∑(Cpini)B(TFeO/FeEq - TFeO/FeEq) = 0 ; …………............................................[16]
QsBl = ∑(Cpini)Bl(TBl - TFeO/FeEq) ; ……………...................................................[17]
and
QsI = ∑(Cpini)I(TFuel - TFeO/FeEq) . ………………...................................................[18]
The Output heat and heat loss term are
HEAT OUT = QSG+QSHM+QSL ; …………….....................................................[19]
QsG = ∑(Cpini)G(TG - TFeO/FeEq) ≈ 0 ………………................................................[20]
QsHM = CpHMnHM(THM - TFeO/FeEq)+CpSlnSl(TSl - TFeO/FeEq); ………………...............[21]
And
QsL = ф (QsL)T . ………………..........................................................[22]
Eq [14] can be written as
QSBl+QSI = QSHM+QSL+ QRFe+QRSL +QRWGS+QRBl + QRH2+QRI + QRM + QRHM+QRSl [23]
To obtain the ordinates for point P in the Rist diagram above Eq is rewritten as
a function of noBl and ncSL
QRSL = ncSL ΔHRSL ………………...............................................................[24]
ncSL = nCT-nOBl-nH2OBl-nOM-nOI ………………...............................................[25]
QSBl = noBl ΔHSBl ………………...................................................................[26]
Where
Cp N 2 CpO 2 Cp H 2O
ΔHRSL =[ 2 R + 2
+ 2 G](TBl-TEqFeO/Fe ) ……………............................
[27]
 1
−1
R
G= 1 ………………….....................................................[28]
−1
s
O
ncWGS =(nH2OBl+nH2 I )( H 2 )Eq ……………….....................................................[29]

nO Bl O O
Thus, QRWGS = 2 ( H 2 ¿Eq G ΔHRWGS+nH2I( H 2 ¿Eq ΔHRWGS …………………...............[30]

Also,
n OBl
QRH2 = 2
GΔHRH2 ; …………………..................................................[31]

And
QRBl =(noBl+noI)ΔHRBl ……………….....................................................[32]
Eq [23] can be rearranged as follows :
noBl Q1 =ncSLΔHRSL+Q2 ; ………………......................................................[33]
where,
G O
Q1=ΔHSBl - 2 [ ( H 2 )EqΔHRWGS+ΔHRH2] – ΔHRBl ; ……………....................[34]
and,
O
Q2= QSHM+QSL-QsI+ QRFe+Q RI +QRM +QRHM+QRSl +noIΔHRBl+nH2I( H 2 ¿EqΔHRWGS …[35]

Eq [33] can be rearranged

noBl ΔHRSL Xp
ncSL+Q2 / ΔHRSl
=
Q1
= 1−Xp
……………........................[36]

1
Xp = 1+ Q1/ ΔHRSL ……………..............................
[37]
Q2
Yp = [(nOM+nOI+nH2I) – ΔHRSL ]Xp – (nOM+nOI+nH2I) ……………............................[38]

1.2 (b) Wustite Point (W)

The dependency of W on h is readily demonstrated in operating diagram is as
follows
Where,
nH 2 T
h= ncT + n H 2 T .……................................................................................[39]

Wc = xCO-CO2Eq +1 ……….............................................................................[40]
Wh= xH2-H2OEq +1 ………...............................................................................[41]
Real value for W in combination of carbonaceous and hydrogenaceous gases in
the system
W=Wc(1-h)+hWh ………...............................................................................[42]
Here W is abscissa of Wustite Point ,XW
And Yw=(O/Fe) =1.05 ≈ 1.0

2.1 Effect of thermal point (P) and Wustite Point (W) With Increasing PCI Value
The data for Rist Diagram are as follows

C from Coke 444 kg/thm

Slag Mass 300  kg/thm
Specific Blast   Unknown Nm3/thm
 
O2 enrichment 0 %
Humidification   0.01 gm/Nm3
Blast Temperature 1373 K
Thermal Reserve Zone 1273 K
Hot Metal Temperature 1716 K
Slag Temperature 1773 K

Specific Blast is calculated based on Fuel Rate and Shaft Efficiency.

Here Hot Metal Composition are
Hot Metal Composition  
Fe 94.57
C 4.58
Mn 0.47
 Si 0.32
P 0.13

Ultimate Analysis of PCI

C 82.97
H2 5.58
O2 8.75
N2 2.3
S 0.64

Proximate Analysis of PCI

Fixed C

Volatile Matter

Ash

**Here Coke contains 88% Fixed C and C from Coke is 444Kg/thm.

1.5
Rist Diagram of Pulverized Coal Injection

0.5
W Without Coal
( Linear (Without Coal)
O
+ With 50 Kg Coal
H Linear (With 50 Kg Coal)
20 With 100 Kg Coal
/ 0.4 0.6 0.8 1 1.2 1.4 Linear (With 100 Kg Coal)
F
e P With 150 Kg Coal
) Linear (With 150 Kg Coal)
-0.5 With 200 Kg Coal
Linear (With 200 Kg Coal)

Increasing PCI

-1

-1.5

(O+H2)/(C+H2)

Appendix (Definition of Variables)

O
( C ¿J = Total moles of carbon –bound oxygen per mole of oxygen –bound carbon at location
j in the blast furnace .
O
( H 2 ¿J = Moles of hydrogen – bound oxygen per total moles of hydrogen in the system at
location j in the blast furnace.
O+ H 2
( C+ H 2 ¿j = Total moles of carbon bound and hydrogen bound oxygen per total moles of
hydrogen and oxygen bound carbon in the system at location j.

S = Moles of H2Oin the blast per total moles of blast (wet)=NM3 H2O/NM3 blast (wet)
R=Molar ratio (pct O2/pct N2) in the blast (dry analysis)
G= Parameter .characterizing the oxygen relative to nitrogen content and moisture content
of the blast.
1
−1
R
G= 1
−1
s

ncT=Total moles of Carbon in the top gas

niJ = Moles of gas species i at location j in the furnace , per mole of iron
niI= Total moles of species i from the injected fuel , where i=N ,H
2 2 or O .

nH2T= Total moles of hydrogen in the system = n H2O

Bl
+nH2I

Vg = Total molar flow rate of carbonaceous and hydrogenaceous gases. =FR*V Fe

ybl =Ordinate for the Rist diagram for the reducing gas that is proportional to the wind
rate=2nH2OBl +noBl

FR= Total fuel rate =n c

T
+nH2T .

noB = Total moles of iron-bound oxygen per mole of iron in the burden as charged
=3nOFe2O3+4noFe3O4+noFeO .

nFe ,nFeO= Moles of iron in the burden and in wustite respectively, per mole of iron
product=1moles Fe/mole Fe

nHM = Weight of hot metal per kg-mole of iron product (or per NTHM)=59.7 kg HM/kg-mole
Fe

ncHM=Moles of carbon in the hot metal; for 4.5 pct C =0.224 moles C/mole Fe.
njHM= Moles of element j in the hot metal per mole of iron calculated from the hot metal
chemistry , where j = Si,Mn,P and S.

nI = Moles of CO and H2 in the injected fuel per mole of Fe (or per NTHM).
nOM = Moles of oxygen from the reduction of SiO2,MnO,P2O5 in the lower bosh and hearth
per mole of iron (or per NTHM), = 2nSiHM+nMnHM+2.5nPHM

nSl = Slag weight, as kg/kg-mole Fe

nSlCaO =Moles of CaO in the slag per mole of iron.
nCSL=Moles of carbon per mole of iron participating in the solution loss reaction.
ncWGS=Moles of carbon per mole of iron participating in water gas shift reaction.
O+ H 2
yi , O/Fe , Fe = Ordinates for the Rist diagram for the moles of iron –bound oxygen
or iron bound oxygen and hydrogen per mole of iron.

XB,YB =Co-ordinates for Rist diagram locating the amount of oxygen exchanged by
B B Sl
solution loss reaction on the operating line. where X =1 and Y =nc .

XW,YW = Co-ordinates for Rist diagram locating the conditions of equilbrium of Wustite
W Eq W
and gas phase on the operating line, where X = X ,Y =1.05 moles O/Fe

XP,YP= Co-ordinates for Rist diagram locating the heat balance for the bosh and hearth on
the operating line.

yf = nOI+nH2I+nOM.
TBl = Temperature of the blast
TEqFeO/Fe = Temperature for the FeO-Fe gas equilbrium
TFuel = Temperature of the injected fuel
THM =Temperature of the hot metal.
TSl = Temperature of the slag assumed to be 50 F+T0 HM
.

Cpi = Mean heat capacity of gas and solid species i at constant pressure
CpHM,CpSl = Mean heat Capacity for hot metal and slag at constant pressure respectively.
QsI = Sensible heat of the burden for i=Bl ; of the gas stream for i=G; of the injected fuel
for i=I; of the hot metal and slag for i=HM; and the heat losses for the bosh and hearth for
i=L .

(QLS)T =Total heat losses for the blast furnace (stack ,bosh,and hearth).
QLS = Heat losses for the bosh and hearth.
ΔHsBl= Sensible heat of the blast
Q1 = Term appearing in the heat balance equations that includes the specific sensible heat
of the blast , ΔHsBl ,and the reaction heat per mole of oxygen for the water gas shift ,
combustion of the blast moisture and combustion of the blast oxygen, ΔHRWGS ,ΔHRH2 and
ΔHRBl respectively.

Q2= Term appearing in the heat balance equation which consist of both sensible heats and
heats of reactions.

Ф = Fraction of total heat Losses attributed to the bosh and the hearth,

ΔHRI = Standard heat of reaction in KJ/kgmole

QRI =Net heat for reaction i in KJ/Kg mole of Iron = ΔHRI *ni