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Metallurgy of Iron and Steelmaking

The document outlines the course content for a class on metallurgy of iron and steelmaking. It includes 15 topics that will be covered over the semester, such as ironmaking in blast furnaces, mass and heat balances in ironmaking, and stainless steelmaking. It also provides three sample mass balance case studies involving iron blast furnaces, showing calculations to determine input materials, output of pig iron and slag, and slag composition.

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Agustine Setiawan
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362 views

Metallurgy of Iron and Steelmaking

The document outlines the course content for a class on metallurgy of iron and steelmaking. It includes 15 topics that will be covered over the semester, such as ironmaking in blast furnaces, mass and heat balances in ironmaking, and stainless steelmaking. It also provides three sample mass balance case studies involving iron blast furnaces, showing calculations to determine input materials, output of pig iron and slag, and slag composition.

Uploaded by

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

07. Mass and Heat Balance in


Ironmaking
Metallurgy of Iron and Steelmaking (MG-4113)
Dr.-Ing. Zulfiadi Zulhan
Department of Metallurgical Engineering
Institute of Technology Bandung

Course Content
1.
2.
3.
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14.
15.

Teknik Metalurgi

Introduction
Burden materials preparation for ironmaking
Ironmaking in blast furnace
Blast furnace technology
Smelting reduction (COREX, HISMELT, DIOS, etc.)
Direct reduction (HyL I, HyL III, MIDREX, SL/RN, CIRCORED, etc.)
Mass and Heat balance in ironmaking
Midterm Examination
Hot metal desulphurization & Steelmaking based on hot metal (de-C, de-Si,
De-P, Mn-removal, LD-Converter / BOF)
Steelmaking based on scrap and sponge iron (SIEMENS MARTINS, EAF)
Secondary metallurgy (Deoxidation, Desulphurization, Alloying, LF, CHF)
Vacuum metallurgy (RH, VD)
Stainless steelmaking (AOD, VOD)
Continous casting (CCM)
Final Examination

Dr.-Ing. Zulfiadi Zulhan

2009

MG-4113 Metallurgy of Iron and Steelmaking

Iron and Steelmaking Route

Teknik Metalurgi

LT
Blast furnace
HM de-S

BOF
RH /
RH-TCOB
CCM

COREX Plant

VD/
VD-OB
EAF

Direct Reduction
Plant

Ironmaking
Dr.-Ing. Zulfiadi Zulhan

LF
Ingot
Scrap

Primary
Steelmaking
2009

Secondary
Steelmaking

Casting

MG-4113 Metallurgy of Iron and Steelmaking

Case 1 (mass balance)

Teknik Metalurgi

An iron blast furnace produced 2400 tons of pig iron per day. The analysis
of pig iron was 92.9% Fe, 4%C, 1.38% Si, 0.9% P, 0.8% Mn and 0.02% S.
The iron ore charged into the furnace contained 72.2% Fe2O3, 9.6% SiO2,
7.8% Al2O3, 6.2%H2O, 3.1% MnO and 1.1%P2O5.
The coke used contained 89%C, 8% SiO2, 2%Al2O3 and 1% FeS.
Lime stone flux was 96.5% CaCO3 and 3.5%SiO2.
The input rates of coke and limestone were 1800 and 1200 tons per day,
respectively.
98.5% of all the iron entering the furnace was accounted for by pig iron.
Determine:
1. Input rate of ore
2. Output rate and composition of slag
Dr.-Ing. Zulfiadi Zulhan

2009

S: Y.K. Rao, Stoichiometry and Thermodynamics of


metallurgical processes, Cambridge University Press,
1985
MG-4113 Metallurgy of Iron and Steelmaking

Solution 1: 1. input rate of iron ore

Teknik Metalurgi

Assume: steady state operation


Input rate of ith component = output rate of ith componet

For iron:
W in (0.722*111.7/159.7) + 1800*1/100*(55.85/87.85) = 2400*(0.929/0.985)
Input rate of iron ore (W in)= 4462 tons / day

Dr.-Ing. Zulfiadi Zulhan

2009

MG-4113 Metallurgy of Iron and Steelmaking

Solution 1: 2. output rate and composition of slag

Teknik Metalurgi

Slag forming components are: Al2O3, CaO, CaS, FeO, MnO, P2O5, SiO2
Total Al2O3 input to the furnace=4462 * 0.078 + 1800*0.02 = 384 tons
All of this Al2O3 is accounted for by the slag
Total sulfur input to the furnace = 1800*0.01*32/87.85 = 6.55 tons
Sulfur in pig iron = 2400*0.00002 = 0.48 tons
Sulfur going into slag = 6.55 0.48 = 6.07 tons
CaS in the slag = 6.07*(72/32) = 13.7 tons
Total CaO input to the furnace = 1200*0.965 * 56/100 = 648.5 tons
Amount of CaO converted into CaS = 13.7*(56/72) = 10.6 tons
Amount of CaO going into slag = 648.5 10.6 = 637.9 tons
Dr.-Ing. Zulfiadi Zulhan

2009

MG-4113 Metallurgy of Iron and Steelmaking

Solution 1: 2. output rate and composition of slag


(cont.)

Teknik Metalurgi

Amount of iron going into slag = 2400*0.929 * 1.5/98.5 = 34 tons


Amount of FeO in the slag = 34*(71.85/55.85) = 43.7 tons
Total Mn input to the furnace = 4462*0.031 * 54.94/70.94 = 107.2 tons
Amount of Mn in pig iron = 2400*(0.008) = 19.2 tons
Amount of MnO going into slag = (107.2 19.2)*70.94/54.94 = 113.6 tons
Total P2O5 input to the furnace = 4462*0.0011 = 49.1 tons
Total P input to the furnace = 49.1* (62/142) = 21.6 tons
Amount of P in pig iron = 2400*0.009 = 21.6 tons
No P enters the slag

Dr.-Ing. Zulfiadi Zulhan

2009

MG-4113 Metallurgy of Iron and Steelmaking

Solution 1: 2. output rate and composition of slag


(cont.)

Teknik Metalurgi

Total SiO2 input to the furnace = 44.62*9.6 + 18*8 + 12*3.5 = 614.4 tons
Amount of Si in pig iron = 24*(1.38) = 33.1 tons
Amount of SiO2 reduced to metal = 33.1(60.1/28.1) = 70.8 tons
Amount of SiO2 going into slag =614.4 70.8 = 543.6 tons
Rate of output of slag = 1736.5 tons per day
Slag composition:
Al2O3

= 22.12%

FeO

= 2.52%

CaO

= 36.74%

MnO

= 6.53%

CaS

= 0.79%

SiO2

= 31.3 %

Dr.-Ing. Zulfiadi Zulhan

2009

MG-4113 Metallurgy of Iron and Steelmaking

Case 2 (mass balance)

Teknik Metalurgi

The daily charge to an iron blast furnace consists of 3600 tons of hematite
ore, 2000 tons of coke and limestone sufficient to produce a slag containing
35% SiO2.
Ore: 74.4% Fe2O3, 9.8% SiO2, 0.9% P2O5, 3.4% MnO2, 4.3% Al2O3 and 7.2%
H2O
Coke: 88% C, 8.5% SiO2, 1.6% FeS, and 1.9% H2O
Limestone: 97.6% CaCO3, 0.8% Al2O3, 1% SiO2 and 0.6% H2O
Pig iron contains 3.8% C. All of the phosphorous in the charge enters the pig
iron, and so do 40% of the manganese and 15% of the silicon in the charge.
All of the sulfur and 1.2% of the iron in the charge are slagged off.
The amount of blast per ton of coke charged is 3600 m3 at 17C and 1 atm.
The blast is preheated to 771C and steam content in the blast is 5 g/m3.
Find the composition of pig iron, slag and top gas!
Dr.-Ing. Zulfiadi Zulhan

2009

S: Y.K. Rao, Stoichiometry and


Thermodynamics of metallurgical processes,
Cambridge University Press, 1985
MG-4113 Metallurgy of Iron and Steelmaking

Case 3 (mass balance)

Teknik Metalurgi

The daily charge to an iron blast furnace consisted of the following:


Pellets: 2400 tons
86% Fe2O3, 9% SiO2, 0.6%CaO, 0.5% Al2O3, 0.4% FeO, 0.4% MgO, 0.25%
MnO, 0.04% P2O5,0.01% FeS, 2.8% H2O
Sinter: 2400 tons
66% Fe2O3, 14% FeO, 8.5% SiO2, 6%CaO, 2% Al2O3, 1% MgO, 0.75%
MnO, 0.1% P2O5, 0.05% FeS, 1.6% H2O
Limestone: 375 tons
96.5% CaCO3, 1.8% MgCO3, 0.7% Fe2O3, 0.5% Al2O3, 0.5% SiO2
Dolomite: 375 tons

54.6% CaCO3, 43.8% MgCO3, 0.6% Fe2O3, 0.5% Al2O3, 0.5% SiO2
Dr.-Ing. Zulfiadi Zulhan

2009

MG-4113 Metallurgy of Iron and Steelmaking

Case 3 (mass balance), cont.

Teknik Metalurgi

Coke: 1875 tons


87% C, 3.5% SiO2, 2.5% Al2O3, 1.5% FeS, 0.4% CaO, 0.1% MgO, 5% H2O
The amount of blast supplied to the tuyeres was 5.85*106 m3/day measured
at 37C and 1 atm. The moisture content was 30 g/m3 of non preheated
blast.
The solid particles carried away by the upward moving gases were collected
in the dust catchers. This flue dust amounted to 65 tons/day and contained
the following:
60% Fe2O3, 18.5% C, 8.5% CaCO3, 8% SiO2, 3.5%MgCO3, 1.5% Al2O3
All the phosphorous charged, one-half of the Mn, one-seventh of the Si, and
one-tenth of the sulfur entered the pig iron which also contained 93.5% Fe.
Assume: no iron was lost in the slag.

S: Y.K. Rao, Stoichiometry and


Thermodynamics of metallurgical processes,
Cambridge University Press, 1985

Find the amount and composition of pig iron, slag and top gas!
Dr.-Ing. Zulfiadi Zulhan

2009

MG-4113 Metallurgy of Iron and Steelmaking

Case 4 (heat balance) (HOMEWORK)

Teknik Metalurgi

Prepare a heat balance for the iron blast furnace described in case 3. The
blast is preheated to 900C, the solid charge is at 25C, and the top gases
from the furnace are at 190C. The pig iron is tapped at 1450C, and the
slag temperature is 1550C.
Use 1 ton of pig iron as the basis of calculation and 298K as the reference
temperature.
The heat supply consists of(a) sensible heat in the preheated blast, (b)
sensible heat in the solid charge (negligible), and (c) heat generated by
exothermic reactions
The heat consumption consists of (d) heat adsorbed by endothermic
reactions, (e) sensible heat in the pig iron, (f) sensible heat in the slag, (g)
sensible heat in the top gases, (h) sensible heat in the flue dust, and (i) heat
losses.
S: Y.K. Rao, Stoichiometry and
Thermodynamics of metallurgical processes,
Cambridge University Press, 1985

Dr.-Ing. Zulfiadi Zulhan

2009

MG-4113 Metallurgy of Iron and Steelmaking

Thank you for your attention!

Teknik Metalurgi

Dr. -Ing. Zulfiadi Zulhan


Program Studi Teknik Metalurgi
Fakultas Teknik Pertambangan dan Perminyakan
Institut Teknologi Bandung
Jl. Ganesha No. 10
Bandung 40132
INDONEISIA

Telefon
Fax
Mobil

: +62 (0) 22 250 2239


: +62 (0) 22 250 4209
: +62 (0) 813 22 93 94 70

E-Mail: [email protected]

Dr.-Ing. Zulfiadi Zulhan

2009

MG-4113 Metallurgy of Iron and Steelmaking

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