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    Nice EAF Mass Balance (Old Is Gold)

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    Karthik Gutti
    The document provides material balance calculations for an electric arc furnace (EAF) steelmaking process. It includes: 1) Material input compositions including iron ore, limestone, scrap, and their weights. 2) Material output compositions for slag, steel, and gases. 3) Equations solving for the material balances of iron, silicon dioxide, calcium oxide, carbon, and oxygen in the process. 4) The calculations determine the weights of steel (147 tons), slag (2.118 tons), and limestone (4.8 tons) produced.

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    © All Rights Reserved
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    Nice EAF Mass Balance (Old Is Gold)

    Uploaded by

    Karthik Gutti
    38 views16 pages
    The document provides material balance calculations for an electric arc furnace (EAF) steelmaking process. It includes: 1) Material input compositions including iron ore, limestone, scrap, and their weights. 2) Material output compositions for slag, steel, and gases. 3) Equations solving for the material balances of iron, silicon dioxide, calcium oxide, carbon, and oxygen in the process. 4) The calculations determine the weights of steel (147 tons), slag (2.118 tons), and limestone (4.8 tons) produced.

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    Eaf

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    Nice EAF mass balance ( Old is Gold )

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    The document provides material balance calculations for an electric arc furnace (EAF) steelmaking process. It includes: 1) Material input compositions including iron ore, limestone, scrap, and their weights. 2) Material output compositions for slag, steel, and gases. 3) Equations solving for the material balances of iron, silicon dioxide, calcium oxide, carbon, and oxygen in the process. 4) The calculations determine the weights of steel (147 tons), slag (2.118 tons), and limestone (4.8 tons) produced.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    38 views16 pages

    Nice EAF Mass Balance (Old Is Gold)

    Uploaded by

    Karthik Gutti
    The document provides material balance calculations for an electric arc furnace (EAF) steelmaking process. It includes: 1) Material input compositions including iron ore, limestone, scrap, and their weights. 2) Material output compositions for slag, steel, and gases. 3) Equations solving for the material balances of iron, silicon dioxide, calcium oxide, carbon, and oxygen in the process. 4) The calculations determine the weights of steel (147 tons), slag (2.118 tons), and limestone (4.8 tons) produced.

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    HBI (X)(Wt%) O2 Lance Carbon(Wt%) Gases(Vol%)

    Feo 53.4 Fe 0.07 CO2 35.5


    ++
    Fe 32.1 C 86 O2 2.5
    Fetotal 85.5 S 0.55 N2 62
    O (associated with Fe) 9.2 SiO2 3
    SiO2 1.8 CaO 5.6

    Al2O3 2.1 (3.5 ton)


    CaO 0.022
    MgO 0.017
    P2O5 0.34
    S 0.02
    C 2
    P 0.09

    (20 ton)

    EAF
    Burnet Lime(W3)(Wt%)
    Slag(W2)(Wt%)
    CaO 94.4 FeO 21.05
    SiO2 1.5 CaO 36.5
    S 0.04 MnO 1.64
    MgO 1.06 SiO2 14.9
    Lai 3 Al2O3 4.64
    MgO 12

    Scrap(Wt%) Steel(W1)(Wt%)
    Fe 93 Fe 98.69
    SiO2 1.3 C 0.25
    CaO 0.7 S 0.03
    C 0.3 P 0.03
    FeO 1.5 Mn 0.75

    (140 ton) Si 0.2


    Material balance on EAF

    1)Material balance on( Fe)

    2Fe+O2→ 2𝐹𝑒𝑂
    2*56+16*2→ 144

    32.1 53.4 93 112 1.5 0.7


    ∗ 20 + ∗ 20 + ∗ 140 + ∗ ∗ 140 + ∗ 3.5
    100 100 100 144 100 100
    112 21 99
    = ∗ ∗ 𝑤2 + 𝑤1
    144 100 100

    6.42+10.68+130.2+1.63+0.0245=0.99w1+0.163w2
    𝟎. 𝟗𝟗𝒘𝟏 + 𝟎. 𝟏𝟔𝒘𝟐 = 𝟏𝟒𝟗 → 𝒆𝒒𝒖 𝟏

    2)Material balance on( SiO2)

    Si+O2→SiO2
    28+(16*2) → 60

    1.8 1.3 1.5 3 15


    ∗ 20 + ∗ 140 + ∗ w3 + ∗ 3.5 = ∗ w2
    100 100 100 100 100

    0.36+1.82+0.015w3+0.105=0.15w2
    𝟎. 𝟏𝟓𝒘𝟐 − 𝟎. 𝟎𝟏𝟓𝒘𝟑 = 𝟐. 𝟐𝟖𝟓 → 𝒆𝒒𝒖 𝟐
    3)Material balance on( CaO)

    Ca+ O2→CaO

    40+16→ 56

    0.022 94.4 0.7 5.6 36.5


    ∗ 20 + ∗ 𝑤3 + ∗ 140 + ∗ 3.5 += 𝑤2
    100 100 100 100 100

    0.0044+0.0944w3+0.98+0.196=0.365w2
    𝟎. 𝟑𝟔𝟓𝒘𝟐 − 𝟎. 𝟗𝟒𝟒𝒘𝟑 = 𝟏. 𝟏𝟖𝟎𝟒 → 𝒆𝒒𝒖 𝟑

    ‡
    𝟎. 𝟗𝟗𝒘𝟏 + 𝟎. 𝟏𝟔𝒘𝟐 = 𝟏𝟒𝟗 → 𝒆𝒒𝒖 𝟏
    𝟎. 𝟏𝟓𝒘𝟐 − 𝟎. 𝟎𝟏𝟓𝒘𝟑 = 𝟐. 𝟐𝟖𝟓 → 𝒆𝒒𝒖 𝟐
    𝟎. 𝟑𝟔𝟓𝒘𝟐 − 𝟎. 𝟗𝟒𝟒𝒘𝟑 = 𝟏. 𝟏𝟖𝟎𝟒 → 𝒆𝒒𝒖 𝟑

    𝟎. 𝟗𝟗 𝟎. 𝟏𝟔𝟑 𝟎
    ∆= 𝟎 𝟎. 𝟏𝟓 −𝟎. 𝟎𝟏𝟓
    𝟎 𝟎. 𝟑𝟔𝟓 −𝟎. 𝟗𝟒𝟒

    0.99[(0.15*-0.944)-(0.365*-0.015)]
    =0.99[-0.1416 +5.475*10-3]
    = -0.135
    𝟏𝟒𝟗 𝟎. 𝟏𝟔𝟑 𝟎
    ∆𝟏 = 𝟐. 𝟐𝟖𝟓 𝟎. 𝟏𝟓 −𝟎. 𝟎𝟏𝟓
    𝟏. 𝟏𝟖𝟎𝟒 𝟎. 𝟑𝟔𝟓 −𝟎. 𝟗𝟒𝟒

    ∆𝟏 = 𝟏𝟒𝟗[(𝟎. 𝟏𝟓 ∗ −𝟎. 𝟗𝟒𝟒) − (𝟎. 𝟑𝟔𝟓 ∗ −𝟎. 𝟎𝟏𝟓) ] −


    𝟎. 𝟏𝟔𝟑[(𝟐. 𝟐𝟖𝟓 ∗ −𝟎. 𝟗𝟒𝟒) − (𝟏. 𝟏𝟖𝟎𝟒 ∗ −𝟎. 𝟎𝟏𝟓) ]

    ∆𝟏 =
    𝟏𝟒𝟗[−𝟎. 𝟏𝟒𝟔 + 𝟎. 𝟎𝟎𝟓. 𝟒𝟕𝟓] − 𝟎. 𝟏𝟔𝟑[−𝟐. 𝟏𝟓𝟕 +
    𝟎. 𝟎𝟏𝟖]
    ∆𝟏 = −𝟐𝟎. 𝟐𝟖𝟑 + 𝟎. 𝟑𝟒𝟗
    ∆𝟏 =
    𝒘𝟏 =
    𝒘𝟏 = 𝟏𝟒𝟕
    𝒘𝟏(𝑺𝒕𝒆𝒆𝒍 𝒘𝒆𝒊𝒈𝒉𝒕) = 𝟏𝟒𝟕
    𝟎. 𝟗𝟗 𝟎. 𝟏𝟒𝟗 𝟎
    ∆𝟐 = 𝟎 𝟐. 𝟐𝟖𝟓 −𝟎. 𝟎𝟏𝟓
    𝟎 𝟏. 𝟏𝟖𝟎𝟒 −𝟎. 𝟗𝟒𝟒

    ∆𝟐 = 𝟎𝟗𝟗[(𝟐. 𝟐𝟖𝟓 ∗ −𝟎. 𝟗𝟒𝟒)


    − [(𝟏. 𝟏𝟖𝟎𝟒 ∗ −𝟎. 𝟎𝟏𝟓)]
    = 𝟎. 𝟗𝟗(−𝟐. 𝟏𝟓𝟕 + 𝟎. 𝟎𝟏𝟕𝟗)
    = −𝟐. 𝟏𝟏𝟖
    ∆𝟐
    𝒘𝟐 =
    ∆
    𝟎. 𝟗𝟗 𝟎. 𝟏𝟔𝟑 𝟏𝟒𝟗
    ∆𝟑 = 𝟎 𝟎. 𝟏𝟓 𝟐. 𝟐𝟖𝟓
    𝟎 𝟎. 𝟑𝟔𝟓 𝟏. 𝟏𝟖𝟎𝟒

    ∆𝟑 = 𝟎. 𝟗𝟗[(𝟎. 𝟏𝟓 ∗ 𝟏. 𝟏𝟖𝟎𝟒) − (𝟎. 𝟑𝟔𝟓 ∗ 𝟐. 𝟐𝟖𝟓)]


    = 𝟎. 𝟗𝟗[𝟎. 𝟏𝟕𝟖 − 𝟎. 𝟖𝟑𝟒]
    = −𝟔𝟒𝟗
    ∆𝟑
    𝒘𝟑 =
    ∆
    𝒘𝟑 = −𝟎. 𝟔𝟒𝟗/−𝟎. 𝟏𝟑𝟓

    𝒘𝟑 = 𝟒. 𝟖
    𝒘𝟑(𝑳𝒊𝒎𝒆 𝒘𝒆𝒊𝒈𝒉𝒕) = 𝟒. 𝟖 𝒕𝒐𝒏
    4)Material balance on( Carbon)

    2 0.3 86
    ∗ 20 + ∗ 140 + ∗ 3.5
    100 100 100
    0.25
    = ∗ 137 + [𝐶 𝑔𝑎𝑠𝑒𝑠]
    100
    𝐶 𝑔𝑎𝑠𝑒𝑠 = 0.4 + 0.42 + 3 − 0.343
    𝐶 𝑔𝑎𝑠𝑒𝑠 = 𝟑. 𝟓 𝒕𝒐𝒏

    5)Material balance on( Oxygen)

    O2 in CO2
    C+O2→CO2
    12 32→ 44
    3.5 𝑥
    44
    𝑥 = 3.5 ∗
    12
    𝑥 = 12.8
    𝑥 (𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐶𝑂2) = 12.8 𝑡𝑜𝑛
    12.8→ 35.5
    T.gases→100

    • Total weight of gases=36 ton


    •O2 in CO2
    32
    = 12.8 ∗ = 9.3 𝑡𝑜𝑛
    44

    •O2 in FeO
    2Fe + O2 → 2FeO
    2 ∗ 56 2 ∗ 16 → 144

    •Amount of O2 in FeO input


    9.2 1.5 32
    ∗ 20 + ∗ ∗ 140
    100 100 144
    = 1.84 + 0.467
    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 in FeO input = 2.307 𝑡𝑜𝑛

    •Amount of O2 in FeO output

    21 32
    ∗ 14.5 ∗ = 0.677
    100 144
    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 output in FeO = 0.677 𝑡𝑜𝑛
    •O2 in SiO2
    Si + O2 → SiO2
    28 32 60

    •Amount of O2 in SiO2 input


    1.8 32 1.5 32
    ∗ 20 ∗ + ∗ ∗ 4.5
    100 60 100 60
    1.3 32 3 32
    + ∗ 140 ∗ + ∗ 3.5 ∗
    100 60 100 60
    = 0192 + 0.036 + 0.971 + 0.056
    = 1.255
    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 in SiO input = 1.255 𝑡𝑜𝑛

    •Amount of O2 in SiO2 output


    15 32
    ∗ 14.5 ∗ = 1.16
    100 60

    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 in SiO output = 1.16 𝑡𝑜𝑛


    •O2 in Al2O3

    2Al + O2 → Al2O3

    (2 ∗ 27)+ ( ∗ 32) → 102

    •Amount of O2 in Al2O3 input

    2.1 48
    ∗ 20 ∗ = 0.198
    100 102

    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 in Al O input = 0.198 𝑡𝑜𝑛

    •Amount of O2 in Al2O3 output


    4.64 48
    ∗ 14.5 ∗ = 0.317
    100 102

    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 in Al O output = 0.317 𝑡𝑜𝑛


    •O2 in CaO

    Ca + O2 → CaO

    40 16 56

    •Amount of O2 in CaO input


    0.022 16 94.4 16
    ∗ 20 ∗ + ∗ 4.5 ∗
    100 56 100 56
    0.7 16 5.6 16
    + ∗ 140 ∗ + ∗ 3.5 ∗
    100 56 100 56
    = 1.257 ∗ 10 + 1.214 + 0.28 + 0.056
    = 1.55
    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 in CaO input = 1.55 𝑡𝑜𝑛

    •Amount of O2 in CaO output


    36.5 16
    ∗ 14.5 ∗ = 1.51
    100 56

    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 in CaO output = 1.51 𝑡𝑜𝑛


    •O2 in MgO

    Mg + O2 → MgO

    24 16 40

    •Amount of O2 in MgO input


    0.017 16 1.06 16
    ∗ 20 ∗ + ∗ 4.5 ∗
    100 40 100 40
    = 1.36 ∗ 10 + 0.0191 = 0.0205
    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 in MgO input = 0.025 𝑡𝑜𝑛

    •Amount of O2 in MgO output


    12 16
    ∗ 14.5 ∗ = 0.696
    100 40

    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 in MgO output = 0.696 𝑡𝑜𝑛


    •O2 in MnO

    Mn + O2 → MnO

    55 16 71

    •Amount of O2 in MnO input


    16 0.11
    ∗ ∗ 20 = 4.958 ∗ 10
    71 100
    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 in MnO input = 4.958 ∗ 10 𝑡𝑜𝑛

    •Amount of O2 in MnO output


    16 1.64
    ∗ ∗ 14.5 = 0.054
    71 100

    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 O2 in MnO output = 0.054 𝑡𝑜𝑛


    •O2 in P2O5

    2P + O2 → P2O5

    62 80 142

    •Amount of O2 in P2O5 input


    80 0.34
    ∗ 20 ∗ = 0.038
    142 100
    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓O in P O input = 0.038 𝑡𝑜𝑛

    •Amount of O2 in P2O5 output


    80 0.53
    ∗ ∗ 14.5 = 0.043
    142 100
    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓O in P O output = 0.043 𝑡𝑜𝑛
    Total O2 input
    𝑂 𝐿𝑎𝑛𝑐𝑒 + 2.307 + 1.255 + 0.198 + 1.55 + 0.0205
    + 4.958 ∗ 10 + 0.038 =
    = 5.33 + 𝑂 𝐿𝑎𝑛𝑐𝑒

    Total O2 output

    2.5
    9.3 + ∗ 36 + 0.677 + 1.16 + 0.317 + 1.51
    100
    + 0.696 + 0.054 + 0.043 = 14.6
    𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓O 𝑜𝑢𝑡𝑝𝑢𝑡 = 14.6 𝑡𝑜𝑛
    𝑂 𝑜𝑢𝑡𝑝𝑢𝑡 = 𝑂 𝑖𝑛𝑝𝑢𝑡 + 𝑂 𝐿𝑎𝑛𝑐𝑒
    ∴ 𝑂 𝐿𝑎𝑛𝑐𝑒 = 14.6 − 5.33 = 9.3 𝑡𝑜𝑛
    𝑃𝑉 = 𝑛𝑅𝑇
    9.3
    ∴ 0.76 ∗ 13600 ∗ 9.8 ∗ 𝑉 = ∗ 10 ∗ 8.3 ∗ 273
    32

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