... who can tell which of her forms has shown her substance right?

William Butler Yeats (in" A Bronze Head". 1933)

CHAPTER SEVEN

HEAT AND MASS BALANCE

7.0. Introduction

Heat and mass balance plays a very important role to increase the

productivity and maintain the quality of product of any metallurgical

industry. In sponge iron production through coal based rotary kiln process

raw materials used are iron ore, coal and flux (lime stone or dolomite). In

process metallurgy any one of the following factor is important.

i) . Given the composition of the charge put in the furnace, including their

weight what will be the amount and compositions of the resulting products

is known as the charge balance. If the process is one of smelting or refining

these products are mainly the metals, the slag and the gases.

ii) . Given the composition of various ores, fluxes and reducing agents

available, in what amount or proportions shall these be taken to yield

products of desired composition is known as charge make up.

Finally third important step is the heat balance of the system i.e.

iii) . With given charge undergoing known reactions and yielding certain

products, what are the heat requirements, or how much heat is supplied or

generated and how it is distributed is called heat balance.

The heat balance is an extremely useful calculation in all kind of

furnaces and operations. It has been widely employed in the design of

175
furnaces and processes for the purpose of estimating fuel requirements and

also in the determination of furnace efficiencies and general thermal study

of the process.

A heat balance consists of a listing and evaluation of all items of

heat supplied or available and a similar listing or evaluation of heat used,

lost, or distributed, the sum of the first set of items being equal to the sum

of the second set. In practice it is not possible to evaluate all items. In most

cases the heat lost by radiation, convection and conduction to the ground or

supports cannot be determined, and the difference between the total heat

supplied and the determined amount of heat distributed is then called heat

lost by radiation, convection and conduction, the two sides thus being

caused a balance. In other case it may be possible from a prior knowledge

of similar furnace or processes to estimate fairly, closely the amount of heat

that would be lost by radiation, convection and conduction, and this

estimate may be entered in the balance sheet to afford a determination by

difference of some other unknown item. This procedure is followed in

estimating the . quantity of heat to be supplied by fuel when the fuel

requirements are sought.

7.0.1. Items of Heat Supply

The source of heat supply and the points of distribution vary in

different processes. In general the source of heat entering may include the

following:

176
 i) . Heat of combustion of the fuel (or electric energy in case of electric

furnace)

ii) . Sensible heat in the fuel.

iii) . Sensible heat in the air supplied.

iv) . Sensible heat in the furnace charge

v) . Heat developed by the exothermic reactions in the furnace.

7.0.2. Items of Heat Distribution

In general the items of heat leaving may include the following:

i) . Heat consumed in the endothermic reactions in the furnace.

ii) . Heat used in evaporation of moisture.

iii) . Sensible heat in the hot flue gases.

iv) . Sensible heat in the principal furnace product.

v) . Sensible heat in the slag/by product.

vi) . Heat absorbed by cooling water.

vii) . Heat lost to radiation to surroundings.

viii) .Heat lost by convection to air in contact with furnace directly; but all

other items of important magnitude may be determined gives idea about

a. What is the thermal efficiency of the process or the furnace.

b. How much fuel or how much electrical energy is required.

7.1 Calculation
7.1.1.Data used.
1) . Sponge iron produced : 12.54 TPH
2) . Iron ore used : 18.45 TPH
3) . Coal used

177
 a) . Feed end (F.E.) : 6.31 TPH
b) . Discharge end (D.E.) 6.51 TPH
c) . Back Spill 0.267 TPH
4). Dolomite 0.38 TPH
5). Char out 1.96 TPH
6). Fly ash going out with flue gas 2.23 TPH
n8
).
Temp, of the bed inside the kiln
Temp, of the solid discharged from
1067°C(1340K)

the kiln 1050°C(1323 K)

9). Temp of the waste gases 827° C (1000 K)
10). Outside temp of the kiln shell 150° C ( 423 K)
11). Inside diameter of the kiln
(after lining) 3.82 mtrs
12). Outside diameter of the kiln 4.00 mtrs
13). Length of the kiln 70.8 mtrs

Heat values used for heat balance calculation (As per Janaf Table)

a). Heat of formation at 1340 K (k. Cal/Kg.)

Fe203 = -1209.82
FeO = - 896.45
CO = -974.33
C02 = -2146.57
H20 = -3315.22

b). Sensible heat, at 1325 K (k. Cal/Kg.)

Fe (metallic) = 168.344
FeO = 194.711
Si02 =271.875

c). Ash (same as Si02)= 271.871(k. Cal/Kg.)

C =380.917

d). Latent heat of vaporization (k. Cal/Kg.)

Water = 540
Phenol = 122

e). Sensible heat at 1100 K (k. Cal/Kg.)

Fe203 = 172.299 N2 =211.32 Methane = 680.438

C =278.917 C02 =211.27
Si02 = 209.070 02 = 195.812
V.M =32.000 CO =213.679
Water = 400.550 H2 =2835.00
7.1.2. Chemistry of raw materials

ron ore: % Coal Coal Char %

■e = 67.02 Proximate analysis Ultimate analysis C =28.26
langue = 4.251 Feed End: % Feed End: % Ash = 70.32
Moisture= 7.3 C = 64.348 V.M = 1.42
(Donee iron: % V.M =27.3 H= 3.373 C in V.M = 60
F.C =47.6 N= 0.979 = 1.42x0.6=852
re (Metallic)= 83.50 Ash = 17.80
?e (Total) = 92.50 Oxygen = 6.20 Solid out in flue gas %
■eO (Fe as FeO in Moisture =7.30 Fe203 =4L5(Fe=28.98)
ponge iron)=11.71 Gross. C.V= C = 14.20
langue =4.62 5325 k.Cal/Kg. V.M=5.70(C=60%=3.42)
Si02 + Al203 = 33.92
Jolomite Discharge End: % Discharge End: % CaO = 2.46
:aO = 30.02 % Moisture= 8.73 C= 65.21 38.6 38.6
tlgO =16.50% V.M = 27.01 H= 3.40
Si02 =4.31 % F.C =50.10 N= 1.01 MgO = 2.22
Ash= 15.50
Oxygen =6.27
Moisture =8.7 Total =38.6%
Gross. C.V=
5496 k. Cal/Kg.

7.1.3.Mass Balance

7.I.3.I. Iron balance

Innut in Kg.. /hr. Output in Kg., /hr.
0.6702 x. 18,450= 12,365.19 i). Fe metallic = 12,540 x 0.83
= 10,470.9
ii). Fe in dust = 2230 x 0.2966
= 661.4
iii). Fein FeO = 12,540x0.09
= 1128.6
*Un accounted loss = 104.272

Total = 12365.19 Total = 12365.19

""Unaccounted loss is

i) . In magnetic separation
ii) . In dust extraction system
iii) . In accretion inside the reactor.

179
 7.I.3.2. Carbon balance

Input in Kg../hr Output in Kg./hr

F.E Coal (6310-267) x 0.6043 F.C., Out in char

= 3888.7 = 1960x0.2826 =553.9
D.C Coal (6510) x 0.6521 - F.C., out in flue dust
= 4545.2 = 2230x0.142 =316.7
C in CO2 generated from dissociation F.C,, going to sponge iron
of dolomite =38.57 = 12540x0.0017 =21.32
F.C., used in reaction {assuming that
Total = 8172.47 reaction is FejOj + 3CO = 2Fe + 3CO2, in
this reaction Fe (Kg.): C (Kg.) = 112:36.
F.C. in F.E. Coal Here Fe we mean Fe (Met) in sponge iron +
= 6043x0.4760 = 2876.5 Fe as FeO in sponge iron)
F.C. in D.E. coal = 3728.4
= 6510x0.5010 = 3265.5
Excess F.C. burnt = 1556.41
Total = 6138.0 ‘C’of V.M. burnt =418.34
Unburnt V.M. Carbon (D.E.) = 565.32
Qnburnt ‘C’ in V.M. (F.E.) = 1012.08

C. in F.E., Y.M Total =8172.47

= 6043x0.16748 = 1012.08
C. in D.E., V.M
= 6510x0.1511 =983.66

Total: - = 1995.74

7.I.3.3. Gangue balance.

Input in Kg. /hr Output in Kg. /hr

From ore = 18450 x .04251 = 784.43 Gangue in sponge iron = 12540 x .0462
= 579.35
Lost in flue dust = 205.08

Total: - = 784.43

180
 7.I.3.4. Coal ash balance

nput in Kg. /hr Output in Kg. /hr

?oal ash in F.E. Coal = 6043 x . 178 Ash in char = 1960 x 0.7032 = 1378.3
= 1075.654. Ash flying dust = (2230x0.3392)-205.08
^oal ash in D.E. Coal = 6510 x .1596 = 551.336
= 1038.996 Ash to cooler free gangue loss and other
losses =(2114.65-1929.636)
= 185.014

Total =2114.65 Total =2114.65

7.1.4. Heat balance

7.1.4. L Reaction-1
Total FeiOa input = 1B450 x 0.6702.x 160/112 = 17664.557 Kg./hr
Fe203 lost in flying dust =2230x0.2898x160/112 = 923.22 Kg./hr

Hence Fe203 undergoing reduction = 17664.557 - 923.2 =16721.334 Kg./hr.

Fe203 + CO = 2FeO + C02
104.5 104.5 209 104.5
(moles) (moles) (moles) (moles)

16721.33 2926.3 15048 4598

(Kg.) (Kg.) (Kg.) (Kg.)
A Hi -» 20228190 + 2850889.58 = 13489779.6 + 9869928.9
= 23079079.58 - 23359708.46 = -280628.88 k. Cal.

7.I.4.2. Reaction-2
FeO undergone reduction = 15048.72-FeO in sponge iron
= 15048 - 1468.4
= 13580.32 Kg./hr.
FeO + CO = Fe +C02
188.6 188.6 188.6 188.6
(moles) (moles) (moles) (moles)

13580.32 5280.8 10561.6 8298.4

(Kg.) (Kg.) (Kg.) (Kg.)

181
AH2—> 12174077.86 + 5145241.864 = 0 + 17800217.07
= 17319319.7- 17800217.07
=(-) 480897.346 k. Cal.

7.I.4.3. Reaction-3
Total C02 formed due to the reduction of iron oxides =
8298.4 + 4598 = 12896.4
(Ri) (R2)
This CO2 will combine with carbon to generate CO
co2 + C = 2CO
293.1 293.1 586.2
(moles) (moles) (moles)

12896.4 3517.2 16413.6

(Kg.) (Kg.) (Kg.)

AH3 —► 27683025.35 :=1599226

= (+) 11690762.46 k. Cal

7.1.4.4. Reaction-4
Excess CO for combustion
R3 - (Ri + R2)
16413.6 - (2926 + 5280.8) = 8206.8 Kg..

This CO is oxidized to C02

2CO + O2 = 2C02
293.1 146.55 293.1
(moles) (moles) (moles)

8206.8 4689.6 12896.4

(Kg.) (Kg.) (Kg.)
AH4^ 799613 + 0 = 27683025.35 = (-) 19686894.35 k. Cal.

7.I.4.5. Reaction-5
Excess fixed carbon burnt = Net fixed Carbon input - Carbon consumed in
reduction reaction i.e. CO formation. — Carbon
lost in various ways
= 6137.978 - 3728.4 - (553.896 + 316.66 + 21.32 = 891.876)
= 1517.7 Kg.
C +O2 = C02
126.47 126.47 126.47
(moles) (moles) (moles)

1517.7 4047.04 5564.68

(Kg.) (Kg.) (Kg.)

182
A H5 -► 5564.68 x (-) 2146.54 = (-) 11944975.15 k. Cal

7.I.4.6. Assumption:

1) . All V.M. of F.E.Coal goes to After Burner

2) . 40 % of SL V.M. goes to After Burner and 67% of SL V.M. burnt in

the kiln

3) . 42 % of V.M.C. is burnt to C02 and 25% V.M.C. to CO

Burnt in Kiln- -To After Burner

V.M.C v.m.h2 C h2 C h2

F.E.Coal 1012.08 203.83 NIL NIL 1012.08 203.83

D.E. Coal 983.66 223.94 580.18 131.02 403.3 91.81

Total 1995.74 427.77 580.36 131.02 1415.38 295.64

7.1.4.7.CaIculatiori
For C from discharge end (983.66 - 16.70) x 0.67 = 647.863 Kg.
Char
H2 from V.M of D.E. Coal (223.94 - 5.57) x 0.67 = 146.30 Kg.
Char
42% V.M.C burnt to C02 = (983.66 - 16.70) x 0.42 = 406.123 Kg.
25% V.M.C burnt to CO = (580.18 - 406.123) x 0.25 = 241.74 Kg.

7.1.4.8. Reaction-6,
a). C + 02 = C02
33.84 3.84 33.84
(moles) (moles) (moles)
406.12 1082.88 1488.96
(Kg.) (Kg.) (Kg.)

A He (a) —> 0 + 0 - (1488.96 x 2146.57) =(-) 3196156.867 k. Cal

b). 2C + 02 = 2CO
20.145 10.07 20.145
(moles) (moles) (moles)

241.74 322.24 564.06

(Kg.) (Kg.) (Kg.)

183
A H6 (b) —> 0 + 0 - (564.06 x 974.33) =(-) 549580.6 k. Cal

c). 2H2 + 02 =. 2H20

73.15 36.58 73.15
(moles) (moles) (moles)

146.31 1170.48 1316.75

(Kg.) (Kg.) (Kg.)

A Hs (c) —>■ 0 + 0 (1316.75

- 3315.92) = (-) 4366250.924 k. Cal

7.1.4.9. Radiation heat loss.

Heat Transfer = 6366 k. Cal/hm2

A x Dia x Length x 6366 = 5738475.3 k.Cal.

7.1.4.10. Heat of Vaporization of coal V.M.

Assuming that all V.M. is same as phenol which has heat value
=122 k. Cal/Kg..
Total V.M. vaporized =(6043 x 0.273 + 6510 x 0.2701) - 2230 x 0.0570
= 3280.98
Heat of vaporization = 3280.98 x 122 = (+) 400279.56 k. Cal

7.1.4.11. Heat lost in evaporation of moisture in coal at 1100 K.

Total moisture input from coal = (6310-267) x 0.0730 + (6510 x 0.0873)
= 1009.462 Kg..
Heat lost = 1009.462 x 540 = (+) 545109.5 k. Cal

7.1.4.11. (a). Sensible heat lost in sponge iron.

Sensible heat in sponge iron
Mass Sensible heat Total heat k. Cal
(Kg.) at 1325 K
fk. Cal/Kg.)
FeM 10470.9 168.344 1762713.19
FeO 1468.4 194.711 285913.63
Gangue 573.348 271.875 157510.24

Metallic iron loss in 104.27 168.344 17553.229

magnetic separation +
in dust separation +
in accretion inside the Total heat=2223690.29
reactor k. Cal

184
 7.1.4.11. (b). Sensible heat lost in char and ash at 1325 K.
i) . Sensible heat lost through C in char
= 558.6 x 380.9 = 212770.74 k. Cal.
ii) . Sensible heat lost through V.M. in char
= 1960 x 0.0190 x 380.9 = 14184.72 k.cal
iii) . Sensible heat lost through Ash in char
= 1960x0.6960x271.875 = 370881.0 k. Cal
iv) . Sensible heat lost through free coal ash going to cooler
= (2114.65 - 1378.27 - 551.334) x 271.875
= 50309.38 k. Cal

Total = 648145.84 k. Cal

7.1.4.11. (c). Heat lost in flue dust at 1100 K.

Fe203 = (2230 x 0.4150) x 172.299 = 159454.11 k. Cal
F.C. =(2230x0.1420) x 278.917 = 88321.9 k. Cal
V.M. =(2230x0.570) x 132.00 = 4067.52 k.Cal
Gangue =(2230x0.3860) x 209.00 = 179903.02 k. Cal

Total =431746.55 k. Cal

7.1.4.11. (d). Sensible heat in CaO and MgO at 1325 K.

Sensible heat in CaO at 1325 K
= (150.58x271.875) =40938.94 k. Cal
Sensible heat in MgO at 1325 K
= (82.764x265.7) = 21990.3948k. Cal

7.1.5. Dolomite addition.

@ 40 Kg./ton of sponge iron
for 12.54 ton of sponge iron = 501.6 Kg.
Heat of decomposition of 501.6 Kg. of dolomite
= 253037.79 k. Cal

7.1.6. Sensible heat lost in Unburnt V.M. and Tar.

Total Unburnt carbon in V.M. = 1415.38 Kg.
Sensible heat =1415.38 x 278.917 = 394773.544 k. Cal
Total Unburnt H2 = 295.64 x 2835 = 838139.4 k. Cal
Sensible heat of 02 = (6043 x 0.620) x 195.92
= 73404.563 k. Cal

Total = 1307732,887 k. Cal

7.2. Total air requirement for combustion.
Total 02 -»• 4103.4 + 4603.2 + 1082.88 +322.24 + 1170.48 = 10111.72 Kg.
Eqn.4 Eqn:5 Eqn.6.a Eqn.6.b Eqn.6.c

Total air = 10111.72/0.23 = 43964 Kg.

Nitrogen = 43964x0.77 =33852.28 Kg.
Nitrogen from coal = (6043 x .00979) + (6510 x .0101)
= 59.22+ 65.75 = 124.75 Kg.
22 4
Total nitrogen =33977.03%. x— = 27181.624/VM3
28.

7.3. Flue gas composition.

COz = 12896.4 Kg. + 6329.4 Kg. + 1488.96 Kg. + 208.6298 Kg.
Eqn.4 Eqn.5 Eqn.6.a from dolomite
22 4
= 19237.219%.x—— = 9793.5/VM3
44
22 4
CO = 564.06%. x^ = 451.245JW3
28
22 4
Hz = 146.31 x—= 163 8.56/VM3
2
CBU = i H2 from F.E coal will go as CH4

C + 2H2 = CH4
(ix203.83) ofH2 = 67.943 Kg. ofH2 = 67.943x^ = 271.77Kg. of

CH4 = 271.77 x — = 3 80.48 NM3 CH,

16
H?Q = 1324.44 Kg. from burning of coal + 1009.5 Kg. from coal
moisture= 2333.94 Kg. = 2904.46 NM3

From F.E. Coal 6813 x 0.0620 = 422.406 Kg.

From D.E. Coal 7300x0.0627 = 457.710 Kg.

Total =880.166 Kg.

= 661.08 NM3

186
 Table-7.1. Composition of Flue gas and its sensible heat

Constit Sensible heat G.Cal NMC/hr %

uents k. Cal/Kg.
Kg./hr

n2 = 33977.03 x211.32 7.180 27181.624 64.046

C02 = 19237.219x211.27 4.064 9793.50 23.076
CO = 564.06x213.68 0.1205 451.25 1.063
h2 = 146.31x2835 0.4147 1638.56 3.860
h2o = 2333.94x400.55 0.935 2333.94 5.499
02 = 880.116x 195.812 0.17234 661.08 1.557
CH4 = 271.77x680.44 0.185 380.48 0.896

Total = 13.0715 42440.434 100

Table-7.2. Heat balance

SI. No G.Cal/hr. G.Cal/hr.

1. Reaction Fe203 —> FeO -0.281

2. Reaction FeO —> Fe - 0.481
3. Reaction C + 02-+ 2CO + 11.691
4. Combustion of excess CO to C02 - 19.687
5. Combustion of excess C to C02 - 11.94
6. a). SI. VM C burnt to C02 -3.196
b). SI. VM C burnt to CO -0.55
c). SI. VM H2 burnt to H20 -4.391
7. Radiation loss + 5.738
8. Coal devolatilisation + 0.4002
9. Vaporisation of moisture + 0.545
10. Sensible heat
a). Sponge iron +2.224
b). Char Ash + 0.6481
c). Flue dust + 0.432
d). CaO + 0.041
c). MgO + 0.022
e). Unbumt VM + 1.308
11. Heat of decomposition of 501.6 Kg. dolomite +0.25
12. Sensible heat in flue gas +13.072
13. Heat loss due to leakages & measurement error + 4.155
by difference.
Total =
40.526
40.526

187
 7.4. Overall heat balance.
Heat input
a) . F.E. Coal = 6309.733 x 5325.80 = 33.6044 G.Cal
b) . D.E. Coal = 6510.000 x 5497.54 = 35.7890 G.Cal

Total = 69.394 G.Cal

Heat output
i). Heat utilised in the kiln = 36.1349 G.Cal
ii). Heat value of coal char
(Cal. Value char = 3000 k. Cal/Kg.)
= 1960x3000 = 5.880 G.Cal
iii). Differential heat i.e. unaccounted = 4.155 G.Cal
heat loss.
iv). Heat value carried by Unburnt coal VM
Unburnt VMC = 1415.38Kg.
Unburnt VMH2 =295.64 Kg.
a). C + 02 = C02
1415.38 3774.35 5189.73
(Kg.) (Kg.) (Kg.)
AH = 5189.73 x 2146.57
b). H2 +i/202= H20 = 11.1401 G.Cal
295.64 2365.12 2660.76
(Kg.) (Kg.) (Kg.)
AH =2660.76x3315.22
Total heat carried by Unburnt VM = 8.821 G.Cal

v). ‘C’ loss in flue dust = 392.926 Kg.

‘C’loss going to sponge iron=21.32 Kg. = 19.9611 G.Cal
Hence total Unbumt carbon = 414.246 Kg.
c + o2 = co2
414.246 1104.656 1518.902
(Kg.) (Kg.) (Kg.)
AH = 1518.902x2146.57 = 3.26043 G.Cal

HEAT BALANCE
Heat input in G.Cal Heat utilized in G.Cal
69.394 i). Heat utilized in kiln
= 36.1349
ii). Heat out in char
= 5.88
iii). Unaccounted loss
= 4.155
iv). Heat out by Unburnt
VMC + VMH2
= 19.9611

188
 v). Heat out by flue dust and
sponge iron
= 3.26043

Total = 69. 394

40 526
Kiln efficiency = —1---- = 100 » 58%
69.394

7.5. Conclusion
The thermal efficiency of the of the rotary kiln used for the

investigation is 58%. The remaining heat is wasted in the non-magnetic

fraction at the kiln discharge end and in the kiln waste gas. However in JSPL

heat of waste gas is used for power generation.

189