1

1
.L
CHAPTER 6
ENERGY BALANCES
6.0 INTRODUCTION
In the previous chapter, the basis for process energy bal-
.ance calculations was presented, namely, the Law of Conservation
of Energy. The energy effects of various reactions, transforma-
tions, and changes of state were presented. In this chapter all
of these effects are brought together as metallurgical process
plants and operations are analyzed.
As in the case of material balances, the purpose of the
energy balance must be considered before the problem can be pro-
perly formulated. The purpose may be to compare several complete
processes which produce the same product, to see which requires
less total energy from the universe. Or, it may be to compare
alternative modes of operation of an existing process, or it may
be to develop information needed for control of a process. Each
purpose requires differing details, and will require different
data. Consider for example, the basic oxygen steelmaking process.
If the process is being compared with the electric furnace steel-
making process for purposes of total energy consumption comparison,
the energy consumption of the process would have to include the
electrical energy required to tilt the vessel, the electrical
energy to hoist the oxygen lance, the energy required to produce
the oxygen from air, the energy to run the waste gas recovery sys-
tem, etc.
electricity
Dust
Co 11 ector
"",. r:':----:- -
fluxes ~
I
el ectricity
electricity
247
water
l,as te
Gases
I electricity
I
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
On the other hand, if an energy balance was being developed to
be used to control the process, many of these inputs would not be
required. In other words, we would draw the system boundary dif-
ferently:
2 ( Waste Gases (Hot)
/' tl---,
'< X Fluxes
Molten Pig Iron
\
_ I Heat Losses
I
\ 0 I
X BOF J--...MOlten Steel
Slag ''''''----''1
System
Boundary
6.1 THE HEAT BALANCE
The most common type of energy balance on metallurgical
processes is the "heat" balance, in which only the thermal energy
(heat) into and out of a process is accounted for. It should more
properly be referred to as a thermal energy balance, but common
usage dictates that we call it a heat balance. All that is re-
quired to successfully develop a heat balance on a process is an
accountant's mind! Referring again to Chapter 5 and limiting
consideration to thermal energy:
Heat Into
System
Heat out
of System
+
Heat Accumulated
in System
In a steady-state process, no heat is accumulated.
(6.1-1)
The biggest problem, and the place where more mistakes are
made than anywhere else, is in the choice of reference temperature.
This will be considered in the following general discussion, but
first the reader is reminded that heats of reaction can be calcu-
lated at any temperature according to Kirchoff's Law, since enthal-
py is a state function. Also, since most metallurgical processes
are constant pressure pr.ocesses, enthalpy, rather than internal
energy, is the measure of heat energy.
248
ENERGY BALANCES
Consider a process in which solid materials, fuels and
preheated air enter a process, react, and release process gases
and products at elevated temperatures, and loose energy by radia-
tion and convection to the surroundings:
In Out
So 1 i ds @ 298 K } {Gases @ 1800 K
Fue 1@298 K Condensed Products@1600K
Air @ 1000 K
The heat balance for such a process can be represented as follows,
if the reference temperature is taken as 298K:
Gases, 1800 K
Products, 1600 K
t Ai r 1000 K
T
298
298 Fuel ... _ .... -"-__ .... loss
Reactants
The enthalpy terms would be as follows, with the sign of the term
being as indicated.
Term Sign of Term
298
11
,
Cp,air
dT
1800
1
,
Cp,gases
dT +
1600
1
,
=
Cp,products
dT +
249
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
Sum of the Heats of Reaction at
LLlHR 298 = 298K to form the output products
, and gases.
I
LlHlos
s
= net heat loss to surroundings.
The energy balance, then, is
Sign of Term
+ if endothermic
- if exothermic
+
(6.1-2)
This is if great care is taken to follow
the proper dlrectlon of lntegration, from tail to head of the
arrows on the diagram.
Now, the same process, but instead of calculating
the heats reactlon at 298 K, assume, for example, that it is
more convenlent to calculate LLlHR at 1000 K (because, perhaps, the
data reactants and products are available at 1000K.) The
dlagram wlth 1000 K as the reference temperature would be:
T
Gases .1800 K
I 4 Products @ 1600 K
LlH3 I
LlHR 1000 LlH
1000 ___ ______ .. I
-- LlHl
oss
I I
LlHl LlH2
298 Fuel U Reactants
The terms in this case would be
Term Sign of Term
I 1000
I
LlH =
J Cp,Fuel
dT
1
+
298
I 1000

LlH2
J
+
298
I 1800
I
LlH3
J C dT
p,gases
1000
+
250
I
LlH
loss
Term
I
LlH =
4
1600
J
I
C dT
p,products
1000
LLlHf,lOOO
products
LLlHf,lOOO
reactants
ENERGY BALANCES
Sign of Term
+
+ or -
+
Again, as long as the integration direction follows the arrows, the
enthalpy balance is:
(6.1-3)
This time, however, note that there is no term involving the sen-
sible heat contained in the incoming air and that none of the terms
(except possibly LLlHR,lOOO) is a negative term.
The argument can be carried further. The result would always
be the same. To set up the balance properly, use the following
algorithm:
Step 1:
Step 2:
Step 3:
Decide at which temperature heats of reaction will
be calculated. This is the reference temperature.
Draw a temperature scale.
Place the reactants at their initial temperatures
on the scale and draw an arrow from that tempera-
ture to the reference temperature.
Step 4: Repeat Step 3 for all products leaving the system.
Step 5: Calculate all sensible heat terms by integrating
heat capacity data in the direction of the arrow
to the reference temperature.
Step 6: Calculate the heats of reactions, solution, etc.,
at the reference temperature.
Step 7: Add all of the terms obtained in previous steps.
Step 8: The heat loss term is the result. A positive
value means that there is a loss from the system
to the surroundings.
EXAMPLE 6.1-1: Show how the thermal energy balance can be obtained
from the First Law of Thermodynamics.
Solution: The most general form of the First Law is given in
251
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
Eq. (5.2-2). For a system at constant pressure, this formulation
becomes
-2
" n V.
d(E + PV ) = oq - ow* + E omi (hi + __ 1 + z.)
i=l 2g
c
gc 1
Since the thermal energy or heat balance considers changes
in enthalpy only, the changes in kinetic and potential energy of
the system can be assumed to be equal to zero and
* d(E'+ PV') = d(U' + PV') = dH' = oq + Eomi hi - oW
If no electrical work is put into the system or produced by the
system,
For a system at steady-state there is no change in the state func-
tion:
dH' = 0
or, therefore, the heat put into or lost from the system,
or
oq = (enthalpy of outputs)
from system
(enthalpy of inputs)
to the system
On a molar basis, oq = -EoniHi
To show that this approach is equivalent to the heat balance
given in Eq. (6.1-2), consider the example with a reference tem-
perature of 1000 K. For the process,
lIHi + lIH2 + lIH3 + lIH4 + ElIHR,lOOO = lIHioss
However,
TRetlOOO
= f = - H'fuel@(T
in
=298)]
T i n=298
252
,
lIH
3
ENERGY BALANCES
!
Ref=lOOO
,
= = H @ T =1000
Cp,reactants
dT
[ reactants ( Ref, )
Tin = 298 -Hreactants@(Tin=298)]
T
fout
=1800
, ,
C dT= H @(T =
p,gas [gas out
1800) - H @(T = 1000)]
gas Ref
T Ref=l 000
, " ,
J
T
out
=1600
lIH = C dT=[H @(T =1600)-H d @(T
R
f=lOOO)]
4 p,prod. prod. out pro. e
T Retl 000
and
ElIH = E lIHF @ (TRef=lOOO) - E lIH
F
@ (T
Ref
= 1000)
R,lOOO products reactants
E H @ (TRef = 1000)- E H (T
R
f = 1000)
products reactants e
, ,
Hproducts @ (T
Ref
= 1000) + H
gas
@ (T
Ref
= 1000)
, , ,
-[H @(T =lOOO)+H @(T
R
f=lOOO)+H . (TRef=lOOO)]
fuel Ref reactants e a1r
Finally, combination of these equations yields
+ H -H @(T. )]

[ ants Ref) reactants 1n
, ,
+ [Hgas@(Tout)
+
253
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
Since the inlet temperature of the air was the reference
tempera ture
I I I I I
+ + + +
= [H I @ (T ) + H' @ (T ) ]
products out gases out
I I I
-[H @(T.) + H @(T. ) + H . @(T. )]
fuel ln reactants ln alr ln
= (enthalpy of outputs from system)
- (enthalpy of inputs to system)
Finally, the negative of the heat loss from the system must
correspond to the heat gained by the system
or
I
- = oq
oq = enthalpy of products
leaving system
enthalpy of inputs
to system
which is equivalent to the statement of the First Law.
The previous example demonstrates that the First Law and the
heat balance are equivalent. It also shows that the choice of
the reference temperature is completely arbitrary since all terms
based upon this value cancel out during the calculation. The heat
loss term will be the same, regardless of what reference
is chosen, if the problem is set up properlX.
EXAMPLE 6.1-2: A furnace for reheating billets, prior to their
being rolled, uses fuel oil and air to produce hot gases which
pass over the billets, transferring heat to both the billets and
the furnace walls. Some of the heat in the walls is re-radiated
to the billets and some travels through the walls and is lost to
the surrounding. The gases finally exit from the furnace at a
reduced temperature.
254
ENERGY BALANCES
Air
Air
o Fuel -==y ___
JLc - ODD Billets In
C"" --:c 0 0 0 0 - DODD 000 - 1 ___ 1
.--J)
\)Il't Gases to stack _
. "e't
s
'0'
* h f 1 oil is 40,000 kJ/kg, 25%
The net value of u:
ses
analyze 4.6% 02. The
excess air is supplled, and the wa dgTeave at 1400 K at a rate
billets enter the furnace at 298 K an at 1500 K. The oil is
of 130,000 kg/hr. The waste gases 85% C, 14% Hand 1%
supplied at a rate of 100 thermal efficiency. For pur-
S. Compute the heat losses an heat capacity of flue gases =
poses of the example, use a
1.05 kJ/kgK. (=0.27 Btu/lb- F).
f e temperature is clearly 298 K,
Solution: The heat balance re the heat of combustion of
since that is the temperature aWl
the fuel is available.
The diagram thus becomes:
1500 K
1400 K
I

t
T
I

__________ L-__________
air
oil
298
. h rmochemical energy liberated by
* The net heating value H20(9) and C02 at.298 K. The
complete c?mbustion of 1 refers to the energy by
gross heatlng of a fu(e) d CO at 298 K. The dlfference
complete combustlon to H2
0
t of water at 298 K and the
is obviously of fuels made up or pure ele-
heat of vaporlzatlon of wa ere the calorific power can be
ments, or a mixture of of the individual compounds,
calculated from heats of are indefinite in com-
but for fuels values must be used.
position, experlmenta y e
255
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
The enthalpy terms are:
= Combustion = -(100 kg)(40,000 kJ/kg)
= -4 x 10
6
kJ
I

steel = (130,000 kg)(103 g mol/55.85kg)(10,120 cal/g mol)
= 5.651 x 10
5
kJ
(lkJ/4.186 x 10
3
cal)
The enthalpy content (sensible h )
after combustion calculatl'o eat of the gases can be found
f . f' . ns are made in d . ,
o ln lltrate alr (unmeasurable oth . )or er to flnd the amount
erwlse. For 1 kg oil:
products
(0.85 kg C)(44/12) 7 3.12 kg C02
(0.14 kg H2)(18/2) 7 1.26 kg H
2
0
19.01 kg SL(64/32) 7 kg S02
1. 00 kg oil
4.40 kg
wt.

3.12 kg CO2
0.0709
1.26 kg H
2
O
0.07
0.02 kg S02
0.0003
0.87 kg O
2 0.0272
15.10 kg N2
0.5393
20.37 kg gases
0.7077
required O
2
2.34 kg
1.12
0.01
3.47 kg O
2
The 25% excess
so that the
.YL!
10.03
9.90
0.0004
3.85
76.21
100
. Since the oxygen analyzer i d' t 0
ly lnfiltrate air present. Furth n lCf 4:6% O2, there is clear-
analysis, on a volume basis . er ca atlons show that this
per mole of oil enters the lf 1 additional kg of air
waste ases must amount to 21 us, the amount of
I ases/k 011, and
gases = (2137 kg gas)(1.05 kJ/kgK)(1500 K-298 K)
2,697,100 kJ/hr.
256
1
ENERGY BALANCES
The balance then is:
I
-4,000,000 + 565,100 + 2,697,100 =
I
= 737,800 kJ/hr.
The thermal efficiency of the process can be measured or described
in several ways. Since the requirement of the process is to heat
steel from 298K to 1400K, the efficiency has to be measured
against this requirement. However, the base of this efficiency
can vary.
For instance, in order that the steel reach 1400K, the
energy required to raise it to that temperature must be available
at temperatures above 1400K. The gases cannot transfer energy to
the metal unless they are hotter than the metal. In a counter-
current system such as in this Example, the gases could exit from
the furnace at any temperature abgve 298K. Therefore, the poten-
tial available energy is 4.0 x 10 kJ, and the efficiency is
Efficiency =
enerqy absorbed by product x 100
energy supplied
565,100
4,000,000 x 100
14.1%
On the other hand, had this been a batch type furnace, with
a cold charge going into the furnace and staying there until the
entire charge reaches 1400K, the energy available to be transfer-
red to the metal would have been less than 4.0 x 10
6
kJ, because
as the stock heated up, the waste gases could not transfer energy
at temperatures below the stock temperature. This would cause
the numerator in the efficiency equation to become smaller, in-
creasing the apparent efficiency.
Finally, the efficiency of the furnace could be measured by
the effectiveness of the insulation, in which case the efficiency
would be
Efficiency = Loss x 100
4.0 x 10
6
- 0.74 x 10
6
4.0 x 10
6
81.5%
6.1.1 SANKEY DIAGRAMS
An excellent technique for visualizing the distribution of
energy in a process, or for that matter in an entire plant, is
the Sankey diagram. All incoming energy sources and all outgoing
257
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
energy streams are placed on the diagram; the width of each stream
being proportional to the amount of energy contained in it. For
example, the Sankey diagram for the furnace in Example 6.1-2 would
be as fo 11 ows :
Chemical
Energy in
Fuel Oil,
4.0 x 106kJ
Reheating
Furnace
Heat Losses, 0.74 x 10
6
kJ
Sensible Heat in Steel, 0.56 x 10
6
kJ
Sensible
Heat in
Flue Gases,
2.7 x 10
6
kJ
It is immediately obvious that, in this case, a large amount
of the energy put into the furnace is lost from this furnace as
sensible heat in the flue gases, and that the efficiency of heating
of the steel is low. Thus, it is easy to visualize where efforts
ought to be made to increase the energy efficiency of the operation.
Redesign of the furnace, for example, to decrease heat losses or
improve heat transfer so that less fuel is required would be one
way, but even more obvious would be to utilize the heat in the
flue gases. This might be accomplished by using the gases to pro-
duce steam in a boiler and then using the steam to produce elec-
tricity via a turbine. The use of waste-heat boilers is common in
many large process plant complexes.
Another way to utilize the energy in the flue gas would be
to transfer its energy to the incoming combustion air, thus re-
circulating some of the energy and reducing the requirement for
fuel oil. This is done by means of a recuperator, in which energy
is Ireco!Jped", the French word for regained. Recuperators take
many forms, such as shell and tube heat exchangers, crossflow or
counter-current in arrangement, and they may be continuous or
intermittent in operation. As far as energy efficiency is con-
cerned, it is only the efficiency of heat exchange that is of
interest here.
EXAMPLE 6.1-3: Taking the situation in Example 6.1-2, examine
what happens if the heat recuperator shown in Fig. 6.1-1 was put
on the flue gas stream and it was assumed that the recuperator
was 50% efficient at heat exchange.
Solution: Since the use of preheated air will decrease the require-
ment for chemical heat, the fuel requirements must be recalculated.
Also, since less fuel is required, less combustion air will be
258
ENERGY BALANCES
required and fewer kg of waste gases will be available. The heat
balance is somewhat different now:
f
T
I
l'IH
flue
gas
298
I

---
__ 1-
00 _--___ ---
"- --- '\
- ,"h''',d e
__ ----' \ '-. '-- '- cold air
---------.",.'"
recuperator
Fig. 6.1-1 Billet heating furnace with recuperator.
259
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
lIH' is the
steel
is the same, because
lIH'. is taken to be
alr
exchange efficiency.
same, and for the moment, assume that lIH10s
s
virtual11 the same temperatures are involved.
(0.5) lIHfl ' based on the assumed heat
ue gas
Letting F be the number of kg of fuel oil.
Heat In Heat Out (m) (C
p
) (LIT)
(0.5)(21.37F)(1.05)(1202)+40,000F=565,100+737,800+(21 .37F)(1 .05)(1202)
13,485F+40,000F=1,302,900. + 26,971F
F=49.14 kg fuel oil
,
lIHfl =1,325,300 kJ/hr
ue gas
,
lIHrecouped=662,650 kJ/hr
lIHcombustion=1,965,500 kJ/hr.
The Sankey diagram for this situation would look as follows:
Recovered
Therma 1
Energy
Chemical energy
in fuel oil
1.96 x 10
6
kJ
Heat losses
/
0.74 x 10
6
Reheating 10
6
Sensible Heat in
Furnace ~ ; . ; . : " . . . . . ; . . ; . ~ ~ Steel
0.66 x 10
6
kJ
Combustion Air
Sensible Heat in
Flue Gases to
Stack
2O
i
l
ENERGY BALANCES
Now, total fuel consumption has been drastically decreased,
from 100 kg oil/hr to 49.1 and the efficiency is up to 21%. Heat
recovery of this type should be practiced as often as possible,
and usually is, consistent with local economic conditions.
The Sankey diagram for processes involving chemical reactions
other than combustion of fuel also helps to highlight the potential
areas for fuel savings. Such a diagram, for the sinter plant
illustrated in Fig. 4.3-2 is given in Fig. 6.1-2. Notice first
that the heat losses, as a percentage of the energy in, are small.
This is typical of most gas-solid packed bed systems, such as
sinter plants and shaft furnaces. Notice also that the energy to
evaporate moisture is not insignificant. Hydrated ores, such as
Fe203'H20 require extra energy to process. The only potential
energy savings can be made by recouping heat from the waste gases
or the hot sinter itself. These amount to about 50% of the overall
thermal output of the process. Some sinter plants do have sinter
coolers in which the heat recovered from the hot sinter by air is
transferred to the sinter on the machine via huge ducts that empty
just above the sinter bed. Some fuel savings are effected in this
manner.
One might be tempted to think that if these sensible heat
streams could be removed as outputs, the fuel required would be
decreased. They do look like "losses". However, this would be a
mistake, because they result from the fact that within the process,
certain temperatures must be attained, and in order to reach those
temperatures, the fuel is necessary in the first place. Further-
more, none of the streams leaving the system is at a temperature
anywhere near the maximum temperatures reached in the process it-
self, and may not be useful, except in neighboring processes or
plants. This is a result of where the system boundary has been
drawn. In other words, the "qual ity" of the energy being lost is
too low for the energy to be useful. Thus, the use of Sankey
diagrams from the standpoint of understanding a process can be
misleading. More on the subject of energy guality is presented
in Section 6.4.
261
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
Heat in flue
dust, 7.7% I
to '\.
Sinter mix) 1
Sinter
t1achi ne
f
Formation of
Fe
3
0
4
, 0.8%
(3FeO + -+ Fe
3
0
4
)
To evaporate
moisture, 15.7%
To
' .. :. . "- carbonates, 14.1%
Sensible (CaC03 -+ CaO + CO
2
)
Heat in waste
""" 259:"'"ti" hee' jj . . .. "2
0
(91)
of carbon in
sinter, 2.4%
(unburned)
Sensible
heat in
sinter, 25.4%
Fig. 6.1-2 Sankey diagram of the heat balance on
the sinter plant depicted in Fig. 4.3-2.
Energy values are as percent of total
energy input and output. (Adapted from
Agglomeration of Iron Ores. D. F. Ball.
et al . American Elsevier. New York.
1973.)
262
ENERGY BALANCES
EXAMPLE 6.1-4: In Example 4.3-7. the material balance for a "heat"
of basic oxygen steel was developed. Using the results of that
calculation prepare a heat balance for the same "heat". Additional
pertinent data are on the figure below:
80 kg 02 as @ 273 K
86 k
Burnt Lime
@ 298 K
o
Infiltrate air
@ 298 K
179 kg
I
264 kg
"waste Gas
f I @ 2000 K
Solution: The choice of a reference temperature requires that
which reactions are taking place and what the heats of those
reactions are be known. In this case the reactions are
C + 02(g)
Si + 02(g)
+ 1/2 02(g) +
1.65 CaO(S) + Si0
2
+ 1 .65
(a)
(b)
( c)
(d)
where the underline. eg., Si, indicates that the element is dis-
solved in molten iron. From Chapter 5. we saw that since Eqs. (a),
(b) and (c) involve two steps. eg
) + 31,100 cal/mol
263
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
AH
f
,Si0
2
= - 217,700 cal/mol
the sum of the two steps gives the net reaction and its enthalpy:
AHR,(b) = - 186,600 cal/mol Si0
2
In other words, we find the net heat effect by adding the heat
effects of the two steps. This involves knowing the heat of
solution of the elements in liquid iron. This data is available
(Table 6.1-1) at 1600C (2912F, 1873 K) and since data for the
other reactions are also available at 1600C, it is convenient,
this case, to choose 1600C as the reference temperature.
TABLE 6.1-1
Heats of Sol ution of Elements in r10lten Iron
at 1 wt.% Concentration and 1600C (1373 K)
-m
Reaction: H. ca1/g mol
1
C (gr) + C (1 % in Fe) + 5,100
Si(q,) + Si (1% in Fe) - 31,100
Mn + Mn (1 % in Fe)
0
Cr( s) + Cr (1% in Fe) + 5,000
A 1 + AT (1% in Fe)
- 10,300
1/2 02(g) + o (1% in Fe) - 28,000
1/2 S2(g) + S (1% in Fe) - 31.500
Co( + Co (1% in Fe) 0
+ Cu (1% in Fe) + 8,000
+ Ni (1% in Fe)
- 5,000
At 1600C, the heat effects of reactions (a), (b), and (c) are:
(a)
(b)
( c)
C + 02(g) + C02(g)
Si + 02(9) +
Fe + 1/2 02(g) +
AH R, 1873
- 99,940 cal/mol
-186,000
"
- 55,780
"
In the case of reaction (d), this reaction is the closest that we
can come to estimating the heat of mixing of the slag from CaO,
Si02, and FeO. The FeO - Si0
2
liquid system is nearly ideal from
a thermodynamic standpoint, so the heat of mixing of those two
constituents is small and will be ignored, but it is known
264
in
ENERGY BALANCES
(however inaccurately) that there is a heat evolution
and are mixed to form a liquid. The heat effect ln thlS
case will be approximated by:
(d) 1.65CaO(s) + + AHR = -20,000 cal/mol
Now, draw the heat balance diagram:
walte
2000
AH R,1873 AH6
I
..;.
- AH
1873
Steel Slag loss
I
AH4
Heat
1620 Hot Metal Losses
T,K
Infiltrate Air
The heat balance is then:
I I I I I I
AH1 + AH2 + AH3 + AH4 + AH5 + AH
R
,1873 = - AH
1
0s
s
This is the heat to bring the oxygen to 1873 K.
lB
r
3 C
p
,02dT " [H
1B73
- H273l02 x 10
3

= 35.0 x 10
6
cal.
This is the heat needed to heat and melt scrap steel and
bring it to 1873 K.
I 341 3
AH2 = nscrap [H
1873
- H
298
]Fe = 55.85' [18550] x 10
265
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
= 113.1 x 10
6
cal.
This is the heat required to bring the lime to 1873 K. Since
this lime is going to react with Si0
2
(t) to form the slag,
and since the heat of fonnation, equation (d), is written
in of CaO(s), there is no need to add the heat of
fusion.
1873
8H; ""CaD J Cp.CaO
dT
" [H
1873
- H
298
] x 10
3
298
30.4 x 10
6
cal.
The sensible heat increase in the liquid pig iron from its
initial temperature to 1873 K.
1873 K
= n J C dT=53
750
6[16J[1873-1620JX10
3
4 pi g iron p ,P1 g 1 ron
1620 K
= 56.6 x 10
6
cal.
The infiltrate air is heated from room temperature to 1873K
before it reacts with CO in the waste gas duct.
= nair Cp,air [1873-298J = [7.85J[1575J x 10
3
= 76. x 10
6
cal.
1873: Now that all of the reactants are at the reference
' temperature, compute the amounts of reactants, the
heats of reaction and add:
Based on the waste gas analysis,
(0.4499 kg CO
2
)(264 kg gas)(103 mol CO
2
)
(1.0 kg gas) (44 kg CO
2
) = 2699 mol CO
2
are formed.
Based on the slag analysis,
FeO,
and
* See footnote on page 210.
266
ENERGY BALANCES
(172 kg slag)(0.149 kg Si02)(103 mol Si02)= 427 mol 5i0
2
(1.0 kgslag)(60 kg 5i0
2
)
are formed.
Heats of Reaction at 1873 K:
-99,940 cal
(a) (2699 mol C) mol C02 formed
(b) (427 mol 5i02)
(c) (836 mol FeO) -55,780 cal
mol FeO
-269.7 x 10
6
cal
= - 79.4 x 10
6
cal
= - 46.6 x 10
6
cal
-20,000 cal = _ 8.54 x 106 cal
(d) (427 mol 5i02) mol 1.65 CaO 5i0
2
-404.2 x 10
6
cal
, the enthalpy contained in the waste gases : This represents
above 1873 K.
= n0
2
[H2000-H1873]02 + n
C02
[H2000-H1873]C02 + n
N2
[H2000-H1873]N2
10.7 x 10
6
cal.
Finally,
or
-lIH'l xlO-
6
=35.0 + 113.1 + 30.4 + 56.6 + 76.3 + 10.7 - 404.2
oss
,

loss
= + 322.1 - 404.2.
= - 82.1
82.1 x 10
6
calor 20.3% of heat input.
This amount of heat is lost via convection and/or the
surroundings, including the water-cooled hood, uP.to t e p01n
b where the 2000K gas temperature was measured, or 1S absorbed y
the refractory lining of the furnace.
A 5ankey diagram for the BOF process with a reference tem-
perature of 1873K would look as follows:
267
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
lIH
S
' SO
--.!. -+ 1 2
BOF
Process
1IH'
O2, 298 -+ 1873
1IH'
Scrap, 298 -+ 1873
_lIHpig iron, 1620 -+ 1873
1-----0::::---
H
' .......- ,\ Fe -+ FeO .....
lIHCaO'SiO
2
lIHWaste Gases, 1873 -+ 2000
1IH'
losses
On the other hand, we could have chosen 298 K as the reference
temperature, in which case the heat balance diagram would have
been:
2000 Waste gases
,
1873 ,Steel 4 Slag
I
Hot Metal t.H
1620
4
I
gases
f
llH 1
s ag
I
llH
T K
steel
_ EllH
R

298
I

273- .nH
O
scrap CaO Infiltrate
2 air
268
ENERGY BALANCES
and the Sankey diagram would be:
BOF

steel
Process I-_____
f'.W
gases
f'.W
loss
Figures 6.1-3 and 6.1-4 illustrate the material flows and a Sankey
diagram of the energy balance for an entire integrated steel plant,
incorporating the preceding diagram for the BOF process.
Finally, another way to graphically present a heat balance
is by means of a bar graph. This is more useful for a batch pro-
cess than for a continuous one. For the process in Example 6.1-4,
such a diagram would be as follows, for the reference temperature
of 1873 C:
Energy In Energy Out
100
Fe -+ FeO
Heat Losses

90
Si -+ Si0
2
Waste Gas,Suoerheat

r-
Infiltrate I-
air heating
70

s-
a>
s::
LLJ
- 60
0
Hot metal
,
+-'
Heating - 50
s::
a>
u
C -+ CO
2
CaO heating
-
s-
40
a>
a..
I- 30
Scrap heating
and melting
l- 20
I- 10
02 Sensible heat
formation 'L--
8.1%
0
269
MATERIAL AND ENERGY BALANCE CALCULATIONS IN METALLURGICAL PROCESSES
Row 1
dolOtrUte
limettcne
1
451b 276lb
C4 or
24701> 46
J
581b
1660 Ib 1

incl udes coke ovens

27110 I.'
I Boilers I



iSS .....,h
I
I
Electricity
I
I
I

I
!
I

I
01)' en
I and blast furnaces

i
J !
1
: '
Q 2 ei
1--'1'--"'",,=='-=-1 oornlre lme I'-d
Burnt lime
Taldolomlte
CO. 00,
O.... ,n 2090 I.'
32kwh
AE
12380 It'
39 kwh
... I Plan.
I Costinq Pi. I
oS oS
iD
j
[ Sookinq P,t. J
'"

1
I
J
.W;lb
mill scrap
I"",
2iu,2in 8.lleh
Fig. 6.1-3 Material flows in a primary steelmaking plant in which
coke is produced in slot ovens, ore is reduced in a
blast furnace, molten pig iron (B.F. metal) and scrap
are charged to a BOF shop, and ingots are cast and hot-
rolled after soaking to even out temperature gradients.
(Ref. The Effect of Various Steelmaking Processes on
the Energy Balances of Integrated Iron and Steel Works,
Spec. Report 71, The Iron and Steel Inst., London, 1962)
270
Fig. 6.1-4
541

2,
aenzol Tar
28'44
C.O.Ga.
H
ENERGY BALANCES
1-12
I Ca.,.nq Pit;

, i
1 Ton-X. taille"
All figures in ther.ns/ton billets AE=ancillarye"uipment
Sankey diagram for plant shown Fig. 6.1-3, with a
reference temperature of 298 K Joules (ref. Spec o Re-
8
port 71, op cit.) 1 Therm - 100,000 BTU = 1.055 x 10
joules.
271