Bepaitamento ue Ingenieiia Netaligica y ue Nateiiales

NET-1S6 Teimouinmica Netaligica I

Tarea N1

Solve the following pioblems:

8.2. Aluminum is being heateu by an inuuction fuinace that opeiates at one kW, anu
tiansfeis 9u% of the electiical eneigy to the aluminum. The aluminum enteis the
fuinace at 2S C, at one kgmin. Calculate the tempeiatuie of the aluminum as it
leaves the fuinace.

8.4. Steel paits (assume puie Fe) initially at 8uu C aie quencheu in oil. The specific
heat of the oil is 2.1u k} kg
-1
ueg
-1
, anu is initially at 28 C. Bow much oil shoulu be
piesent in the quench tank to attain a final oilsteel tempeiatuie of 6S C.

8.7. A wet coppei concentiate initially at SS C consists of chalcopyiite with wB
2
u =
u.u9S. It is to be uiieu in a fluiuizeu beu ieactoi by supeiheateu steam enteiing at
24u C anu 2u bai. The uischaige tempeiatuie of the uiy chalcopyiite anu steam is
11S C anu 1 bai. Calculate the mass of steam iequiieu pei kg of moist chalcopyiite.

8.1S. A fuinace heats 46,8uu kgh steel billets fiom 2S C to 118u C using 7uuu
m
S
hi (STP) CB
4
as a fuel, with 2u % excess combustion aii. A sketch of the piocess is
shown below. Calculate the theimal efficiency (%) anu the heat loss fiom the fuinace
in kcalsec.




An example of a theimally-ueficient piocess is a conceptual uesign of a BRI piouucei
that uses a C0-iich gas to ieuuce Fe
2
u
S
to iion in a fluiuizeu beu ieactoi at 12uu K.
Figuie 9.S shows a sketch of the piocess. In oiuei to assuie complete ieuuction of the
Fe
2
uS, the minimum <pC0 in the offgas at 1200 ! is u.7S. We want to know if it is
theimally possible to opeiate this piocess at <pCu
2
= u.7S in the offgas, with stieam
Chapter 8 Enthalpy Balances in Non-Reactive Systems 503
mass Qf cold air that should be added to 1 kg of warm air to condense the largest amount of water.
P = 95kPa.
8.12. A continuous process operates to clean and dehumidify the top gas from an iron ore
reduction furnace. The gas exits the blast furnace at 380 C and 1.8 atm, its composition is <jpH
2
=
0.55, balance H
2
0, and its concentration is 25 g of Fe20
3
per actual m
3
of gas. The top gas is
quenched by passing it into an ice bed from which it exits at 0 C. A slurry containing all the
Fe
2
0
3
plus the condensed water from the gas and water from the melted ice exits at 0 C. What
mass of ice (at 0 C) is required per 1000 actual m
3
of dusty top gas?
8.13. A furnace heats 46,800 kg/h steel billets from 25 C to 1180 C using 7000 m
3
/hr (STP) CH
4
as a fuel, with 20 % excess combustion air. A sketch of the process is shown below. Calculate the
thermal efficiency (%) and the heat loss from the furnace in kcal/sec.
% excess air ^
(125 C) ^
CM, ^
4
7
(25 C)
St
Comb, gas
(1800 C)
H n r l flj
Di l l J JF
X^
000
^
^
! ^
(1180
W
C)
Steel heating
furnace
^ Stack g
-^1230
L Steel
(25 C)
8.14. A heat exchanger is added to the above process such that the stack gas transfers half of its
sensible heat to the air. The billet heating rate and the heat loss remain the same. Make a system
balance for the process, and calculate the thermal efficiency.
8.15. Five moles of gas consisting of <pCl
2
= 0.400; <pHCl = 0.200; <pSiCl
4
= 0.100; <pSiHCl
3
=
0.300 are initially at 800 K. Five moles of N
2
initially at 300 are mixed with the gas under
adiabatic conditions. Calculate the resulting gas temperature accurately.
8.16. A spent iron ore reduction gas has the following composition:
<pCO
2
= 0.18; #$ = 0.21;
2
= 0.31; balance H
2
0
The gas enters a spray quench tower at 550 C, where water at 5C is used to cool (and
eventually dehumidify) it. Gas volumes are actual. Make a system balance for the cooling process
to calculate the actual m
3
of gas leaving the cooler, starting at an exit temperature of 450 C and
thereafter at 50 temperature intervals down to the dew point. Continue the material and heat
balance calculations at 10 C intervals from the dew point to 20 C, calculating the mass of water
and actual m
3
of gas leaving the quench tower. The stack gas (and water, if any) leave the tower at
the same temperature. P = 2 bar. Neglect heat loss.
Water
(5 C)
Stack gas
(100m
3
/secT
2 bar, 550 C)
Quench
tower
Stack gas
Water
8.17. A spent iron ore reduction gas is quenched to it's dew point temperature by recycled 25C
water. The gas is filtered to remove all the dust, then chilled to 25 C before being sent back for
recycling. A heat exchanger cools the water to 8 C before it is reused in the chiller. Make a
anu piocess tempeiatuies as uesciibeu in Figuie 9.S. The heat loss is 11 k}mol of
Fe
2
u
S
ieuuceu. Equation |9.2j shows the chemical ieaction foi the oveiall ieuuction
of one mole of Fe
2
u
S
.
SC0(g) + Fe
2
u
S
(c) -> SCu
2
(g) + 2Fe(c); !"
rx
at 12uu K = -SS.44 k} |9.2j













Chapter 9 System Balances on Reactive Processes
507
5000
CM
8
I -5000
8 -10000
g -15000
% -20000

-25000
300
Heat Balance for S0
2
Oxidation
I--
Net device heat
Linear (Net device heat)
I I I
I I I
I I \
i I I
1 .
-{- ^f^
" ^ !
netheat=77.85T-47,140
. _ + 4. 4
i ! I
350 400 450 500
T(K)
550 600 650
Figure 9.2 Thermal effect for the oxidation of one mole of S0
2
in a process gas to form one mole
of S0
3
. The net heat is the sum of the heat of oxidation of one mole of S0
2
at 298 plus the heat
content of the product gas (containing 10.53 %S0
3
), and is a nearly linear function of temperature.
The text box equation was obtained from the Trendline tool.
For a process gas with a higher composition of S0
2
, the exothermic nature of the SOX
reaction can produce more heat than desired. If the reaction temperature goes too high, the catalyst
may be damaged. Also, ZRS0
2
becomes significantly less than one when the value of goes
below about 100. The Reaction tool table shows that this happens at about 720 K. We will
examine how to control a high S0
2
-content SOX reactor temperature in a later section.
An example of a thermally-deficient process is a conceptual design of a DRI producer that
uses a #-rich gas to reduce Fe
2
0
3
to iron in a fluidized bed reactor at 1200 K. Figure 9.3 shows a
sketch of the process. In order to assure complete reduction of the Fe
2
03, the minimum <pCO in
the offgas at 1200 is 0.75. We want to know if it is thermally possible to operate this process at
<pC0
2
= 0.75 in the offgas, with stream and process temperatures as described in Figure 9.3. The
heat loss is 11 kJ/mol of Fe
2
0
3
reduced. Equation [9.2] shows the chemical reaction for the overall
reduction of one mole of Fe
2
0
3
. A#
rx
is from FREED's Reaction tool.
3CO(g) + Fe
2
0
3
(c) -> 3C0
2
(g) + 2Fe(c); $%
&'
at 1200 = -35.44 kJ [9.2]
Fe
2
O
3
(600K)
Rdn gas (1300 K) _ 2 I
CO = 0.96;
2
= 0.04~
Fluid bed
reactor
(1200 K)
A . - ^ Offgas (1200 K)
CO = 0.75; <pCO
2
= 0.25
-> DRI (1200 K)
Figure 9.3 Sketch of fluidized bed process for the reduction of hematite to iron by a CO-rich
reducing gas. Solids are represented by solid lines, and gases by dashed lines. The DRI is pure Fe.
The first step is to make a material balance for the reduction of one mole of Fe
2
0
3
to produce
2 moles of Fe, according to the listed reduction gas and offgas compositions. We start by noting
that an oxygen balance shows rcC0
2
out
= nC0
2
in
+ 3, and the nCO
ui
= <

- 3. We also know
the ratio of the reduction gas and offgas species, which with a carbon balance gives us enough
information to calculate the amount of each gas species in and out.
<

= 13.714; C0
2
in
= 0.517; nCO
ut
= 10.714; rcC0
2
out
= 3.517
The next step is to make a heat balance, which, as we've seen, is uncoupled from the material
balance. This requires selection of a basis temperature. 1200 seems appropriate because that's