Dainty Monica Orate
2018-09906
PS4
MetE 136: Production Metallurgy
April 20, 2022
A. Determine the amount of steel scrap and silicon carbide that needs to be charged with 500 kg of hot metal and 10 kg of cast
iron. Account for all the input and output items. Heat loss is 7000 kcal/MT.
Input
Fuel/
Coolant
Weight, kg
Weight in
MT
kg
31.5
Burnt
Dolomite
Multiplier
20
Burnt Lime
99.5% O2
Total
Hot Metal
500
0.5
Multiplier
63
Steel Scrap
680
0.68
0
0
0
0
3
2.04
682.04
Cast Iron
10
0.01
158
1.58
49
0.49
92
0.92
12.99
Silicon
Carbide
62.4
0.0624
5298
330.5952
1648
102.8352
1900
118.56
614.3904
164.52
1893.9204
1252.4
363.6752
kg
10
Multiplier
86
kg
43
584.5
113.3252
Output
Item
Weight, kg
Weight in
MT
kg
70.5
Gas and
Fumes
Multiplier
116
Hot Metal
500
0.5
Multiplier
912
kg
456
Multiplier
141
kg
58
584.5
Steel Scrap
680
0.68
981
667.08
13
8.84
9
6.12
682.04
Cast Iron
10
0.01
877
8.77
340
3.4
82
0.82
12.99
Silicon
Carbide
62.4
0.0624
-2081
-129.8544
11070
690.768
857
53.4768
614.3904
118.4168
1893.9204
Steel
Slag
1001.9956
773.508
Total
B. Determine the amount of iron ore and calcium carbide need for the following conditions. Prepare the Input and
Output tables for each case and rationalize any differences observed. Heat loss is 7000 kcal/MT.
1. 500 kg hot metal + 100 kg steel scrap
Equation 1 W,hm(0.912) + W,ss(0.981) + W,io(0.599) + W,cc(0.014) = 1
Equation 2 W,hm(-131552) + W,ss(315801) + W,io(1484527) + W,cc(-2325126) + 7000 = 0
Weight of hot metal
W,hm
500
kg
Equation 1 Equation 2
Weight of steel scrap
W,ss
100
kg
c
0.4459
27195.9
734
0.599
1484527
Weight of iron ore
W,io
kg
a coeff
Weight of calcium carbide
Input
Fuel/
Coolant
Weight, kg
W,cc
Weight in
MT
457.00
kg
b coeff
Multiplier
kg
Burnt
Dolomite
Multiplier
Burnt Lime
0.014
a
0.734
-2325126
b
0.457
99.5% O2
Total
kg
Multiplier
kg
Hot Metal
500
0.5
63
31.5
20
10
86
43
584.5
Steel Scrap
100
0.1
0
0
0
0
3
0.3
100.3
Iron ore
734
0.734
149
109.366
33
24.222
-265
-194.51
673.078
Calcium
carbide
457.00
0.457
-937
-428.209
12
5.484
655
299.335
333.61
148.125
1691.488
1791
-287.343
39.706
Output
Item
Weight, kg
Weight in
MT
kg
Gas and
Fumes
Multiplier
Multiplier
kg
Multiplier
Hot Metal
500
0.5
912
456
141
kg
70.5
116
58
584.5
Steel Scrap
100
0.1
981
98.1
13
1.3
9
0.9
100.3
Iron ore
734
0.734
599
439.666
313
229.742
5
3.67
673.078
Calcium
carbide
457
0.457
14
6.398
-32
-14.624
748
341.836
333.61
404.406
1691.488
Steel
Slag
1000.164
286.918
Total
2. 500 kg hot metal + 100 kg cast iron scrap
Equation 1 W,hm(0.912) + W,ci(0.877) + W,io(0.599) + W,cc(0.014) = 1
Equation 2 W,hm(-131552) + W,ci(122947) + W,io(1484527) + W,cc(-2325126) + 7000 = 0
Weight of hot metal
W,hm
500
kg
Equation 1 Equation 2
Weight of cast iron
W,ci
100
kg
c
0.4563
46481.3
Weight of iron ore
W,io
75.1
kg
a coeff
0.599
1484527
Weight of calcium carbide
W,cc
46
kg
b coeff
0.014
-2325126
a
b
0.751
0.46
Input
Fuel/
Coolant
Weight, kg
Weight in
MT
kg
31.5
Burnt
Dolomite
Multiplier
20
Burnt Lime
99.5% O2
Total
Hot Metal
500
0.5
Multiplier
63
Cast Iron
100
0.1
158
15.8
49
4.9
92
9.2
129.9
Iron ore
75.1
0.0751
149
11.1899
33
2.4783
-265
-19.9015
68.8667
Calcium
carbide
46.00
0.046
-937
-43.102
12
0.552
655
30.13
33.58
62.4285
816.8467
721.1
15.3879
kg
10
Multiplier
86
kg
43
584.5
17.9303
Output
Item
Weight, kg
Weight in
MT
kg
70.5
Gas and
Fumes
Multiplier
116
Hot Metal
500
0.5
Multiplier
912
kg
456
Multiplier
141
kg
58
584.5
Cast iron
100
0.1
877
87.7
340
34
82
8.2
129.9
Iron ore
75.1
0.0751
599
44.9849
313
23.5063
5
0.3755
68.8667
Calcium
carbide
46
0.046
14
0.644
-32
-1.472
748
34.408
33.58
100.9835
816.8467
Steel
Slag
589.3289
126.5343
Total
Conclusion: When using steel scrap instead of cast iron scrap, the burnt lime needed became negative due to the largely negative
value of lime needed for calcium carbide. When steel scrap is used, the calcium carbide needed to supply heat is almost ten times
more that when using cast iron. This is because cast iron contains more carbon (around 4%) than steel (less than 2%).