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Parâmetros que afetam o consumo de energia para produzir Ferromanganês de alto carbono em forno de arco fechado e submerso.
Categoria: Documentos.
Biografia: AzzaAhmed, PostGdoctor, AssociateProfessor; EGmail: azzaazza40 @ yahoo􀆰com; Data recebida: janeiro de 9,2013 CorrespondingAuthor: MamdouhEissa, PostGdoctor, Professor; EGmail: mamdouh_eissa @ yahoo􀆰com 􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇 􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇 JOURNALOFIRONANDSTEELRESEARCH, INTERNATIONAL􀆰2014,21 (7): 666G672 􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉 􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉 􀪉􀪉􀪉􀪉 ParametersAffectingEnergyConsumptionforProducingHigh CarbonFerromanganeseinaClosedSubmergedArcFurnace AzzaAhmed, Hossam Halfa, MohamedK. ElGFawakhry, HodaElGFaramawy, MamdouhEissa (SteelTechnology, MetallurgicalResearchandDevelopmentInstitute, Helwan11421, Cairo, Egito) Resumo: O Consumo de energia é considerado como themostimportantfactoraffectingtheproductioncostofferG romanganesealloy. Differentparametersaffectingtheenergyconsumptionforindustrialproductionofhighcarbon ferromanganeseHCFeMnwereinvestigatedinaclosedsubmergedarcfurnace. TheanalysisofindustrialdatareG vealedthatthemostenergyGconsumedfactorswerethedirectreductionbysolidcarbon, Boudouardreaction, andslagformation de metal, anddecompositionoffluxingmaterials (limestoneanddolomite).ToreducetheenergyconG sumptionandminimizetheenergylossesintheproductionprocessofHCFeMn, itwasrecommendedtouseMn blendwithminimum MntoFeratioof6andlowerSiO2contentorhigherbasicity. Theaddedcokemustbeadjusted accordingtothematerialbalancetopreventtheoverGcokeandtominimizethehighlyendothermic “BoudouardreacG ção”.Inaddition, itwasrecommendedtoworkatbasicslagswiththeratioof (CaO + MgO) toSiO2equalto1􀆰0- 1􀆰2insteadofmuchhigherslagbasicity. Furthermore, themasslosseshadtobeminimizedthroughadjustingthe processando e processando de todos os produtos produzidos. Palavras-chave: produção de alto carbonoferromanganês, consumo de energia, composição carbonatada, reação de Boudouard, slagbasicity, energyloss Manganeseis com base na economia industrial. A indústria industrial consume 90% -95% de todo o ganão humano na forma das mangueiras de manganês de ferromanganeseandangico, que são utilizadas como desoxidantes e desulfurantes do moltensteel [1-3]. Eles distribuíram diversas propriedades de aço em muitas grades de aço. As eletroeletrônicas são muito flexíveis, uma vez que podem ser utilizadas para produzir uma maior quantidade de carbono nos manganês e a economia de manganês e a economia nas pequenas unidades de produção. As maiores descobertas são possíveis de uma forma mais baixa e uma tomada de decisão é muito diferente das superfícies de chamas [1,4-6]. No entanto, theapplicationofelectricfurnaceisburG denedbytheescalatingcostofelectricpower [7-10].A fourkeycostfactorsforhighcarbonferromanganese productionaremainlyore, electricidade, reductantand labor. Themostimportanttwofactorsareoreand electricidade, whichrepresentmorethan50% oftotal plantoperatingcosts. Therefore, highcarbonferroG manganeseproductioninelectricarcfurnacesisconG sideredasanenergyGintensiveindustry, andthusthe priceofenergyaffectsconsiderablytheproduction costofferromanganesealloyandconsequentlythe priceoftheproducedferromanganese. A crescente crise na comercialização de energia elétrica para as centrais mundiais para se concentrarem em todos os esforços para impedir o consumo de energia. Produção de carbono reduzindo a produção de gansos. A indústria gráfica e o consumo de energia elétrica. Fator de análise de energia no processo de produção; é necessário auxiliar o desenvolvimento de uma rede de produção de energia elétrica. Em outro estudo, diferentes parâmetros afetam o consumo de energia para a produção industrial de alta densidade de carbono. O HCFEservou-se em uma habitação de vegetais misturadas, e como se questionou o consumo de energia e minimizou as perdas de energia. O processo foi analisado. 1 Produção Industrial de HCFeMn HCFeProduzido de forma isolada em EgyptatSinai ManganeseCompany, SMC, usando uma21MVAelecG tricarcfurnaceasaclosedtopunit. HCFeMnisproG ducedby carbothermicreductionofablendomanganeseoresfunhantes e modificadosintrinados. CuzisusedasareG ductantandbothdolomiteandlimestoneareusedas fluxingmaterials. O consumo médio de energia elétrica para produzir1tferromangansese é de 3.000kWh, o que mais pode representar uma figura de 2036 a 2600kWh. A descrição de diferentes parâmetros da atuação gráfica na produção de produtos industriais e corporativos foi realizada por um período de tempo alternativo. Usou-se no grupo de informações coletadas, o engenho de consumo de HCFe foi calculado e correlacionado com os diferentes parâmetros do processo de produção. 2 ResultsandDiscussion 2􀆰1 Effectofinputmaterialsonenergyconsumption 2􀆰1􀆰1 EffectofMnores Fig􀆰1illustratestheeffectofmasspercentof Mnsinterinthecharged Mnblendonthepower consumptionandtotalMnblendmass. AsMnsinter percentinMnblendincreases, thepowerconsumpG tiondecreasesasshowninFig􀆰1 (a).Thiscouldbe attributedtothedecreaseofthemassofMnblend accompaniedwiththeincreaseofMnsinter (com higherMntoFeratio) percentinMnblend (Fig􀆰1 (b)). UsingMnoreswithalowerMntoFeratio necessitatescharginghigheramountofMnsinterto obtainahigherMntoFeratio . Fig􀆰1 MnsintermasspercentinMnblendversus powerconsumption (a) andMnblendmass (b) forproducing1tFeMn 2􀆰1􀆰2 Effectofflux Fig􀆰2revealstheeffectofflux (limestoneand dolomita) fluxmassincreases massonthepowerconsumption. Asthe, thepowerconsumptionforproG Fig􀆰2 Powerconsumptionvariationwithfluxmass, coque consumptionandslagmassforproducing1tFeMn ducing1tHCFeMnincreases. Thedecompositionof bothcalciumandmagnesiumcarbonatesisendotherG micreactionwhichrequireadditionalenergy. InadG dição, CaOandMgOwillallenterintoslag, afectam a quantidade, a composição e as características de fusão de escórias. A adição exagerada deste tipo de ângios é o ponto de vista e a visibilidade da luz, afeta o processo de difusão e a diminuição do consumo de energia. 2􀆰1􀆰3 Effectofcoke Fig􀆰2showstheeffectofcokemassonthepower consumption. Asthecokemassincreases, thepower consumptionpertonHCFeMnincreases. Thehigher cokeconsumptionisaccompanied withthehigher MnGblendconsumption. Inaddition, thehighercoke consumptionresultsinhighercokeash. Cokeash containsSiO2, Al2O3andsmalleramountsofCaO andMgO. Theseoxidesentertheslagandrequire additionalenergyfor melting. Foranovercooked chargemixture, thegasratiodecreases (lessCO2), indicatingthatthecokeisnotproperlyutilized. The excesscarbonreactswithCO2toform CO ( BoudG ouardreaction). Esta afirmação é muito avançada, resultando em um maior consumo de energia. Isso será discutido com mais detalhes. 2􀆰2 Effectofoutputmaterialsonenergyconsumption 2􀆰2􀆰1 Effectofslag Theeffectofslagmassont aconstrução da força de trabalhoGeração naFig􀆰2.AstheslagmassforproG ducingHCFeMnincreases, o consumo de energia aumenta. Os dados foram correlacionados com massa de Mnblend (Fig. 3), fluxmass (Fig. 4 (a)) e estrutura celular (Fig. 4 (b)). Pode ser o mesmo. Diminui os limites da mescla e da discussão. As pessoas que viajam pela grandeza podem ser atribuídas ao aumento da indulgência. 766Issue7 ParametersAffectingEnergyConsumptionforProducingHighCarbonFerromanganese Fig􀆰3 Mnblendmassversusslagmassforproducing1tFeMn Fig􀆰4 Fluxmassversusslagmassperton FeMn (a) andslagbasicity (b) 2􀆰2􀆰2 EffectofoffGgases TheoffGgaseshaveaneffectonthepowerconG sumptionasshowninFig􀆰5.AstheoffGgasesmass pertonHCFeMnincreases, thepowerconsumption increases. TheratioofCO2to (CO + CO2) inthe offGgasesseemstoaffectthepowerconsumptionas bem, asshowninFig􀆰6.ThehigherratioofCO2to Fig􀆰 5 OffGgasesmassversuspowerconsumptionpertonFeMn Fig􀆰6 Razão de CO2to (CO + CO2) inoffGgases versus consumo de energia pertonFeMn (CO + CO2) na parte externa do gás. Os dados maiores do pré-geração e a reatividade do CO2 pelo CO2, o que diminui a necessidade de interferência térmica (C + CO2 → 2CO) e o consumo de energia elétrica. 2􀆰3 Effectofmassssobre o consumo de energia As economias de liquidação de material exibiram as perdas de massa de média de 5% a 5% da massa de compressão. As perdas de compensação, além de um efeito significativo no consumo de potência, foram calculadas em Fig􀆰7. Fig. 7 Massas variáveis ​​de percentagem de massa compensada versus consumo de energia por minutoFeMn 2􀆰4 Calor térmico e avaliação 2􀆰4􀆰1 Considerações teóricas O processo preliminar de implantação na produção de alta circulação de oxigênio na região resultante da fusão de carbono: secagem, calcinação, redução indireta, reação de Boudouard, redução direta, formação de manganesecarbideandslagformaG ção [10-15]. (1) Seção de secagem A temperatura de gás é uma temperatura diferente da temperatura entre 500 e 500 ºC. Por exemplo, a evaporação da água na mistura de enchimento será: H2O (l) + H2O (g) ΔH298 = 44􀆰0kJ (1) (2) Calcination Carbonatesareaddedasflux in thecharge. DeG compositionofMgCO3andCaCO3 willoccuratabout 300and900 ℃, respectivamente. Thedolomite, CaMg (CO3) 2, decomposesintwostepsfirstlyataround500 ℃ whereMgCO3isdecomposedtoMgOandCO2while CaCO3isdecomposedinthenextstep (900 ℃) para CaOandCO2 MgCO3 → MgO + CO2 ΔH298 = 101􀆰1kJ (2) CaCO3 → CaO + CO2 ΔH298 = 178􀆰3kJ (3) (3) manganeseores Indirectreduction Highermanganeseoxidesthatpredominatein (MnO2, Mn2O3 e Mn3O4 ) são 866 JournalofIronandSteelResearch, International Vol􀆰21 relativamente baixas e também produzem um sólido solidificado em presença de gás com gás: MnO2 + 1 2CO 1 2Mn2O3 + 1 2CO2 ΔH298 = -99􀆰9kJ (4) 1 2Mn2O3 + 1 6CO → 1 3Mn3O4 + 1 6CO2 ΔH298 = -31􀆰3kJ (5) 1 3Mn3O4 + 1 3CO → MnO + 1 3CO2 ΔH298 = -16􀆰9kJ (6) As reacções de outras espécies com uma quantidade considerável de aquecimento , evitando assim o carregamento de materiais na alimentação. Ironisalwayspresentinmanganeseores, e thereductionofironoxidesrunparalleltoreduction ofthehighermanganeseoxides. Completereduction inthesolidstateispossible: 1 2Fe2O3 + 3 2CO → Fe + 3 2CO2 ΔH298 = -12􀆰9kJ (7) No entanto, themostpossiblereactionistheinG directreductionofhigherironoxides (Fe2O3) inthe solidstatebyCOtoFeO: Fe2O3 + CO + CO2 → 2FeO ΔH298 = -124􀆰3kJ (8) (4 ) Boudouardreaction Whenthetemperaturehasreached800-1000 ℃, thereactionatthesurfaceofthecokeissufficiently rapidtomaketheorereductionandthe “reacção de Boudouard” runsimultaneously. Asaresult, theCO2 gasformedbyreductionoforemayinturnreact withcarbontogivethereaction: C + CO2 → 2CO ΔH298 = 172􀆰5kJ (9) O “Boudouardreaction” isstronglyendotherG mic. Therelativeextentofthegasreductionand BoudouardreactionisreflectedbytheratioofCO2 a () inthefurnaceoffGgas CO + CO2. (5) Retirada direta Embora ele possa ser cortado no estado sólido por gás com gás, deve ser reduzido com carbono sólido: FeO + C → Fe + CO ΔH298 = 154􀆰3kJ (10) Não é eliminada a suspensão de óxidos de óxido, além de redução de gases de MnOtomanganes não é possível. MnOsfarmorestable doFeO. Considera-se que a fusão de outras misturas de óxido de nitrogênio1250 ℃ e a redução final de MnOtoMnmetal devem ter lugar com carbono sólido com cofragem: MnO (l) + C → Mn (l) + CO ΔH298 = 274􀆰6kJ (11) ThereductionofsilicaandP2O5takesplace também com carbono sólido: SiO2 (l) + 2C → Si (l) + 2CO ΔH298 = 754􀆰9kJ (12) P2O5 (l) + 5C → 2P (l) + 5CO ΔH298 = 960􀆰7kJ (13) As reações de redução direta de carbono sólido são muito anti-micro e variam em relação à energia elétrica. (6) Formação do equilíbrio do carbono Somecarbondissolveinmetaluptocarbonatação saturada: 3Mn (l) + C → Mn3C ΔH298 = -36􀆰4kJ (14) (7) Slagformation Slagisformedby theoxidesofilium, calciG um, magnésio, alumínio, manganês e ferro, o qual foi feito em um processo de fusão. Siliconalmostentirelyentersslag. OnlyasmallporG tionofsiliconisreducedfromslagandappearsin themetal. About70% -80% ofmanganeseisreG ducedandpassestothemetal, whiletheunreduced oxidesremainintheslag. Almostalloftheironis reducedandentersthemetal, sotheslaghaslittle ferrousoxide. TheoxidesofSi, Ca, MgandAl, whichmakeupthebulkoftheslag, meltingpoints. However haveveryhigh, tainproportions iftheyaremixedincerG, a mistura pode meltatlower temperatures. ThisiswhatactuallyoccursinsmelG tingprocessasthechargedescendstothelowerpart ofthefurnace; suchmixturesfusetogetherandthen melttoproduceslag. 2􀆰4􀆰2 Caldeira de equilíbrio térmico O consumo de energia elétrica é determinado por meio das reações neotéficas e exotérmicas no processo, de acordo com o uso de células antitransportantes, em vez da energia. As soluções térmicas de equilíbrio térmico basearam-se na revisão de informações técnicas para o processo de produção de HCFeMnatSMC. AnexampleofthembalanceialaterialtheheproG ductionof1tHCFeMnatSMCdurante os períodos de recolhadataisgiveninTable1. O equilíbrio de energia correspondente, baseado na mistura de materiais de alimentação e produtos (dado na balança de material), é ilustrado na Tabela 2. Foi assinalado que tais materiais se aproximariam da temperatura de 25 ℃ e armazenaram a superfície de combustível em 1500 ℃. A eliminação da temperatura foi assumida como 200 ℃. 966Issue7 ParâmetrosAssimitaçãoEnergiaConsumo paraProduçãoHighCarbonFerromanganese Tabela1 Materialbalanceforprodução1tHCFeMnalloy Matérias-primas Massa / kg MnO2 MnO Fe Fe2O3 SiO2 Al2O3 CaO MgO Na2O BaO P2O5 C CO2 CO H2O Mnore1 976 458􀆰4 206 118􀆰6 83􀆰3 24􀆰4 26􀆰4 13􀆰7 3􀆰416 27􀆰 13 2􀆰235 7􀆰12 Mnore2 392 166􀆰7 78􀆰8 68􀆰99 43􀆰1 9􀆰016 8􀆰04 3􀆰53 1􀆰254 5􀆰88 0􀆰763 2􀆰55 Mnsinter 653 130􀆰6 382 42􀆰 9 50􀆰4 25􀆰47 1􀆰96 1􀆰18 2􀆰612 2􀆰612 1􀆰137 4􀆰83 Dolomite 245 2􀆰132 11􀆰9 3􀆰185 72 46􀆰8 107 1􀆰27 Calcário 140 0􀆰742 5 􀆰74 1􀆰022 72􀆰 0􀆰98 58 0􀆰56 Coca-Cola 458􀆰3 0􀆰34 7􀆰975 23􀆰9 17􀆰01 1􀆰55 0􀆰13 0􀆰033 394 4􀆰58 Eletrodos 16􀆰9 16􀆰9 Elecção 0􀆰708 0 􀆰708 Sum 2882 755􀆰7 667 0􀆰71 241􀆰3 218 80􀆰1 182 66􀆰3 7􀆰28 35􀆰62 4􀆰17 411 165 20􀆰9 kmol 8􀆰69 9􀆰4 0􀆰013 1􀆰51 3 􀆰64 0􀆰79 3􀆰25 1􀆰64 0􀆰117 0􀆰232 0􀆰029 34􀆰2 3􀆰76 1􀆰16 Produtos Massa / kg Mn Fe MnO FeO SiO2 Al2O3 CaO MgO C CO2 CO H2O FeMn 1000 752 173 70 Escória 690 129􀆰9 5􀆰87 182 80􀆰05 185 63􀆰8 Gases 1024 278 725 20􀆰9 Perdas 168 Soma 2882 75 2 173 129􀆰9 5􀆰87 182 80􀆰05 195 53􀆰8 70 278 725 20􀆰9 kmol 13􀆰67 3􀆰09 1􀆰83 0􀆰08 3􀆰03 0􀆰78 3􀆰48 1􀆰35 5􀆰83 6􀆰32 25􀆰9 1􀆰16 Composição do metal / massa% Slagcomposição / massa% Gascomposição / kmol Mn Fe CP Si MnO FeO CaO MgO SiO2 Al2O3 CO2 CO H2O 75􀆰2 17􀆰3 7 0􀆰18 0􀆰18 18􀆰8 0 􀆰85 26􀆰8 9􀆰2 26􀆰3 11􀆰6 6􀆰32 25􀆰9 1􀆰16 Tabela2 Balanço de energia para a produção1tHCFeMnalloy Reacções kmol MJ ​​kWh H2O (l) = H2O (g) 1􀆰16 51 14 MgCO3 = MgO + CO2 1􀆰19 121 34 CaCO3 = CaO + CO2 2􀆰58 459 128 MnO2 + CO = MnO + CO2 8􀆰69 -1287 -357 Fe2O3 + CO = 2FeO + CO2 1􀆰51 -187 -52 C + CO = 2CO 6􀆰46 1114 310 FeO + C = Fe (l) + CO 3􀆰09 477 132 MnO + C = Mn (l) + CO 13􀆰67 3755 1043 SiO2 + 2C = Si (l) + 2CO 0􀆰06 44 12 P2O5 + 5C = 2P (l) + 5CO 0􀆰06 62 17 3Mn (l) + C = Mn3C 5􀆰83 -212 -59 Totalheatofreactions 1222 Productsenthalpies (de 25 ℃ aT) Metal (T = 1500 ℃) Mn 13􀆰67 1093 304 Fe 3􀆰09 214 59 C 5􀆰83 373 104 Si 0􀆰06 5 2 P 0􀆰06 10 3 Escória (T = 1500 ℃) MnO 1􀆰83 238 66 FeO 0􀆰08 7 2 SiO2 3􀆰03 372 103 Al2O3 0􀆰78 242 67 CaO 3􀆰48 563 156 MgO 1􀆰35 210 58 OffGgas (T = 200 ℃) CO2 6􀆰32 41 11 CO 25􀆰88 132 37 H2O 1􀆰16 7 2 Totalproductsenthalpie s 974 Totalprocessenergy 2196 Perdas 794 Consumo de energia real 2990 Nota: Tistemperaturein ℃. 2􀆰4􀆰3 Correlação entre equilíbrio térmico e diferentes parâmetros de operação. De acordo com as ciclos térmicos, a manutenção do consumo de energia no processo de ferromanganês de carbono elevado na Tabela 3. Tabela3 Principaissobre o consumo de energia para a produção de oxigênio de carbonoProcessão de HCFeMensificação de energia Consumo de energia por tonelada de HCFeMn / kWh Rácio Média 1 Evaporação de água 9-19 14 2 Decomposição de carbonatos 67-217 153 3 Redução indireta (-340) - (- 535) -420 4 Reação de Boudouard 107-798 361 5 Reação direta 1171-1214 1198 6 Formação de carbubrato ( -58) - (- 59) -59 7 Metalat1500 ℃ 468-473 470 8 Slagat1500 ℃ 233-696 426 9 OffGgasat200 ℃ 41-67 50 Consumo de energia teórica 1751-2885 2193 Energylosses 418-1210 800 Consumo de energia real 2500-3906 2993 Operações de energia mais gerais com a redução direta de carbono sólido, BoudouardreacG ção, metalurgia e informação e distribuição de materiais offluxing (lim estoneanddolomite). Retiradas diretas de acordo com o excesso de temperatura e a produção de melharucos consideráveis. Os resultados obtidos são a maior parte do tempo, a maior parte do tempo, a partir de 07 de julho, a revista de Pesquisa de aleatórios e internacionais, os parâmetros internacionais voltados para o consumo energético são a composição de carbonatos, reação de Boudouard, slagformação e energia elétrica. A energia sugeriu que a substituição das bonates do carro não dependia de materiais de filtração aderentes e a separação descrita com a base de Mnblend (MnoresandMnsintermix), mostrada em Fig􀆰8. Fig. 8 Basicity ofMnblendversusflux consumptionpertonFeMn Theenergyconsumedinslagformationisdeg pendentonslagmassandesteparameteriscorrelaG tedwithMnblendmassandfluxaddition, asillusG tratedinFigs􀆰3and4 (a). A energia consumida em "Reação de Boudouard" é dependente do monitoramento de carbôndexidação na sua resposta. Isso se refletirá no consumo total de energia para HCFeMn. Insmeltingofhighcarbonferromanganese, um actionsofMnO portionofCOresultingfromthedirectreductionreG, FeO, SiO2andP2O5bysolidcarG bonisconsumedintheindirectreductionreactionsof higheroxidesofmanganeseandiron (i􀆰e􀆰, Fe2O3 e Mn2O3).Consequently, thehigheramountof COintheoffGgasthanexpectedasaresultofdirect andindirectreductionreactionsshouldbearesultof theendothermicBoudouardreaction. So, astheCO contentintheoffGgasincreases, theenergyconG sumptioninBoudouardreactionincreases. Além disso, o baixo CO2to (CO + CO2) ratioin theoffGgasindicateshigherCO2consumedinBoudG ouardreaction e, consequentemente, a alta energia elétrica sumergiu-se em uma nova reação térmica. OverGcokeencouragestheendothermicBoudG ouardreactiontoqueque pode ser incluído de Fig. 9.Asaddedcokemassincreases, theCOamount in theGoGasingestionsGracias, no momento, o CO2 para (CO + CO2) ratiointheoffGgasdecreasesandenG ergyconsumedinBoudouardreactionincreases. 2􀆰4􀆰4 Energylosses Thermalbalancecalculationsrevealedenergylosses Fig􀆰9 CokemasspertonFeMnversusCOamountin offGgaspertonFeMn (a), ratioofCO2to (CO + CO2) (b) andenergyconsumedinBoudouardreaction (c) pertonHCFeMnrangebetween420and1210kWh (average800kWh).Theseenergylossesrepresent 16% -38% (average26􀆰7%) ofthetotalconsumed paredes heatlossthroughthefurnace energy. Theenergylossescouldbeattributedtothe. Além disso, alguns dos mais importantes materiais serão o destino com as fugas. Estabilidade da infiltração de minérios. Além disso, eles devem ser detectados em meio de balanços materiais. A separação entre muitas perdas e perdas energéticas foi traduzida em Fig􀆰10.Asthemasslassegastando-se o vinco, aumentando o grau de aumento. As explosões de gás, o potencial de aumento de 478kWhfor1tHCFeMn, que poderia ser atribuído ao calor através das paredes de vidro. O mais completo gerador de uma geração de idade322kWhfor1tHCFeMn poderia ser atribuído a elas. O assunto foi analisado e controlado Fig. 10 Relacionamento entre os problemas e as funções externas 176Issue7 ParâmetrosAssimitação da energia para o processoProcessingHighCarbonFerromanganese processo, dustleavingthefurnacewithoffGgas, mass errorsandmetallostinslagandincrushing para o suitablesizes. Um dos mais altos e importantes números de produtos industriais, na dependência dos meios de comunicação e da mobilidade do combustível, está disponível para todos os produtos produzidos por metal. O ForexamG ple, 5% dos achados da indústria emagrecimento aumentou o consumo de energia por meio de cerca de 150kWhfor1t HCFeMn. 3 Conclusões (1) Os parâmetros compreendem o consumo de energia para a produção de HCFeMnarethemass deMnblend, materiais de fluxo, redução de calcário, produção de lâminas, gatos e musas. Além disso, a escoriação, o calor através das paredes de vento e o forno, e a energia consumida na regeneração do Boudouard tem uma influência considerável sobre o consumo de energia. (2) As operações de energia mais representativas são a redução direta do carbono sólido, da reação do Boudouard, do metal e da informação e dos materiais de deslocamento da posição (limestoneanddolomite). (3) Repetições diretas por meio de uma solução exotérmica e produtiva de um bom sono. (4) Os parâmetros mais flexíveis que afetam o consenso energético na eliminação da classificação de carbono, energia, reação de Boudouard, slagformation e geradores de gás. (5) A energia elétrica consumiu acomposição de carbono dos carbonatos independentes de materiais de fluxo aderente e esteparameteriscorrelacionado com o acetato de silicone e a base de Mnblend. (6) A energia elétricaconsumedinslagformationis é dependente de uma acumulação e essa discriminação de separação está relacionada com a diferença e a extensão de memória. (7) A energia elétrica foi consumada. A resposta ao governo foi dependente do consumo de carbôxido de dióxido de carbono consumido na sua reacção. O conteúdo do COV no deslocamento aumentou, a energia foi consumida na reacção de aquecimento. (8) OverGcokeencouragestheendothermicBoudG ouardreactiontooccurandincreasesthehetoforofofGasascompetiçãofinmentar o consumo de energia. (9) Energylossesrepresentar a média de 26% da energia consumida total detectada no fluxo de calor através das superfícies de gás e as explosões. (10) ToreducetheenergyconsumptionandminiG mizetheenergylossesintheproductionprocessof HCFeMn, itisrecommendedtouseMnblendwith mínimo MntoFeratioof6andlowerSiO2content orhigherbasicity. Theaddedcokemustbeadjusted accordingtothematerialbalancetopreventtheoverG cokeandtominimizethehighlyendothermicBoudG ouardreaction. Inaddition, itisrecommendedto workatbasicslagwithratioof (CaO + MgO) para SiO2equalto1􀆰0-1􀆰2insteadofthemuchhigher slagbasicity. Furthermore, themasslosseshavetobe minimizedthroughadjustingthehandlingandcharG gingprocessandtotakecareofallmetalproduced. Os autores deveriam reconhecer a CIÊNCIA e o Fundo Tecnológico de Desenvolvimento Tecnológico (STDF) em compensar o apoio financeiro e a melhor facilidade oferecida para realizar esse trabalho. As partes do consumidor da SMC apresentaram todas as facilidades e dados exigidos para a realização desse estudo. As atribuições especiais e a gratidão são os membros principais noSteelandFerroalloysDeG parte, CMRDI e técnico da SMC Company. Referências: [1] E􀆰C. Vanderstaay, D􀆰R. Swinbourne, M. Monteiro, Miner. Process. Extract. Metall.113 (2004) 38G44. [2] M. Salah, H. ElFamaamawy, A. Ahmed, S􀆰N. Ghali, A􀆰T. Kandil, J. Min. Mater. Charact. Eng.1 (2013) 68G74. [3] M. Eissa, H. ElGFaramawy, G. Farid, SteelRes.69 (1998) 373G380. [4] R. Kononv, O. Ostrovski, S. Ganguly, ISIJInt.49 (2009) 1099G 1106. [5] M. Eissa, A. Fathy, A. Ahmed, A. ElGMohammady, K. ElG Fawakhry, SteelRes. Int.78 (2007) 24G30. [6] H. ElGFaramawy, T. Mattar, A. Fathy, M. Eissa, A. Ahmed, Ironmak. Steelmak.31 (2004) 31G36. [7] B. Asphang, ElkemTrainingManual, ElkemConsultants, 1992. [8] R. Ishak, M. Tangstad, Inovações na Indústria Federal, ING FACONXI, MacmillanPublishersIndiaLimited, NewDelhi, 2007. [9] Y. Miyauchi, T. Nishi, K. Saito, Y. Kizu, Transformação através da tecnologiaINFACONX, CapeTown, África do Sul, 2004. [10] S􀆰E. Olsen, M. Tangstad, T. Lindstad, Produção de MangaG neseFerroalloys, SINTEFandTapirAcademicPress, TrondG heim, 2007. [11] E􀆰F. Wegmann, AReferenceBookforBlastFurnaceOperaG tors, MirPublishers, Moscow, 1984. [12] F􀆰P. Edneral, ElectrometallurgyofSteelandFerroalloys, Vol􀆰2, MirPublishers, Moscow, 1979. [13] M. Eissa, S. Ghali, A. Ahmed, H. ElGFaramawy, Ironmak. Steelmak.39 (2012) 419G430. [14] E. Trejo, F. Martell, O. Micheloud, L. Teng, A. Llamas, A. MontesinosGCastellanos, Energy42 (2012) 446G456. [15] M. Eissa, H. ElGFaramawy, A. Ahmed, S. Ghali, H. Halfa, J. Min. Mater. Charact. Eng.11 (2012) 1G20. 276 JournalofIronandSteelResearch, International Vol􀆰21.
Biografia: AzzaAhmed, PostGdoctor, AssociateProfessor; EGmail: azzaazza40 @ yahoo􀆰com; Data recebida: janeiro de 9,2013 CorrespondingAuthor: MamdouhEissa, PostGdoctor, Professor; EGmail: mamdouh_eissa @ yahoo􀆰com ...
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Conformal Field Theories, Graphs and Quantum Algebras.
Valentina Petkova Jean-Bernard Zuber.
This article reviews some recent progress in our understanding of the structure of rational conformal field theories, based on ideas that originate for a large part in the work of A. Ocneanu. The consistency conditions that generalize modular invariance for a given RCFT in the presence of various types of boundary conditions—open, twisted—are encoded in a system of integer multiplicities that form matrix representations of fusion-like algebras. These multiplicities are also the combinatorial data that enable one to construct an abstract “quantum” algebra, whose 6 j - and 3j-symbols contain essential information on the operator product algebra of the RCFT and are part of a cell system, subject to pentagonal identities. It looks quite plausible that the classification of a wide class of RCFT amounts to a classification of “Weak C *- Hopf algebras”.
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Valentina Petkova 1 2 Jean-Bernard Zuber 3 1. School of Computing and Mathematics University of Northumbria Newcastle upon Tyne UK 2. Institute for Nuclear Research and Nuclear Energy Sofia Bulgaria 3. Service de Physique Théorique CEA Saclay Gif-sur-Yvette cedex France.
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Parameters Affecting Energy Consumption for Producing High Carbon Ferromanganese in a Closed Submerged Arc Furnace.
Categoria: Documentos.
Biography:AzzaAhmed, PostGdoctor, AssociateProfessor; EGmail:azzaazza40@yahoo􀆰com; ReceivedDate:January9,2013 CorrespondingAuthor:MamdouhEissa, PostGdoctor, Professor; EGmail:mamdouh_eissa@yahoo􀆰com 􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇􀪇 JOURNALOFIRONANDSTEELRESEARCH, INTERNATIONAL􀆰2014,21(7):666G672 􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉􀪉 ParametersAffectingEnergyConsumptionforProducingHigh CarbonFerromanganeseinaClosedSubmergedArcFurnace AzzaAhmed, Hossam Halfa, MohamedK.ElGFawakhry, HodaElGFaramawy, MamdouhEissa (SteelTechnology, MetallurgicalResearchandDevelopmentInstitute, Helwan11421,Cairo, Egypt) Abstract:ThepowerconsumptionisconsideredtobethemostimportantfactoraffectingtheproductioncostofferG romanganesealloy.Differentparametersaffectingtheenergyconsumptionforindustrialproductionofhighcarbon ferromanganeseHCFeMnwereinvestigatedinaclosedsubmergedarcfurnace.TheanalysisofindustrialdatareG vealedthatthemostenergyGconsumedfactorswerethedirectreductionbysolidcarbon, Boudouardreaction, metal andslagformation, anddecompositionoffluxingmaterials(limestoneanddolomite).ToreducetheenergyconG sumptionandminimizetheenergylossesintheproductionprocessofHCFeMn, itwasrecommendedtouseMn blendwithminimum MntoFeratioof6andlowerSiO2contentorhigherbasicity.Theaddedcokemustbeadjusted accordingtothematerialbalancetopreventtheoverGcokeandtominimizethehighlyendothermic“BoudouardreacG tion”.Inaddition, itwasrecommendedtoworkatbasicslagswiththeratioof(CaO+MgO)toSiO2equalto1􀆰0- 1􀆰2insteadofmuchhigherslagbasicity.Furthermore, themasslosseshadtobeminimizedthroughadjustingthe handlingandchargingprocessandtotakecareofallmetalproduced. Keywords:highcarbonferromanganeseproduction;energyconsumption;carbonatedecomposition;BoudouardreacG tion;slagbasicity;energyloss Manganeseisanimportantindustrialcommodity. Thesteelindustryconsumes90%-95%ofallmanG ganeseintheformoftheferromanganeseandsilicoG manganesealloys, whichareusedbothasdeoxidiG zersand desulphurizersofthe moltensteel[1-3]. Theyarealsousedasalloyingadditionsin many steelgrades. Electricarcfurnacesareveryflexibleinthat theycanbeusedtoproduceeitherhighcarbonferroG manganeseorsilicomanganeseandareeconomicat smallproductioncapacities.HighrecoveriesareposG siblefromlowgradeoresandcokeconsumptionis muchlessthanthatofblastfurnaces[1,4-6]. However, theapplicationofelectricfurnaceisburG denedbytheescalatingcostofelectricpower[7-10].The fourkeycostfactorsforhighcarbonferromanganese productionaremainlyore, electricity, reductantand labor.Themostimportanttwofactorsareoreand electricity, whichrepresentmorethan50%oftotal plantoperatingcosts.Therefore, highcarbonferroG manganeseproductioninelectricarcfurnacesisconG sideredasanenergyGintensiveindustry, andthusthe priceofenergyaffectsconsiderablytheproduction costofferromanganesealloyandconsequentlythe priceoftheproducedferromanganese. Thecurrentcrisisinenergymarketalloverthe worldcallsforconcentratingalltheeffortstoreduce theenergyconsumption.AshighcarbonferromanG ganeseproductionisanenergyGintensiveindustry andelectricpowerconsumptionisakeycostfactor intheproductionprocess, itisnecessarytolookfor developedtechniquestoreducetheenergyconsumpG tioninthisimportantindustry. Inthisstudy, differentparametersaffectingthe energyconsumptionforindustrialproductionofhigh carbonferromanganeseHCFeMnwasinvestigatedin aclosedsubmergedarcfurnace, andhowtoreduce theenergyconsumptionand minimizetheenergy lossesinthisprocesswasanalyzed. 1 IndustrialProductionofHCFeMn HCFeMnislocallyproducedinEgyptatSinai ManganeseCompany, SMC, usinga21MVAelecG tricarcfurnaceasaclosedtopunit.HCFeMnisproG ducedbycarbothermicreductionofablendoflumpy andsinteredmanganeseores.CokeisusedasareG ductantandbothdolomiteandlimestoneareusedas fluxingmaterials. Theaverageelectricpowerconsumptionfor producing1tferromanganeseisabout3000kWh, whichishigherthanthestandardfigureof2036- 2600kWh. ThedataofdifferentparametersofactualinG dustrialHCFeMnproductionatSMChavebeencolG lectedforaperiodoffouryears.BasedonthecolG lecteddataatSMC, theenergyconsumptionperton HCFeMnhasbeencalculatedandcorrelatedwiththe differentparametersofproductionprocess. 2 ResultsandDiscussion 2􀆰1 Effectofinputmaterialsonenergyconsumption 2􀆰1􀆰1 EffectofMnores Fig􀆰1illustratestheeffectofmasspercentof Mnsinterinthecharged Mnblendonthepower consumptionandtotalMnblendmass.AsMnsinter percentinMnblendincreases, thepowerconsumpG tiondecreasesasshowninFig􀆰1(a).Thiscouldbe attributedtothedecreaseofthemassofMnblend accompaniedwiththeincreaseofMnsinter(with higherMntoFeratio)percentinMnblend(Fig􀆰1 (b)).UsingMnoreswithalowerMntoFeratio necessitatescharginghigheramountofMnsinterto obtainahigherMntoFeratio. Fig􀆰1 MnsintermasspercentinMnblendversus powerconsumption(a)andMnblendmass (b)forproducing1tFeMn 2􀆰1􀆰2 Effectofflux Fig􀆰2revealstheeffectofflux(limestoneand dolomite)massonthepowerconsumption.Asthe fluxmassincreases, thepowerconsumptionforproG Fig􀆰2 Powerconsumptionvariationwithfluxmass, coke consumptionandslagmassforproducing1tFeMn ducing1tHCFeMnincreases.Thedecompositionof bothcalciumandmagnesiumcarbonatesisendotherG micreactionwhichrequireadditionalenergy.InadG dition, CaOandMgOwillallenterintoslag, affectG ingtheamount, compositionandcharacteristicsof slagduringsmelting.ExcessiveadditionoftheseoxG idesraisesthemeltingpointandviscosityofslag, affectsthediffusionprocessandcausestheincrease ofpowerconsumption. 2􀆰1􀆰3 Effectofcoke Fig􀆰2showstheeffectofcokemassonthepower consumption.Asthecokemassincreases, thepower consumptionpertonHCFeMnincreases.Thehigher cokeconsumptionisaccompanied withthehigher MnGblendconsumption.Inaddition, thehighercoke consumptionresultsinhighercokeash.Cokeash containsSiO2,Al2O3andsmalleramountsofCaO andMgO.Theseoxidesentertheslagandrequire additionalenergyfor melting.Foranovercooked chargemixture, thegasratiodecreases(lessCO2), indicatingthatthecokeisnotproperlyutilized.The excesscarbonreactswithCO2toform CO (BoudG ouardreaction).Thisreactionishighlyendothermic resultinginhigherpowerconsumption.Thiswill bediscussedinsomedetailsinthenextsections. 2􀆰2 Effectofoutputmaterialsonenergyconsumption 2􀆰2􀆰1 Effectofslag TheeffectofslagmassonthepowerconsumpG tionisallshowninFig􀆰2.AstheslagmassforproG ducingHCFeMnincreases, thepowerconsumption increases.TheslagmassiscorrelatedwithMnblend mass(Fig􀆰3),fluxmass(Fig􀆰4(a))andslagbasicG ity(Fig􀆰4(b)).ItcanbeseenthattheslagmassinG creaseswithincreasingbothblendmassandfluxadG dition.Thehigherslagmassathigherslagbasicity couldbeattributedtotheincreaseoffluxaddition. 766Issue7 ParametersAffectingEnergyConsumptionforProducingHighCarbonFerromanganese Fig􀆰3 Mnblendmassversusslagmassforproducing1tFeMn Fig􀆰4 Fluxmassversusslagmassperton FeMn(a)andslagbasicity(b) 2􀆰2􀆰2 EffectofoffGgases TheoffGgaseshaveaneffectonthepowerconG sumptionasshowninFig􀆰5.AstheoffGgasesmass pertonHCFeMnincreases, thepowerconsumption increases.TheratioofCO2to(CO+CO2)inthe offGgasesseemstoaffectthepowerconsumptionas well, asshowninFig􀆰6.ThehigherratioofCO2to Fig􀆰5 OffGgasesmassversuspowerconsumptionpertonFeMn Fig􀆰6 RatioofCO2to(CO+CO2)inoffGgases versuspowerconsumptionpertonFeMn (CO+CO2)intheoffGgasindicateshigherdegreeof preGreductionandlowerreactivityofthecoketoward CO2,whichhindersthestronglyendothermicBoudG ouardreaction (C+CO2→2CO)andhencelowers powerconsumption. 2􀆰3 Effectofmasslossesonenergyconsumption Materialbalancecalculationsshowedthemass lossesofaverage5􀆰5%ofthechargemix.Thesemass lossesalsohaveasignificanteffectonthepower consumptionasshowninFig􀆰7. Fig􀆰7 Masslossesaspercentageofchargemass versuspowerconsumptionpertonFeMn 2􀆰4 Thermalbalanceconsideration 2􀆰4􀆰1 Theoreticalconsiderations TheprincipalprocessestakingplaceintheproG ductionofhighcarbonferromanganeseinthesubG mergedarcfurnaceare:drying, calcination, indirect reduction, Boudouardreaction, directreduction, formationof manganesecarbideandslagformaG tion[10-15]. (1)Drying TheoffGgastemperatureontopofthecharge variesfromfurnacetofurnace, usuallybeingsomeG whatbetween200and500℃inaclosedfurnace.As aresult, evaporationofwaterinthechargemixture willtakeplace: H2O(l)+H2O(g) ΔH298=44􀆰0kJ (1) (2)Calcination Carbonatesareaddedasfluxintothecharge.DeG compositionofMgCO3andCaCO3 willoccuratabout 300and900℃,respectively.Thedolomite, CaMg(CO3)2, decomposesintwostepsfirstlyataround500 ℃ whereMgCO3isdecomposedtoMgOandCO2while CaCO3isdecomposedinthenextstep(900 ℃)to CaOandCO2 MgCO3→MgO+CO2 ΔH298=101􀆰1kJ (2) CaCO3→CaO+CO2 ΔH298=178􀆰3kJ (3) (3)Indirectreduction Highermanganeseoxidesthatpredominatein manganeseores (MnO2,Mn2O3 and Mn3O4)are 866 JournalofIronandSteelResearch, International Vol􀆰21 relativelyunstableandeasilyreducedinsolidstate inthepresenceofCOgas: MnO2+ 1 2CO→ 1 2Mn2O3+ 1 2CO2 ΔH298=-99􀆰9kJ (4) 1 2Mn2O3+ 1 6CO→ 1 3Mn3O4+ 1 6CO2 ΔH298=-31􀆰3kJ (5) 1 3Mn3O4+ 1 3CO→MnO+ 1 3CO2 ΔH298=-16􀆰9kJ (6) Theseareexothermicreactionsproducinga considerableamountofheat, therebypreheatingthe chargematerialsinthefurnace. Ironisalwayspresentinmanganeseores, and thereductionofironoxidesrunparalleltoreduction ofthehighermanganeseoxides.Completereduction inthesolidstateispossible: 1 2Fe2O3+ 3 2CO→Fe+ 3 2CO2 ΔH298=-12􀆰9kJ (7) However, themostpossiblereactionistheinG directreductionofhigherironoxides(Fe2O3)inthe solidstatebyCOtoFeO: Fe2O3+CO→2FeO+CO2 ΔH298=-124􀆰3kJ (8) (4)Boudouardreaction Whenthetemperaturehasreached800-1000℃, thereactionatthesurfaceofthecokeissufficiently rapidtomaketheorereductionandthe“Boudouard reaction”runsimultaneously.Asaresult, theCO2 gasformedbyreductionoforemayinturnreact withcarbontogivethereaction: C+CO2→2CO ΔH298=172􀆰5kJ (9) The“Boudouardreaction”isstronglyendotherG mic.Therelativeextentofthegasreductionand BoudouardreactionisreflectedbytheratioofCO2 to(CO+CO2)inthefurnaceoffGgas. (5)Directreduction AlthoughtheFeOcanbereducedinthesolid statebyCOgas, itisoftenreducedwithsolidcarbon: FeO+C→Fe+CO ΔH298=154􀆰3kJ (10) Unlikethereductionofironoxides, furthergas reductionofsolid MnOtomanganesemetalisnot possible.MnOisfarmorestablethanFeO. Considerablesmeltingoftheremainingoxide mixturestartsatabout1250℃,andthefinalreducG tionofMnOtoMnmetalwilltakeplacewithsolid carboninthecokebed: MnO(l)+C→Mn(l)+CO ΔH298=274􀆰6kJ (11) ThereductionofsilicaandP2O5takesplacealso withsolidcarbon: SiO2(l)+2C→Si(l)+2CO ΔH298=754􀆰9kJ (12) P2O5(l)+5C→2P(l)+5CO ΔH298=960􀆰7kJ (13) Thedirectreductionreactionsbysolidcarbon arehighlyendothermicandwillconsumeahighamount ofelectricenergy. (6)Formationofmanganesecarbide Somecarbonwilldissolveinmetaluptocarbon saturation: 3Mn(l)+C→Mn3C ΔH298=-36􀆰4kJ (14) (7)Slagformation Slagisformedbytheoxidesofsilicon, calciG um, magnesium, aluminum, manganeseandiron, whichhavefailedtobereducedinsmeltingprocess. Siliconalmostentirelyentersslag.OnlyasmallporG tionofsiliconisreducedfromslagandappearsin themetal.About70%-80% ofmanganeseisreG ducedandpassestothemetal, whiletheunreduced oxidesremainintheslag.Almostalloftheironis reducedandentersthemetal, sotheslaghaslittle ferrousoxide.TheoxidesofSi, Ca, MgandAl, whichmakeupthebulkoftheslag, haveveryhigh meltingpoints.However, iftheyaremixedincerG tainproportions, the mixture may meltatlower temperatures.ThisiswhatactuallyoccursinsmelG tingprocessasthechargedescendstothelowerpart ofthefurnace;suchmixturesfusetogetherandthen melttoproduceslag. 2􀆰4􀆰2 Thermalbalancecalculation Theenergyconsumptionisdeterminedbythe neteffectofexothermicandendothermicreactions intheprocess, aswellastheenthalpyofthemateriG alsgoing, inandoutofthefurnace. ThermalbalancecalculationsbasedonthetheoG reticalconsiderationwerecarriedoutfortheproducG tionprocessofHCFeMnatSMC. AnexampleofthematerialbalancefortheproG ductionof1tHCFeMnatSMCduringtheperiods ofcollecteddataisgiveninTable1. Thecorrespondingenergybalance, basedon thesamemixtureofchargematerialsandproducts (giveninmaterialbalance)isillustratedinTable2. Itisassumedthattheraw materialswillenter thefurnaceat25℃andtappedslagandmetalleave thefurnaceat1500 ℃.TheoffGgastemperatureis assumedtobe200℃. 966Issue7 ParametersAffectingEnergyConsumptionforProducingHighCarbonFerromanganese Table1 Materialbalanceforproducing1tHCFeMnalloy Raw materials Mass/ kg MnO2 MnO Fe Fe2O3 SiO2 Al2O3 CaO MgO Na2O BaO P2O5 C CO2 CO H2O Mnore1 976 458􀆰4 206 118􀆰6 83􀆰3 24􀆰4 26􀆰4 13􀆰7 3􀆰416 27􀆰13 2􀆰235 7􀆰12 Mnore2 392 166􀆰7 78􀆰8 68􀆰99 43􀆰1 9􀆰016 8􀆰04 3􀆰53 1􀆰254 5􀆰88 0􀆰763 2􀆰55 Mnsinter 653 130􀆰6 382 42􀆰9 50􀆰4 25􀆰47 1􀆰96 1􀆰18 2􀆰612 2􀆰612 1􀆰137 4􀆰83 Dolomite 245 2􀆰132 11􀆰9 3􀆰185 72 46􀆰8 107 1􀆰27 Limestone 140 0􀆰742 5􀆰74 1􀆰022 72􀆰2 0􀆰98 58 0􀆰56 Coke 458􀆰3 0􀆰34 7􀆰975 23􀆰9 17􀆰01 1􀆰55 0􀆰13 0􀆰033 394 4􀆰58 Electrodes 16􀆰9 16􀆰9 Elect􀆰casing 0􀆰708 0􀆰708 Sum 2882 755􀆰7 667 0􀆰71 241􀆰3 218 80􀆰1 182 66􀆰3 7􀆰28 35􀆰62 4􀆰17 411 165 20􀆰9 kmol 8􀆰69 9􀆰4 0􀆰013 1􀆰51 3􀆰64 0􀆰79 3􀆰25 1􀆰64 0􀆰117 0􀆰232 0􀆰029 34􀆰2 3􀆰76 1􀆰16 Products Mass/ kg Mn Fe MnO FeO SiO2 Al2O3 CaO MgO C CO2 CO H2O FeMn 1000 752 173 70 Slag 690 129􀆰9 5􀆰87 182 80􀆰05 185 63􀆰8 Gases 1024 278 725 20􀆰9 Losses 168 Sum 2882 752 173 129􀆰9 5􀆰87 182 80􀆰05 195 53􀆰8 70 278 725 20􀆰9 kmol 13􀆰67 3􀆰09 1􀆰83 0􀆰08 3􀆰03 0􀆰78 3􀆰48 1􀆰35 5􀆰83 6􀆰32 25􀆰9 1􀆰16 Metalcomposition/mass% Slagcomposition/mass% Gascomposition/kmol Mn Fe C P Si MnO FeO CaO MgO SiO2 Al2O3 CO2 CO H2O 75􀆰2 17􀆰3 7 0􀆰18 0􀆰18 18􀆰8 0􀆰85 26􀆰8 9􀆰2 26􀆰3 11􀆰6 6􀆰32 25􀆰9 1􀆰16 Table2 Energybalanceforproducing1tHCFeMnalloy Reactions kmol MJ kWh H2O(l)=H2O(g) 1􀆰16 51 14 MgCO3=MgO+CO2 1􀆰19 121 34 CaCO3=CaO+CO2 2􀆰58 459 128 MnO2+CO=MnO+CO2 8􀆰69 -1287 -357 Fe2O3+CO=2FeO+CO2 1􀆰51 -187 -52 C+CO2=2CO 6􀆰46 1114 310 FeO+C=Fe(l)+CO 3􀆰09 477 132 MnO+C=Mn(l)+CO 13􀆰67 3755 1043 SiO2+2C=Si(l)+2CO 0􀆰06 44 12 P2O5+5C=2P(l)+5CO 0􀆰06 62 17 3Mn(l)+C=Mn3C 5􀆰83 -212 -59 Totalheatofreactions 1222 Productsenthalpies(from25℃toT) Metal(T=1500℃) Mn 13􀆰67 1093 304 Fe 3􀆰09 214 59 C 5􀆰83 373 104 Si 0􀆰06 5 2 P 0􀆰06 10 3 Slag(T=1500℃) MnO 1􀆰83 238 66 FeO 0􀆰08 7 2 SiO2 3􀆰03 372 103 Al2O3 0􀆰78 242 67 CaO 3􀆰48 563 156 MgO 1􀆰35 210 58 OffGgas(T=200℃) CO2 6􀆰32 41 11 CO 25􀆰88 132 37 H2O 1􀆰16 7 2 Totalproductsenthalpies 974 Totalprocessenergy 2196 Losses 794 Actualenergyconsumption 2990 Note:Tistemperaturein℃. 2􀆰4􀆰3 Correlationbetweenthermalbalanceand differentoperationparameters Accordingtothethermalbalancecalculations, themainitemsofenergyconsumptioninthehighcarbon ferromanganeseprocessaresummarizedinTable3. Table3 Mainitemsofenergyconsumptionfor producing1thighcarbonferromanganese ProcessinHCFeMnsmelting Energyconsumptionper tonHCFeMn/kWh Range Average 1 Evaporationofwater 9-19 14 2 Decompositionofcarbonates 67-217 153 3 Indirectreduction (-340)-(-535) -420 4 Boudouardreaction 107-798 361 5 Directreaction 1171-1214 1198 6 FormationofMnGcarbide (-58)-(-59) -59 7 Metalat1500℃ 468-473 470 8 Slagat1500℃ 233-696 426 9 OffGgasat200℃ 41-67 50 Theoreticalenergyconsumption 1751-2885 2193 Energylosses 418-1210 800 Actualenergyconsumption 2500-3906 2993 Themostenergyconsumedoperationsarethe directreductionbysolidcarbon, BoudouardreacG tion, metalandslagformation, anddecomposition offluxingmaterials(limestoneanddolomite).IndiG rectreductionsbyCOareexothermicandproducea considerableamountofheat. TheobtainedresultsrevealthatthemostfluctuG 076 JournalofIronandSteelResearch, International Vol􀆰21 atedparametersaffectingtheenergyconsumption aredecompositionofcarbonates, BoudouardreacG tion, slagformation, andenergylosses. TheenergyconsumedfordecompositionofcarG bonatesisdependentonthemassofaddedfluxing materialsandthisparameteriscorrelatedwithbasicG ityofMnblend(MnoresandMnsintermix),asshown inFig􀆰8. Fig􀆰8 BasicityofMnblendversusflux consumptionpertonFeMn TheenergyconsumedinslagformationisdeG pendentonslagmassandthisparameteriscorrelaG tedwithMnblendmassandfluxaddition, asillusG tratedinFigs􀆰3and4(a). Theenergyconsumedin“Boudouardreaction” isdependentontheamountofcarbondioxideconG sumedinthisreaction.Thiswillbereflectedonthe totalpowerconsumptionpertonHCFeMn. Insmeltingofhighcarbonferromanganese, a portionofCOresultingfromthedirectreductionreG actionsofMnO, FeO, SiO2andP2O5bysolidcarG bonisconsumedintheindirectreductionreactionsof higheroxidesofmanganeseandiron (i􀆰e􀆰,Fe2O3 and Mn2O3).Consequently, thehigheramountof COintheoffGgasthanexpectedasaresultofdirect andindirectreductionreactionsshouldbearesultof theendothermicBoudouardreaction.So, astheCO contentintheoffGgasincreases, theenergyconG sumptioninBoudouardreactionincreases. Besides, thelowerCO2to(CO+CO2)ratioin theoffGgasindicateshigherCO2consumedinBoudG ouardreactionandconsequentlyhigherenergyconG sumedinthisendothermicreaction. OverGcokeencouragestheendothermicBoudG ouardreactiontooccurwhichcanbeconcludedfrom Fig􀆰9.Asaddedcokemassincreases, theCOamount intheoffGgasincreases;atthesametime, theCO2 to(CO+CO2)ratiointheoffGgasdecreasesandenG ergyconsumedinBoudouardreactionincreases. 2􀆰4􀆰4 Energylosses Thermalbalancecalculationsrevealedenergylosses Fig􀆰9 CokemasspertonFeMnversusCOamountin offGgaspertonFeMn(a),ratioofCO2to(CO+CO2) (b)andenergyconsumedinBoudouardreaction(c) pertonHCFeMnrangebetween420and1210kWh (average800kWh).Theseenergylossesrepresent 16%-38% (average26􀆰7%)ofthetotalconsumed energy.Theenergylossescouldbeattributedtothe heatlossthroughthefurnace walls.Inaddition, someofthematerialswillleavethefurnaceasdust withtheoffGgases.Thisisonlyofminorinfluence. Furthermore, themasslossesdetectedin material balancecalculationalsocauseenergylosses. Therelationbetweenthemasslossesandenergy lossesisillustratedinFig􀆰10.AsthemasslossesinG crease, theenergylossesincrease.Atzeromasslosses, theenergylossisabout478kWhfor1tHCFeMn, whichcouldbeattributedtotheheatlossthrough thefurnacewalls.ThefurtherenergylossesofaverG age322kWhfor1tHCFeMncouldbeattributedto themasslosses. Themasslossesareduetohandlingandcharging Fig􀆰10 Relationshipbetweenmasslossesandenergylosses 176Issue7 ParametersAffectingEnergyConsumptionforProducingHighCarbonFerromanganese process, dustleavingthefurnacewithoffGgas, mass errorsandmetallostinslagandincrushingtothe suitablesizes. Oneofthemostimportantindustrialissues, inG dependentofchargematerialsandfurnaceoperation, istotakecareofallthemetalproduced.ForexamG ple,5%lossofmetalintheslagwillincreasetheapG parentenergyconsumptionbyabout150kWhfor1t HCFeMn. 3 Conclusions (1)Theparametersmostaffectingtheenergy consumptionforproducing1tHCFeMnarethemass ofMnblend, fluxingmaterials, reducingagentcoke, producedslag, offGgases, andlosses.Inaddition, the slagbasicity, theheatlossthroughthefurnacewalls androof, andenergyconsumedintheendothermic Boudouardreactionhavealsoconsiderableinfluence ontheenergyconsumption. (2)Themostenergyconsumedoperationsare thedirectreductionbysolidcarbon, BoudouardreacG tion, metalandslagformation, anddecomposition offluxingmaterials(limestoneanddolomite). (3)IndirectreductionsbyCOareexothermic andproduceaconsiderableamountofheat. (4)Themostfluctuatedparametersaffecting theenergyconsumptionaredecompositionofcarbonG ates, Boudouardreaction, slagformation, andenerG gylosses. (5)Theenergyconsumedfordecompositionof carbonatesisdependentonthemassofaddedfluxing materialsandthisparameteriscorrelatedwiththe silicacontentandbasicityofMnblend. (6)Theenergyconsumedinslagformationis dependentonslagmassandthisparameteriscorreG latedwithMnblendmassandfluxaddition. (7)TheenergyconsumedinBoudouardreacG tionisdependentontheamountofcarbondioxide consumedinthisreaction.AstheCOcontentinthe offGgasincreases, theenergyconsumedinBoudouard reactionincreases. (8)OverGcokeencouragestheendothermicBoudG ouardreactiontooccurandincreasestheamountof offGgaseswiththeresultofincreasingtheenergy consumption. (9)Energylossesrepresentthatonaverage26􀆰7% ofthetotalconsumedenergyisdetectedduetothe heatlossthroughthefurnacewallsandthemasslosses. (10)ToreducetheenergyconsumptionandminiG mizetheenergylossesintheproductionprocessof HCFeMn, itisrecommendedtouseMnblendwith minimum MntoFeratioof6andlowerSiO2content orhigherbasicity.Theaddedcokemustbeadjusted accordingtothematerialbalancetopreventtheoverG cokeandtominimizethehighlyendothermicBoudG ouardreaction.Inaddition, itisrecommendedto workatbasicslagwithratioof(CaO+MgO)to SiO2equalto1􀆰0-1􀆰2insteadofthemuchhigher slagbasicity.Furthermore, themasslosseshavetobe minimizedthroughadjustingthehandlingandcharG gingprocessandtotakecareofallmetalproduced. TheauthorswouldliketoacknowledgetheSciG enceandTechnologicalDevelopmentFund (STDF) duetotheirfinancialsupportandallfacilitiesthey offeredtoperformthiswork.Thecounterpartsof SMCofferedallfacilitiesandrequireddataforperG formingthisstudy.Specialthanksandgratitude areduetoallmembersinSteelandFerroalloysDeG partment, CMRDIandtechnicalstaffof SMC Company. References: [1] E􀆰C.Vanderstaay, D􀆰R.Swinbourne, M.Monteiro, Miner. Process.Extract.Metall.113(2004)38G44. [2] M.Salah, H.ElFaramawy, A.Ahmed, S􀆰N.Ghali, A􀆰T. Kandil, J.Min.Mater.Charact.Eng.1(2013)68G74. [3] M.Eissa, H.ElGFaramawy, G.Farid, SteelRes.69 (1998) 373G380. [4] R.Kononv, O.Ostrovski, S.Ganguly, ISIJInt.49(2009)1099G 1106. [5] M.Eissa, A.Fathy, A.Ahmed, A.ElGMohammady, K.ElG Fawakhry, SteelRes.Int.78(2007)24G30. [6] H.ElGFaramawy, T.Mattar, A.Fathy, M.Eissa, A.Ahmed, Ironmak.Steelmak.31(2004)31G36. [7] B.Asphang, ElkemTrainingManual, ElkemConsultants,1992. [8] R.Ishak, M.Tangstad, InnovationsinFerroalloyIndustry, ING FACONXI, MacmillanPublishersIndiaLimited, NewDelhi, 2007. [9] Y.Miyauchi, T.Nishi, K.Saito, Y.Kizu, Transformationthrough TechnologyINFACONX, CapeTown, SouthAfrica,2004. [10] S􀆰E.Olsen, M.Tangstad, T.Lindstad, ProductionofMangaG neseFerroalloys, SINTEFandTapirAcademicPress, TrondG heim,2007. [11] E􀆰F.Wegmann, AReferenceBookforBlastFurnaceOperaG tors, MirPublishers, Moscow,1984. [12] F􀆰P.Edneral, ElectrometallurgyofSteelandFerroalloys, Vol􀆰2, MirPublishers, Moscow,1979. [13] M.Eissa, S.Ghali, A.Ahmed, H.ElGFaramawy, Ironmak. Steelmak.39(2012)419G430. [14] E.Trejo, F.Martell, O.Micheloud, L.Teng, A.Llamas, A. MontesinosGCastellanos, Energy42(2012)446G456. [15] M.Eissa, H.ElGFaramawy, A.Ahmed, S.Ghali, H.Halfa, J.Min.Mater.Charact.Eng.11(2012)1G20. 276 JournalofIronandSteelResearch, International Vol􀆰21.
Biography:AzzaAhmed, PostGdoctor, AssociateProfessor; EGmail:azzaazza40@yahoo􀆰com; ReceivedDate:January9,2013 CorrespondingAuthor:MamdouhEissa, PostGdoctor, Professor; EGmail:mamdouh_eissa@yahoo􀆰com…
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