Lecture17:Basicsofheatbalanceinroasting

Contents:
Introduction
Heatbalance
Calculationprocedurefortemperature
Illustration
Keywords:Roasting,metalextraction,heatbalance,thermochemistry
Introduction
Heatbalanceisanimportantexerciseinallhightemperatureprocesses.Heatbalancecanbeusedto
determinethetemperature,theoretically,whichcanbeattainedduringroasting.Knowledgeof
temperatureisusefultotakeadecisionabouttherefractorymaterial.
Heatbalance
Atunsteadystate
Heatinput=Heatoutput+Heataccumulation+Heatlosses
Inhightemperatureprocesses,certainamountofthermalenergyisretainedwithinthereactorto
maintainprocessingtemperature.Atsteadystateandatconstanttemperature.
Heatinput=Heatoutput+Heatlosses......1)
CalculationProcedurefortemperature
Inroastingoreconcentrateandcoalaremixedtoconvertsulphideintooxide.Heatgeneratedbyroasting
andcombustionraisesthetemperatureoftheproductsofroastingandcombustion.Thermodynamically
itispossibletocalculatethetemperatureunderadiabaticcondition,i.e.noheatisallowedtoloss.This
calculatedtemperaturecanthenbeadjustedbyincorporatingheatlosses.Weconsideran
adiabaticprocessofroasting:
Variousheatinputtermsare:

Heatofreaction
Heatofcombustion
Sensibleheatinreactants

Thisamountofheatinputraisesthetemperatureofproducts.
Theproductsconsistsofsolidproductsandgaseous

HT

m c

Cp dT ......2)

HereTistheadiabatictemperature.Thusforadiabaticroastingandcombustion.
HT

H
m c

forreactants+Heatofreactionandcombustion
T

Cp dT

......3)

Whereiisnumberofreactantsandcombustionproducts.
Inequation3heatofreaction&combustionhastobeadded,sinceitisliberated.
Ifthematerialbalanceforroastingisknown,aswellastemperaturesoffuelandair,heatcontentdata
andheatofreactiondatacanbeusedtosetupanequationinwhichtemperatureoftheproductsis
unknown.Letmeillustrateitwithaproblem.

Illustration
InafluidbedreactorZincconcentrateofcomposition
ZnS 75%, FeS 18%, PbS 3%, SiO2 3% and H O 1% isroastedwithstoichiometricamountofair.
Roastproductisdischargedfromtheotherendofthereactor.
Duringroasting1%oftotalZnSremainsunoxidized,whereas80%oftotalironchargedformsZnO.Fe2O3.
Findthebedtemperaturewhen10%ofheatinputislosttothesurrounding.
MaterialBalance:consider1000kgZnconcentrate
Roastingproducesroastproductandgases.Materialbalanceisleftfortheexercise.
Roastproduct
ZnS
ZnO
Fe2O3
ZnO.Fe2O3
PbSO4
SiO2
H2O

Heatliberatingreactionsare:

Kgmols
0.077
6.837
0.204
0.818
0.126

Gases
SO2
N2

Kgmols
9.7
57.58

0.50
0.555

ZnS

1.5O

ZnO

SO ; H

2O

PbSO

; H

ZnO

ZnO.

2 Fe S

3.5 O

PbS

kcal

kg mol ZnO

197000 kcalkg mol PbS O

4750 kcalkg mol ZnO

SO

105950

292600 kcalkg mol

Heatliberated=1138938kcal.
Forcalculationsofheatoutputinroastedproductsandgasesonerequiresspecificheatvalues.All
specificheatvaluesareobtainedfromthereferencesgiveninthereferencesection.
Usingthethermochemicaldatafollowingvaluesarecalculated;
Sensibleheatinroast product

122.78

500.35 T

Sensibleheatingases

148

36399

10

10 3 T 2

35

TotalSensibleheatinproduct+gasesis623.13 T

160619

49.83

10 3 T 2

197018

Heatinput=Heatoutput+Losses
SubstitutingthevaluesandsolvingforTweget
.

Answer

Similarcalculationcanbedonefor20%excessairand40%excessair
Temperaturewhen20% excess air

1545k

Temperaturewhen40% excess air

1407K

Excessairdecreasesthetemperature
Thefollowingdataareusedforcalculations
HT

|ZnO

|ZnS

11.71 T

0.61

10

12.16

0.62

10

|Fe O
|ZnO. Fe O

31.71
27.71

2.18

0.88
8.86

10
T

1.36

10
10

10

8446
9044

4277 kcalkg mole.

4137

|PbS O
HT
HT

HT

10.96
|SiO

|SO

11.04 T

|N

6.83 T

15.5
14.41 T
0.94

0.45

O liquid, 298K

H O g, 373K
|

H O g, T
7.16

10
0.97
10

10

4.2 0

T
10

7.30 T
0.50

10

4455 kcalkgmole.

1.84

10
T
10

O gas, 373K

1.23
T

3327 kcalkgmole.

0.12

10

3992 kcalkgmole.

2117 kcalkgmole.

11170 kcalkgmole.

10

0.40

10
T

2286 kcalkgmole.
2313 kcalkgmole.

Conclusion
Inthislecturebasicsofheatbalanceareillustratedwithaproblem.Readersareadvisedtosolvethe
problemthemselves.
References:
1)Rao,Y.K:Stoichiometryandthermodynamicsofmetallurgicalprocess
2)Butts:Metallurgicalproblem