my 202 very good

7/27/2019 My 202 Very Good

1/50

MY-202 Fuels and Furnaces Department of Metallurgical Engineering

1

PRACTICAL WORKBOOK

FUELS & FURNACES

Name: _______________________________

Year: ________________________________

Batch: _______________________________

Roll No: ______________________________Department: ___________________________

Metallurgical Engineering Department

NED University of Engineering & Technology,

Karachi 75270, Pakistan

7/27/2019 My 202 Very Good

2/50


2

PRACTICAL WORKBOOK

MY 202 - FUELS & FURNACES

Prepared By: Engr. Nafis-Ul-Haque

LECTURER

Approved By: Dr. Muhammad Tufail

CHAIRMAN

Metallurgical Engineering Department

NED University of Engineering & Technology

7/27/2019 My 202 Very Good

3/50


3

CERTIFICATE

Certified that Mr. / Miss____________________________________

Student of Class ________________________ Batch ___________

Bearing Roll No. ____________________________ has completed

his / her course work in the subject of________________________

as prescribed and approved by Board of Review of Metallurgical

Engineering Department.

His / her performance is reflected by index of his / her practical

Workbook. This overall performance of the student is Excellent/

Good/ Satisfactory/ Not satisfactory.

_____________

Course Teacher

7/27/2019 My 202 Very Good

4/50


4

Contents

PR.NO DATE PRACTICAL OBJECT REMARKS

1. To study the various fuels their significance & uses

2. To Plot the drying process on psychrometric chart and use the resultto perform a basic mass balance on the air.

3.To study the coke as a fuel, its importance and uses

4. To study different furnaces their uses and types

5. To study & analyze Blast furnace and its functions

6. To study about Cupola Furnace & its operations.

7. To study Electric Arc Furnaces & its operations

8. To study Induction Furnace & its operations

9. To study the ladle furnace and its operation

10. To perform the "proximate analysis" of given sample of air driedcoal

7/27/2019 My 202 Very Good

5/50


5

Practical No 1

Object:To study various fuels, their significance & uses.

What is a Fuel?Fuel is any material that is burned or altered in order to obtain energy and

to heat or to move an object.Fuel releases its energy either through a

chemical reaction means, such as combustion, or nuclear means, such as

nuclear fission ornuclear fusion. An important property of a useful fuel is

that its energy can be stored to be released only when needed, and that the

release is controlled in such a way that the energy can be harnessed to

produce work. Examples: Methane, Petrol and Oil.

All carbon-based life formsfrom microorganisms to animals and humansdepend on and use fuels

as their source of energy. Their cells engage in an enzyme-mediated chemical process called

metabolism that converts energy from food or light into a form that can be used to sustain life.

Additionally, humans employ a variety of techniques to convert one form of energy into another,

producing usable energy for purposes that go far beyond the energy needs of a human body. The

application of energy released from fuels ranges from heat to cooking and from powering weapons to

combustion and generation ofelectricity. A large majority of currently-known fuels ultimately derive

their energy from a small number of sources. Much of the chemical energy produced by life forms,

such as fossil fuels, is derived from the utilization of solar energy through photosynthesis. Solar

energy in turn is generated by the thermonuclear fusionprocess at the core of the Sun. The radioactive

isotopes used as fuel to power nuclear plants were formed in supernova explosions.

Solid fuelSolid fuels refer to various types ofsolid material that are used as fuel to produce energy and

provide heating, usually released through combustion. Solid fuels include wood (see wood

fuel), charcoal,peat, coal, Hexamine fuel tablets, and pellets made from wood (see wood

pellets), corn, wheat, rye and othergrains. Solid-fuel rocket technology also uses solid fuel

(see solid propellants). Solid fuels have long been used by humanity to create fire. Coal was

the fuel source, which enabled the industrial revolution, from firing furnaces, to running

steam engines. Wood was also extensively used to run steam locomotives. Both peat and coalare still used in electricity generation today. The use of some solid fuels (eg. coal) is

restricted or prohibited in some urban areas, due to unsafe levels of toxic emissions. The use

of other solid fuels such as wood is increasing as heating technology and the availability of

good quality fuel improves. In some areas, smokeless coal is often the only solid fuel used. In

Ireland, peat briquettes are used as smokeless fuel. They are also used to start a coal fire

Liquid FuelsLiquid fuels are those combustible or energy-generating molecules that can be harnessed to

create mechanical energy, usually producing kinetic energy; they also must take the shape of

their container. Most liquid fuels, in widespread use, are or derived from fossil fuels;

however, there are several types, such as hydrogen fuel (forautomotive uses), which are alsocategorized as a liquid fuel. It is the fumes of Liquid fuels that are flammable instead of the

Coal- A fossil fuel
http://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Nuclear_fissionhttp://en.wikipedia.org/wiki/Nuclear_fusionhttp://en.wikipedia.org/wiki/Mechanical_workhttp://en.wikipedia.org/wiki/Carbon-based_lifehttp://en.wikipedia.org/wiki/Microorganismhttp://en.wikipedia.org/wiki/Animalhttp://en.wikipedia.org/wiki/Humanhttp://en.wikipedia.org/wiki/Cell_%28biology%29http://en.wikipedia.org/wiki/Enzymehttp://en.wikipedia.org/wiki/Metabolismhttp://en.wikipedia.org/wiki/Metabolismhttp://en.wikipedia.org/wiki/Foodhttp://en.wikipedia.org/wiki/Lighthttp://en.wikipedia.org/wiki/Human_bodyhttp://en.wikipedia.org/wiki/Heathttp://en.wikipedia.org/wiki/Cookinghttp://en.wikipedia.org/wiki/Weaponhttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Electric_powerhttp://en.wikipedia.org/wiki/Fossil_fuelhttp://en.wikipedia.org/wiki/Photosynthesishttp://en.wikipedia.org/wiki/Thermonuclear_fusionhttp://en.wikipedia.org/wiki/Sunhttp://en.wikipedia.org/wiki/Radioactivehttp://en.wikipedia.org/wiki/Isotopehttp://en.wikipedia.org/wiki/Supernovahttp://en.wikipedia.org/wiki/Solidhttp://en.wikipedia.org/wiki/Fuelhttp://en.wikipedia.org/wiki/Energyhttp://en.wikipedia.org/wiki/Heatinghttp://en.wikipedia.org/wiki/Woodhttp://en.wikipedia.org/wiki/Wood_fuelhttp://en.wikipedia.org/wiki/Wood_fuelhttp://en.wikipedia.org/wiki/Charcoalhttp://en.wikipedia.org/wiki/Peathttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Hexamine_fuel_tablethttp://en.wikipedia.org/wiki/Wood_pelletshttp://en.wikipedia.org/wiki/Wood_pelletshttp://en.wikipedia.org/wiki/Cornhttp://en.wikipedia.org/wiki/Wheathttp://en.wikipedia.org/wiki/Ryehttp://en.wikipedia.org/wiki/Cerealhttp://en.wikipedia.org/wiki/Solid-fuel_rockethttp://en.wikipedia.org/wiki/Rocket_fuel#Solid_propellantshttp://en.wikipedia.org/wiki/Making_firehttp://en.wikipedia.org/wiki/Industrial_revolutionhttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Steam_enginehttp://en.wikipedia.org/wiki/Steam_locomotivehttp://en.wikipedia.org/wiki/Electricity_generationhttp://en.wikipedia.org/wiki/Urban_areahttp://en.wikipedia.org/wiki/Anthracitehttp://en.wikipedia.org/wiki/Briquettehttp://en.wikipedia.org/wiki/Mechanical_energyhttp://en.wikipedia.org/wiki/Kinetic_energyhttp://en.wikipedia.org/wiki/Fossil_fuelshttp://en.wikipedia.org/wiki/Automotivehttp://en.wikipedia.org/wiki/Automotivehttp://en.wikipedia.org/wiki/Fossil_fuelshttp://en.wikipedia.org/wiki/Kinetic_energyhttp://en.wikipedia.org/wiki/Mechanical_energyhttp://en.wikipedia.org/wiki/Briquettehttp://en.wikipedia.org/wiki/Anthracitehttp://en.wikipedia.org/wiki/Urban_areahttp://en.wikipedia.org/wiki/Electricity_generationhttp://en.wikipedia.org/wiki/Steam_locomotivehttp://en.wikipedia.org/wiki/Steam_enginehttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Industrial_revolutionhttp://en.wikipedia.org/wiki/Making_firehttp://en.wikipedia.org/wiki/Rocket_fuel#Solid_propellantshttp://en.wikipedia.org/wiki/Solid-fuel_rockethttp://en.wikipedia.org/wiki/Cerealhttp://en.wikipedia.org/wiki/Ryehttp://en.wikipedia.org/wiki/Wheathttp://en.wikipedia.org/wiki/Cornhttp://en.wikipedia.org/wiki/Wood_pelletshttp://en.wikipedia.org/wiki/Wood_pelletshttp://en.wikipedia.org/wiki/Hexamine_fuel_tablethttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Peathttp://en.wikipedia.org/wiki/Charcoalhttp://en.wikipedia.org/wiki/Wood_fuelhttp://en.wikipedia.org/wiki/Wood_fuelhttp://en.wikipedia.org/wiki/Woodhttp://en.wikipedia.org/wiki/Heatinghttp://en.wikipedia.org/wiki/Energyhttp://en.wikipedia.org/wiki/Fuelhttp://en.wikipedia.org/wiki/Solidhttp://en.wikipedia.org/wiki/Supernovahttp://en.wikipedia.org/wiki/Isotopehttp://en.wikipedia.org/wiki/Radioactivehttp://en.wikipedia.org/wiki/Sunhttp://en.wikipedia.org/wiki/Thermonuclear_fusionhttp://en.wikipedia.org/wiki/Photosynthesishttp://en.wikipedia.org/wiki/Fossil_fuelhttp://en.wikipedia.org/wiki/Electric_powerhttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Weaponhttp://en.wikipedia.org/wiki/Cookinghttp://en.wikipedia.org/wiki/Heathttp://en.wikipedia.org/wiki/Human_bodyhttp://en.wikipedia.org/wiki/Lighthttp://en.wikipedia.org/wiki/Foodhttp://en.wikipedia.org/wiki/Metabolismhttp://en.wikipedia.org/wiki/Enzymehttp://en.wikipedia.org/wiki/Cell_%28biology%29http://en.wikipedia.org/wiki/Humanhttp://en.wikipedia.org/wiki/Animalhttp://en.wikipedia.org/wiki/Microorganismhttp://en.wikipedia.org/wiki/Carbon-based_lifehttp://en.wikipedia.org/wiki/Mechanical_workhttp://en.wikipedia.org/wiki/Nuclear_fusionhttp://en.wikipedia.org/wiki/Nuclear_fissionhttp://en.wikipedia.org/wiki/Combustion

7/27/2019 My 202 Very Good

6/50


6

fluid.This article deals primarily with the concept of liquid fuels in relation to ground

transport. However, others such as rocket fuel also play an important role in the economy.

Bio fuelsBiofuel can be broadly defined as solid, liquid, or gas fuel consisting of, or derived from

biomass. Biomass can also be used directly for heating or powerknown as biomass fuel.Biofuel can be produced from any carbon source that can be replenished rapidly e.g. plants.

Many different plants and plant-derived materials are used for biofuel manufacture. Perhaps

the earliest fuel that was employed by humans is wood. Evidence shows controlled fire was

used up to 1.5 million years ago at Swartkrans, South Africa. It is unknown which hominid

species first used fire, as bothAustralopithecusand an early species ofHomowere present at

the sites. As a fuel, wood has remained in use up until the present day, although it has been

superseded for many purposes by other sources. Wood has an energy density of 1020

MJ/kg.

Fossil Fuels:

Fossil fuels are hydrocarbons, primarily coal and petroleum (liquid petroleum ornatural gas), formedfrom the fossilized remains of dead plants and animals

[5]by exposure to heat and pressure in the

Earth's crust over hundreds of millions of years . In common parlance, the term fossil fuel alsoincludes hydrocarbon-containing natural resources that are not derived entirely from biologicalsources, such as tar sands. These latter sources are properly known as mineral fuels. Modern large-scale industrial development is based on fossil fuel use, which has largely supplanted water-drivenmills, as well as the combustion ofwood orpeat for heat.

Nuclear fuel:Nuclear fuel is any material that is consumed to derive nuclear energy. Technically speaking

this definition includes all matter because any element will under the right conditions release

nuclear energy, the only materials that are commonly referred to as nuclear fuels though arethose that will produce energy without being placed under extreme duress

Gasoline:

It is the most widely used liquid fuel. Gasoline, as it is known in United States and Canada,

orpetrol in India, Britain, Australia, New Zealand, South Africa and many English-speaking

countries, is made of hydrocarbon molecules forming aliphatic compounds, or chains of

carbons with hydrogen atoms attached. However, many aromatic compounds (carbon chains

forming rings) such as benzene are found naturally in gasoline and cause the health risks

associated with prolonged exposure to the fuel. Production of gasoline is achieved by

distillation of crude oil. The desirable liquid is separated from the crude oil in refineries.

Crude oil is extracted from the ground in several processes; the most commonly seen may bebeam pumps. To create gasoline, petroleum must first be removed from crude oil.

Diesel:Conventional diesel is similar to gasoline in that it is a mixture of aliphatic hydrocarbons

extracted from petroleum. Diesel may cost more or less than gasoline, but generally costs less

to produce because the extraction processes used are simpler. Many countries (particularly in

Europe, as well as Canada) also have lower tax rates on diesel fuels. After distillation, the

diesel fraction is normally processed to reduce the amount of sulfur in the fuel. Sulphur

causes corrosion in vehicles, acid rain and higher emissions of soot from the tail pipe

(exhaust pipe). In Europe, lower sulfur levels than in the United States are legally required.

However, recent US legislation will reduce the maximum sulphur content of diesel from3,000 ppm to 500 ppm by 2007, and 15 ppm by 2010. Similar changes are also underway in
http://en.wikipedia.org/wiki/Rocket_fuelhttp://en.wikipedia.org/wiki/Biofuelhttp://en.wikipedia.org/wiki/Biomasshttp://en.wikipedia.org/wiki/Woodhttp://en.wikipedia.org/wiki/Swartkranshttp://en.wikipedia.org/wiki/South_Africahttp://en.wikipedia.org/wiki/Australopithecushttp://en.wikipedia.org/wiki/Australopithecushttp://en.wikipedia.org/wiki/Australopithecushttp://en.wikipedia.org/wiki/Homo_%28genus%29http://en.wikipedia.org/wiki/Homo_%28genus%29http://en.wikipedia.org/wiki/Homo_%28genus%29http://en.wikipedia.org/wiki/Joulehttp://en.wikipedia.org/wiki/Kilogramhttp://en.wikipedia.org/wiki/Hydrocarbonhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Petroleumhttp://en.wikipedia.org/wiki/Liquid_petroleumhttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Fossilhttp://en.wikipedia.org/wiki/Fuels#cite_note-4http://en.wikipedia.org/wiki/Fuels#cite_note-4http://en.wikipedia.org/wiki/Fuels#cite_note-4http://en.wikipedia.org/wiki/Earthhttp://en.wikipedia.org/wiki/Crust_%28geology%29http://en.wikipedia.org/wiki/Hydrocarbonhttp://en.wikipedia.org/wiki/Natural_resourcehttp://en.wikipedia.org/wiki/Tar_sandshttp://en.wikipedia.org/wiki/Woodhttp://en.wikipedia.org/wiki/Peathttp://en.wikipedia.org/wiki/Nuclear_energyhttp://en.wikipedia.org/wiki/Moleculeshttp://en.wikipedia.org/wiki/Aliphatic_compoundhttp://en.wikipedia.org/wiki/Aromatic_compoundhttp://en.wikipedia.org/wiki/Benzenehttp://en.wikipedia.org/wiki/Distillationhttp://en.wikipedia.org/wiki/Crude_oilhttp://en.wikipedia.org/wiki/Refinerieshttp://en.wikipedia.org/wiki/Beam_pumphttp://en.wikipedia.org/wiki/Petroleumhttp://en.wikipedia.org/wiki/Sulfurhttp://en.wikipedia.org/wiki/Acid_rainhttp://en.wikipedia.org/wiki/Acid_rainhttp://en.wikipedia.org/wiki/Sulfurhttp://en.wikipedia.org/wiki/Petroleumhttp://en.wikipedia.org/wiki/Beam_pumphttp://en.wikipedia.org/wiki/Refinerieshttp://en.wikipedia.org/wiki/Crude_oilhttp://en.wikipedia.org/wiki/Distillationhttp://en.wikipedia.org/wiki/Benzenehttp://en.wikipedia.org/wiki/Aromatic_compoundhttp://en.wikipedia.org/wiki/Aliphatic_compoundhttp://en.wikipedia.org/wiki/Moleculeshttp://en.wikipedia.org/wiki/Nuclear_energyhttp://en.wikipedia.org/wiki/Peathttp://en.wikipedia.org/wiki/Woodhttp://en.wikipedia.org/wiki/Tar_sandshttp://en.wikipedia.org/wiki/Natural_resourcehttp://en.wikipedia.org/wiki/Hydrocarbonhttp://en.wikipedia.org/wiki/Crust_%28geology%29http://en.wikipedia.org/wiki/Earthhttp://en.wikipedia.org/wiki/Fuels#cite_note-4http://en.wikipedia.org/wiki/Fossilhttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Liquid_petroleumhttp://en.wikipedia.org/wiki/Petroleumhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Hydrocarbonhttp://en.wikipedia.org/wiki/Kilogramhttp://en.wikipedia.org/wiki/Joulehttp://en.wikipedia.org/wiki/Homo_%28genus%29http://en.wikipedia.org/wiki/Australopithecushttp://en.wikipedia.org/wiki/South_Africahttp://en.wikipedia.org/wiki/Swartkranshttp://en.wikipedia.org/wiki/Woodhttp://en.wikipedia.org/wiki/Biomasshttp://en.wikipedia.org/wiki/Biofuelhttp://en.wikipedia.org/wiki/Rocket_fuel

7/27/2019 My 202 Very Good

7/50


7

Canada, Australia, New Zealand and several Asian countries. Biodiesel is similar to diesel,

but has differences akin to those between petrol and ethanol. For instance, biodiesel has a

highercetane rating (45-60 compared to 45-50 for crude-oil-derived diesel) and it acts as a

cleaning agent to get rid of dirt and deposits.

Liquefied Natural GasLiquefied natural gas or LNG is natural gas (primarily methane, CH4) that has been

converted to liquid form for ease of storage or transport. Liquefied natural gas takes up about

1/600th the volume of natural gas at a stove burner tip. It is odorless, colorless, non-toxic and

non-corrosive. Hazards include flammability, freezing and asphyxia.

IMPORTANCE OF VARIOUS FUELS:

Fossil fuels are of great importance because they can be burned (oxidized to carbon dioxide

and water), producing significant amounts of energy. The use of coal as a fuel predates

recorded history. Coal was used to run furnaces for the melting of metal ore. Semi-solid

hydrocarbons from seeps were also burned in ancient times, but these materials were mostly

used for waterproofing and embalming. Commercial exploitation ofpetroleum, largely as a

replacement for oils from animal sources (notably whale oil) for use in oil lamps began in the

nineteenth century. Natural gas, once flared-off as an un-needed byproduct of petroleum

production, is now considered a very valuable resource. Heavy crude oil, which is very much

more viscous than conventional crude oil, and tar sands, where bitumen is found mixed with

sand and clay, are becoming more important as sources of fossil fuel. Oil shale and similar

materials are sedimentary rocks containing kerogen, a complex mixture of high-molecular

weight organic compounds, which yield synthetic crude oil when heated (pyrolyzed). These

materials have yet to be exploited commercially. These fuels are employed in internal

combustion engines, fossil fuel power stations and other uses. Prior to the latter half of theeighteenth century, windmills orwatermillsprovided the energy needed for industry such as

milling flour, sawing wood or pumping water, and burning wood or peatprovided domestic

heat. The wide-scale use of fossil fuels, coal at first and petroleum later, to fire steam engines,

enabled the Industrial Revolution. At the same time, gas lights using natural gas orcoal gas

were coming into wide use. The invention of the internal combustion engine and its use in

automobiles and trucks greatly increased the demand for gasoline and diesel oil, both made

from fossil fuels. Other forms of transportation, railways and aircraft also required fossil

fuels. The other major use for fossil fuels is in generating electricity. Fossil fuels are also the

main source of raw materials for the petrochemical industry.
http://en.wikipedia.org/wiki/Cetane_numberhttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Methanehttp://en.wikipedia.org/wiki/Odorlesshttp://en.wikipedia.org/wiki/Colorlesshttp://en.wikipedia.org/wiki/Toxicityhttp://en.wikipedia.org/wiki/Corrosivehttp://en.wikipedia.org/wiki/Asphyxiahttp://en.wikipedia.org/wiki/Oxidizedhttp://en.wikipedia.org/wiki/Carbon_dioxidehttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Embalminghttp://en.wikipedia.org/wiki/Petroleumhttp://en.wikipedia.org/wiki/Whale_oilhttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Heavy_crude_oilhttp://en.wikipedia.org/wiki/Tar_sandshttp://en.wikipedia.org/wiki/Bitumenhttp://en.wikipedia.org/wiki/Oil_shalehttp://en.wikipedia.org/wiki/Sedimentaryhttp://en.wikipedia.org/wiki/Kerogenhttp://en.wikipedia.org/wiki/Synthetic_fuelhttp://en.wikipedia.org/wiki/Pyrolysishttp://en.wikipedia.org/wiki/Fossil_fuel_power_stationhttp://en.wikipedia.org/wiki/Windmillhttp://en.wikipedia.org/wiki/Watermillhttp://en.wikipedia.org/wiki/Flourhttp://en.wikipedia.org/wiki/Sawmillhttp://en.wikipedia.org/wiki/Peathttp://en.wikipedia.org/wiki/Steam_engineshttp://en.wikipedia.org/wiki/Industrial_Revolutionhttp://en.wikipedia.org/wiki/Gas_lightinghttp://en.wikipedia.org/wiki/Coal_gashttp://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Automobileshttp://en.wikipedia.org/wiki/Truckshttp://en.wikipedia.org/wiki/Gasolinehttp://en.wikipedia.org/wiki/Dieselhttp://en.wikipedia.org/wiki/Rail_transporthttp://en.wikipedia.org/wiki/Aircrafthttp://en.wikipedia.org/wiki/Electrical_power_industryhttp://en.wikipedia.org/wiki/Petrochemicalhttp://en.wikipedia.org/wiki/Petrochemicalhttp://en.wikipedia.org/wiki/Electrical_power_industryhttp://en.wikipedia.org/wiki/Aircrafthttp://en.wikipedia.org/wiki/Rail_transporthttp://en.wikipedia.org/wiki/Dieselhttp://en.wikipedia.org/wiki/Gasolinehttp://en.wikipedia.org/wiki/Truckshttp://en.wikipedia.org/wiki/Automobileshttp://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Coal_gashttp://en.wikipedia.org/wiki/Gas_lightinghttp://en.wikipedia.org/wiki/Industrial_Revolutionhttp://en.wikipedia.org/wiki/Steam_engineshttp://en.wikipedia.org/wiki/Peathttp://en.wikipedia.org/wiki/Sawmillhttp://en.wikipedia.org/wiki/Flourhttp://en.wikipedia.org/wiki/Watermillhttp://en.wikipedia.org/wiki/Windmillhttp://en.wikipedia.org/wiki/Fossil_fuel_power_stationhttp://en.wikipedia.org/wiki/Pyrolysishttp://en.wikipedia.org/wiki/Synthetic_fuelhttp://en.wikipedia.org/wiki/Kerogenhttp://en.wikipedia.org/wiki/Sedimentaryhttp://en.wikipedia.org/wiki/Oil_shalehttp://en.wikipedia.org/wiki/Bitumenhttp://en.wikipedia.org/wiki/Tar_sandshttp://en.wikipedia.org/wiki/Heavy_crude_oilhttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Whale_oilhttp://en.wikipedia.org/wiki/Petroleumhttp://en.wikipedia.org/wiki/Embalminghttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Carbon_dioxidehttp://en.wikipedia.org/wiki/Oxidizedhttp://en.wikipedia.org/wiki/Asphyxiahttp://en.wikipedia.org/wiki/Corrosivehttp://en.wikipedia.org/wiki/Toxicityhttp://en.wikipedia.org/wiki/Colorlesshttp://en.wikipedia.org/wiki/Odorlesshttp://en.wikipedia.org/wiki/Methanehttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Cetane_number

7/27/2019 My 202 Very Good

8/50


8

TEST YOURSELF:

Q: What is the main difference b/w fossil fuel and Bio-fuel?

A:______________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

Q: Coal was the fuel source which enabled the industrial revolution? Explain

in three lines:

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

Fill in the blanks:

1. Wood has an energy density of _________________MJ/kg

2. Liquefied natural gas takes up about _________the volume of natural gas

at a stove burner tip.

3. Solid fuels include___________,_______ , ________,___________

,___________ , and________

4. Recent US legislation will reduce the maximum sulphur content of diesel

from ________ ppm to _______ ppm by 2007, and _______ ppm by

2010

5. Biomass can also be used directly for heating or power known as

_________________

Investigation corner:

Uses of Bio-fuels are:

1.___________________________________________

2.___________________________________________

3.___________________________________________

4.___________________________________________
http://en.wikipedia.org/wiki/Industrial_revolutionhttp://en.wikipedia.org/wiki/Joulehttp://en.wikipedia.org/wiki/Kilogramhttp://en.wikipedia.org/wiki/Kilogramhttp://en.wikipedia.org/wiki/Joulehttp://en.wikipedia.org/wiki/Industrial_revolution

7/27/2019 My 202 Very Good

9/50


9

Practical No 2

Object:Determine the gross calorific value of given sample of coal using Bomb Calorimeter.

Apparatus: Thermometer

Stop watch

Balance

Briquette press

Copper or Platinum wire

Oxygen cylinder

Bomb Calorimeter.

THEORY OF CALORIMETRY

Calorimetry is derived from the Latin word "color" meaning heat, and theGreek word "metry" meaning to measure. So it is the science, of measuring theamount of heat. All calorimetric techniques are therefore based on the measurement ofheat that may be generated (exothermic process), consumed (endothermic process)or simply dissipated by a sample.

One method of determining the energy exchange between the reaction

system and its environment is to conduct a calorimetric analysis. On this basis we candefine the term calorimetry as:

"It is the measurement of the amount of heat evolved or absorbed in achemica l r e ac t ion , in chang ing o f s ta te , o r in t he fo rma t ion o f a so lu t ion" .

Or

"It is the measurement of heat production. It can either be direct or indirectwhen heat production is estimated from the quantity of oxygen used or carbondioxide produced"

CALORIMETER:

A ca lor imeter is a device used to measure hea t of reac t ion. I t can besophisticated and expensive or simple and cheep. A calorimeter may be operatedunder constant (atmosphere) pressure, or constant volume. Whichever kind to use, wefirst need to know its heat capacity.

HEAT CAPACITY:

The heat capacity is the amount of heat required to raise the temperature of theentire calorimeter by 1 K.

Heat capacity is usually determined experimentally before or after the actual

measurements o f hea t o f r e ac t ion . The hea t c apac i ty o f the ca lo r ime te r i sdetermined by transferring a known amount of heat into i t and measuring i ts

7/27/2019 My 202 Very Good

10/50


10

temperature increase. Because the temperature differences are very small, extremesensitive thermometers are required for these measurements.

CALORIFIC VALUE:

The calorific value or heat of combustion or heating value of a sample of fuel isdefined as the amount of heat evolved when a unit weight ( or volume in the case of asample of gaseous fuels) of the fuel is completely burnt and the products of

combustion cooled to a standard temperature of 298 degree K.

The calorific value of natural gas is expressed in kWh per cubic meter. It isusually expressed in Gross Calorific Value (GCV) or Higher Heating Value (HHV)and Net Calorific Value (NCV) or Lower Calorific Value (LHW).

The difference being the latent heat of condensation of the water vapourproduced during the combustion process.

Since most gas burning appliances cannot utilize the heat content of the watervapor, gross calorific value is of little interest. Fuel should be compared based on the netcalorific value. This is especially true for natural gas, since increased hydrogen contentresults in high water formation during combustion.

UNITS:

Heating values are given in BTU/mol or BTU/lb for liquid and solid fuels, whilethe values for gaseous fuels are given in BTU/mol or BTU / ft

3.

Other names used for the heating value of a fuel are the heat of combustion,

calorific value, and heat of reaction.

MEASUREMENT OF CX OF A FUEL:

By burning a small quantity of fuel in a calorimeter, where the heat release canbe measured precisely, heating values and rela ted informat ion may be checked. There aretwo types of calorimeters in general use today: -

o Bomb Calorimeter or Constant-volume Calorimeter.o Junker's Gas Calorimeter or Constant-pressure Calorimeter.

HIGHER HEATING VALUE:

This is the theoretical total of the energy in the fuel. It is defined as totalamount of hea t l ibera ted when one uni t of the fue l is burnt comple te ly and

combustion products are cooled to room temperature.

The Higher Calorific Value (or Gross Calorific Value - GCV) supposes that thewater of combustion is entirely condensed and that the heat contained in the water vaporis recovered.

7/27/2019 My 202 Very Good

11/50


11

UNITS OF MEASUREMENT:

The basic heat unit is joule. The units of measurement employed in this method are:

1 BTU 4.326 J / G

1 cal 4.186 8J

1 Btu 1055.06 J

1 Btu 251,996 cal

1 cal / g 1.8 Btu / lb

LOWER HEATING VALUE:

It is defined as the amount of heat liberated when one unit of the fuel is

burned completely and the combustion products are allowed to escape.

The Lower Calorific Value (or Net Calorific Value - NCV) supposes that theproducts of combustion co ntain the wa ter va por . The hea t contai ned in the wa ter vaporis not recovered.

RELATION BETWEEN NCV & GCV:

For Solids & Liquids:

CN = CG - 53H

CN and CG are net gross CV representing % age of H 2 in Kcal / Kg in coal.

For Gases:

CN = CG 4.7 V

V= Volume % age of H2.

NCV at constant pressure:

NC V at co nst an t pres su re implies that co mbustion takes place at co nstan t

pressure.

NCV < GCV

AIR-DRIED COAL:

Freshly mined coals get air & sun-dried during its storage, hence its moisturecontent varies depending on the humidity and temperature of the atmospheric air. For

getting accurate and comparable results the coal is exposed to an artificial and standardatmospheric.

7/27/2019 My 202 Very Good

12/50


12

EFFECTS OF H2, N2, S2, O2, P AND Cl IN COAL:

H2 increases the CV. It is associated with VM.

N2 decreases the CV.

S inc. the CV but its presence causes corrosion in association with moisture. It also

causes hot shortness (cracking by hot rolling) to steel. O2

reduces the CV.

P creates cold shortness.

Cl reduces the flash pt. of ash of coal.

FACTORS WHICH DECREASES THE CV:

Higher moisture content.

Higher VM.

Higher Ash.

Higher N2.

Lower fixed carbon. Lower H2.

CALORIFIC VALUE OF DIFFERENT FUELS

Fuel Calorific Value (MJ / Nm3

)

Bituminous Coal 41,600

Lignite Coal 19,000

Kerosine / Diesel 36,700

Gasoline / Petrol 31, 320

Heavy / Residual Fuel Oil 40,000

Natural Gas 33.8

Producer Gas 6.0

7/27/2019 My 202 Very Good

13/50


13

HHV AND LHV OF DIFFERENT FUELS

FUEL TYPE HHV LHV % CHANGEMJ/kg

Light fuel oil 44.003 41.255 6.24

Coal A 21.693 20.236 6.72

Wood, very dry (10% H2O) 17.739 16.308 8.07

Wood, freshly cut (70% H2O) 5.913 3.808 35.61

LPG (90% Propane) 50.250 46.256 7.95

Carbon, C 34.095 34.095 0

Bagasse (50% H2O) 9.855 7.974 19.08

APPLICATIONS OF CALORIMETRY:

Calorimetry has a very broad range of applicability, with examples ranging from drug

design in the pharmaceutical industry, to quality control of process streams in thechemical industry, and the study of metabolic rates in biological (people included) systems.

PROCEDURE:

Take 1 ~ 2 g. of sample of air dried coal and compress it into a cylindrical coal bybriquette press machine and place it into the crucible of calorimeter.

A piece of firing wire, copper or fine Platinum (0.003in thick) is stretchedacross the inner terminals of the bomb and a piece of sewing cotton isattached to it with the other end in contact the sample. (As an alternate alonger platinum wire may be used an d bent in to a loop so as to touch the coalpellet)

10g of distilled water may be introduced into the bomb to absorbed vapours ofsulphuric acid and nitric acid formed during the combustion.

The bomb is charged with oxygen to a pressure of 25 atmosphere through needlevalve without displacing the original air.

The calorimeter vessel is then charged with a weighed quantity of water(usually 2.5 liters) to submerge the bomb up till cover completely

Place the bomb in calorimeter after complete assurance of its tightness (i.e.sewing the bomb cover tightly).

Beckmann's thermometer is adjusted along with the cover of calorimeter, start thestirrer and allow it to run for 5 minutes before observations to begin.

The temperature of water is read to the nearest 0.002C at minute intervals for 5

minutes. If after 5 minutes the rate of change is constant, close the electrical circuit

7/27/2019 My 202 Very Good

14/50


14

momentarily to fire the change and continue the readin gs of temperature for 5minutes after a maximum has been reached. ( in the first 2 minutes after firing thetemperature rises so rapidly that readings are possible only to the nearest 0.01 C,after that the r ate ris e decrease s and readings may be t aken to the nearest 0.002 C)

Now the stirrer is stopped and Bomb is removed from the calorimeter, allowed to

stand for 30 minutes to allow acid mist to settle and pressure is released throughvalve.

On opening the bomb, the crucible is inspected for signs of carbon (if these arefound the result is rejected and a fresh determination is made). Otherwise the Bomb andcrucible are rinsed with a small quantity of distilled water and the washings (Ifdesired) for the determination of sulphur.

NOTE: In case of Anthracite or coke a tendency to incomplete combustion can beavoided by placing a thin layer of pure silica or granular fused alumina (0.75g, 120 240 B.S mesh) on the bottom of the crucible. This is also helpful with coals of high

Ash contents or heaving fusible ash.

CORRECTIONS:

Following corrections can be done in order to determine precise calorific value ofcombustion (at constant volume process) of coal.

Correction for Acids formed:

Certain acids l ike H2 SO4 and HNO 3 may be formed during combustion dueto presence of nitrogen and hydrogen in coal. Thus value of heat of formation of theseacids must be subtracted from determined heating value.

Correction for Cotton Thread / Fuse Wire:

The measured value of heat also includes heat given by ignition of cottonthread or fuse wire; hence its heating value must also be subtracted from determinedcalorific value of combustion of coal.

Cooling Correction:

The observed maximum temperature rise of water in calorimeter is actually

lower than the true maximum by reason of the fact that the calorimeter vessel issubjected to a small but definite loss of heat due to radiation; therefore its value (i.e. he at

los t due to r ad ia t ion) mus t be added on de te rmined ca lo r i f i c va lue o f combustion of coal.

OBSERVATION AND CALCULATION:

Room temperature = TR = C

Weight of air dried coal sample = W = g

Volume of water in Calorimeter = V = 2500 ml

Density of Water at TR= w = g/cc

7/27/2019 My 202 Very Good

15/50


15

Mass of water = M = (density volume) = g

Specific heat of water at TR= CP cal / g - C

Initial temperature of water T 1 = C

Final temperature of water T2 = C

Maximum rise in temperature T = T 2T1 = C

Now

Where: Wc is water equivalent of apparatus

Since not only the water in the calorimeter which is heated during the experiment but also themetal of bomb, stirrer, thermometer and calorimeter itself, therefore it is necessary toknow the amount of heat absorbed by them to cause their temperature to rise onedegree.

The water equivalent can be determined from the sum of the products of theweights and specific heats of various parts of the apparatus i.e. Steel Bomb,Copper Calorimeter, Brass Stirrer and glass thermometer.

Thus

In our case Wc , after solving above equation is 4800 g.

RESULTS:

1. G.C.V of Coal is

2. Report G.C.V coal in different system of units.

DISCUSSION ON RESULTS:

________________________________________________________________________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

_______________________________________________________________

7/27/2019 My 202 Very Good

16/50


16

TEST YOURSELF:

Q: What do you know about Air-dried Coke?A:______________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

Q: Effects of H2, N2, S2 in coal are:

A:______________________________________________________________

________________________________________________________________________________________________________________________________

________________________________________________________________

Fill in the blanks:

6. H2SO4 and HNO3 may be formed during combustion due to

presence of ______________ and _____________ in coal .

7. Fuel should be compared based on the _________________ value.

8. Oxygen in COAL causes _______________________________

__________________.

9. Factors which decreases the CV are ____________,___________,

____________ , _______________ & _________________.

Investigation corner:

List some calorific values of fuels (except already mentioned in this practical):

1.___________________________________________2.___________________________________________

3.___________________________________________

4.___________________________________________

5.___________________________________________

7/27/2019 My 202 Very Good

17/50


17

Practical No 3

Object

To study the Coke as a fuel, its importance and uses

Definition of Coke

Cokes are the solid carbonaceous material derived from destructive distillation of low-ash,

low-sulfurbituminous coal. Cokes from coal are grey, hard, and

porous.

Coking (coke-making)

Volatile constituents of the coalincluding water, coal-gas,

and coal-tarare driven off by baking in an airless furnace

or oven at temperatures as high as 2,000 degrees Celsius.This fuses together the fixed carbon and residual ash. Most

cokes in modern facilities are produced in "by-product"

coking ovens and the resultant cokes are used as the main

fuel in iron-making blast furnaces. Today, the hydrocarbons

are considered to be by-products of modern coke-making

facilities (though they are usually captured and used to produce valuable products. Non by-

product coking furnaces or cokes furnaces (ovens) burn the hydrocarbon off gases produced

by the coke-making process to drive the carbonization process.

Properties and usage

The bulk density of coke is typically around 0.77. It is highly

porous. The most important properties of coke are ash and sulfur

content, which are linearly dependent on the coal used for

production. Coke with less ash and sulfur content is highly priced

on the market. Other important characteristics of coke include M10,

M25, and M40 test crush indexes as they convey the strength of

coke during transportation into the blast furnaces (BF); depending

on BF size, there are certain requirements for coke size before

entering the blast furnace, finely crushed coke pieces must not be

allowed into the BF because gas dynamics would be impededinside. Coke Strength After Reaction or CSR index is another

important characteristics of coke as it represents coke's ability to

withstand the violent conditions inside the blast furnace before

turning into fine particles.The volatility of coke reaches minimum

levels at the end of the coking process. Volatility is an important

property index for bituminous coal used in coke production, the

greater volatile matter inside coal the more by-product could be produced, but there are some

limitations on acceptable volatile content depending on the technical specifications of the

coke batteries. Coal is being blended in proportions among different types of coal to reach

acceptable levels of volatility before the coking process begins. Too low or too high levels of

volatile matter in the coal blend results in inferior coke produced in respect to coke quality

Coke oven at smokeless fuel

plant, South Wales

Hanna furnaces of the

Great Lakes Steel

Corporation, Detroit. Coal

tower atop coke ovens.

November 1942.
http://en.wikipedia.org/wiki/Carbonaceoushttp://en.wikipedia.org/wiki/Destructive_distillationhttp://en.wikipedia.org/wiki/Bituminous_coalhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Waterhttp://en.wikipedia.org/wiki/Coal-gashttp://en.wikipedia.org/wiki/Coal-tarhttp://en.wikipedia.org/w/index.php?title=Fixed_carbon&action=edit&redlink=1http://en.wikipedia.org/wiki/Blast_furnaceshttp://en.wikipedia.org/wiki/Poroushttp://en.wikipedia.org/wiki/Smokeless_fuelhttp://en.wikipedia.org/wiki/Waleshttp://en.wikipedia.org/w/index.php?title=Hanna_furnace&action=edit&redlink=1http://en.wikipedia.org/wiki/Great_Lakeshttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Corporationhttp://en.wikipedia.org/wiki/Detroithttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Detroithttp://en.wikipedia.org/wiki/Corporationhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Great_Lakeshttp://en.wikipedia.org/w/index.php?title=Hanna_furnace&action=edit&redlink=1http://en.wikipedia.org/wiki/Waleshttp://en.wikipedia.org/wiki/Smokeless_fuelhttp://en.wikipedia.org/wiki/Poroushttp://en.wikipedia.org/wiki/Blast_furnaceshttp://en.wikipedia.org/w/index.php?title=Fixed_carbon&action=edit&redlink=1http://en.wikipedia.org/wiki/Coal-tarhttp://en.wikipedia.org/wiki/Coal-gashttp://en.wikipedia.org/wiki/Waterhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Bituminous_coalhttp://en.wikipedia.org/wiki/Destructive_distillationhttp://en.wikipedia.org/wiki/Carbonaceous

7/27/2019 My 202 Very Good

18/50


18

properties, it is generally considered that levels of 26-29 % of volatile matter in the coal

blend is good for coking purposes.

The water content in coke is practically zero at the end of the coking process, but coke is

often water quenched to reduce its temperature so that it can be transported inside the BF.

The porous structure of coke absorbs some water, usually to 3-6 % of its mass. In moderncoke plants an advanced method of coke cooling is by air quenching. Since smoke-producing

constituents are driven off during the coking of coal, coke forms a desirable fuel for stoves

and furnaces in which conditions are not suitable for the complete burning ofbituminous coal

itself. Coke may be burned with little or no smoke under combustion conditions which would

result in a large amount of smoke if bituminous coal were the fuel. Bituminous coal must

meet a set of criteria for use as coking coal, determined by particular coal assay techniques.

These include moisture content, ash content, sulfur content, volatile content, tar, and

plasticity.

Coke is used as a fuel and as a reducing agent in

smelting iron ore in a blast furnace. Discovered byaccident to have superior heat shielding properties

when combined with other materials, coke was one

of the materials used in the heat shielding on

NASA's Apollo program space vehicles. In its final

form, this material was called AVCOAT 5026-39.

This material has been used most recently as the

heat shielding on the Mars Pathfinder vehicle.

Although not used for modern day space shuttles,

NASA is utilizing coke and other materials for a

new heat shield for its next generation space craft,

named Orion, which is due to be completed in 2014.

The solid residue remaining from refinement ofpetroleumby the "cracking" process is also a

form of coke. Petroleum coke has many uses besides being a fuel, such as the manufacture of

dry cells, electrodes, etc. Gas works manufacturing syngas also produce coke as an end

product, called gas house coke.

Fluid coking is a process which converts heavy residual crude into lighter products such as

naphtha, kerosene, heating oil, and hydrocarbon gases. The "fluid" term refers to the fact that

coke particles are in a continuous system versus older batch-coking technology.

Uses:

Coke may be used to make fuel gases. It appears that the names have different meanings in

the USA and the UKso confusion is possible. The following are UK meanings:

Water gas: a mixture ofcarbon monoxide and hydrogen, made by passing steamover red-hot coke (or any carbon based char)

Producer gas, wood gas, generator gas, synthetic gas, suction gas: a mixture of

carbon monoxide, hydrogen and nitrogen, made by passing air over red-hot coke(or any carbon based char)

The Illawarra Coke Company

(ICC) in Coalcliff, New South

Wales, Australia.
http://en.wikipedia.org/wiki/Smokehttp://en.wikipedia.org/wiki/Stovehttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Bituminous_coalhttp://en.wikipedia.org/wiki/Coal_assayhttp://en.wikipedia.org/wiki/Sulfurhttp://en.wikipedia.org/wiki/Tarhttp://en.wikipedia.org/wiki/Plasticity_%28physics%29http://en.wikipedia.org/wiki/Fuelhttp://en.wikipedia.org/wiki/Redoxhttp://en.wikipedia.org/wiki/Smeltinghttp://en.wikipedia.org/wiki/Iron_orehttp://en.wikipedia.org/wiki/Heat_shieldhttp://en.wikipedia.org/wiki/NASAhttp://en.wikipedia.org/wiki/Apollo_programhttp://en.wikipedia.org/wiki/Space_vehiclehttp://en.wikipedia.org/w/index.php?title=AVCOAT_5026-39&action=edit&redlink=1http://en.wikipedia.org/wiki/Mars_Pathfinderhttp://en.wikipedia.org/wiki/Space_shuttlehttp://en.wikipedia.org/wiki/Orion_%28spacecraft%29http://en.wikipedia.org/wiki/Petroleumhttp://en.wikipedia.org/wiki/Cracking_%28chemistry%29http://en.wikipedia.org/wiki/Petroleum_cokehttp://en.wikipedia.org/wiki/Dry_cellhttp://en.wikipedia.org/wiki/Electrodehttp://en.wikipedia.org/wiki/Syngashttp://en.wikipedia.org/wiki/Naphthahttp://en.wikipedia.org/wiki/Kerosenehttp://en.wikipedia.org/wiki/Heating_oilhttp://en.wikipedia.org/wiki/Hydrocarbonhttp://en.wikipedia.org/wiki/USAhttp://en.wikipedia.org/wiki/UKhttp://en.wikipedia.org/wiki/Water_gashttp://en.wikipedia.org/wiki/Carbon_monoxidehttp://en.wikipedia.org/wiki/Hydrogenhttp://en.wikipedia.org/wiki/Producer_gashttp://en.wikipedia.org/wiki/Wood_gashttp://en.wikipedia.org/w/index.php?title=Generator_gas&action=edit&redlink=1http://en.wikipedia.org/wiki/Synthetic_gashttp://en.wikipedia.org/w/index.php?title=Suction_gas&action=edit&redlink=1http://en.wikipedia.org/wiki/Carbon_monoxidehttp://en.wikipedia.org/wiki/Hydrogenhttp://en.wikipedia.org/wiki/Nitrogenhttp://en.wikipedia.org/wiki/Illawarra_Coke_Companyhttp://en.wikipedia.org/wiki/Coalcliffhttp://en.wikipedia.org/wiki/New_South_Waleshttp://en.wikipedia.org/wiki/New_South_Waleshttp://en.wikipedia.org/wiki/Australiahttp://en.wikipedia.org/wiki/Australiahttp://en.wikipedia.org/wiki/New_South_Waleshttp://en.wikipedia.org/wiki/New_South_Waleshttp://en.wikipedia.org/wiki/Coalcliffhttp://en.wikipedia.org/wiki/Illawarra_Coke_Companyhttp://en.wikipedia.org/wiki/Nitrogenhttp://en.wikipedia.org/wiki/Hydrogenhttp://en.wikipedia.org/wiki/Carbon_monoxidehttp://en.wikipedia.org/w/index.php?title=Suction_gas&action=edit&redlink=1http://en.wikipedia.org/wiki/Synthetic_gashttp://en.wikipedia.org/w/index.php?title=Generator_gas&action=edit&redlink=1http://en.wikipedia.org/wiki/Wood_gashttp://en.wikipedia.org/wiki/Producer_gashttp://en.wikipedia.org/wiki/Hydrogenhttp://en.wikipedia.org/wiki/Carbon_monoxidehttp://en.wikipedia.org/wiki/Water_gashttp://en.wikipedia.org/wiki/UKhttp://en.wikipedia.org/wiki/USAhttp://en.wikipedia.org/wiki/Hydrocarbonhttp://en.wikipedia.org/wiki/Heating_oilhttp://en.wikipedia.org/wiki/Kerosenehttp://en.wikipedia.org/wiki/Naphthahttp://en.wikipedia.org/wiki/Syngashttp://en.wikipedia.org/wiki/Electrodehttp://en.wikipedia.org/wiki/Dry_cellhttp://en.wikipedia.org/wiki/Petroleum_cokehttp://en.wikipedia.org/wiki/Cracking_%28chemistry%29http://en.wikipedia.org/wiki/Petroleumhttp://en.wikipedia.org/wiki/Orion_%28spacecraft%29http://en.wikipedia.org/wiki/Space_shuttlehttp://en.wikipedia.org/wiki/Mars_Pathfinderhttp://en.wikipedia.org/w/index.php?title=AVCOAT_5026-39&action=edit&redlink=1http://en.wikipedia.org/wiki/Space_vehiclehttp://en.wikipedia.org/wiki/Apollo_programhttp://en.wikipedia.org/wiki/NASAhttp://en.wikipedia.org/wiki/Heat_shieldhttp://en.wikipedia.org/wiki/Iron_orehttp://en.wikipedia.org/wiki/Smeltinghttp://en.wikipedia.org/wiki/Redoxhttp://en.wikipedia.org/wiki/Fuelhttp://en.wikipedia.org/wiki/Plasticity_%28physics%29http://en.wikipedia.org/wiki/Tarhttp://en.wikipedia.org/wiki/Sulfurhttp://en.wikipedia.org/wiki/Coal_assayhttp://en.wikipedia.org/wiki/Bituminous_coalhttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Stovehttp://en.wikipedia.org/wiki/Smoke

7/27/2019 My 202 Very Good

19/50


19

These are useful gases but require careful handling because of the risk ofcarbon monoxide

poisoning.

Metallurgical Coke at Pakistan Steel Mills, Karachi

Coke is produced at the Coke Oven and By-products Plant and is the solid reduce of the

destructive distillation of coal blend. It is cellular, infusible and heterogeneous in both

physical and chemical properties. It is used as a fuel and reducing agent in the Blast Furnace

for the manufacturing of Pig Iron. The standard specifications of Pakistan Steel coke are listed

below. Excessive quantity is saleable in the market.

Sizes: 0 - 25mm

25 - 80mm

+80mm

Moisture Content 3% typical

Ash Content 13% (max)Volatile matter 1.5% (max)

Sulphur 0.8% (max)

Calorific Value 7000 - 8000 K cal/kg

Packing: Loose

USES

Widely used as a fuel by foundries in cupolas for melting iron scrap and pig iron In sugar mills employing the carbonizing process. For making chemicals/calcium carbide. Used in the pharmaceutical industries. Coke breeze is used for steam generation in boiler houses. Used in Steel making for carbon adjustment.

Metallurgical Coke Production at Pakistan Steel Mills, Karachi
http://en.wikipedia.org/wiki/Carbon_monoxide_poisoninghttp://en.wikipedia.org/wiki/Carbon_monoxide_poisoninghttp://en.wikipedia.org/wiki/Carbon_monoxide_poisoninghttp://en.wikipedia.org/wiki/Carbon_monoxide_poisoning

7/27/2019 My 202 Very Good

20/50


20

TEST YOURSELF:

Q: What is the relation of coal with coke?

A:_________________________________________________________________________

______________________________________________________________________________________________________________________________________________________

___________________________________________________________________________

Q: What do you understand by calorific value of a coke?

A:_________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

Fill in the blanks:

1. The porous structure of coke absorbs some water, usually to 3-6 % of its mass.

2. Coke is used as a fuel and ______________________ in the Blast Furnace for the

manufacturing of _______________.

3. Ash content in them metallurgical coke by Pakistan Steel Mills is _______________.

4. The bulk density of coke is typically around ____________.

5. It is generally considered that levels of ___________% of volatile matter in the coal

blend are good for coking purposes.

6. Fluid coking is a process which converts heavy residual crude into lighter productssuch as____________,___________ ,____________ , and ________________.

Use your brain and answer below:

Q: Why Pakistan Steel Mills is importing coke even though it is available in Pakistan?

A:_________________________________________________________________________

______________________________________________________________________________________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

7/27/2019 My 202 Very Good

21/50


21

Practical No 4

OBJECT:To study different furnaces their uses and types

What is a Furnace?

A furnace is a device used for heating. The name derives from Latin fornax, oven. The

earliest furnace was excavated at Balakot, a site of the Indus Valley Civilization, dating back

to its mature phase (c. 2500-1900 BC). The furnace was most likely used for the

manufacturing of ceramic objects. In American English and Canadian English, the term

furnace on its own is generally used to describe household heating systems based on a central

furnace (known either as a boileror a heaterin British English), and sometimes as a synonym

forkiln, a device used in the production ofceramics. In British English the term furnace is

used exclusively to mean industrial furnaces which are used for many things, such as the

extraction of metal from ore (smelting) or in oil refineries and other chemical plants, forexample as the heat source forfractional distillation columns. The termfurnace can also referto a direct fired heater, used in boiler applications in chemical industries or for providing heat

to chemical reactions for processes like cracking, and are part of the standard English names

for many metallurgical furnaces worldwide. The heat energy to fuel a furnace may be

supplied directly by fuel combustion, by electricity such as the electric arc furnace, or

through Induction heating in induction furnaces.

In metallurgy, several specialized furnaces are used. These include:

Furnaces used in smelters, including:o The blast furnace, used to reduce iron ore to pig iron

Steelmaking furnaces, including: Puddling furnace Reverberatory furnace Bessemer converter Open hearth furnace Electric arc furnace Electric induction furnace

Blast furnace:

A blast furnace is a type of metallurgical furnace used for smelting to produce metals,generally iron. In a blast furnace, fuel and ore are continuously supplied through the top of

the furnace, while air (sometimes with oxygen enrichment) is blown into the bottom of the

chamber, so that the chemical reactions take place throughout the furnace as the material

moves downward. The end products are usually molten metal and slag phases tapped from

the bottom, and flue gases exiting from the top of the furnace.
http://en.wikipedia.org/wiki/Heathttp://en.wikipedia.org/wiki/Latinhttp://en.wikipedia.org/wiki/Ovenhttp://en.wikipedia.org/wiki/Balakothttp://en.wikipedia.org/wiki/Indus_Valley_Civilizationhttp://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/American_Englishhttp://en.wikipedia.org/wiki/Canadian_Englishhttp://en.wikipedia.org/wiki/Househttp://en.wikipedia.org/wiki/Boilerhttp://en.wikipedia.org/wiki/Heaterhttp://en.wikipedia.org/wiki/Kilnhttp://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/British_Englishhttp://en.wikipedia.org/wiki/Industryhttp://en.wikipedia.org/wiki/Resource_extractionhttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Orehttp://en.wikipedia.org/wiki/Smeltinghttp://en.wikipedia.org/wiki/Oil_refinerieshttp://en.wikipedia.org/wiki/Fractional_distillationhttp://en.wikipedia.org/wiki/English_languagehttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Electric_arc_furnacehttp://en.wikipedia.org/wiki/Induction_heatinghttp://en.wikipedia.org/wiki/Induction_furnacehttp://en.wikipedia.org/wiki/Metallurgyhttp://en.wikipedia.org/wiki/Smelterhttp://en.wikipedia.org/wiki/Blast_furnacehttp://en.wikipedia.org/wiki/Redoxhttp://en.wikipedia.org/wiki/Iron_orehttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Steelmakinghttp://en.wikipedia.org/wiki/Puddling_furnacehttp://en.wikipedia.org/wiki/Reverberatory_furnacehttp://en.wikipedia.org/wiki/Bessemer_converterhttp://en.wikipedia.org/wiki/Open_hearth_furnacehttp://en.wikipedia.org/wiki/Electric_arc_furnacehttp://en.wikipedia.org/wiki/Electric_induction_furnacehttp://en.wikipedia.org/wiki/Metallurgyhttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Smeltinghttp://en.wikipedia.org/wiki/Ironhttp://en.wikipedia.org/wiki/Orehttp://en.wikipedia.org/wiki/Chemical_reactionhttp://en.wikipedia.org/wiki/Slaghttp://en.wikipedia.org/wiki/Slaghttp://en.wikipedia.org/wiki/Chemical_reactionhttp://en.wikipedia.org/wiki/Orehttp://en.wikipedia.org/wiki/Ironhttp://en.wikipedia.org/wiki/Smeltinghttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Metallurgyhttp://en.wikipedia.org/wiki/Electric_induction_furnacehttp://en.wikipedia.org/wiki/Electric_arc_furnacehttp://en.wikipedia.org/wiki/Open_hearth_furnacehttp://en.wikipedia.org/wiki/Bessemer_converterhttp://en.wikipedia.org/wiki/Reverberatory_furnacehttp://en.wikipedia.org/wiki/Puddling_furnacehttp://en.wikipedia.org/wiki/Steelmakinghttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Iron_orehttp://en.wikipedia.org/wiki/Redoxhttp://en.wikipedia.org/wiki/Blast_furnacehttp://en.wikipedia.org/wiki/Smelterhttp://en.wikipedia.org/wiki/Metallurgyhttp://en.wikipedia.org/wiki/Induction_furnacehttp://en.wikipedia.org/wiki/Induction_heatinghttp://en.wikipedia.org/wiki/Electric_arc_furnacehttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/English_languagehttp://en.wikipedia.org/wiki/Fractional_distillationhttp://en.wikipedia.org/wiki/Oil_refinerieshttp://en.wikipedia.org/wiki/Smeltinghttp://en.wikipedia.org/wiki/Orehttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Resource_extractionhttp://en.wikipedia.org/wiki/Industryhttp://en.wikipedia.org/wiki/British_Englishhttp://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/Kilnhttp://en.wikipedia.org/wiki/Heaterhttp://en.wikipedia.org/wiki/Boilerhttp://en.wikipedia.org/wiki/Househttp://en.wikipedia.org/wiki/Canadian_Englishhttp://en.wikipedia.org/wiki/American_Englishhttp://en.wikipedia.org/wiki/Ceramichttp://en.wikipedia.org/wiki/Indus_Valley_Civilizationhttp://en.wikipedia.org/wiki/Balakothttp://en.wikipedia.org/wiki/Ovenhttp://en.wikipedia.org/wiki/Latinhttp://en.wikipedia.org/wiki/Heat

7/27/2019 My 202 Very Good

22/50


22

Puddling Furnace:The puddling furnace is a metal making technology used to create wrought iron or steel

from the pig ironproduced in ablast furnace. The furnace is constructed to pull the hot air

over the iron without it coming into direct contact with the fuel, a system generally known as

a reverberatory furnace or open-hearth process. The major advantage of this system is

keeping the impurities of the fuel separated from the charge.

Reverberatory furnace:A reverberatory furnace is a metallurgical or process furnace that isolates the material

being processed from contact with the fuel, but not from contact with combustion gases. The

term reverberation is used here in a generic sense of rebounding or reflecting, not in the

acoustic sense ofechoing.

Bessemer ConverterThe process is carried on in a large ovoid steel container lined with clay ordolomite called

the Bessemer converter. The capacity of a converter was from 8 to 30 tons of molten ironwith a usual charge being around 15 tons. At the top of the converter is an opening, usually

tilted to the side relative to the body of the vessel, through which the iron is introduced and

the finished product removed. The bottom is perforated with a number of channels called

tuyres through which air is forced into the converter. The converter is pivoted on trunnions

so that it can be rotated to receive the charge, turned upright during conversion, and then

rotated again for pouring out the molten steel at the end

Open hearth furnaceOpen hearth furnaces are one of a number of kinds of furnace where excess carbon and

other impurities are burnt out of the pig iron to produce steel. Since steel is difficult to

manufacture due to its high melting point, normal fuels and furnaces were insufficient and the

open hearth furnace was developed to overcome this difficulty. Most open hearth furnaces

were closed by the early 1990s, not least because of their fuel inefficiency, being replaced by

the basic oxygen furnace orelectric arc furnace. Technically perhaps, the first primitive open

hearth furnace was the Catalan forge, invented in Spain in the 8th century, but it is usual to

confine the term to certain 19th century and later steelmaking processes, thus excluding

bloomeries (including the Catalan forge), finery forges, and puddling furnaces from its

application.

Electric arc furnace

An electric arc furnace (EAF) is a furnace that heats charged material by means of anelectric arc. Arc furnaces range in size from small units of approximately one ton capacity

(used in foundries for producing cast iron products) up to about 400 ton units used for

secondary steelmaking. Arc furnaces used in research laboratories and by dentists may have a

capacity of only a few dozen grams. Electric arc furnace temperatures can be up to 1,800

degrees Celsius. Arc furnaces differ from induction furnaces in that the charge material is

directly exposed to the electric arc, and the current in the furnace terminals passes through the

charged material.
http://en.wikipedia.org/wiki/Technologyhttp://en.wikipedia.org/wiki/Wrought_ironhttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Blast_furnacehttp://en.wikipedia.org/wiki/Reverberatory_furnacehttp://en.wikipedia.org/wiki/Open-hearth_processhttp://en.wikipedia.org/wiki/Metallurgyhttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Fuelhttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Gaseshttp://en.wikipedia.org/wiki/Reflection_%28physics%29http://en.wikipedia.org/wiki/Reflection_%28physics%29http://en.wikipedia.org/wiki/Acousticshttp://en.wikipedia.org/wiki/Clayhttp://en.wikipedia.org/wiki/Dolomitehttp://en.wikipedia.org/wiki/Trunnionhttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Steelmakinghttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Melting_pointhttp://en.wikipedia.org/wiki/Basic_oxygen_furnacehttp://en.wikipedia.org/wiki/Electric_arc_furnacehttp://en.wikipedia.org/wiki/Catalan_forgehttp://en.wikipedia.org/wiki/Bloomeryhttp://en.wikipedia.org/wiki/Finery_forgehttp://en.wikipedia.org/wiki/Puddling_furnacehttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Electric_archttp://en.wikipedia.org/wiki/Tonhttp://en.wikipedia.org/wiki/Foundryhttp://en.wikipedia.org/wiki/Cast_ironhttp://en.wikipedia.org/wiki/Steelmakinghttp://en.wikipedia.org/wiki/Dentistryhttp://en.wikipedia.org/wiki/Celsiushttp://en.wikipedia.org/wiki/Induction_furnacehttp://en.wikipedia.org/wiki/Induction_furnacehttp://en.wikipedia.org/wiki/Celsiushttp://en.wikipedia.org/wiki/Dentistryhttp://en.wikipedia.org/wiki/Steelmakinghttp://en.wikipedia.org/wiki/Cast_ironhttp://en.wikipedia.org/wiki/Foundryhttp://en.wikipedia.org/wiki/Tonhttp://en.wikipedia.org/wiki/Electric_archttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Puddling_furnacehttp://en.wikipedia.org/wiki/Finery_forgehttp://en.wikipedia.org/wiki/Bloomeryhttp://en.wikipedia.org/wiki/Catalan_forgehttp://en.wikipedia.org/wiki/Electric_arc_furnacehttp://en.wikipedia.org/wiki/Basic_oxygen_furnacehttp://en.wikipedia.org/wiki/Melting_pointhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Steelmakinghttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Trunnionhttp://en.wikipedia.org/wiki/Dolomitehttp://en.wikipedia.org/wiki/Clayhttp://en.wikipedia.org/wiki/Acousticshttp://en.wikipedia.org/wiki/Reflection_%28physics%29http://en.wikipedia.org/wiki/Gaseshttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Fuelhttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Metallurgyhttp://en.wikipedia.org/wiki/Open-hearth_processhttp://en.wikipedia.org/wiki/Reverberatory_furnacehttp://en.wikipedia.org/wiki/Blast_furnacehttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Wrought_ironhttp://en.wikipedia.org/wiki/Technology

7/27/2019 My 202 Very Good

23/50


23

Induction furnaceAn induction furnace is an electrical furnace in which the heat is applied by induction

heating of a conductive medium (usually a metal) in a crucible placed in a water-cooled

alternating current solenoid coil. The advantage of the induction furnace is a clean, energy-

efficient and well-controllable melting process compared to most other means of metal

melting. Most modern foundries use this type of furnace and now also more iron foundriesare replacing cupolas with induction furnaces to melt cast iron, as the former emit lots ofdust

and otherpollutants. Induction furnace capacities range from less than one kilogram to one

hundred tonnes capacity, and are used to melt iron and steel, copper, aluminium, and precious

metals. The one major drawback to induction furnace usage in a foundry is the lack of

refining capacity; charge materials must be clean of oxidation products and of a known

composition, and some alloying elements may be lost due to oxidation (and must be re-added

to the melt).

BLAST FURNACE INDUCTION FURNACE

LADLE FURNACE ELECTRIC ARC FURNACE

OPEN HEARTH FURNACE REVERBERATORY FURNACE
http://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Induction_heatinghttp://en.wikipedia.org/wiki/Induction_heatinghttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Cruciblehttp://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Solenoidhttp://en.wikipedia.org/wiki/Coilhttp://en.wikipedia.org/wiki/Foundrieshttp://en.wikipedia.org/wiki/Blast_furnacehttp://en.wikipedia.org/wiki/Cast_ironhttp://en.wikipedia.org/wiki/Dusthttp://en.wikipedia.org/wiki/Pollutanthttp://en.wikipedia.org/wiki/Ironhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Copperhttp://en.wikipedia.org/wiki/Aluminiumhttp://en.wikipedia.org/wiki/Precious_metalshttp://en.wikipedia.org/wiki/Precious_metalshttp://en.wikipedia.org/wiki/Precious_metalshttp://en.wikipedia.org/wiki/Precious_metalshttp://en.wikipedia.org/wiki/Aluminiumhttp://en.wikipedia.org/wiki/Copperhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Ironhttp://en.wikipedia.org/wiki/Pollutanthttp://en.wikipedia.org/wiki/Dusthttp://en.wikipedia.org/wiki/Cast_ironhttp://en.wikipedia.org/wiki/Blast_furnacehttp://en.wikipedia.org/wiki/Foundrieshttp://en.wikipedia.org/wiki/Coilhttp://en.wikipedia.org/wiki/Solenoidhttp://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Cruciblehttp://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Induction_heatinghttp://en.wikipedia.org/wiki/Induction_heatinghttp://en.wikipedia.org/wiki/Furnace

7/27/2019 My 202 Very Good

24/50


24

TEST YOURSELF:

Q1: What are the main differences b/w Blast furnace and other furnace?

Ans:_____________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

Q2: Why not Electric Arc furnace is using everywhere in the world?

Ans:_____________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

Q3. What is the major advantage of Puddling Furnace?Ans:_____________________________________________________________

________________________________________________________________

________________________________________________________________

Q4: what is the purpose of using pig iron in steelmaking?

Ans:_____________________________________________________________

________________________________________________________________

________________________________________________________________

Fill in the blanks

1. The term reverberation is used in a generic sense of _______________________.2. An ______________________furnace is a furnace that heats charged material by

means of an electric arc

3. The capacity of a Bessemer converter was from ___ to ___ tons of molten iron with ausual charge being around ____ tons.

4. _________________ are one of a number of kinds of furnace where excess carbonand other impurities are burnt out of the pig iron to produce steel

5. The major advantage of this system is ____________________________________

Investigation Corner:

Name some furnaces & their locations which are using in Pakistan

1.________________________Location ___________________________

2. ________________________Location____________________________

3. ________________________Location____________________________

4. ________________________Location____________________________
http://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Electric_archttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Steelmakinghttp://en.wikipedia.org/wiki/Steelmakinghttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Electric_archttp://en.wikipedia.org/wiki/Furnace

7/27/2019 My 202 Very Good

25/50


25

Practical No 5

OBJECT:To study & analyze Blast furnace and its functions

WHAT IS BLAST FURNACE?A blast furnaceis a type of metallurgical furnace used for smelting to produce metals,

generally iron. Blast furnaces are usually tall shaft-type steel vessels, up to ten stories high,

internally lined with refractory brick, and superimposed over a crucible-like hearth. The

necessary charge to produce molten pig iron consists of iron-bearing materials, coke, and

flux. The charge is introduced into the furnace at the top. Blasts of heated air from large blast

stoves, and in most cases gaseous, liquid, or powdered fuel, are injected into the furnace

through openings (tuyeres) at the bottom of the shaft just above the hearth crucible. As the

hot air encounters the coke, the coke is burned along with the injected fuels, producing thenecessary heat and reducing gas to remove oxygen from the ore in the reduction process. As

the iron melts, it descends and accumulates in the crucible. The molten pig iron and slag are

drained from the crucible through different tapping holes. The gas that exits from the top of

the furnace goes through a cleaning process. The cleaned hot gas is then used in other

operations of the plant, e.g. to pre-heat the blast air, while the collected dust is sent to the

sintering plant for recycling back into the blast furnace. Once fired-up, a blast furnace burns

continuously until the lining needs replacement (approximately 5-6 years). The first blast

furnace in Russia opened in 1637 nearTulaand was called the Gorodishche Works.

Components of Blast Furnace:

Blast furnaces are large intricate systems that are constructed from a combination of off-the-

shelf equipment and custom constructed components. The largest components of the blast

furnace proper include the furnace shell, the furnace internal refractory lining, and the

crucible-like hearth. Most of the stand-alone equipment such as motors, burners, etc., are

associated with the following:

Raw material assembly and transport

Hot metal and slag transfer

Off-gas cleaning

Hot-blast stoves

While all of the equipment used in the above operations may be of interest, the focus here is

placed on the equipment and components specific to the blast furnace.

Skip Car (conveyors) - The skip cars, and in some installations conveyors, are used to deliver theblast furnace charge to the top of the furnace.Bosh - The bosh is an inverted conical section in which the melting starts. Receiving Hopper - The blast furnace charge is loaded into the receiving hopper, which in turndelivers the charge to the rotating distributor. The rotating distributor helps assure a uniformdistribution of the charge in the furnace stack.Hearth - The hearth is an intricately constructed crucible-like vessel upon which the vertical shaft

portion of the furnace sits. All the molten metal and slag collect in the hearth before being drained.
http://en.wikipedia.org/wiki/Metallurgyhttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Smeltinghttp://en.wikipedia.org/wiki/Ironhttp://en.wikipedia.org/wiki/Tula,_Russiahttp://en.wikipedia.org/wiki/Tula,_Russiahttp://en.wikipedia.org/wiki/Tula,_Russiahttp://en.wikipedia.org/wiki/Tula,_Russiahttp://en.wikipedia.org/wiki/Ironhttp://en.wikipedia.org/wiki/Smeltinghttp://en.wikipedia.org/wiki/Furnacehttp://en.wikipedia.org/wiki/Metallurgy

7/27/2019 My 202 Very Good

26/50


26

Bells (large and small) - the large and small bells are conically shaped devices that form a gas-tightlock hopper. The hopper prevents gas from escaping from the furnace while it is being charged.Bustle Pipe - The bustle encircles the blast furnace and delivers the hot blast air from the hot-blastline to the furnace.Stack - The stack is the upper portion of the furnace where the burden is pre-heated.Injection Lance - The injection lance is inserted into the blowpipe that leads up to the tuyeres. Thesupplemental fuel is delivered to the furnace through the injection lance.Iron and Slag Notches- The molten metal is removed from the hearth through the iron notches. Themetal is placed into transfer ladles, while the slag may be transferred to slag pots, drawn off into drypits for solidification, or granulated with a stream of water and flushed into a well pit.Tuyeres - The hot blast air is delivered to the furnace through water-cooled openings called tuyeres.The tuyeres are located at the top of the hearth.Iron-bearing materials - The iron-bearing materials are usually iron ore, sinter, pellets, mill scale,steelmaking slag, scrap, and other materials.Coke - The coke is added to provide the main chemical reagents (carbon and carbon monoxide) forthe iron ore reduction.Flux - The flux, limestone and/or dolomite, is added to combine with ash in the coke and gangue in

the ores, to produce a slag that rises to the top of the pool of molten pig iron that collects in thecrucible.

Blast furnace diagram

1.Hot blastfromCowper stoves

2. Melting zone (bosh)

3. Reduction zone offerrous oxide(barrel)

4. Reduction zone offerric oxide(stack)

5. Pre-heating zone (throat)

6. Feed of ore, limestone, and coke

7. Exhaust gases

8. Column of ore, coke and limestone

9. Removal ofslag10. Tapping of moltenpig iron

11. Collection of waste gases

Modern blast furnaces

The blast furnace remains an important part of

modern iron production. Modern furnaces are highly efficient, including Cowperstoves topre-heatthe blast air and employ recovery systems to extract the heat from

the hot gases exiting the furnace. Competition in industry drives higher production

rates. The largest blast furnaces have a volume around 5580 m3 (190,000 cu ft) andcan produce around 80,000 tonnes (88,000 short tons) of iron per week. This is a great

increase from the typical 18th-century furnaces, which averaged about 360 tonnes

(400 short tons) per year. Variations of the blast furnace, such as the Swedish electric

blast furnace, have been developed in countries which have no native coal resources
http://en.wikipedia.org/wiki/Hot_blasthttp://en.wikipedia.org/wiki/Hot_blasthttp://en.wikipedia.org/wiki/Hot_blasthttp://en.wikipedia.org/w/index.php?title=Cowper_stove&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Cowper_stove&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Cowper_stove&action=edit&redlink=1http://en.wikipedia.org/wiki/Ferrous_oxidehttp://en.wikipedia.org/wiki/Ferrous_oxidehttp://en.wikipedia.org/wiki/Ferrous_oxidehttp://en.wikipedia.org/wiki/Ferric_oxidehttp://en.wikipedia.org/wiki/Ferric_oxidehttp://en.wikipedia.org/wiki/Ferric_oxidehttp://en.wikipedia.org/wiki/Slaghttp://en.wikipedia.org/wiki/Slaghttp://en.wikipedia.org/wiki/Slaghttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Hot_blasthttp://en.wikipedia.org/wiki/Hot_blasthttp://en.wikipedia.org/wiki/Hot_blasthttp://en.wikipedia.org/wiki/Hot_blasthttp://en.wikipedia.org/wiki/Pig_ironhttp://en.wikipedia.org/wiki/Slaghttp://en.wikipedia.org/wiki/Ferric_oxidehttp://en.wikipedia.org/wiki/Ferrous_oxidehttp://en.wikipedia.org/w/index.php?title=Cowper_stove&action=edit&redlink=1http://en.wikipedia.org/wiki/Hot_blast

7/27/2019 My 202 Very Good

27/50


27

TEST YOURSELF

Q1: Define Blast Furnace in 2 lines?

Ans:____________________________________________________________________________________________________________________________

Q2: What is the main difference b/w Blast Furnace and ordinary furnaces?

Ans:____________________________________________________________

________________________________________________________________

________________________________________________________________

____________________________________________________________________________________________________________________________

Fill in the blanks:

1. Modern furnace can produce around ____________tonnes of iron perweek.

2. The largest components of the blast furnace proper include the_______________________, __________________________ and

_________________________.

3._______________is an inverted conical section in which the meltingstarts

4. The largest blast furnaces have a volume around______________________.

5. Pakistan Steel Mills is producing ____________ million tons of Pig iron.6. Pakistan Steel Mills has ____ blast furnaces.

Self Investigation:

List some world wide mills which have Blast furnaces:

1. Name______________________ Location: ________________________2. Name______________________ Location: ________________________3. Name______________________ Location: ________________________

4. Name______________________ Location: ________________________

5. Name______________________ Location: ________________________

7/27/2019 My 202 Very Good

28/50


28

Observations regarding Blast furnace after visit of Pakistan Steel M ills:

________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________

________________________________________________________________

________________________________________________________________

7/27/2019 My 202 Very Good

29/50


29

Practical No 6

Object:

To study about Cupola Furnace & its operations.

What is a Cupola or Cupola furnace?

A Cupola orCupola furnace is a melting device used in foundries that can be used to melt

cast iron, ni-resist iron and some bronzes. The cupola can be made almost any practical size.

The size of a cupola is expressed in diameters and can range from 18 inches to 13 feet . The

overall shape is cylindrical and the equipment is arranged vertically, usually supported by

four legs. The overall look is similar to a large smokestack. The bottom of the cylinder is

fitted with doors which swing down and out to 'drop bottom'. The top where gases escape can

be open or fitted with a cap to prevent rain from entering the cupola. To control emissions a

cupola may be fitted with a cap that is designed to pull the gases into a device to cool thegasses and remove particulate matter.

The shell of the cupola, being usually made of steel, has refractory brick and refractory

patching material lining it. The bottom is lining in a similar manner but often a clay and sand

mixture may be used, as this lining is temporary. The bottom lining is compressed or

'rammed' against the bottom doors. Some cupolas are fitted with cooling jackets to keep the

sides cool and with oxygen injection to make the coke fire burn hotter.

Operations of Cupola Furnace:

To begin a production run, called a 'cupola campaign' the furnace is filled with layersof coke and ignited with torches. Some smaller cupolas may be ignited with wood to

start the coke burning. When the coke is ignited, air is introduced to the coke bed

through ports in the sides called tuyeres.

When the coke is very hot, solid pieces of metal are charged into the furnace throughan opening in the top. The metal is alternated with additional layers of fresh coke.

Limestone is added to act as a flux. As the heat rises within the stack the metal is

melted. It drips down through the coke bed to collect in a pool at the bottom, just

above the bottom doors. A thermodynamic reaction takes place. The carbon in the

coke combines with the oxygen in the air to form carbon monoxide. The carbon

monoxide further burns to form carbon dioxide. Some of the carbon is picked up by

the falling droplets of molten steel and iron which raises the carbon content of the

iron. Silicon carbide and ferromanganesebriquets may also be added to the charge

materials. The silicon carbide dissociates and carbon and silicon enters into the

molten metal. Likewise the ferromanganese melts and is combined into the pool of

liquid iron in the 'well' at the bottom of the cupola.

Th

my 202 very good

Documents