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Problem 3a (70 pts) Problem 3a. Mass Balance An Iron Blast Furnace operates to produce pig iron from a charged iron ore consisting of hematite and magnetite, silica, manganese, alumina, calcium carbonate and lime to produce pig iron with certain grade. The following average data was obtained from the month-long operation. Charge information: - The burden is made out of 58 % Fe where the ratio of the total iron in hematite and magnetite is unity . The burden contains 500 kg moisture by weight Slag produced : 950 kg of slag is produced per metric ton of pig iron The percent composition of the slag is as follow: FeO, % 6.5 SiO2,% 33.5 Cao % 167 MnO % 5.2 A1203 % 38.1 Coke consumption : 1800 kg per MT of Ore, 95% Carbon. 3% moisture Pig Iron analysis - The percent composition of pig iron is as follow Fe,% balance C,% 4.5 Si, % 0.25 . Mn, % 1.8 Enriched Air : Relative humidity at 50% (per weight basis), 25 degrees Celsius 30 % 02 (based on dry volume of air) Initial Assumptions: 1. Assume that all Iron ores are reduced by indirect reduction. 2. A 203, H20 and N2 are inert From the given data, write a complete material balance (weights, percentages, and volume for gases) of the given system with the charge consisting of ore, fluxes, coke, enriched air and moisture while the products are pig iron, slag and flue gas. What is the percent recovery of iron in the smelting operation? Use as basis: Element MW Element MW Element MW Element MW Fe 55.8 27 H20 18 Ca 40 0 16 A1203 102 CO2 44 CaCo3 56 Fe203 159.6 Si 28 CO 28 Cao 100 Fe304 231.4 SiO2 60 Mn 54.9 N 14 Feo 71.8 C 12 Mno 70.9 Problem 3b (70 pts) Problem 3b. Heat Balance Heat balance is important to determine how the fuel sources and energy provided are utilized in pyrometallurgical reactions. Given the iron smelting example in Problem 3a, the chemical reaction on the reduction of iron oxide can be represented by the given equation: FeO + CO => Fe + CO2 (balance this reaction) For this reaction, we assume that carbon monoxide is the reductant, however, in actual systems, Iron oxides can also be directly reduced by carbon as given by the equation: FeO + C => Fe + CO (balance this reaction) Make a heat balance of the 2 reactions at Tref = 25 degrees celsius. All input materials are fed at 25 deg C while the hot metal is tapped at 1300 deg C and the gases are released at 250 deg C. Compare the two reactions using the weight of the FeO in slag (Problem 3a) as the basis