The production of most of the steel manufactured in the United States begins with the reduction of hematite ore (mostly ferric oxide) with coke (carbon) in a blast furnace to obtain pig iron. The basic reaction is Fe2O3 (s) + 3 C (s) →2 Fe (s) + 3 CO (g): ΔHг (77°F) = 2.111 x 105 Btu/lb-mole suppose that stoichiometric amounts of ferric oxide and carbon are fed at 77°F, the reaction is complete, the iron emerges as a liquid at 2800°F, and CO emerges at 570°F. Perform the following calculations for a basis of 1 ton of iron produced.

(a) Draw and label a flowchart and perform all the material balance calculations needed to determine the amounts (lb-mole) of each feed and product stream component.

(b) Taking the reactant and product species in their normal states at 77°F as references, prepare an inlet—outlet enthalpy table and calculate and fill in all unknown component specific enthalpies (Btu/lb-mole). Use the following physical property data for iron: Fe (s): Cp [Btu/ (lb-mole∙°F)] = 5.90 + 1.50 x 10-3 T (°F) Tm = 2794°F, ΔHm (Tm) = 6496 Btu/lb-mole Fe (1): Cp [Btu/ (lb-mole∙°F)] = 8.15

(c) Estimate the furnace heat requirement (Btu/ton Fe produced).

(d) List the assumptions that make the value calculated in part (b) only an approximate estimate of the furnace heat requirement. (One of the assumptions has something to do with the reactor pressure.)