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Evaluation of the Iron Blast Furnace Process using Heat and Material Balances of the Flame-Zone

Sep 13, 2010

By Klaus Tietz, Hamish Adam, John Selby, Ian Glazier, Brian Sinfield

"Room-temperature tunable diode laser (TDL) analyzers are gaining in acceptance for highly critical safety monitoring applications in a variety of industries. This paper describes the testing, evaluation and deployment of a laser-based hydrogen cyanide monitoring system at the Campbell Complex of Goldcorp’s Red Lake Gold Mines in Balmertown, Ontario, Canada.A trial, single channel installation was followed by a staged multi-channel installation. Unexpected technical issues with the multi-channel installation were addressed and resolved.INTRODUCTIONLaser-based gas detection has several advantages over existing gas detection techniques (Ballangrud, 1993; Silver, 1992; Bomse, 1995; Table 1). For practical purposes, lasers generate light at a single wavelength. Room temperature tunable diode lasers (TDL) emit light in the near infrared (NIR) part of the electro-magnetic spectrum. Many gases of interest, including HCN, NH3 and others, absorb energy in the near infrared (NIR). Each gas has a unique absorption signature, or spectrum, made up of a large number of individual “absorption lines”. A TDL can be tuned to select a single absorption line of a target gas, which does not overlap with absorption lines from any other gases. Therefore, laser gas sensing is selective and does not suffer from interference from other gases. The single-wavelength nature of laser light also means that laser gas analysers have a linear response over a wide dynamic range.Tunable Diode Lasers (TDL) generate only a few mW of power. However, all this power is concentrated at one wavelength, the wavelength where gas absorption occurs, resulting in high signal-to-noise ratios and short response times, typically of about 1 or 2 seconds (Ballangrud, 1993). This also means that long path lengths can be used, enabling accurate measurements of very low concentrations, even with weakly absorbing gases. Tunable Diode Lasers provide all the advantages of other semiconductor devices: they are small, solid-state devices, operate at room temperature, and have long-term reliability (over 15 years). Currently, they can be obtained for any wavelength throughout the NIR (700nm to 2000nm). Because many gases absorb in the NIR, the technique is widely applicable."

Jan 1, 2011

By Robert F. Jenkins

This document addresses the use of practical and basic engineering principles to develop a computer model for the analysis of the various issues which affect heat transfer in aluminum sidewell furnaces. These issues include furnace charge conditions, furnace operating conditions, furnace general arrangement, furnace combustion conditions, and furnace ambient heat loss. The engineering principles applied to this model were first put to test over 20 years ago. A prototype computer model developed 12 years ago has been in continuous use by Thorpe Technologies to determine the performance of sidewell furnaces for the aluminum industry. A new computer model has enhanced capabilities for more detailed performance analysis including regenerative and oxygen enriched combustion.

Jan 1, 2000

By C. J. Fauconnier

The various methods of detecting fires and heatings in collieries are reviewed. The methods described range from those relying principally on human senses to sophisticated methods employing infrared technology to detect traces of the products of oxidation and combustion. The advantages and disadvantages of various gases employed as indicator gases for the early detection of heatings and fires are discussed, and recommendations are made in this regard. The operation of a modern infrared carbon monoxide detection system is described, and the differences in operation and application of telemetric systems, tube-bundle systems, and up cast-shaft monitors are discussed In conclusion, some indication is given of the capital outlay required for typical early-detection systems.

Jan 1, 1981

By T. Estelle Gardner

The Bureau of Mines made enthalpy measurements on sodium bromide and sodium iodide in the temperature range 400° to 1,200° K using an ice calorimeter. Equations representing enthalpy as a function of temperature were derived from the data by the method of least squares. These equations were used to calculate smooth values of heat capacity, enthalpy, and entropy at 50° K intervals from the ice point to 1,200° K. The melting point determined for sodium bromide was 1,020° K; the melting point of sodium iodide was 934° K. The heats of fusion of sodium bromide and sodium iodide were calculated to be 6,270 and 5,680 cal/mole, respectively.

Jan 1, 1967

By Jianjun Tang, Wenjuan Bai

This paper presents a new method of formulation design for multi-component composite explosives. Based on the thermochemistry of the detonation process, the mathematic model of formulation design is established by optimization mathematics. Using the heat of detonation as target functions and taking the constraint conditions such as oxygen balance and costs etc into consideration, this model can provide an optimal solution quickly by means of personal computer. Using this method, the calculation and the simulation tests for a series of constituent sets and various constraint conditions can be conducted easily. In this way, the optimal formulation for the explosive can be determined, on the basis of the maximum heat of detonation and the lower cost.

Jan 1, 1997

By C. C. Spencer

A CHARGE of 12,200 lb of scrap was used on all heats. The slag materials that were added to the furnace along with manganese ore were kept constant; that is, 230 lb Coxey sand was put on the banks at the slag line before each heat was charged, 35 lb limestone was added after the carbon boil. manganese ore was the only item varied in the four series described herein. I might add here that it is impractical for us to get the carbon clown in one boil, for the steel would come out through the doors and run over the floor. We take the carbon down in two vigorous boils.

Jan 1, 1947

By Frank Julian

After the solution of an iron ore, or metallic iron, in an acid, for the determination of phosphorus, it is necessary to evaporate the solution to dryness and to heat the residue to effect the complete separation of silica. Authorities differ as to the temperature required, some recormmentling not over 100' C., others as high as dull redness. For the purpose of securing some indications as to the degree of heat which may be safely or advantageously employed, I selected a gray pig-iron, a piece of Bessemer steel rail, and a sample of Ludington ore having the following composition; the phosphorus in the pig and steel being determined by Giutl's ferric chloride method:

Jan 1, 1884

By D. Zaharaki

In the present experimental study the geochemical stability of inorganic polymers was studied by immersing them in various solutions (distilled water, seawater and 0.5N HCl) for a period of 7 months. Inorganic polymers were synthesised by mixing ferronickel slag with kaolinite, potassium hydroxide and sodium silicate solution. The cement like paste was heated at 80 °C for 48 hours and left for curing at room temperature. Their structural integrity was assessed by compressive strength testing after subjection to freeze-thaw cycles as well as high temperature heating. XRD studies were carried out in order to identify new formed phases and provide useful information regarding the progress of the mechanisms involved.

Jan 1, 2008

By Chaves AP, Delboni H. Jr

Thermal comminution is an industrial process specially suited to very abrasive material, when contamination with Fe from wearing parts of conventional crushing and grinding equipment must be avoided. It involves an initial step of heating the material to be comminuted, followed by sudden cooling (quenching) and finally by a conventional mechanical process to disassemble the particle aggregates. The thermal step is, in fact, a pre-fracturing process. The heating operation causes changes in phase of the minerals and changes in volume of these minerals and other substances included in pores and cracks. The cooling operation causes thermal shock reversions or the phase transformation and consequent generation of internal stresses, high enough to fracture the solid.

Jan 1, 1993

To inexpensively monitor the ventilating airflow anywhere in underground working places. The Approach: The Bureau has developed a small self-contained monitor which sounds an audible alarm and energizes a flashing lamp if air velocity decreases below normal. How It Works: The sensing element of this inexpensive monitor is a thermistor, which is self-heated by a constant-current electrical source. Airflow over the thermistor increases heat removal and lowers the thermistor temperature. Since the electrical resistance of a thermistor is a function of temperature change, the voltage across it varies with temperature, and, therefore, the air velocity. Changes in the voltage across the thermistor are amplified, and can be used to trigger the alarms.

Jan 1, 1975

By S. R. Rao

Interaction of potassium amyl xanthate with pyrrhotite has been studied thermochemically. Heats of adsorption of xanthate on unactivated mineral and the mineral activated with cupric ions have been compared with heats of reactions between potassium amyl xanthate and ferrous and cupric salts. It is shown that xanthate is consumed by stoichiometric exchange with anions present at the mineral surface. The floatability of the unactivated mineral is poor since xanthate is precipitated in bulk without creating a hydrophobic surface on the mineral. At the activated mineral surface, xanthate is adsorbed in certain isolated patches (active spots) and thereby creates a hydrophobic surface. The hydrophobicity of the mineral is greatly improved by lowering the pH to 4.5.

Jan 1, 1972

By K. Biswas

A finite-element algorithm was developed for an axisymmetric heat-transfer problem involving phase change. The finite-element treatment of the phase-change problem was dealt with by using the enthalpy method. The finite-element algorithm was subsequently applied to model the heat exchange between mine ventilation air and frozen ground in the presence of roof bolts in an underground mine with permafrost. This paper analyzes a single bolt in the problem domain with the convection boundaries at the roof level of the mine airway. A short-term study, comprising the evaluation of roof bolting (friction-anchored type), was conducted, and recommendations were made regarding the applicability of roof bolts as a support system for a given thermal condition.

Jan 1, 1996

By M. Guney, A. R. Bell

In Mindola mine on the Zambian Copperbelt, there is a plan to extend the current production level of 1.2- 1.5 km (3,900-4,900 ft) with five additional production levels. Research work indicated that the present total heat output of 38.6 MW will inevitably increase to 63.2 MW in 25 years. Estimated WE and DB temperatures, representing the total heat generation in stope faces and development headings during these same periods are predicted to increase to 33.8/40.2°C (93/104°F) and 35.3/42.1°C (95/108°F) respectively. It is assessed that the nominal refrigeration capacity needs to be progressively increased to 9,000 M W.

Jan 1, 1984

By H. Y. Sohn, M. Pérez-Tello, J. Löttiger

An investigation of the oxidation reactions of two industrial copper mattes was performed using dflerential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) at heating rates of 20°C and 8°C/min, respectively. The temperature of incipient reaction, the total exothermic and endothermic heats of reaction and the weight change during the oxidation process were measured as functions of the oxygen concentration in the oxidizing gas, matte grade and matte particle size. The temperatures of incipient reaction measured from the DSC experiments were found to increase monotonically with all three input variables. TGA experiments showed that Cu2O and CuO CuSO4 are formed before the complete oxidation of Cu2S to CuO.

Jan 1, 2000

By Thomas E. McNider

Preliminary studies were conducted at Jim Walter Resources, Inc. Blue Creek No. 3 Mine to determine the influence propane operated heaters exert on the mine ventilation system when two of three intake airshafts were heated. During initial use of the heaters, it was found that change in density caused by heating a portion of the air at two of three intake shafts altered under- ground air flow changes sufficient to be considered a violation of Part 75.322 of the Federal Coal Mine Health and Safety Act of 1969 as amended by Public Law 95.164. The primary concern was to accurately define the problem in order to derive a workable solution.

Jan 1, 1980

By J. E. Ryan

TRONA, Calif., is a miniature urban community of some 3500 people, located on the northwest shore of dry Searles Lake in the extreme northwest corner of San Bernardino County, approximately 186 miles north and east of Los Angeles. Since it is situated on the Mojave Desert, a typically desert climate prevails with wide variations in temperature between day and night, extreme daytime summer heat, and cool to cold winters. Rainfall averages somewhat less than 4 in. per year, and dust storms are common. The rate of evaporation, however, is great, amounting to 6 to 9 ft of water per year. The extremely low humidity makes the summer heat of 110°F tolerable with only a mild, temporary discomfort.

Jan 5, 1951

By George W. Healy, Ko Yamaguchi

In typical calorimetry the energy given off by a material under study is transferred to a water bath, whose temperature is sensed by a thermometer; for correct measurement the water bath must attain a uniform temperature to which the thermometer must respond. This introduces two sources of error, non-uniformity of the heat sink and a time lag until its temperature is registered. These errors may become important where a rapid process such as solidification of metals and alloys is being studied by means of Oelsen'sl quantitative thermal analysis. To overcome this difficulty, a calorimeter sink was conceived in which the water bath is replaced by a copper coil, which serves simultaneously as heat

Jan 1, 1967

By J. H. Fletcher

AIR has been cooled, heated, washed; humidified and dehumidified for many purposes and in many industries. At a number of metal mines air is conditioned to reduce the high humidity and unbearable heat found in deep workings, and at some mines air is washed to allay siliceous dust. Steam is introduced into the intake air at many coal mines, particularly in winter, for the purpose of keeping loose coal dust so moistened that the hazard of an explosion is lessened. This paper will describe a further successful application of air conditioning in a coal mine, where, for over three years, all intake air has been cooled to a constant temperature for the sole purpose of preventing roof falls.

Jan 1, 1931

By Tony P. Suckling

This paper presents a case study of a piling contract undertaken at Keble College in Oxford in the year 2001. Unusually, and for the first time in the United Kingdom, piles were successfully constructed containing a network of plastic pipes, which are subsequently to be connected to the heating and cooling system for the new building. The pipes cast in the piles facilitate the transfer and storage of geothermal energy between the structure and the underlying ground mass, allowing the new building to be both heated in winter and cooled in summer economically and in an environmentally friendly way. The philosophy of the geothermal pile technology is presented, together with the modified pile construction techniques employed on the site.

Jan 1, 2002