Handbook on. Materials Processing. Material and Energy Balance Calculations in TIMS WILEY. Third Edition. Arthur E. Morris Gordon Geiger. H.

Transcription

1 Handbook on Material and Energy Balance Calculations in Materials Processing Third Edition Arthur E. Morris Gordon Geiger H. Alan Fine TIMS WILEY A JOHN WILEY & SONS, INC., PUBLICATION

2 Temperature Preface to the First Edition Preface to the Third Edition xiv xvii Acknowledgements xix Chapter 1. Dimensions, Units, and Conversion Factors The SI System of Units Derived Units Units Outside the SI Comments on Some Quantities and Their Units The American Engineering System (AES) of Units Conversion of Units Conversion Factor Tables The Dimension Table Conversion Equations and Pressure Unit Conversions Using the U-Converter Program Amount of Substance the Mole Unit Density and Concentration Density Composition and Concentration Composition of Gases Electrical Units Calculation Guidelines Summary 22 References and Further Reading 23 Exercises 23 Chapter 2. Thermophysical and Related Properties of Materials State of a System and Properties of a Substance The Gibbs Phase Rule Consequences of the Phase Rule for Non-Reactive and Reactive Systems Application of the Phase Rule to One-Phase Non-Reactive Systems Application of the Phase Rule to Multi-Phase Non-Reactive Systems Application of the Phase Rule to Reactive Systems The Gas Phase The Ideal Gas Law Non-Ideal Gas Behavior Condensed Phases Vapor-Liquid Equilibrium (VLE) Mixtures of Condensable and Non-Condensable Gases Software for Making Dew Point and Humidity Calculations Effect of Pressure on Phase Transformation Temperatures Steam and Air Property Calculators 44 v

3 Raoult's vi 2.8 Properties of Solutions Ideal Solutions Law Non-Ideal Solutions Activity Coefficients Solutions of Gases in Condensed Phases The Solubility Limit The Solubility of Ionic Species in Water; the Solubility Product Summary 50 References and Further Reading 51 Exercises 52 Chapter 3. Statistical Concepts Applied to Measurement and Sampling 54 Tools Basic Statistical Concepts and Descriptive Histograms and Frequency Distributions Mean, Standard Deviation, and Variance Median, Percentile and Quantile Distributions of Random Variables The Uniform Distribution The Normal Distribution Basic Applications of Inferential Statistics to Measurement Sampling Distributions of the Mean and the Central Limit Theorem Confidence Intervals Treatment of Errors Error Propagation Curve Fitting Simple Linear Regression and Excel's Trendline Tool Using Solver to Develop Single-Variable Regression Models Multiple Linear and Non-linear Regression Using Solver and Excel's SSD Tool to Find Equation Coefficients Choosing Among Models Polynomial vs. Rational Function Models Outliers Warnings Experimental Design Factorial Design Fractional Factorial Design Summary 137 References and Further Reading 137 Exercises 138 Chapter 4. Fundamentals of Material Balances with Applications to Non-Reacting Systems System Characteristics Process Classifications Flowsheets The General Balance Equation Material Balances on Simple Non-Reactive Systems Strategy for Making Material Balance Calculations Guidelines for Setting up a Materials Balance Guidelines for Resolving a Set of Equations Objectives of a Material Balance 157

4 Counter-Current vii 4.7 Degree-of-Freedom Analysis DOF Concepts DOF Calculation Strategy for a Single Non-Reactive Device A Washing Process Having Zero Degrees of Freedom A Washing Process Having a DOF = A Leaching Process Having a DOF = Using Excel-based Calculational Tools to Solve Equations Goal Seek and Solver as Calculational Aids Software for Conversion of Stream Units: MMV-C Balances on Systems with Multiple Devices Extension of Excel's Calculational Tools for Repetitive Solving SuperGS SuperSolver Special Multiple-Device Configurations I Recycle and Bypass Special Multiple-Device Configurations II 4.13 Using FlowBal for Material Balance Calculations FlowBal Example # FlowBal Example # FlowBal Example # Continuous-Mixing Devices Steady-State Processes Unsteady-State Systems Inert Gas Flushing 229 Flow 205 Mixer/Splitter 217 Evaporation/Condensation Process 219 Systems with Multi-Phase Streams Graphical Representation of Material Balances Measures of Performance Controllers Summary 239 References and Further Reading 240 Exercises 241 Chapter 5. Stoichiometry and the Chemical Equation Atomic and Molecular Mass Composition of Compounds and the Gravimetric Factor Writing and Balancing Chemical Equations Chemical Reaction Concepts Writing and Balancing Chemical Reactions for Simple Processes Calculations Involving Excess and Limiting Reactants Progress of a Reaction Extent of Species Reaction and Rate of Reaction Terminology Chemical Reaction Kinetics Reaction Progress and Keq ^eq Values from FREED Guidelines for Using eq to Determine Maximum Reaction Extent Application of Equilibrium Limitations for Gas-Condensed Phase Reactions Application of Equilibrium Limitations to Gas-Phase Reactions Practical Indicators of the Progress of Reactions and Processes Parallel, Sequential and Mixed Reactions Independence of Chemical Reactions 274

5 viii 5.9 Practical Examples of Reaction Writing and Stoichiometry Calculations in Gas-Condensed Phase Processes Calculations in Gas-Phase Processes Use of Chemical Reactions in FlowBal FlowBal's Extent of Reaction Tool FlowBal's Insert Equation Tool Balancing Aqueous (Ionic) Reactions Summary 286 References and Further Reading 288 Exercises 288 Chapter 6. Reactive Material Balances The General Material Balance Procedure for a Reactive System Independent Chemical Reactions, Independent Species, and Independent Elements Molecular Species Material Balance Method Atomic Species Method Atomic and Molecular Species Balance Examples The Use of Excel-based Computational Tools in Reactive System Balances Application of SuperSolver Reactive System Material Balances Using FlowBal Combustion Material Balances Material Balance for the Combustion of a Gaseous Fuel Combustion of Liquid Fuels Combustion of Solid Fuels Use of Feed-Forward and Stack Gas Analysis for Combustion Control Use of FlowBal for Combustion Calculations Trace Combustion Products The Production of a Reducing Gas Gas-Solid Oxidation-Reduction Processes Oxidation-Reduction During Calcination The Reduction of Iron Ore Concentrate The Chemistry of Fluidized Bed Reduction of Iron Ore by Hydrogen Excel Simulation of the Fluidized Bed Reduction of Hematite FlowBal Simulation of the Fluidized Bed Reduction of Hematite Shaft Furnace Reduction of Iron Ore Concentrate The Roasting of a Sulfide Concentrate The Production of Gases with Controlled Oxygen and Carbon Potential Processes Controlled by Chemical Reaction Kinetics The Reconciliation of an Existing Materials Balance The Use of Distribution Coefficients in Material Balance Calculations Use of Tabulated Distribution Coefficients Thermodynamic Databases as a Source of Distribution Coefficient Data Time-Varying Processes Systems Containing Aqueous Electrolytes The Stability of Ions Aqueous Processes The Solubility of Ionizable Gases in Water Summary 402 References and Further Reading 404 Exercises 405

6 ix Chapter 7. Energy and the First Law of Thermodynamics Principles and Definitions General Statement of the First Law of Thermodynamics First Law for an Open System Enthalpy, Heat Capacity, and Heat Content Enthalpy Change of Phase Transformations Enthalpy Change of Chemical Reactions Thermodynamic Databases for Pure Substances Effect of Temperature on Heat of Reaction Application of Kirchhoffs Equation to Chemical Reactions Heat of Transformation for Non-Standard and Non-Physical States The Properties of Steam and Compressed Air Properties of Steam Properties of Compressed Air Temperature Change for Free Expansion of a Gas Cooling by Steam Venting Enthalpy of Psychrometry The Use of FREED in Making Heat Balances Heat of Solution Formation of Non-ideal Metallic Solutions Polymeric Solutions Aqueous Solutions Summary 445 References and Further Reading 446 Exercises 447 Chapter 8. Enthalpy Balances in Non-Reactive Systems Combined Material and Heat (System) Balances Heat Balances for Adiabatic Processes Psychrometric Calculations Energy Efficiency Recovery and Recycling of Heat Heat Exchange Between Fluids Heat Exchange between Solids and Fluids Application of Heat Recovery Techniques to Aluminum Melting Heat Exchange Accompanied by Material Transfer Multiple-Device System Balances Use offlowbal for System Balances Heat Balances Involving Solution Phases Enthalpy Change During Dissolution of an Electrolyte Graphical Representation of a Heat Balance Summary 500 References and Further Reading 501 Exercises 502

7 X Chapter 9. System Balances on Reactive Processes Thermal Constraints on a Material Balance Uncoupled System Balances Strategy for Coupled System Balance Combustion of Fuels Heat of Combustion Calculations Use of Wobbe Index for Combustion Burner Control Combustion of Fuels of Uncertain Molecular Composition Adiabatic Processes System Balances Involving Combustion Reactions ART for Condensed-Phase Reaction Processes System Balances Using FlowBal Quality of Heat and Thermal Efficiency System Balances with Heat Exchangers Aqueous Processes Electrolytic Processes Energy Requirement for Electrorefining Energy Requirement for Electrowinning Summary 573 References and Further Reading 574 Exercises 574 Chapter 10. Case Studies Material Balance for an H-Iron Reduction Process with Gas Tempering and Recycle 10.2 Mass and Heat Balance Simulation for the Use of DRI in EAF Steelmaking Natural Gas Combustion Control and the Wobbe Index The Stoichiometry of NG Combustion with Excess Air The Wobbe Index as a Natural Gas Combustion Control Parameter Reduction of Hematite to Magnetite Preliminary Calculations Single Reactor Simulation of Hematite Reduction by a Multi-Stage 10.5 Conversion of Quartz to Cristobalite in a Fluidized Bed Process Characteristics Device Sizing and Heat Loss Calculation Material and Heat Balance Calculations 599 Exercise 600 Process 595 Appendix. Computational Tools for Making Material and Heat Balance Calculations 601 A.l U-Converter 601 A.2 Thermophysical Properties of Steam and Air 602 A.3 Stream Units Conversion Calculator (MMV-C) 602 A.4 Extension of Excel Tools for Repeat Calculation 603 A.5 Thermodynamic Database Programs 604 A.6 Flowsheet Simulation and System Balancing 604 General References 605 Index 606

8 I II Mg List of Examples Chapter 1. Dimensions, Units, and Conversion Factors.1 Mass and Weight of Aluminum 5.2 Kinetic Energy 6.3 Energy of Lifting 6.4 Units of Energy 7.5 Dimensions for Flowrate 8.6 Conversion of Temperature 9.7 Conversion Formula 9.8 Conversion of Pressure Conversion of Pressure - II Pressure in a. Liquid The SI and AES Mole The Density of a Slurry Bulk. Density of a Solid.14 Bulk Density of a Solid Concentration Conversion Composition of a Gas on a Wet and Dry Basis Electrical Flow in a Wire Electrical Energy for Metal Deposition Number of. Significant Figures 22 Chapter 2. Thermophysical and Related Properties of Material 2.1 Removal of Air by a Vacuum Pump Gas Volume and Flowrate Compressibility of Steam Thermal Expansion of Titanium Evaporation of Water in a Closed Vessel Humidity and Dew Point Moisture Content of Clay Dryer Streams Effect of Pressure on the Freezing Point of Water Effect of Pressure on the Vapor Pressure of Water Vapor and Liquid Phase Composition for the Cu Evaporation from Liquid Cd Volumetric Solubility of C02 in Water The Solubility of CaF2 in Water 49 Alloys at 700 C 47 Ni System 45 Chapter 3. Statistical Concepts Applied to Measurement and Sampling 3.1 A Histogram of Ceramic Strength Measurements Percentiles of the %Cu Data using Excel Uniformity of Vermiculite Particles Evaluation of the Normal Distribution for Ceramic Strength Data Finding a 90% Confidence Interval Relationship Between Sample Size and Interval Width Using the Si2ON2 Example

9 xii 3.7 Heat Capacity Systematic Error Ore Assay Improving Measurement Precision The Professor Tries Again Linear Random Error Propagation Multiplicative Random Error Propagation Other Random Error Propagation The Difference Between Propagation of Random and Systematic Errors Modeling the Heat Capacity of TiOx Non-linear Models for the CpTiOx Data An Asymptotic Model for the Heat Capacity of TiOx Using the Regression Tool to Find Non-Linear Models Removing the Thickness Variable from the Galvanized Corrosion Example Hypothesis Testing for the Galvanized Steel Model with Three Independent Variables Selecting a Model for the Hydrogen Reduction ofnio Calculating the Pressure-Catalyst Interaction Effect of a Fractional Factorial Design: How Much Information is Lost? 135 Chapter 4. Fundamentals of Material Balances with Applications to Non-Reacting Systems 4.1 Distillation ofacd-zn Alloy Charge Calculation for Feed to a Brass Melting Furnace Vacuum De-Zincing of Lead Leaching of Salt Cake from Aluminum Recycling Refining Crude Boric Acid by a Two-Stage Aqueous Process Recovery of KM11O4 by Evaporation Removing Dust and S02 from a Roaster Gas Absorption of HC Preparation of a Pigment Precursor Removal of CuS04 from a Pollution Control Residue Catalyst Reactivation Dissolution of ZnCl Removal of Hydrogen from Steel Vacuum Refining ofacd-zn Alloy Control Strategy for Upgrading Spent Reducing Gas 235 Chapter 5. Stoichiometry and the Chemical Equation 5.1 Use of the Gravimetric Factor for Silicon Mineralogical Constituents of a Concentrate Reduction ofwustite by CO Production of Molybdenum Carbide Production of Titanium by the Kroll Process The Reaction Between Oxygen and Carbon Reduction of Molybdenum Oxide with Hydrogen Carbothermic Reduction of Zinc Oxide Steam Reforming of Methane 278

10 xiii Chapter 6. Chapter 7. Chapter Controlled Oxidation of Pyrite Dissolution of Gold in Cyanide Solution 285 Reactive Material Balances 6.1 Production of Sulfur by Reduction of Sulfur Dioxide Chlorination of Silicon Application of FlowBal to Stack Gas Desulfurization Combustion of Natural Gas with XSA Effect of Oxygen Enrichment on the Oxidant Required for Complete Combustion Stack Gas Composition and Dew Point for Coal Combustion with Dry Air Calculation of% Excess Air from Stack Gas Analysis Calculation of CO, H2 and NO content in Hot Stack Gas Calculation of Reformer Gas Composition Calculation of dpt from Gas Analysis Calcination of Wet Pickling Cake Simulation of a Pre-Reduction Fluidized Bed Process Material Balance on Shaft Furnace Reduction of Hematite Roasting a Zinc Sulfide Concentrate Material Balance for BOF Steelmaking Leaching of Scrubber Dust The Optimum Precipitation of CaC03 by C Energy and the First Law of Thermodynamics 7.1 Work and Heat During the Compression of an I deal Gas Heat Capacity and Enthalpy for a Flux Heat of Fusion of Lead Standard Heat of the Water-Gas Shift Reaction from 800 to 1500 K Supercooling Liquid Tin Combustion of CO with Preheated Air Adiabatic Compression of Steam Enthalpy Change During Reduction of NiO with C Temperature Change of an Adiabatic Reaction 440 Enthalpy Balances in Non-Reactive Systems 8.1 Heat Balance for Melting Aluminum Heat Balance for Spray Cooling of Hot Air Fog Cooling ofceramic Parts Atomization of a Molten Metal Dehumidifying Spent Gas from an Iron Ore Reducing Furnace Using Stack Gas to Dry Cadmium Powder Heat Exchange in a Waste Heat Boiler Preheating HC1 in a Pebble-Bed Vertical Shaft Heat Exchanger Lowering the Water Temperature from a Crystallizer Condensation of Zinc Vapor from a Gas Production of Distilled Water 492

11 xiv Chapter 9. System Balances on Reactive Processes 9.1 Heat of Combustion of a Spent Gas from a Reduction Process 9.2 Effect of Preheating Combustion Air on AFT Production of a Reducing Gas Adiabatic Reforming of Fuel Oil Oxidation of S02 to S03 for Sulfuric Acid Production Metallothermic Reduction of Uranium Tetrafluoride Lime-Assisted Reduction of Magnetite Calcination of Magnesium Carbonate Formation of Nickel Ferrite by Spray Roasting 561 CD 1 CD Content Descriptions 2 Air 3 Atmospheres 4 Charts 5 Combustion Documents 6 Copper Smelting 7 FlowBal and MMV-C 8 Material and Heat Balance Notes 9 NG Combust & Wobbe Index 10 Statistics 11 Steel 12 SuperGoalSeek 13 SuperSolver 14 Thermodynamic Database 15 Unit Conversions