NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY
DEPARTMENT OF CHEMICAL ENGINEERING
TCE 5107 – ADVANCED MINERALS ENGINEERING
TUTORIAL 03 – 08/09/2022
Qn.1
Limestone mixed with coke is being burnt in a kiln. An average analysis of the limestone is
CaCO3 84.5%, MgCO3 11.5% and the rest are inerts. The coke contains 76% C, 21% ash and
3% moisture. The calcinations of CaCO3 and MgCO3 are 95% and 90% complete respectively.
The C in coke is completely burnt to carbon dioxide. The kiln is fed with 1 kg of coke per 5kg
of limestone. Calculate the weight percent of each product leaving the kiln. Assume that the
moisture in the feed is completely vaporized.
Qn. 2
A fluidised bed roaster, designed to treat 1000 tons/day of concentrates is currently
working at 7.5 % below capacity, and is used roast wet concentrates with the following
composition;
Composition of concentrates: ZnS = 58 %; PbS = 24%; Cu2S = 11%
Ambient air is used during fluidisation; the calcine which is discharged at 1400 K has the
following compositions;
Composition of calcine : ZnS, ZnO, PbO, Cu2O
The analysis of the flue gases show that the gases are made up of 15 % SO2 which accounts
for 97 % of the sulphur originally contained in the concentrates.
(i) What is the composition of the wet feed?
(ii) What is the composition of the calcine?
(iii) How much theoretical air is air is required?
(iv) How much excess air is required?
Qn. 3
a) “The control of sulphur in iron is the prime consideration in the fixation of slag
basicity.” Explain.
b) A sinter of iron ore consisting mainly of heamatite is charged into the blast
furnace.
Give a full description of the reactions that take place in each zone as well as the
operating conditions in each zone.
Qn. 4
a) Calculate the raw material rates/100 kg sinter produced, given the following data;
(i) sinter basicity = 1.5
(ii) FeO in sinter = 8 %
(iii) coke/fuel rate = 9 kg/100 kg of sinter
(iv) iron ore = heamatite concentrates
(v) fluxing reagents = limestone (CaCO3)
(vi) 10 % of the fuel is SiO2 and 5% is Al2O3
Qn. 5
a) What is the difference between super-fluxed and self-fluxing sinter?
b) Compare and contrast the steelmaking processes BOF and EAF.
c) The formation of slag is an integral part of the iron smelting process. Clearly outline the
chemistry of slag formation.
d) One of the essential characteristics of iron ore charged into the blast furnace is its
size and size distribution. Explain why this is important?
e) (i) What is the difference between pig iron and sponge iron?
(ii) What is the purpose of flux material in blast furnace iron making?
Qn. 6
a) Sintering is one of the methods that is used for agglomeration of fine iron ore particles
before charging into the furnace. With the aid of a diagram describe the different zones that
are established midway through the sintering process.
b) Blast furnace iron-making is the traditional technology that has been in use for a very long
time, however alternative technologies have been developed to counter some of the
challenges experienced with Blast furnace iron-making.
(i) Identify three of these challenges and highlight how they affect continued use of the
Blast furnace as an iron making process.
(ii) Give a detailed description of an alternative iron-making technology that you would
recommend for the Zimbabwean Iron and Steel Industry. Your description should include
raw materials, reactions and products.
