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19 views3 pages

Tutorial 1

Uploaded by

oceetera.002
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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NATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING


ECE 5107 – EXTRACTIVE METALLURGY 1A
TCE 5107 – ADVANCED MINERALS ENGINEERING 1A
TUTORIAL 1 – 11/11/2024

Question 1

A pyritic ore is reduced with hydrogen according to the following reaction:

FeS2 (s) + 2H2 (g) ↔ Fe (l) + 2H2S (g)

The ore contains 15% inert solid (gangue). 25% excess hydrogen is used, and the cinder
(solid residue) remaining contains 5% FeS2 by weight.

Calculate the volume (m3) of furnace gases (at 400oC and 1 atm) per 100 kg of ore charged.

Question 2

A limestone is analysed as follows:


CaCO3 = 93.1 wt. %
MgCO3 = 5.38 wt. %
Insoluble matter = 1.5 wt. %

(a) How many kg of CaO could be obtained from 10tons of limestone?


(b) How many kg of CO2 will be produced?

Question 3

An annealing furnace uses a fuel oil containing 16% hydrogen. The fuel is burnt with 25%
excess air.
Calculate the flue gas analysis assuming complete combustion. Repeat the calculation
assuming that 5% of the fuel is burnt to CO only.

Assume 100kg fuel: 84kg C and 16kg H

Question 4

A copper ore contains 7% Cu and 36% S. The copper mineral is chalcopyrite CuFeS2 and S is
also present as iron pyrite (FeS2). The rest of the ore is gangue containing no Cu, S and Fe.

1
The ore is roasted until all the sulphur is removed; the following reactions are taking place:

4FeS2 + 11O2 ↔ 2Fe2O3 + 8SO2


4CuFeS2 + 13O2 ↔ 4CuO + 2Fe2O3 + 8SO2

Calculate the following;


(a) Weight of each mineral and the gangue in 1000kg of ore
(b) Oxygen required in m3
(c) Air required in m3
(d) Weight of Fe2O3
(e) Volume of SO2 in m3

Question 5

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.

Question 6

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?
How much excess air is required?

2
Question 7

In the electrolysis of aluminium, anhydrous alumina (Al2O3) is required. This is achieved by


calcining Al(OH)3 at 1700K in a rotary kiln. The feed to the kiln is a damp filter cake analyzing
55% Al(OH)3 and 45% H2O, and this is calcined to give pure Al2O3 as a solid product. The fuel
consumption is estimated to be 0.2kg per kg of alumina, fuel composition is; 84% C and 16%
H. Air for combustion is 20% in excess of the theoretical air required. Assuming complete
combustion, calculate;

a) The volume of gases (@1atm and 27K) leaving the kiln per 1000kg of alumina
produced.
b) The wet and dry composition of the flue gas.

Question 8

A copper ore concentrate with the following composition (wt.%); Cu – 8.8%, SiO2 – 19%, Fe –
29.7%, S – 36.9%, Al2O3 – 5.3%, CaO – 0.3%
is roasted to give a calcine of the following composition (wt.%); Cu – 11.1%, SiO2 – 24%, Fe –
37.6%, S – 10%, Al2O3 – 6.7%, CaO – 0.4%, O2 – 10.2%.

All copper in the calcine is in the form of Cu2S and Fe is partly oxidized to Fe2O3 and Fe3O4.
During roasting 5000m3 of air is supplied per ton of concentrate. Fuel consumption is 5kg C
per ton of concentrate. Of the Sulphur oxidized 85% goes to SO2 and 15% goes to SO3,
calculate:

a) Weight of calcine per ton of concentrate.


b) Composition of the calcine
c) % Sulphur eliminated
d) Volume and composition of gases (@STP)
e) Excess air used for combustion and roasting

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