SMELTING OF CHROMITE AND LATERITE ORES WITH

PROBLEM

BLEND 6 (SCO & SCM)

BLEND 1 (SCO & SAP)

BLEND 7 (SCO, SCM & SAP)

BLEND 2 (SCO & LIM)

BLEND 8 (SCO, SCM & LIM)

BLEND 3 (SCM & SAP)

BLEND 9 (SCO, SAP & LIM)

BLEND 4 (SCM & LIM)

BLEND 10 (SCM, SAP & LIM)

BLEND 5 (SAP & LIM)

BLEND 11 (SCO, SCM, SAP & LIM)

TE ORES WITH CARBON

SMELTING OF CHROMITE AND LATERIT

Problem:

Composition of Feed Mat

A total of

3.00

grams mixture of chromite and

laterite ores, with Carbon requirement of mass(g)

0.3252

as a reducatant, is smelted in a vertical tube furnace.

Components

Four (4) Blends, as follows: SCO & SAP; SCO & LIM;

Cr2O3

35.665

SCM & SAP and SCM & LIM, are made out of the

Fe2O3

33.475

two types of chromite and laterite ores.

MgO

13.568

Al2O3

9.762

SiO2

5.875

laterite are considered in the operation in a particular

TiO2

0.273

blend.

MnO

0.293

ZnO

0.071

SO3

0.020

A percentage of

10.00

chromite and

90.00

Assumptions:
a.) % Cr goes to slag:

1.00

CaO

0.151

b.) % Fe goes to slag:

1.00

NiO

0.020

c.) % Ni goes to slag:

1.00

Cl

0.040

d.) % C goes to metal:

7.00

Br

0.353

LOI

0.434

HOME

100.000

99.06

AND LATERITE ORES WITH CARBON

sition of Feed Materials:

Chromite Ores (% wt)

Laterite Ores (% wt)

SCO

SAP

SCM

LIM

35.330

31.024

30.770

1.553

1.550

2.606

2.600

33.160

24.178

23.980

38.591

38.510

74.008

73.830

13.440

21.224

21.050

18.539

18.500

0.742

0.740

9.670

9.710

9.630

1.273

1.270

2.205

2.200

5.820

9.629

9.550

23.449

23.400

2.496

2.490

0.270

0.192

0.190

0.020

0.020

0.050

0.050

0.290

0.171

0.170

0.461

0.460

1.604

1.600

0.070

0.040

0.040

0.030

0.030

0.080

0.080

0.020

0.040

0.040

0.040

0.040

0.180

0.180

0.150

0.000

0.000

0.000

0.000

0.000

0.000

0.020

0.313

0.310

2.646

2.640

1.714

1.710

0.040

0.060

0.060

0.030

0.030

0.231

0.230

0.350

0.625

0.620

0.241

0.240

0.551

0.550

0.430

2.793

2.770

13.128

13.100

13.532

13.500

99.060

100.000

99.180

100.000

99.790

100.000

99.760

Blend 1: SCO & SAP

mass (g)

total mass (g):

3.000

% chromite ore

10.00

0.300

% laterite ore

90.00

2.700

Chemical Reaction:

FeOCr2O3 + NiOFe2O3 + C --> Cr

mass input (g)

Blend 1

Ores
Cr2O3 0.1489
Fe2O3 1.1424
0.0715
NiO
MnO
0.0133
Reductant
0.3252
C

Components
SCO

SAP

Cr2O3

0.1070

0.0419

Fe2O3

0.1004

1.0420

MgO

0.0407

0.5006

Al2O3

0.0293

0.0344

SiO2

0.0176

0.6331

TiO2

0.0008

0.0005

MnO

0.0009

0.0124

ZnO

0.0002

0.0008

SO3

0.0001

0.0011

CaO

0.0005

0.0000

NiO

0.0001

0.0714

Cl

0.0001

0.0008

Br

0.0011

0.0065

LOI

0.0013

0.3544

TOTAL:

1.7013

0.00047032
0.0470322

0.00015313

mass Fe for FeO 0.343364917

O input:

0.0022891

c for CO
0.302394187

Fe

0.015313255

Cr

0.405710373 0.00291255

Ni
O
C
N

total
Mn
O for CO
0.4

Cr2O3
Fe2O3

NiO
CO

MnO
FeO

2O3 + C --> Cr + Fe + Ni + C + CO + FeO + NiO + Cr2O3 + MnO

mass output (g)

0.3252

Matte
Cr
0.1009
Fe
0.7910
Ni
0.0556
Slag
FeO
0.0103
Cr2O3 0.0015
NiO
0.0007
MnO 0.0133
Flue gas
CO
0.7052
C in metal
C
0.0228
1.7013
HOME

55.845
51.996
58.693
15.999
12.011
14.007

54.938

151.989
159.687

74.692
28.01

70.937
71.844

Blend 2: SCO & LIM

mass (g)

total mass (g):

3.000

% chromite ore

10.00

0.300

% laterite ore

90.00

2.700

Chemical Reaction:
FeOCr2O3 + NiOFe2O3 + C --> Cr
mass input (g)

Blend 2

Ores
Cr2O3 0.1774
Fe2O3 2.0986
0.0463
NiO
MnO
0.0442
Reductant
0.5585
C

Components
SCO

LIM

Cr2O3

0.1070

0.0704

Fe2O3

0.1004

1.9982

MgO

0.0407

0.0200

Al2O3

0.0293

0.0595

SiO2

0.0176

0.0674

TiO2

0.0008

0.0014

MnO

0.0009

0.0433

ZnO

0.0002

0.0022

SO3

0.0001

0.0049

CaO

0.0005

0.0000

NiO

0.0001

0.0463

Cl

0.0001

0.0062

Br

0.0011

0.0149

LOI

0.0013

0.3654

TOTAL:

2.9250

Fe
Cr
Ni
O
C
N
Mn
Cr2O3
Fe2O3
NiO
CO
MnO
FeO

55.845
51.996
58.693
15.999
12.011
14.007
54.938

mass Fe for FeO

O input:
0.014678462
total

151.989
159.687
74.692
28.01
70.937
71.844

O for CO
0.1
0.69185574 0.6
0
0.7

O output

0.000560104
9.92636E-05
0.004205223
0.004864592

2O3 + C --> Cr + Fe + Ni + C + CO + FeO + NiO + Cr2O3 + MnO

mass output (g)

0.5585

Matte
Cr
0.1201
Fe
1.4532
Ni
0.0361
Slag
FeO
0.0189
Cr2O3 0.0018
NiO
0.0005
MnO
0.0442
Flue gas
CO
1.2113
C in metal
C
0.0391
2.9250
HOME

c for CO

0.519399917

Chemical Reaction:

Blend 3: SCM & SAP

total mass (g):

3.00

3.00

% chromite ore
% laterite ore

10.00
90.00

0.30
2.70

FeOCr2O3 + NiOFe2O3 + C --> C

mass input (g)

Blend 3

Ores
Cr2O3
Fe2O3
NiO
MnO
Reductant
C

Components
SCM

SAP

Cr2O3

0.0931

0.0419

Fe2O3

0.0725

1.0420

MgO

0.0637

0.5006

Al2O3

0.0291

0.0344

SiO2

0.0289

0.6331

TiO2

0.0006

0.0005

MnO

0.0005

0.0124

ZnO

0.0001

0.0008

SO3

0.0001

0.0011

CaO

0.0000

0.0000

NiO

0.0009

0.0714

Cl

0.0002

0.0008

Br

0.0019

0.0065

LOI

0.0084

0.3544

TOTAL:

mass Fe for FeO

0.007795106

O input:

O output

0.00042636
0.00015501
0.00223322
c for CO

total

0.00281458

O for CO
0.390304392

0.293014942

Reaction:

+ NiOFe2O3 + C --> Cr + Fe + Ni + C + CO + FeO + NiO + Cr2O3 + MnO

ass input (g)

0.1350
1.1145
0.0724
0.0130
eductant
0.3151 0.3151

1.6499

mass output (g)

Matte
Cr
0.0915
Fe
0.7717
Ni
0.0563
Slag
FeO
0.0100
Cr2O3 0.0014
NiO
0.0007
MnO
0.0130
Flue gas
CO
0.6833
C in metal
C
0.0221
1.6499
HOME

Fe
Cr
Ni
O
C
N

55.845
51.996
58.693
15.999
12.011
14.007

Mn

54.938

Cr2O3
Fe2O3

151.989
159.687

NiO

74.692

CO
MnO

28.01
70.937

FeO

71.844

+ MnO

Blend 4: SCM & LIM

mass (g)

3.00

3.00

% chromite ore

10.00

0.30

% laterite ore

90.00

2.70

total mass (g):

Chemical Reaction:

FeOCr2O3 + NiOFe2O3 + C --> Cr

mass input (g)
Ores
Cr2O3 0.1634
Fe2O3 2.0707
0.0472
NiO
MnO
0.0438
Reductant
0.5484
C

Blend 4
Components
SCM

LIM

Cr2O3

0.0931

0.0704

Fe2O3

0.0725

1.9982

MgO

0.0637

0.0200

Al2O3

0.0291

0.0595

SiO2

0.0289

0.0674

TiO2

0.0006

0.0014

MnO

0.0005

0.0433

ZnO

0.0001

0.0022

SO3

0.0001

0.0049

CaO

0.0000

0.0000

NiO

0.0009

0.0463

Cl

0.0002

0.0062

Br

0.0019

0.0149

LOI

0.0084

0.3654

TOTAL:

2.8736

Fe
Cr
Ni
O
C
N

mass Fe for FeO

Mn

O input:
0.014483396

Cr2O3
Fe2O3
NiO

total

CO
MnO

O for CO
0.6793623

FeO

0.1 O output
0.6
0
0.7

0.000516138
0.000101142
0.004149339
0.00476662

2O3 + C --> Cr + Fe + Ni + C + CO + FeO + NiO + Cr2O3 + MnO

mass output (g)

0.5484

Matte
Cr
0.1107
Fe
1.4339
Ni
0.0367
Slag
FeO
0.0186
Cr2O3 0.0016
NiO
0.0005
MnO 0.0438
Flue Gas
CO
1.1894
C in metal
C
0.0384
2.8736
HOME

c for CO

0.510020671

Blend 5: SAP & LIM

total mass (g):

mass (g)
3

% chromite ore

10

0.3

% laterite ore

90

2.7

Chemical Reaction:

FeOCr2O3 + NiOFe2O3 + C --> Cr +

mass input (g)
Ores
Cr2O3 0.0750
Fe2O3 2.1140
0.0542
NiO
MnO 0.0447
Reductant
0.5377
C

Blend 5
Components
SAP

LIM

Cr2O3

0.0047

0.0704

Fe2O3

0.1158

1.9982

MgO

0.0556

0.0200

Al2O3

0.0038

0.0595

SiO2

0.0703

0.0674

TiO2

0.0001

0.0014

MnO

0.0014

0.0433

ZnO

0.0001

0.0022

SO3

0.0001

0.0049

CaO

0.0000

0.0000

NiO

0.0079

0.0463

Cl

0.0001

0.0062

Br

0.0007

0.0149

LOI

0.0394

0.3654

TOTAL:

2.8256

Fe
Cr
Ni
O
C
N
Mn

55.845
51.996
58.693
15.999
12.011
14.007
54.938

mass Fe for FeO

O input:
0.014785818
total

Cr2O3
Fe2O3
NiO
CO
MnO
FeO

151.989
159.687
74.692
28.01
70.937
71.844

0.023693498
O for CO
0.635397003
0.7 0.011613421
0.670703923

O output

0.000236935
0.000116134
0.00423598
0.004589049

2O3 + C --> Cr + Fe + Ni + C + CO + FeO + NiO + Cr2O3 + MnO

mass output (g)

0.5377

Matte
Cr
0.0508
Fe
1.4638
Ni
0.0422
Slag
FeO
0.0190
Cr2O3 0.0008
NiO
0.0005
MnO 0.0447
Flue Gas
CO
1.1662
C in metal
C
0.0376
2.8256
HOME

c for CO

0.500075364

Blend 6: SCM&SCO

mass (g)
3.00

% chromite ore

3.00
10.00

% laterite ore

90.00

2.70

total mass (g):

0.30

Chemical Reaction:

FeOCr2O3 + NiOFe2O3 + C --> Cr + F

mass input (g)
Ores
Cr2O3 0.2001
Fe2O3 0.1730
0.0010
NiO
MnO 0.0014
Reductant
0.0923
C

Blend 6
Components
SCM

SCO

Cr2O3

0.0931

0.1070

Fe2O3

0.0725

0.1004

MgO

0.0637

0.0407

Al2O3

0.0291

0.0293

SiO2

0.0289

0.0176

TiO2

0.0006

0.0008

MnO

0.0005

0.0009

ZnO

0.0001

0.0002

SO3

0.0001

0.0001

CaO

0.0000

0.0005

NiO

0.0009

0.0001

Cl

0.0002

0.0001

Br

0.0019

0.0011

LOI

0.0084

0.0013

TOTAL:

0.4678

mass Fe for FeO

0.001209727

O input:
O output
0.063180295
0.051986086
0.000213827
total 0.115380208
O for CO
0.1

0.000631803
2.13827E-06
0.000346574
0.000980515

2O3 + C --> Cr + Fe + Ni + C + CO + FeO + NiO + Cr2O3 + MnO

mass output (g)

0.0923

Matte
Cr
0.1355
Fe
0.1198
Ni
0.0008
Slag
FeO
0.0016
Cr2O3 0.0020
NiO
0.0000
MnO 0.0014
Flue Gas
CO
0.2003
C in the Metal
C
0.0065
0.4678
HOME

c for CO

0.085883787

Fe
Cr
Ni
O
C
N
Mn
Cr2O3
Fe2O3
NiO
CO
MnO
FeO

55.845
51.996
58.693
15.999
12.011
14.007
54.938
151.989
159.687
74.692
28.01
70.937
71.844

Blend 7: SCM, SCO & SAP

mass (g)
3.00

3.00

% chromite ore

10.00

0.30

% laterite ore

90.00

2.70

total mass(g):

Chemical Reaction:

FeOCr2O3 + NiOFe2O3 + C -->

mass input (g)
Ores
Cr2O3
Fe2O3
NiO
MnO
Reductant
C

Blend 7
Components
SCM

SCO

SAP

Cr2O3

0.0931

0.1070

0.0419

Fe2O3

0.0725

0.0000

1.0420

MgO

0.0637

0.0407

0.5006

Al2O3

0.0291

0.0293

0.0344

SiO2

0.0289

0.0176

0.6331

TiO2

0.0006

0.0008

0.0005

MnO

0.0005

0.0009

0.0124

ZnO

0.0001

0.0002

0.0008

SO3

0.0001

0.0001

0.0011

CaO

0.0000

0.0005

0.0000

NiO

0.0009

0.0001

0.0714

Cl

0.0002

0.0001

0.0008

Br

0.0019

0.0011

0.0065

LOI

0.0084

0.0013

0.3544

TOTAL:

mass Fe for FeO

0.0077951

O input:
O output
0.076424027
0.334982282
0.015514108
total
0.426920416
O for CO
0.4

c for CO
0.318137089
0.0007642
0.0001551
0.0022332
0.0031526

Reaction:

+ NiOFe2O3 + C --> Cr + Fe + Ni + C + CO + FeO + NiO + Cr2O3 + MnO

ass input (g)

0.2420
1.1145
0.0724
0.0138
eductant
0.3421 0.3421

1.7848

mass output (g)

Matte
Cr
0.1639
Fe
0.7717
Ni
0.0563
Slag
FeO
0.0100
Cr2O3 0.0024
NiO
0.0007
MnO 0.0138
Flue Gas
CO
0.7419
C in metal
C
0.0239
1.7848
HOME

Fe
Cr
Ni
O
C
N
Mn
Cr2O3
Fe2O3
NiO
CO
MnO
FeO

55.845
51.996
58.693
15.999
12.011
14.007
54.938
151.989
159.687
74.692
28.01
70.937
71.844

O3 + MnO

Blend 8: SCM, SCO & LIM

mass (g)
3.00

3.00

% chromite ore

10.00

0.30

% laterite ore

90.00

2.70

total mass of ores (g):

Chemical Reaction:

FeOCr2O3 + NiOFe2O3 + C -mass input (g)

Ores
Cr2O3
Fe2O3
NiO
MnO
Reductant
C

Blend 8
Components
SCM

SCO

LIM

Cr2O3

0.09307 0.10700 0.07037

Fe2O3

0.07253 0.10042 1.99821

MgO

0.06367 0.04070 0.02003

Al2O3

0.02913 0.02929 0.05954

SiO2

0.02889 0.01763 0.06739

TiO2

0.00057 0.00082 0.00135

MnO

0.00051 0.00088 0.04330

ZnO

0.00012 0.00021 0.00217

SO3

0.00012 0.00006 0.00487

CaO

0.00000 0.00045 0.00000

NiO

0.00094 0.00006 0.04628

Cl

0.00018 0.00012 0.00622

Br

0.00188 0.00106 0.01489

LOI

0.00838 0.00130 0.36538

TOTAL:

Fe
Cr

55.845
51.996

Ni
O
C
N
Mn

58.693
15.999
12.011
14.007
54.938
mass Fe for FeO

Cr2O3
Fe2O3
NiO
CO
MnO
FeO

151.989
159.687
74.692
28.01
70.937
71.844

O input:

total
O for CO
0.742808871

Reaction:

+ NiOFe2O3 + C --> Cr + Fe + Ni + C + CO + FeO + NiO + Cr2O3 + MnO

ass input (g)

0.2704
2.1712
0.0473
0.0447
eductant
0.5996 0.5996

3.1332

mass output (g)

Matte
Cr
0.1832
Fe
1.5034
Ni
0.0368
Slag
FeO
0.0195
Cr2O3 0.0027
NiO
0.0005
MnO 0.0447
Flue Gas
CO
1.3005
C in metal
C
0.0420
3.1332
HOME

ss Fe for FeO

0.015185792
O output

0.085402268
0.65258525
0.010127216
0.748114734

c for CO
0.000854023
0.000101272
0.004350568
0.005305863

0.557652188

O3 + MnO

Blend 9: SCO, LIM &SAP

mass (g)

total mass(g):

3.00

3.00

% chromite ore

10.00

0.30

% laterite ore

90.00

2.70

Chemical Reaction:

FeOCr2O3 + NiOFe2O3 + C mass input (g)

Ores
Cr2O3
Fe2O3
NiO
MnO
Reductant
C

Blend 9
Components
SCO

LIM

SAP

Cr2O3

0.10700 0.07037 0.041938

Fe2O3

0.10042 1.99821 1.041958

MgO

0.04070 0.02003 0.500551

Al2O3

0.02929 0.05954 0.034362

SiO2

0.01763 0.06739 0.63313

TiO2

0.00082 0.00135 0.000541

MnO

0.00088 0.04330 0.012446

ZnO

0.00021 0.00217 0.000812

SO3

0.00006 0.00487 0.001082

CaO

0.00045 0.00000 0.000000

NiO

0.00006 0.04628 0.07143

Cl

0.00012 0.00622 0.000812

Br

0.00106 0.01489 0.006494

LOI

0.00130 0.36538 0.354444

TOTAL:

Fe
Cr
Ni
O
C
N
Mn
Cr2O3
Fe2O3
NiO
CO
MnO
FeO

55.845
51.996
58.693
15.999
12.011
14.007
54.938
151.989
159.687
74.692
28.01
70.937
71.844

mass Fe for FeO

0.021966237

O input:

O output

total
O for CO
1.031206997

0.1
0.9
0
1

0.000692542
0.000252266
0.006293094
0.007237902

Reaction:

+ NiOFe2O3 + C --> Cr + Fe + Ni + C + CO + FeO + NiO + Cr2O3 + MnO

ass input (g)

0.2193
3.1406
0.1178
0.0566
eductant
0.8324 0.8324

4.3667

mass output (g)

Matte
Cr
0.1485
Fe
2.1747
Ni
0.0916
Slag
FeO
0.0283
Cr2O3 0.0022
NiO
0.0012
MnO 0.0566
Flue Gas
CO
1.8054
C in metal
C
0.0583
4.3667
HOME

c for CO

0.774162588

2O3 + MnO

Blend 10: SCM, LIM &SAP

mass (g)

total mass (g):

3.00

3.00

% chromite ore

10.00

0.30

% laterite ore

90.00

2.70

Chemical Reaction:

FeOCr2O3 + NiOFe2O3 + C mass input (g)

Blend 10

Ores
Cr2O3
Fe2O3
NiO
MnO
Reductant
C

Components
SCM

LIM

SAP

Cr2O3

0.83766 0.07037 0.041938

Fe2O3

0.65281 1.99821 1.041958

MgO

0.57305 0.02003 0.500551

Al2O3

0.26216 0.05954 0.034362

SiO2

0.25998 0.06739 0.63313

TiO2

0.00517 0.00135 0.000541

MnO

0.00463 0.04330 0.012446

ZnO

0.00109 0.00217 0.000812

SO3

0.00109 0.00487 0.001082

CaO

0.00000 0.00000 0.000000

NiO

0.00844 0.04628 0.07143

Cl

0.00163 0.00622 0.000812

Br

0.01688 0.01489 0.006494

LOI

0.07541 0.36538 0.354444

TOTAL:

Fe
Cr
Ni
O
C
N
Mn
Cr2O3
Fe2O3
NiO

55.845
51.996
58.693
15.999 mass Fe for FeO
0.025829816
12.011
14.007 O input:
O output
54.938
0.2999921
1.1099952
151.989
0.0270213
159.687 total
1.4370087
74.692
28.01 O for CO

0
0
0
0

c for CO

CO
MnO
FeO

70.937
71.844

1.4263386

Reaction:

+ NiOFe2O3 + C --> Cr + Fe + Ni + C + CO + FeO + NiO + Cr2O3 + MnO

ass input (g)

0.9500
3.6930
0.1262
0.0604
eductant
1.1514 1.1514

5.9809

mass output (g)

Matte
Cr
0.6435
Fe
2.5572
Ni
0.0981
Slag
FeO
0.0332
Cr2O3 0.0095
NiO
0.0013
MnO 0.0604
Flue Gas
CO
2.4971
C in Metal
C
0.0806
5.9809
HOME

1.07080151

O3 + MnO

Blend 11: SCO, SCM, LIM & SAP

Chemical Reaction:

mass (g)

total mass (g):

3.00

3.00

% chromite ore

10.00

0.30

% laterite ore

90.00

2.70

FeOCr2O3 + NiOFe2O3

Blend 11
Components
SCO

SCM

SAP

LIM

Cr2O3

0.1070

0.09307 0.04194

0.07037

Fe2O3

0.1004

0.07253 1.04196

1.99821

MgO

0.0407

0.06367 0.50055

0.02003

Al2O3

0.0293

0.02913 0.03436

0.05954

SiO2

0.0176

0.02889 0.63313

0.06739

TiO2

0.0008

0.00057 0.00054

0.00135

MnO

0.0009

0.00051 0.01245

0.0433

ZnO

0.0002

0.00012 0.00081

0.00217

SO3

0.0001

0.00012 0.00108

0.00487

CaO

0.0005

NiO

0.0001

0.00094 0.07143

0.04628

Cl

0.0001

0.00018 0.00081

0.00622

Br

0.0011

0.00188 0.00649

0.01489

LOI

0.0013

0.00838 0.35444

0.36538

TOTAL:

mass Fe for FeO

0.02247357

O input:

O output

total
O for CO
1.08216013

0.098646
0.9657658
0.0254275
1.0898393

c for CO
0.00098646
0.00025427
0.00643844
0.00767917

hemical Reaction:

eOCr2O3 + NiOFe2O3 + C --> Cr + Fe + Ni + C + CO + FeO + NiO + Cr2O3 + Mn

mass input (g)

mass output (g)

Ores
Cr2O3 0.3124
Fe2O3 3.2131
0.1187
NiO
MnO
0.0571
Reduction
0.8736 0.8736
C

Matte
Cr
0.2116
Fe
2.2249
Ni
0.0923
Slag
FeO
0.0289
Cr2O3 0.0031
NiO
0.0012
MnO
0.0571
Flue Gas
CO
1.8946
C in metal
C
0.0611

4.5749

4.5749
HOME

0.812414858

Fe
Cr
Ni
O
C
N
Mn
Cr2O3
Fe2O3
NiO
CO
MnO
FeO

55.845
51.996
58.693
15.999
12.011
14.007
54.938
151.989
159.687
74.692
28.01
70.937
71.844

+ Cr2O3 + MnO