The dependence of technical lead production on the composition of the agglomerate has been analyzed on “Water-Jacket” furnace in Trepça. Additionally, the theoretical and real raport of coke consumption per ton of technical lead was studied. The goal of this study was to optimize the parameters of the process with respect to the amount of technical lead produced, the amounts of lead in the agglomerate and the air in the furnace. Special attention was also placed on minimization of energy consumption and environmental pollution.Ovisno o proizvodnji olova, sastav aglomerata je analiziran u „Water-Jacket“ peći u Trepči. Osim toga, teoretski i stvarni odnos potrošnje koksa po toni tehničkog olova je studira. Cilj ovog istraživanja bio je optimizirati parametre procesa s obzirom na količinu olova tehničke proizvodnje, količine olova u aglomerata i zraka u peći. Posebna je paźnja bila posvećana na smanjenje potrošnje energije i onečiŝćenja okoliša

A. Haxhiaj

E. Haxhiaj

Ovisno o proizvodnji olova, sastav aglomerata je analiziran u „Water-Jacket“ peći u Trepči. Osim toga, teoretski i stvarni odnos potrošnje koksa po toni tehničkog olova je studira. Cilj ovog istraživanja bio je optimizirati parametre procesa s obzirom na količinu olova tehničke proizvodnje, količine olova u aglomerata i zraka u peći. Posebna je paźnja bila posvećana na smanjenje potrošnje energije i onečiŝćenja okoliša.The dependence of technical lead production on the composition of the agglomerate has been analyzed on “Water-Jacket” furnace in Trepça. Additionally, the theoretical and real raport of coke consumption per ton of technical lead was studied. The goal of this study was to optimize the parameters of the process with respect to the amount of technical lead produced, the amounts of lead in the agglomerate and the air in the furnace. Special attention was also placed on minimization of energy consumption and environmental pollution

Haxhiaj, E.

Haxhiaj, A.

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141METALURGIJA 51 (2012) 1, 141-144A. HAXHIAJ, E. HAXHIAJTHE OPTIMIZATION OF THE QUANTITY OF COKE AND AGGLOMERATE IN LEAD PRODUCTION IN “WATER-JACKET” FURNACEReceived – Prispjelo: 2010-11-24Accepted – Prihvaćeno: 2011-03-14Professional Paper − Strukovni radISSN 0543-5846METABK 51(1) 141-144 (2012)UDC – UDK 669.4:622.344:662.74:669.041=111The dependence of technical lead production on the composition of the agglomerate has been analyzed on “Water-Jacket” furnace in Trepça. Additionally, the theoretical and real raport of coke consumption per ton of technical lead was studied. The goal of this study was to optimize the parameters of the process with respect to the amount of technical lead produced, the amounts of lead in the agglomerate and the air in the furnace. Special attention was also placed on minimization of energy consumption and environmental pollution. Key words: Lead, coke, agglomerate, Water-Jacket furnace, optimizationOptimizacija količine koksa i aglomerata u proizvodnji olovo u “Water-Jacket” peći.Ovisno o proizvodnji olo-va, sastav aglomerata je analiziran u „Water-Jacket“ peći u Trepči. Osim toga, teoretski i stvarni odnos potrošnje koksa po toni tehničkog olova je studira. Cilj ovog istraživanja bio je optimizirati parametre procesa s obzirom na količinu olova tehničke proizvodnje, količine olova u aglomerata i zraka u peći. Posebna je paźnja bila posvećana na smanjenje potrošnje energije i onečiŝćenja okoliša.Kljućne rijeći: olovo, koks, aglomerat, „Water-Jacket“ peći, optimizacijaINTRODUCTIONThe capacity of furnaces is depen-dent on many fac-tors and is an area of interest for scientifi c and research institutions, as well as industry. Under-standing furnace capacity helps to maximize production capacity and to minimize environmental pollution. Con-struction, elec-trical energy, load, and load composition are important precon-ditions for the productivity of furnaces and as such they are analyzed with mathematical models and production parameters in lead metallurgy in the “Trepça” complex. The “Water-Jacket” furnace which is used in the lead production is made of three main parts: the bot-tom, the well, and the neck of the furnace. The “Water-Jacket” furnace in Trepça has these parameters: the width of the fi rst line blowers is 1,3 m, and the width of the second line blowers is 2,9 m. The length of the furnace is 7,5 m, and it has a capacity of 260 tPb daily when the second line blowers do not work. The fundamental meas-ure of heat energy is the temperature of a system and the amount of heat energy in the system determines the ki-netic energy of the molecules in the furnace charge, i.e. the coke that is burned during the process. Pyrometallur-gical processes are characterized with chemical reactions, and exchange of heat which is a result of burning coke and convey release of heat from reactive systems. The consumption of coke in reduction processes depends on many factors including: the percentage of lead in ag-A. Haxhiaj, Faculty of Mining and Metallurgy, Mitrovica, Uni-versity of Prishtina, Mitrovica, E. Haxhiaj, American University in Kosovo, Prishtina, Republic of Kosovaglomerate, and thermal value of coke all of which infl u-ence quantity of technical lead produced.THE THEORETICAL CONSUMPTION OF COKEThe theoretical consumption of coke is calculated with this formula [1-3]: k’=0,20U + 0,20 tcoke / tPb (1)U –represents the mass (weight) of load minimized from coke weight, metal and dust which is calculated with the formula [4]: 100 U =  tcoke / tPb (2) netproductionThe net production is the production of lead per ton of load and depends on lead percentage in agglomerate.The theoretical consumption of coke is calculated based on the formula (1) for four different percentages of lead in agglomerate. The results of the calculations are presented on Table 1 Alternative: 1 (50 % Pb); 2 (48 % Pb); 3 (43,6 % Pb); 4 (41 % Pb).Table 1  The theoretical consumption of coke based on the percentage of lead in the agglomerateThe percentage of lead in the agglomerate / %The theoretical consumption of coke / tcoke / tPb504843,6410,6000,6160,6580,687142  METALURGIJA 51 (2012) 1, 141-144A. HAXHIAJ et al.: THE OPTIMIZATION OF THE QUANTITY OF COKE AND AGGLOMERATE IN LEAD PRODUCTION IN...The Real Consumption of CokeThe real consumption of coke is calculated with the formula [4]: k = k’ · f4 · f5 · f6 · f7 · f8 · f9 tcoke / tPB (3)k’ –  The theoretical consumption of coke that is calcu-lated above.fx  –  The corrective factors of coke con-sumption, f4, f5, f6, f7, f8, f9 [4].The real consumption of coke is calculated based on the formula (3) for four different percentages of lead in agglomerate. The results of the calculations are presented on Ta-ble 2. Alternative – 1 (50 % Pb); 2 (48 % Pb); 3 (43,6 % Pb); 4 (41 % Pb).Table 2   The real consumption of coke based on the percentage of lead in the agglomerateThe percentage of lead in the agglomerate / %The real consumption of coke / tcoke / tPb504843,6410,7440,7110,7530,802The Reprise of Theoretical and Real Consumption of Coke Depending on Lead Percentage in AgglomerateBased on the analytical and graphical analyses of theoretical and real coke consumption as a function of lead in the agglomerate, it may be concluded that by increasing lead content, the theore-tical and real con-sumption of coke are both minimized, as shown in Ta-ble 3, Figure 1. Alternative – 1, 2, 3, 4.Table 3  The theoretical and real consum-ption of coke, and the diff erence between them depending on the lead percentage in agglomerateThe percent-age of lead in the agglom-erate / %The theoreti-cal consump-tion of coke/ tcoke / tPbThe real consumption of coke / tcoke / tPbDiff erence between theoretical and real consumption of coke/ tcoke / tPb504843,6410,6000,6160,6580,6870,7440,7110,7530,8020,1440,0950,0950,115The Real Capacity of Coke CombustionThe theoretical combustion of coke depends on many factors and can be calculated with the formula [4]: Kr = K· f1 · f2 · f3 tcoke / 24 h (4)K = 22,6 · db2  this formula is valid for db<5m (5)db  – is the diameter inside the furnace and its length is 2,4m in the “Water-Jacket” furnace in Trepça.f1 · f2 · f3 - are corrective factors [1].K = 2,6· 2,42 tcoke / 24 hK = 130,176 tcoke / 24 hThe real daily coke combustion is calculated based on the formula (4) for three different percentages of lead in agglomerate. The results of the calculations are presented on Ta-ble 4, Figure 2. Alternative – 1 (41 % Pb); 2 (43,6 % Pb); 3 (48 % Pb).Table 4  The daily quantity of real coke combustion depending on lead percentage in the agglomerateLead percentage in agglomerate /%The daily quantity of real coke combustion / tcoke / 24 h4143,648155,6172,6167,3The Determination of Thermal Value of Combusted CokeThe thermal value of coke depends on the percent-ages of carbon, burning matter and non-burning matter, and the strength and metallurgical composition of coke which is based on alternatives 1, 2, 3 of lead composi-Figure 1  Theoretical and real consum-ption of coke, and the diff er-ence between them depending on the lead percentage in the agglomerateFigure 2  The daily quantity of real coke combustion depending on lead percentage in the agglomerate143METALURGIJA 51 (2012) 1, 141-144A. HAXHIAJ et al.: THE OPTIMIZATION OF THE QUANTITY OF COKE AND AGGLOMERATE IN LEAD PRODUCTION IN...tion in agglomerate [4]. The average value for calories of coke used as a reagent is Qf = 29228 kJ/kg as calcu-lated in “Water-Jacket” furnace [3]. The results are shown in Table 5, Figure 3.Table 5  The real quantity of coke com-bustion and thermal value of coke which depends on the lead percentage in the agglomerateThe lead percentage in the agglomer-ate /%The real quan-tity of daily coke combustion / tcoke / 24 hThe real hourly quantity of coke combus-tion / tcoke / hQuantity of heat / kJ / h4143,648155,6172,6167,36,487,196,97189332640210077420203649460The Capacity of “Water-Jacket” FurnaceThe calculation of furnace capacity based on the amount of coke used is one of the most preferred meth-ods and is calculated using the following mathe-matical model [5-9]. Kr N =  tb / 24 h (6) kKr –  The real capacity of daily combus-tion of coke which is calculated with the equation (4).k –  The real consumption of coke depending on percent-age of lead in agglomerate which is calculated with the equation (3).The capacity of “Water-Jacket” furnace is calculated based on formula (6) according to alternatives 1, 2, and 3. The results are presented on Table 6, Figure 4.Table 6 The capacity of the furnace based on the quantity of burnt coke and lead percentage in agglomerateThe percentage of lead in ag-glomerate / %The quantity of burnt coke /tcoke / 24 hThe real con-sumption of coke / tcoke / tPbThe capacity of furnace / tPb / 24 h4143,648155,6172,6167,30,8020,7530,711189,7229,2235,3CONCLUSIONThe results analyzed in this scientifi c paper are based in perennial, profess-ional and scientifi c work in “Wa-ter-Jacket” furnace in lead metallurgy in Trepça. The work method is based on theoretical and experimental elabora-tions of industrial parameters used during the operation of “Water-Jacket” furnace. The following conclusions have been deduced from the analytical and graphical results for theoretical and real coke consump-tion, and the amounts of lead obtained from agglomer-ates of varying composition:If the percentage of lead in the agglomerate is less than 43 %:  Productivity of technical lead is poor.  The consumption of coke is higher for a tonne techni-cal lead produced. The quantity of dust produced increases.If the percentage of lead in the agglomerate is 48 %: Productivity of technological lead is high.  The consumption of coke is smaller for a ton technical lead produced. The quantity of dust produced decreases.If the percentage of lead in the agglomerate is higher than 48 %:  The decreased tendency of technological lead produc-tivity.  The consumption of coke increases for a tonne tech-nological lead produced. The quantity of dust gained in process increases.REFERENCES[1] A. Haxhiaj, Intensifi kimi dhe Optimalizimi i Procesit të Shkrirjes Reduktuese të Aglomeratit të Plumbit në Furrat Shahte, PhD, Universiteti i Prishtinës, 2003, p. 37-41.[2] A. Haxhiaj, Materialna i toplotna bilansa PORT-PIRI peći, MBA, Sveučilište u Zagrebu, 1989, p. 42-48.[3] M. Jovanović, Energetika metalurških peći, TMF Beograd, 1971.Figure 3  The real quantity of coke com-bustion and thermal value of coke which depends on the lead percentage in the agglomerate Figure 4  The capacity of the furnace de-pending on quantity of burnt coke and percentage of lead in agglomerate144  METALURGIJA 51 (2012) 1, 141-144A. HAXHIAJ et al.: THE OPTIMIZATION OF THE QUANTITY OF COKE AND AGGLOMERATE IN LEAD PRODUCTION IN...[4] Z. Popović, M. Jovanović, Zbirka rešenih zadataka iz pre-dmeta peći i projektovanje u metalurgiju, TMF Beograd, 1976.[5] M. Rizaj, Termo-Inxhinieria në Metalurgji, Prishtinë: Uni-versiteti i Prishtinës, 2009, p. 127-146.[6] V. G. Lisienko, Methods of calculating heat transfer in me-tallurgical plants and control models, Journal of Enginee-ring Physics and Thermophysics, (2004) New York.[7] M. Jovanović, Nova tehnologija i postrojenja za proizvo-dnju-olova, Beograd: Zbornik radova II Jugoslovenskog simpozijuma o metalurgij, TMF, 1978, p. 8, 31, 51.[8] D. Malič, B. Đorđevič, and V. Valent, Termodinamika Strujnih Procesa, Beograd: Građevinska Knjiga, 1980, p. 31-41.[9] H. J. Bittrich, Leitfaden der Chemischen Thermodynamic, Berlin, 1976, p. 93-114.Note:  The responsible translator for English language is Agim Po-drimçaku, Peja, Republic of Kosova

Optimizacija količine koksa i aglomerata u proizvodnji olovo u “Water-Jacket” peći

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