The theoretical formula used by operators for conversion of Fe(T) from Fe(M) is
Derivation of the formula:
Let us assume the ore having a having a Fe of 66.5%
Fe2O3% in the ore is
(The molar ratio of Fe2O3 to Fe is 0.6994, as the molecular weight of Fe2O3, and Fe are 159.7 and 111.7 respectfully.
The molar ratio is
Factor calculation:
Consider the ore contains 66.5% Fe (Fe2O3 is 94.36%), Loss on ignition 1%, Rest is the gangue material.
Now the Iron ore is subjected for reduction in Kiln and Fe2O3 is converted to Fe. Some part of Fe2O3 is converted to FeO. The gangue material remains as it is (4.64%)
The molar ratio of Fe to FeO is 0.777, as the molecular weight of FeO, and Fe are 71.85 and 55.85 respectfully. The molar ratio is
Sponge iron calculation:
NOTE: This Formula is valid for a Fe % of 66.5. If the Fe of the Ore changes from 66.5 to 63 or 60 than %age of Gangue material changes and the formula changes. So, the formula used for calculation of Fe(T) from Fe(M) will change if ore Fe is changed.
