Homework 2 Using the information generated from homework 1, perform a detailed mass analysis for the melting process you have selected. The homework will require the following information to establish your

final costs (costs will be given in this homework but will be used in a later homework assignment). Use the below assumptions and information in the material mass balance 1. Induction melting process for ductile produces approximately 2-3% slag per ton of metal and cupola process produces 6% slag per ton. Slag disposal costs is estimated at $0.10 per pound of slag. 2. Materials used to produce ductile iron having a nominial chemical composition of 3.75% C, 2.4% Si, 0.5% Cu, and 0.04% Mg. All other elements in the ductile iron chemicstry is negligible and will not be considered in the calculation. 3. The following materials are available in producing ductile iron and will be assumed to used at the same amount for either induction melting or cupola method. 1. Ductile iron pig chemistry of 4.1% C and 0.2% Si. Cost is estimated at $800 per ton (includes shipping cost). The maximum amount pig iron that can be used is 20% of the total charge. 2. Internal scrap from your foundry operations is approximately 35% having the composition stated for the product final composition. There is no mass cost (though later you will determine the energy cost). During melting of scrap, all Mg is lost. 3. Pure copper in the form of chopped wire is purchased at $4.50 per pound. 4. Steel will make up the remaining bulk quantity. Average composition of the steel scrap is 0.20% C, 0.45% Si, and 0.25% Cu. The average cost of scrap steel is $325 per ton. 5. Any deficiencies in Si or C made up with alloy additions. Carbon is pure and costs around $1.75 per pound and Ferro-75% Si costs around $2.00 per pound. 6. Mg is added in the form of Fe-45%Si-3.5% Mg. Assume a recovery rate of 70% during a tundish treatment. You will assume unused Mg will be released in the form of particulate MgO and will be captured by the bag house. This needs to be accounted and reported in the assignment. You submission will included an exploded view from homework 1 showing the process flow of the melting operation. In the exploded view, indicate the associated mass for input and output from your melting operations. On the flow chart, use a per ton basis. Submit the spreadsheet that was used to determined the mass flow of the foundry operations.