1 Solid Industries

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Solid processing industries

Dr. I Dewa Gede Arsa Putrawan

Department of Chemical EngineeringITB

18 December 2012 TK5006 DGA/1

TK-5006Processing of Particulate Solid


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Solid Processing Industries



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Portland Cement



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Portland cement

"hydraulic cement (cement that not onlyhardens by reacting with water but alsoforms a water-resistant product) producedby pulverizing clinkers consistingessentially of hydraulic calcium silicates,

usually containing one or more of the formsof calcium sulfate as an inter groundaddition. (ASTM C 150)



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Constituents of clinker

Name FormulaAbbrev

.

Tricalcium silicate (CaO) 3 SiO 2 C3S

Dicalcium silicate (CaO) 2 SiO 2 C2S

Tricalcium aluminate (CaO) 3 Al 2O3 C3ATetracalciumaluminoferrite

(CaO) 4 Al 2O3 Fe 2O3

C4AF



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Functions of compounds

C3A : causes set but needs retardation (bygypsum)

C3S and C 3A : responsible for early strength(at 7 or 8 days)

C3S and C 2S : responsible for final strength

(at 1 year) Fe 2O3, Al 2O3, Mg, alkalies: lower

clinkering temperature18 December 2012 TK5006 DGA/6


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Raw Materials

Limestone (rich in Ca) Clay (rich in Si) Sand, bauxite, iron ore (composition) Gypsum (retarder)



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Fertilizer



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Fertilizer

Natural or synthetic material containsprimary macro nutrients at least 5%.

Sources of nutrients Air: C and O Water: H and O

Soil, fertilizer, animal manures: N, P, K, Ca,Mg, S, Fe, Mn, Zn, Cu, B, Mo, and Cl



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18 December 2012 TK5006

Nutrients

(from soil)Element Form Element FormN NO 3-, NH 4+ Fe Fe 2+, Fe 3+, complex

P H 2PO 4-, HPO 4

2-Mn Mn

2+, complex

K K + Zn Zn 2+, complex

Ca Ca 2+ Cu Cu 2+, complex

Mg Mg 2+ B H 3BO 3 S SO 42- Mo MoO 42-

Cl Cl -

Micro/traceMacro, primary

Macro, secondary

DGA/


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Multinutrient Fertilizers

Two or three primary macronutrients MAP, DAP, Superfosfat, Triple superfosfat,

Potassium nitrate, etc NPK Analysis

N as nitrogen P as P 2O5 K as K 2O



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Superphosphate

Raw materials: phosphate rock, sulphuricacid

Main reactionCaF 23Ca 3(PO 4)2 + 7 H 2SO 4 + 3 H 2O

fluoropatite 53-57Be 3CaH 4(PO 4)2H 2O + 2HF + 7CaSO 4



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Triple Superphosphate

Raw materials: phosphate rock, phosphoricacid

Main reactionCaF 23Ca 3(PO 4)2 + 14 H 3PO 4

fluoropatite 10Ca(H 2PO 4)2 + 2HF



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DAP

Raw Materials: Ammonia and phosphoricacid

Reaction2NH 3 + H 3PO 4 (NH 4)2HPO 4



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NPK

Raw materials: Ammonia, Phosphoric acid,Potassiun chloride

Ammonia is reacted with phosphoric acid toproduce ammonium phosphates

Ammonium phosphates is sprayed onpotassium chloride



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NPK

Blending


Granulation


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Sugar



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Raw Materials

Sugar cane 11% to 15% sucrose by weight

Sugar beet 13% to 17% sucrose by weight



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Paper



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Raw material

Wood Straw Baggase Waste papers



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Copper



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Copper

Sulphide minerals chalcopyrite (CuFeS 2) , bornite (Cu 5FeS 4), and

chalcocite (Cu 2S) ore contains 0.5% Cu (open pit mines) and 1-

2% (underground mines)

by pyrometallurgical methods Concentration Smelting Refining



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Copper

Oxidized minerals Carbonates, oxides, hydroxy-silicate,

by hydrometallurgy methods Scrap (accounts for up to 15%)



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Pyrometallurgical Methods

Concentration Concentrate contains 25 to 35%

Smelting Oxidation, autothermal, 1200 C, atmospheric 2CuFeS 2 + 2.5O 2 + SiO 2 Cu 2SFeS + 2SO 2

FeOSiO 2 + heat Typical matte (60%-Cu, 16%-Fe, 24%-S) Typical slag (1%-Cu)



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Pyrometallurgical Methods

Converting Oxidation of FeS followed byoxidation of Cu 2S

Blister copper contains 99%-Cu Electrorefining

Ultrapure copper (20 ppm impurities)



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Concentration of copper



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References

Shreves Chemical Process Industries byG. T. Austin, McGraw-Hill, 1984.


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