OIP IICHE CPT
Name: Ananjan Mukhopadhyay
Email: ananjan3016@[Link]
Assignment -1
1-a) What are the raw materials of single super phosphate? Explain
manufacturing of single super phosphate.
1-b) Describe the industrial process of DAP manufacturing mentioning majorunit
operations involved in it.
Ans 1a): The raw materials of Single Super Phosphate are Rock Phosphate and Sulfuric Acid.
Rock Phosphate required is 0.6 T and sulfuric acid required is 0.36 T.
The manufacturing of SSP is as follows:
The Rock Phosphate is sent to Rock Grinding and then it is sent to Ball Mill of 12 TPH and
Roller Mill of 6 TPH. The ground rock is sent to a 100 Mesh screen. Thefineness of the ground
rock is 85-90 percent. Then this is sent to a mixer where sulfuric acid and FSA/Water are added
at a maintained temperature of about 110- 116 deg C. This is sent to DEN Conveyer where it
stays for 45 minutes. Itis then sent to Curing Shed Godown where filler is added. It is then sent
to two bagging plants where it is dispatched.
The chemical reactions occurring are
Ca3(PO4) +2H2SO4+4H2O => CaH4(PO4)2 + 2(CaSO4.2H2O)CaF2 +
H2SO4 + 2H2O => CaSO4.2H2O + 2HF
4HF + SiO2 => SiF4 + 2H2O
3SiF4 + 2H2O => SiO2 + 2H2SiF6
Overall reaction is
CaF2.3Ca3(PO4)2 + 7H2SO4 + 3H2O => 3CaH4(PO4)2.H2O + 2HF + 7CaSO4
Ans1b): The raw materials required for DAP Manufacturing are NH3 (98.5 % purity),H3PO4
(54% P2O5), H2SO4 (98% purity) and MOP (60% K2O).
The reactions involved are
H3PO4 + NH3 → (NH4) H2PO4 (MAP)+1575 Kcal/kg of NH3
(MAP) + NH3 → (NH4)2HPO4 (DAP)+1080 Kcal/kg of NH3 H2SO4
+ NH3 → (NH4)2SO4 +1800 Kcal/kg of NH3.
The major unit operations involved are
Granulator: The main objective is to solidify the DAP slurry together with therecycled
solid materials into product sized granules and transfer it to the drier.
Dryer: It is a rotating drum made from carbon steel to reduce the water content inthe granules.
Screening: The plant is equipped with two sets of double locked vibratory screensin order to
enable the classification of granules into oversize, product size and undersize.
Pulverizer: They reduce the particle size of granules from an upper limit toundersize.
Cyclone Separator: Consists of dedusting fan and dedusting cyclones which havesuction ducts
in the areas where dust release is significant.
Ammonia Venturi Scrubber: The main objective of the DAP Ammonia Venturiscrubbing
system is to recover ammonia from the various gas streams in order to maintain a high process
efficiency and protect the environment.
Gas Scrubber: It scrubs gas present in the flow stream.
Elevators and Conveyers: They are solid handling transport systems.
2-a) What are the advantages of using Precalciner? Explain briefly in fewsentences.
2-b) What are the differences between calcareous materials and algo
calcareous material? Why both the components are necessary in cement
manufacturing?
2-c) Explain briefly about OPC,PPC & PSC related to cement industry.
Ans2-a) Precalciner is used in the cement industry as it improves the cement decomposition
rate and reduces the heat load of the rotary kiln, and reduces kilnsize and large-scale
production. Almost 95% of calcination is done in the precalciner.
Advantages of Precalciner:-
*It is beneficial to reduce the heat load of rotary kiln, reduce the size of kiln,greatly
improve the production efficiency, and save construction investment.
*It is conducive to the realization of large-scale cement production, reduces airpollution.
*The traditional method of adding all the fuel from the kiln head is changed to asmall part
from the kiln head and most from the calciner. It improves the thermal layout of the cement
rotary kiln system.
*It moves parts of the carbonate decomposition process, which consumes the most heat in
the process of clinker calcination, into the calciner to optimize thecombustion, heat transfer,
and carbonate decomposition.
*The applying of precalciner increases the output and running rate of cementrotary kiln
and prolongs the service life of kiln lining.
*The use of precalciner is helpful to improve the utilization of low-quality fueland has
strong adaptability to raw materials and fuels containing alkali, chlorine, sulfur, and other
harmful components.
Precalciner, also known as cement calciner, is a kind of high-efficiency direct combustion
solid-gas heat exchange cement equipment. It disperses and suspends cement raw meal
powder in airflow, making fuel combustion and calcium carbonate decomposition happen in
a short time (generally 1.5 ~ 3 seconds). To some extent, it replaces part of the calcining
work of a cement rotary kiln. In the calciner, because the fuel combustion and the material
endothermic reaction are carried out at the same time, there is no visible flame,but in a state
of low-temperature flameless combustion at 820 ~ 900 deg C.
Ans2-b) Calcareous materials are those materials which are composed of calcium
carbonate. These are found in rocks, shells, and corals. Examples of calcareousmaterials are
limestone, chalk.
Algo calcareous materials are those materials which are composed of calcareousmaterials and
organic materials such as algae. They are found in aquatic
ecosystems. Both are very important for cement manufacturing as they both arecombined in
specific ratios to produce the clinker which is the basic product of cement manufacturing.
Calcareous materials provide the limestone and algo calcareous materials provide the
necessary alumina and silica.
The mixing of raw materials can be done with two processes:–
I. Dry Process:-
In this method of mixing the raw materials are mixed in dry conditions. Thismethod of
mixing is adopted when the raw materials are hard.
Procedure of mixing in this process is:-
(1). Raw materials are crushed to 25 mm size in crushers.
(2). Dry air is passed through raw materials to remove the moisture content.
(3). After drying raw materials are pulverised to fine powder in ball mills or tubemills.
(4). The raw materials are stored separately.
(5). Then, they are required in required propotions.
(6).This mix is then stored in storage tanks.
From storage tank this mix is passed to rotary kiln for burning.
II. Wet Process:-
In this method the mixing of raw materials is done in wet conditions.
The procedure of mixing of raw materials by wet process is given below –
(1). Calcareous materials are crushed in crushers. After that, they are pulverisedto fine powder
in ball mill and tube mill. Then, they are stored in storage tankscalled silos.
(2). Argillaceous materials are firstly washed with water in a steel container called wash
mill. Then, the washed clay is stored in separate storage tank calledbasin.
(3). The two raw materials (Calcareous and argillaceous) are mixed in requiredproportions.
(4). The wet mixture is then grinded in grinders (Ball mill or tube mill).(5). After
grinding, a thin paste is formed called slurry.
(6). Then, the chemical composition of slurry is examined. If there is any fault, itis corrected
by making necessary adjustments.
(7). The corrected mixture is then stored in storage [Link]
mixture is then sent to rotary kiln for burning.
2-c) (I) Ordinary Portland Cement (OPC):-
There are three grades of OPC available : 33 grade,43 grade and 53-
gradecement.
Cement grade is based on the compression strength (MPa) of the concrete that
will attain after 28 days of setting. Grade 33 refers to the cement attaining compression
strength of 33 MPa in 28 days of setting. This is same for 43 and 53 grades of [Link]
33 and 43 were used for construction in the past. Asper IS standard code Grade 53 grade of
cement is recommended for house construction.
53-grade cement can be partially replaced with 20% of fly ash by the weight ofcement in
the construction site and can be used.
Partial replacement of cement by fly ash not only saves cost but also improves the durability
properties of cement due to the pore refinement (achieved by adding fly ash). This also
increases workability and increases strength. OPC cement is used for structural elements like
beams, columns etc. Since OPC gainsstrength early it has a higher heat of hydration and due
to this, cracks are formed.
(II) Portland Pozzolana Cement (PPC):-
PPC cement is generally used for plastering, brick masonry and waterproofingworks. PPC
has a lower heat of hydration and it is prone to fewer cracks compared to OPC. PPC has
lower strength than OPC but PPC provides better workability and finishing than OPC. PPC
provides greater resistance to chemicals.
(III) Portland Slag Cement (PSC):-
PSC is used for structures built near the sea shore. PSC provides excellent resistance to
sulfate and chloride. PSC has excellent corrosion resistance properties, hence it is widely used
in coastal regions, sewage disposal, and watertreatment plants.
3-a) What are environmental impacts of Cement Industries? What are themeasures
taken by Cement Industries?
3-b) Explain the working principle and importance of Bag House in CementIndustry.
Ans3-a) The cement industry has a lot of negative impacts on the environment. Due toits high
resource consumption while manufacturing and its high emission while production are main
reasons of negative impact on the environment. Many greenhouse gases like CO2 are emitted
which contribute mainly to the climate change of the planet and to global warming.
Cement industry is also a main cause of air pollution Many compounds like NOx,CO and SO2
are emitted into the atmosphere causing respiratory problems and depleting the quality of the
atmosphere. Cement industry also uses much water leading to water shortages and water
pollution. It needs more land area leading to deforestation and soil pollution as raw materials
are mined from the ground. To prevent all these from occurring cement industries are taking up
responsibilities toimprove sustainable growth in the industry.
Some of the measures are as follows
Adoption of green technology such as energy efficient kilns and alternative greenfuels to
reduce the carbon footprint and emissions.
Conserving water is done to reduce the overall water consumption of the industryand use
recycled water to the maximum extent.
Ans3-b) A baghouse is a device which is also known as fabric filter which is used in the
cement manufacturing to control the emissions produced by the industry. The principle of
a baghouse is based upon filtration. The dusty gas is passed through a series of fabric bags
which are generally made up of materials such as polyester and polypropylene. All the
dust particles are trapped inside the fabric bags and theclean gas is sent out into the
atmosphere. These fabric bags are periodically cleaned. Baghouses are energy efficient
devices which help save energy for the industry. Baghouses are a significant part of a
cement industry as they help reduceenergy consumption of the cement industry and help
reduce the harmful emissionsin the manufacturing of cement.