TK-5006 Processing of Particulate Solid Solid processing industries

Dr. I Dewa Gede Arsa Putrawan Department of Chemical Engineering ITB

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Solid Processing Industries

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Portland Cement

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Portland cement
"hydraulic cement (cement that not only hardens by reacting with water but also forms a water-resistant product) produced by pulverizing clinkers consisting essentially of hydraulic calcium silicates, usually containing one or more of the forms of calcium sulfate as an inter ground addition. (ASTM C 150)
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Constituents of clinker
Name Tricalcium silicate Dicalcium silicate Tricalcium aluminate Tetracalcium aluminoferrite
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Formula (CaO)3 SiO2 (CaO)2 SiO2 (CaO)3 Al2O3 (CaO)4 Al2O3 Fe2O3
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Abbrev .
C3S C2S C3A C4AF
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Functions of compounds
C3A : causes set but needs retardation (by gypsum) C3S and C3A : responsible for early strength (at 7 or 8 days) C3S and C2S : responsible for final strength (at 1 year) Fe2O3, Al2O3, Mg, alkalies: lower clinkering temperature
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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 contains primary 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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Macro, primary

Nutrients (from soil)

Form Element

Micro/trace

Element

Form

N
P

NO3-, NH4+
H2PO4-, HPO42-

Fe
Mn

Fe2+, Fe3+, complex

Mn2+, complex

K
Ca Mg

K+
Ca2+ Mg2+

Zn
Cu B

Zn2+, complex
Cu2+, complex H3BO3

SO42Macro, secondary

Mo
Cl
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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 P2O5 K as K2O
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Superphosphate
Raw materials: phosphate rock, sulphuric acid Main reaction CaF23Ca3(PO4)2 + 7 H2SO4 + 3 H2O fluoropatite 53-57Be 3CaH4(PO4)2H2O + 2HF + 7CaSO4
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Triple Superphosphate
Raw materials: phosphate rock, phosphoric acid Main reaction CaF23Ca3(PO4)2 + 14 H3PO4 fluoropatite 10Ca(H2PO4)2 + 2HF
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DAP
Raw Materials: Ammonia and phosphoric acid Reaction 2NH3 + H3PO4 (NH4)2HPO4

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NPK
Raw materials: Ammonia, Phosphoric acid, Potassiun chloride Ammonia is reacted with phosphoric acid to produce ammonium phosphates Ammonium phosphates is sprayed on potassium 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 (CuFeS2) , bornite (Cu5FeS4), and chalcocite (Cu2S) ore contains 0.5% Cu (open pit mines) and 12% (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 2CuFeS2 + 2.5O2 + SiO2 Cu2SFeS + 2SO2 FeOSiO2 + 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 Cu2S 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 by G. T. Austin, McGraw-Hill, 1984.

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