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16 viewsCement & Lime
this is the process of cement and lime
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harshitjoshi200407Copyright
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~vemSNTAND LIME 219
alumina
qo nie GA 3CWO+ ALO,
C8 2Cx0+sio, Aluminate Major
Silicate Mino
GAS 2CaO+ AO, «io, ie
eigen , Mixed — Minor
‘ og hydra
jim
x Cr
ne sees Hydroxide Major
Ca. See IG Silicate Minor
«types of Portland Cement Aluminate Minor
* vaeving the percent
th eee Of constituents changes the rate of Setting, heat evolution, and
«Type I - Regular: 40-60% C8, 10-30% CuS, 7-13% CayA;
seme alee ardens to full strength in 28 days
. NE rf ARNE Higher C,S/C,S to resist sulfate attack
© Type gh Farly Strength: —_Attains Strength of Type I in only 3 days; high
heat Tates—useless on massive structures;
higher C,S and C,A percentage with finer
grinding to increase hydration rate
Designed for massive structure work; low C,S
and C,A which are largest contributors to heat
of hydration
Good for sea water contact; C,A<4%
© Type IV - Low Heat:
* Type V - Sulfate Resistant:
er Types of Cement
-1. High alumina—manufactured by fusing limestone and bauxite; rapid rate of
strength development to high values but with high heat rate liberation; superior
resistance to sea and sulfate waters.
2.3.2. Pozzolana—mixture of volcanic ash, burnt clay or shale in 2-4 parts with
hydrated lime. Mixed with Portland cement as a cheap extender,
Hydraulic lime—used only for brick mortar composition, low price and strength.
Magnesium oxychloride—lightly calcined MgO mixed with MgCl, forms
excellent high-strength, spark-proof, wear-resistant flooring; high bonding
strength to wood fibers so useful in forming indoor construction material with
only fair resistance to water.
14. Relative Compressive Strength Characteristics
Cement when mixed with other ingredients such as sand and gra
siructural purposes under compressive loading since it has very poor
Some comparative data give a general idea of comparative strength pro
Mortar composition _ (1 cement : 3 sand + H,0)
oF
2
Type Compressive Strength, kg/omt
eS Iday 3days 28 days
Portland Type 1 aie 1120) 340
Type I agus 53) 260
Type IIL 103 240 440
Type 1V 20 «49 177
Type V 28 (88 214 ee 4 1.009’ .-”
Narmada Cement Company Ltd. soo
Orient Paper & Industries Ltd.
Orissa Cement Company Ltd. 4 009
Panyam Cements & Mineral Industries Ltd. 531,099
Priyadarshini Cement Company Ltd. } a
Raasi Cement Ltd. ; A 8 009
Saurashtra Cement & Chemical Industries Ltd. 63, 0¢9
aire Cement Ltd. fd i oso
igvija an. : 3075,
ree Digvijay Cement Company “Toul aye
In addition, there are reported to be a number of mini plants (less than 300 T/D) wit
capacities totalling 5,700,000. i
Source: “The Investor’s Guide to Indian Corporates,” I.R.1.S. (1994) .-———
Lime
1. Physical Properties
tl ~ *@RO; Quicklime
Mol. wt. 56.08
M.P. 2,570°C
ee a CEMENT AND LIME be
BP. 2,850°C
_ pensity 3°
i ble in Water and acids > Bm/ce
5 Sol
i
Ca(OHa: Hydrated oF staked lime
CRS
1% Mol. wt. ae
Density aia :
pecomposition to CaO ites
slightly soluble in water 18% at g°¢
: Jalilime 1 0.08% at 100%
: Comm i c:
Se gH, ae eoar exo Ca(OH), but ities with MgO and/or
* high-calei
a RTI RERe ae > 90% CaO); low-magnesium (5-25% MgO),
Hydraulic lime and slaked |;
pereentage, tked lime Ca(OH), plus MgO-Mg(OH), in varying
yacumption Pattern
jsused as a basic flux in the manufacture of icon aL oR TE age
Beach cannot beimclled alee steel. Silicon dioxide is a common impurity
fluid lava called slag. Silicon dioxide j th anc i
ore Qe ae me ee dioxide is a Lewis acid and therefore it reacts with the
sags base Lime. licate slag is less dense than the molten iron and collects at the
’ here
gate = where it can be drawn off. Over 100 Ibs of lime must be used to manufacture
of
a0
pee : CaO + SiO, > Casio,
newses of lime in chemical manufacture are too numerous to discuss since over 150 important
vals are made with this basic material. In fact, only five other raw materials are used more
seally than lime for chemical manufacture: salt, coal, sulfur, air and water.
;Methods of Production
41. Classification of Processes
* Calcining limestone to yield quicklime
¢ Hydration of quicklime
32. Quicklime Process
3.2.1. Reference flow sheet: Figure IIK-3
3.2.2. Chemical reaction
CaCO,(s) > CaO(s) + CO,(g); 4H = +44 Keal
3.2.3. Quantitative requirements
(a) Basis: 1 ton CaO
Limestone (Pure) 1.87 tons
Coal 0.3 ton
(b) Plant capacities: 100-500 tons/day
3.2.4. Process description ij
Limestone is quarried or mixed and put on conveyors
crushing unit. Limestone of several sizes is produced, with jaw or gy
used for hard rock and hammer or roll mills used for soft rock.
on type of calciner as follows: INDUSTRIES
r
CHEMICAL,
INORGANIC
232
10-20 em
© Vertical shaft igen
© Moving bed iste
* Rotary kiln 0.5-0.05 em uy
© Fluidized bed ilaytace! usually specified.
ki
ical shaft or rotary I
Meant shaft kiln is 3-8 ane
with refractory brick and covered wil
is of two types: i
jeakage. Operation is 0! vonton cree
oer naan enited coal is fired in Beparate cor
sition ae ,
vie Sai eae limestone lump; simplifies kiln design, b
ixed—
i to product i
are ie tn os re
gradually slides down the shaft into the calcining zone. This section of the g
Bi
Shaft kj,
operates at 1,000-1,100°C (CaCO,
diameter and 10-25 meters
hi, 4
steel outside for strength ang igh, ling
decomposes at 898°C). The lime lump my
to the cooling section where heat exchange occurs between the secondary air ang.
lime Bee ther cooling in a conveyor, the lime is either Packaged 5 lump lng
or crushed and screened to yield pulverized lime, Containers are jute bags wig
inner seal lining of polyethylene to prevent moisture contact. ‘
A rotary lime kiln operates in a similar manner to that described’ for cemen,
calcining. te.
3.3. Hydrated Lime Process :
3.3.1. Reference flow sheet: Figure IIK-3
3.3.2. Chemical reaction
CaO(s) + H,O (1 or v) > Ca(OH),(s); aH = 15.9 Keal
3.3.3. Quantitative requirements
(a) Basis: 1 ton of Ca(OH),
Quicklime (Pure) 0.787 ton
Water 0.242 ton
(b) Plant capacities: 50-100 tons/day
3.3.4. Process description
bags for shipping.
Steam under pressure is used to more rapidly co,
= ne
is used. The product is known as: hydraulic Time, ail
3.4. Major Engineering Problems 4
Choice of kiln CEMENT AND LIME
e
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sop
Burjoo5,
sased oni4
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BuuisjeD qyeus
jeanua,,
SOTTO
PL 2UOZ JEaU2Jq
Bulpusio,
(SHEP 40; Z4TH1499S) | WW aqnL R
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