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TK-5006 Processing of Particulate Solid

This document discusses processing methods for various solid materials including portland cement, fertilizers, sugar, paper, and copper. It describes the key raw materials and chemical reactions involved in producing products like superphosphate, triple superphosphate, DAP, and NPK fertilizers. Concentration, smelting, converting, and electrorefining steps are outlined for extracting copper from sulfide ore bodies. Processing of other materials such as cement, sugar, and paper is also briefly covered.

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105 views36 pages

TK-5006 Processing of Particulate Solid

This document discusses processing methods for various solid materials including portland cement, fertilizers, sugar, paper, and copper. It describes the key raw materials and chemical reactions involved in producing products like superphosphate, triple superphosphate, DAP, and NPK fertilizers. Concentration, smelting, converting, and electrorefining steps are outlined for extracting copper from sulfide ore bodies. Processing of other materials such as cement, sugar, and paper is also briefly covered.

Uploaded by

hendri_donutzzz5844
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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TK-5006 Processing of Particulate Solid Solid processing industries

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


18 December 2012 TK5006 DGA/1

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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