ENGINEERING CHEMISTRY

Unit 4 Cement: Definition, Composition, basic constituents and their significance, Manufacturing of Portland cement by Rotary Kiln Technology, Chemistry of setting and hardening of cement and role of gypsum. Glass: Definition, Properties, Manufacturing of glass and importance of annealing in glass making, Types of silicate glasses and their commercial uses, Optical fiber grade glass.

1.1 INTRODUCTION:
Cement is made by mixing substances containing lime, silica, alumina, and iron oxide and then heating the mixture until it almost fuses. Cement consists of particles containing compounds of calcium (Ca), iron (Fe), aluminium (Al), silicon (Si) and oxygen (O) in varying proportion. The main four raw material of cements are: 60% to 67% CaO, 17% to 25% SiO2, 3% to 8% Al2O3, up to 6% Fe2O3 and small amounts of magnesium oxide, magnesium sulfate, sodium and potassium oxides. Chemical constituents of cement is: 54% Tricalcium silicate (3CaO.SiO2) (C3S) 16% Dicalcium silicate (2CaO.SiO2) (C2S) 11% Tricalcium aluminate (3CaO.Al2O3) (C3A) 9% Tetracalcium aluminoferrite (4CaO.Al2O3.Fe2O3) (C4AF)

Manufacturing of Portland cement : Portland Cement

Concrete is made by portland cement, water and aggregates. Portland cement is a hydraulic cement that hardens in water to form a water-resistant compound. The hydration products act as binder to hold the aggregates together to form concrete. The name portland cement comes from the fact that the colour and quality of the resulting concrete are similar to Portland stone, a kind of limestone found in England.

1.3 Manufacture of Portland cement Portland cement is made by blending the appropriate mixture of limestone and clay or shale
o

together and by heating them at 1450 C in a rotary kiln. The sequence of operations is shown in

following figure. The preliminary steps are a variety of blending and crushing operations. The raw feed must have a uniform composition and be a size fine enough so that reactions among the components can complete in the kiln. Subsequently, the burned clinker is ground with gypsum to form the familiar gray powder known as Portland cement

Manufacture of Ordinary Portland Cement

The raw materials used for manufacturing Portland cement are limestone, clay and Iron ore. ). Limestone (C CO ) is mainly providing calcium in the form of calcium oxide (CO)
a 3 o

C CO (1000 Or with small amounts of Al O + Fe O

a 3

Clay (1450 C) O + Al O + Fe O + H O
2 2 3 2 3 2

c). Iron ore and Bauxite are providing additional aluminum and iron oxide (Fe O ) which help the
2 3

formation of calcium silicates at low temperature. They are incorporated into the raw mix. d). he clinker is pulverized to small sizes (< 7. 3-5% setting and hardening.

The majority particle size of cement is from 2 to 50 m.

Rotary Kiln Technology

Unique Features:
1. Low pressure drop pre heaters. 2. Raw mill equipped with High efficiency separator. 3. Raw Meal blending in CFC silo. 4. Pre calciner suitable to work with alternative fuels. 5. Inlet & discharge fitted with efficient seals. 6. Benchmark cooler design.

Benefits:
1. Near Zero Maintenance. 2. Operation of Plant is Simple. 3. Gestation period is short. 4. Greater efficiency in Power Consumption. 5. Abundant fuel savings. 6. Low Installed cost. 7. Trusted and proven Trouble free Technology.

ROTARY KILN Cement plants

Process:
Crushing & Proportioning: Limestone rock is the principal raw material, the first step after quarrying in the processes is the primary crushing. Mountains of rock are fed through crushers capable of handling pieces as large as an oil drum. The first crushing reduces the rock to a maximum size of about 15 cm (6 po). The rock then goes to secondary crushers or hammer mills for reduction to about 7.5 cm or smaller. Raw milling & Blending: The next step in the process is to grind the above particles to a size of 90 microns or less which is done in a raw mill, a closed circuit ball mill equipped with high efficiency separator. After achieving the 90 microns size the fine grinded material also known as raw meal is sent to the

continuous blending silos (CFC) for homogenization & extracted by means of load cell hopper for the next step which is feeding to the kiln pre heaters. Pyro processing: The raw material is heated to exceeding 1,450 C (2,700 degrees F) in huge cylindrical steel rotary kilns lined with special firebrick. Kilns are frequently as much as 3.7 M (12 pi) in diameter, large enough to accommodate an automobile and longer in many instances than the Hydration of the Calcium Aluminates When more C3A remains, C6A3H32 + 2C3A + 4H 3C4AH12 Reaction of C4AF occurs more slowly C4AF + 2CH + 14H C4(A,F) H13 + (A,F)H3horizontal. The finely ground raw material or the slurry is fed into the higher end. At the lower end is a roaring blast of flame, produced by precisely controlled burning of powdered coal, oil or gas under forced draft.

Chemistry of setting and hardening of cement androle of gypsum:

Setting and Hardening

Stiffening is the loss of consistency by the plastic cement paste and it is associated with the slump loss phenomena in concrete. Setting : Solidification of the plastic cement paste Initial Set : Beginning of solidification (point in time when the paste has become unworkable) (>45 min.) Final Set : Final solidification (< 375 min.)

Glass
Glass: Definition, Properties, Manufacturing of glass and importance of annealing in glass making, Types of silicate glasses and their commercial uses, Optical fiber grade glass.

A hard, brittle, noncrystalline, more or less transparent substance produced by fusion, usually consisting of mutually dissolved silica and silicates that also contain soda and lime, as in the ordinary variety used for windows and bottles.

These are the main characteristics of glass: - Solid and hard material - Disordered and amorphous structure - Fragile and easily breakable into sharp pieces - Transparent to visible light - Inert and biologically inactive material. - Glass is 100% recyclable and one of the safest packaging materials due to its composition and properties The properties of glass are varied by adding other substances, commonly in the form of oxides, e.g., lead, for brilliance and weight; boron, for thermal and electrical resistance; barium, to increase the refractive index, as in optical glass; cerium, to absorb infrared rays; metallic oxides, to impart color; and manganese, for decolorizing. The term crystal glass, derived from rock crystal, was at first applied to clear, highly refractive glass; it has come to denote in the trade a high-grade, colorless glass and is sometimes applied to any fine hand-blown glass. TYPES OF GLASS: There are many different types of glass with different chemical and physical properties. Each can be made by a suitable adjustment to chemical compositions, but the main types of glass are: Borosilicate Glass Commercial Glass

Glass Fibre Lead Glass Glasses may be devised to meet almost any imaginable requirement. For many specialised applications in chemistry, pharmacy, the electrical and electronics industries, optics, the construction and lighting industries, glass, or the comparatively new family of materials known as glass ceramics, may be the only practical material for the engineer to use.

Types of special glass include: Alkali-barium Silicate Glass Aluminosilicate Glass Glass Ceramics Optical Glass Sealing Glass Technical Glass Vitreous Silica

(1)Silicate glass:Silica (the chemical compound SiO2) is a common fundamental constituent of glass. In nature, vitrification of quartz occurs when lightning strikes sand, forming hollow, branching rootlike structures called fulgurite.

Alkali-barium Silicate Glass Without this type of glass, watching TV would be very dangerous. A television produces X-rays that must be absorbed, otherwise they could in the long run cause health problems. The X-rays are absorbed by glass with minimum amounts of heavy oxides (lead, barium or strontium). Lead glass is commonly used for the funnel and neck of the TV tube, while glass containing barium is used for the screen. Aluminosilicate Glass A small, but important type of glass, aluminosilicate, contains 20% aluminium oxide (aluminaAl2O3) often including calcium oxide, magnesium oxide and boric oxide in relatively small amounts, but with only very small amounts of soda or potash. It is able to withstand high temperatures and thermal shock and is typically used in combustion tubes, gauge glasses for high-pressure steam boilers, and in halogen-tungsten lamps capable of operating at temperature as high as 750C. Borosilicate Glass Pyrex.Borosilicate glass, the third major group, is made mainly of silica (70-80%) and boric oxide (7-13%) with smaller amounts of the alkalis (sodium and potassium oxides) and aluminium oxide. This type of glass has a relatively low alkali content and consequently has good chemical durability and thermal shock resistance (it doesn't break when changing temperature quickly.)As a result it is widely used in the chemical industry, for laboratory apparatus, for ampoules and other pharmaceutical containers, for various high intensity lighting applications and as glass fibres for textile and plastic reinforcement.

Glass Fibre Glass fibre has many uses from roof insulation to medical equipment and its composition varies depending on its application.For building insulation and glass wool the type of glass used is normally soda lime. For textiles, an alumino-borosilicate glass with very low sodium oxide content is preferred because of its good chemical durability and high softening point. This is also the type of glass fibre used in the reinforced plastics to make protective helmets, boats, piping, car chassis, ropes, car exhausts and many other items.In recent years, great progress has been made in making optical fibres which can guide light and thus transmit images round corners. These fibres are used in endoscopes for examination of internal human organs, changeable traffic message signs now on motorways for speed restriction warnings and communications technology without which telephones and the internet would not be possible.

Optical Glass Optical glasses will be found in scientific instruments, microscopes, fighter aircraft and most commonly in spectacles.

The most important properties are the refractive index and the dispersion. The index is a measure of how much the glass bends light. The dispersion is a measure of the way the glass splits white light into the colours of the rainbow. Glass makers use the variations in these characteristics to develop optical glasses.

BY: SHUBHAM KHANDELWAL (FARRE.IN)