Q. What is the chemical composition of Portland cement?

Draw labeled diagram of

rotary kiln used for the manufacture of Portland cement by wet process and state it’s
working.
Ans. Chemical Composition of Portland cement:
Ca2SiO4 (dicalcium silicate (C2S))
Ca3SiO5 (tricalcium silicate (C3S))odule: 5 N164
Ca3Al2O6 (dicalcium aluminate (C2A))
Ca4Al2Fe2O10 (tetracalcium aluminoferrite(C4AF))

Portland cement by rotary kiln technology:

Raw material: Limestone (CaCO3) and clay containing SiO2, Al2O3, Fe2O3, gypsum and fuel
for heating purpose.
Production steps:
1. Crushing of raw materials: Raw materials are crushed, screemed & stockpiled.
2. Mixing of raw materials: Raw materials are mixed with definite proportions to obtain
“raw mix”. They are mixed either dry (dry mixing) or by water (wet mixing).
3. Burning: Prepared raw mix is fed into the rotary kiln for burning from upper end. Burning
fuel is forced through the lower end of the kiln so long hot flame is produced. There are three
zones in rotary kiln.
(a) In drying zone (Upper part of rotary kiln), temperature range is 100 – 400 °C , where
moisture is removed from materials.
(b) In calcination zone (central part of rotary kiln), temperature is around 1000 °C , where
decomposition of lime stone takes place.
CaCO3 = CaO + CO2
(c) The lower part (clinkering zone) has temperature in between 1500-1700 °C where lime
and clay are reacts to yielding calcium aluminates and calcium silicates. These aluminates
and silicates of calcium fuse to gather to form small and hard stones are known as clinker.
2CaO + SiO2 = Ca2SiO4 (dicalcium silicate (C2S))
3CaO + SiO2 = Ca3SiO5 (tricalcium silicate (C3S))odule: 5 N164
3CaO + Al2O3 = Ca3Al2O6 (dicalcium aluminate (C2A))
4CaO + Al2O3 + Fe2O3 = Ca4Al2Fe2O10 (tetracalcium aluminoferrite(C4AF))
4. Clinker is cooled & stored.
5. Clinker is ground with gypsum (3-6%) to adjust setting time.
3CaO.Al2O3 + xCaSO4.7H2O = 3CaO.Al2O3.xCaSO4.7H2O
6. Packing & marketing
Q. What is Electrochemical Corrosion? Write down mechanism involved in
electrochemical corrosion.
Ans. Electrochemical or Wet Corrosion:This type of corrosion occurs when a conducting
liquid is in contact with metal or when two dissimilar metals or alloys are dipped partially in
a solution. This corrosion occurs, due to the existence of separate. ― anodic and cathodic
areas. At anodic area, oxidation reaction takes place, so anodic metal is destroyed by
dissolving in combined state Hence, corrosion always occurs at anodic areas.
On the other hand, at cathodic areas, reduction reaction takes place. Since most metals cannot
be further reduced, therefore, dissolved constituents in the conducting medium accepts the
electrons to form some ions (like OH-, O2-). The metallic ions (at anodic part) and non –
metallic ions (formed at cathodic part) diffuse towards each other through conducting
medium and from a corrosion product somewhere between anode and cathode. The electrons
set free at the anode flow through the metal and are finally consumed in the cathodic reaction.

Mechanism of Electrochemical theory

Example: Rusting of Iron in acidic medium
At Anode: 2Fe → 2Fe2+ + 4e-
At Cathode: 4H+ + 4e- + O2 → H2O
Overall Reaction: 2Fe(s) + 4H+ + O2 → 2Fe2+(aq) + 2H2O
The ferrous ions are oxidized further by atmospheric oxygen to form rust.
4Fe2+(aq) + O2 (g) + 4H2O → 2Fe2O3 + 8H+
Fe2O3 + xH2O → Fe2O3.xH2O (Rust)