CHE 308

Chemical Process Analysis Sessional

Class Work 2
Full Marks: 100
Time: 75 min

1. Consider the following simplified ‘Process Block Diagram’ of a Cement manufacturing plant:
(90)

Process Summary
Limestone is first crushed and then mixed with clay at Raw Mill where further size reduction
occurs. The finely ground raw material then enters the Kiln. The cement kiln heats all the
ingredients to about 2,700 degrees Fahrenheit in huge cylindrical steel rotary kilns lined with
special firebrick. As the material moves through the kiln, certain elements are driven off in the
form of gases. The remaining elements unite to form a new substance called ‘clinker’. Clinker
comes out of the kiln as grey balls, about the size of marbles. After the clinker is cooled, it is
grinded in Cement Mill and mixed it with small amounts of Gypsum (CaSO4.2H2O).

Raw Material Specification

1. Clay (M1 = 15 kg/day)
Composition of Clay:
Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 Inert
% 70.69 14.91 4.5 6 1.5 2.4

2. Limestones (M4 = 85 kg/day)

Composition of Limestone:
Component SiO2 Al2O3 CaCO3 Fe2O3 MgCO3 Inert
% 1.88 1.2 94.45 0.57 1.95 0
 CHE 308
Chemical Process Analysis Sessional
Class Work 2
Full Marks: 100
Time: 75 min

Reactions at the Kiln

CaCO3 → CaO + CO2 ………………………………………… (1)
MgCO3 → MgO + CO2 ………………………………………… (2)
5CaO + 3Al2O3 → 5CaO.3Al2O3 ………………………………………… (3)
2CaO + SiO2 → 2CaO.SiO2 ………………………………………… (4)
4CaO + 5CaO.3Al2O3 → 3(3CaO.Al2O3) ………………………………………… (5)
CaO + 2CaO.SiO2 → 3CaO.SiO2 ………………………………………… (6)
4CaO + Al2O3 + Fe2O3 → 4CaO.Al2O3.Fe2O3 ………………………………………… (7)

Additional Information
❖ 5% of total input loss occurs at ‘Clay storage’ and ‘Crusher’.
❖ 0.5% total input loss occurs at the ‘Raw Mill’.
❖ Assume 100% conversion for all reactions at the Kiln. All the CaCO3, MgCO3, SiO2, Al2O3
and Fe2O3 that enters the Kiln is converted.
❖ Gypsum (CaSO4.2H2O) is mixed with clinkers at a certain ratio such that the final product
(M11) contains 95% clinkers and balance gypsum.

Questions
a) Find the flow rate and composition of the final product.
b) Determine the amount of CO2 emission occurs from the Kiln?
c) Determine the amount of Gypsum required in the Cement Kiln?

2. Briefly answer the following questions: (5×2=10)

a) Why the raw materials are finely grinded before sending to the ‘Kiln’?
b) Why is Gypsum added to the clinkers?
c) Mention one advantage of the ‘wet process’ over the ‘dry process’. Also mention one
disadvantage of the wet process.
d) ‘The length of Kiln is shorter for the wet process’. True/False?
e) Why blending is done in ‘dry process’?