Lecture13:Calcination
Contents
Principlesofcalcination
Applications
Materialsandheatbalanceincalcination
ProblemiDecompositionofCaCO
Problemiiamountoffuelincalcination
ProblemiiicalcinationofAl OH
Problemivfuelsaving
Conclusions
References
Keywords:calcination,electrolysisofalumina,fuelsaving
Principlesofcalcination:
Calcinationisathermaltreatmentprocessandappliedtooresandothersolidmaterialstobring
a) thermaldecomposition
b) phasetransitionand
c) toremovevolatilefractionssuchasCO , H O
[Link]
thesolidstate.
Application:
9 ToproducecementfromCaCO
9 Tocausedecompositionofhydratedmineralsasincalcinationofbauxitetoproducerefractory
gradeAl O .
9 TocausedecompositionofvolatilemattercontainedinpetroleumCoke.
9 Toheattreattoeffectphasetransformationasindevitrificationofglassmaterials.
9 ToproduceanhydrousAl O forelectrolysisofAl O toAl inHallHeroultcell
Materialsandheatbalanceincalcination
[Link],weneed
severalthermochemicalvalueslikeheatofformation,specificheat,[Link]
thermochemicalvaluesarcusedtosolvetheproblemsinthislecture:
Thermochemicalvalues:
CaCO3=CaO+CO2 H 42750 Kcal/[Link]
MgCO3=MgO+CO2 H 24250 Kcal/[Link]
CO+1/2O2=CO2 H 67900 Kcal/[Link]
2Al(OH)3=Al2O3+3H2O H 24290 Kcal/[Link]
C+O2=CO2 H 94300 Kcal/[Link]
H2+1/2O2=H2O H 68370 Kcal/[Link]
CpCaO=49.622+4.519x103T6.945x105 kJ/[Link]
CpMgO=48.995+3.138x103T11.715x105 kJ/[Link]
CpCO2=75.438kJ/[Link]
CpH2O(v)=30.+10.711x103T0.335x105 kJ/[Link]
Heatcontent
H1200H298|CaO =10800 Kcal/[Link]
H500H298|CO2 =1987 Kcal/[Link]
H500H298|N2 =1418 Kcal/[Link]
H500H298|O2 =1455 Kcal/[Link]
H1000H298|Al2O3 =18710 Kcal/[Link]
H800H298|CO2 =5458 Kcal/[Link]
H800H298|O2 =3786 Kcal/[Link]
H800H298|N2 =3598 Kcal/[Link]
H800H298|H2O(l) =14824 Kcal/[Link]
H900H298|CO2 =6708 Kcal/[Link]
H900H298|O2 =4602 Kcal/[Link]
H900H298|N2 =4358 Kcal/[Link]
H900H298|CO =4400 Kcal/[Link]
LatentHeatofvaporizationofwater=10520kJ/[Link]
Problemi:decompositionof
1) Calculatetheheatenergyrequiredtocalcine1000Kglimestoneofcomposition
84%CaCO , 8%MgCO and8% H Ochargedat298K.Limeisdischargedat1173Kandgases
leaveat473K.
Solution:
CaCO CaO CO (1)
Mg CO MgO CO (2)
Materialbalancegives
Calcinedproductandgases
CaO 8.4 kg mols
MgO 0.952 kg mols
CO 9.352kg mols
H O 4.444 kg mols
Heatofdecompositionofreaction1and2 382186 k cal.
UsingCpvaluesonecancalculatesensibleheatincalcinedproductsandgases.Referencestateis298K
Sensibleheatinproducts 8.4 Cp CaO dT 0.952 Cp MgO dT
SensibleheatinCO 9.352 Cp CO dT
SensibleheatinH O l canbeevaluatedas
H O , H O ,
H O , H O ,
H O 4.44 Cp H O dT
. Answer
Problem2:amountoffuelincalcination
[Link] (pure)[Link]
compositionCO 7.2%, O 1.6%, CO 16.6%andN 74.6%iscombustedwith20%excessairtoobtain
thedesiredtemperatureinthekiln.Thelimestoneandairaresuppliedat298K,whereasproducergasis
heatedto900K.Limeisdischargedat1200Kandat500K.
Calculatetheamountofproducergas(1atm.and273K).
LetYkgmolistheproducergas
Materialbalancegives
CO 10 0.238 Y
N 0.74 Y 0.302 Y
O 0.0134 Y
Calorificvalueofproducergas=11271Ykcal.
Performingheatbalance:Heatinput=Heatoutput.
Sensibleheatinproducergas+calorificvalueofproducergasHeatofdecompositionofCaCO =
sensibleheatinCaO sensibleheatinfluegases CO , N and O
Wecalculateallthevaluesandget . Answer
Problem3Calcinationof
Intheelectrolysis,[Link] Al OH iscalcinedat1700Kin
[Link] OH analyzing55% Al O and45%totalH O(free
andcombined)andproduce,pureAl O assolidproduct.Thefuelconsumptionisestimatedtobe0.2Kg
offueloilofcomposition84% Cand16% HperKgofalumina.Airforcombustionis20%excessthan
theoreticalrequired.Assumecompletecombustionandheatlosses10%[Link]
a) Thevolumeofgases(At1atm,273K)leavingthekilnper1000KgofAl O produced.
b) Wetanddrycompositionoffluegases.
c) Performtheheatbalanceandcommentontheresults.Assumereactantsenterat298Kand
productsnamelyAl O at1000Kandfluegasesat800K.
Solution:Basisofcalculation1000KgcalcineAl O
Calcinationreaction:
2Al OH Al O 3H O
Combustionreactions
C O CO
2H 0.5O H O
Materialbalancegivesvolumeoffluegases
Fluegasanalysis:onWetbasis(%) Ondrybasis(%)
CO27.8 11.9
O22.5 3.7
N255.4 84.4
H2O34.3
100% 100%
Heatbalancegivesthefollowingresult:
Heatinput(kcal) Heatoutput(kcal)
Combustionoffuel+2414120* Fluegases1362135
SensibleheatinAl2O3183431
Heatofdecomposition2381370 Heatlosses217598
Heatavailable:2175983 Total1763164kcal
* +indicatedheatinputduetoexothermicandindicatesheatabsorption.
[Link]
notthenamountoffuelmaybereducedasillustratedinproblem4
Problem4:Fuelsaving
Calculatetheminimumamountoffuel1000KgAl O .Usethedatagiveninproblem3.
Letxkgfuelisrequired.
C 0.84 xandH 0.16 x
[Link]
CO 0.07 x
H O 0.08x 45.45
O 0.022 x
N 0.496 x
Heatbalance:
Heat of combustion Heat taken by flue gas Heat taken by Al O heat losses
Performingheatbalancecalculation,wecanget
x 141kgfuelisrequiredtoproduce1000Kgalumina.
Wesave /
Conclusion:
[Link]
calculationsisshowninproblem4whichshowsthatfuelsavingcanbeachieved.
References:
1)Rao,Y.K:StoichiometryandThermodynamicsofMetallurgicalprocess,CambridgeUniversityPress,
1985
2)Butts,Allison:MetallurgicalProblems,McGrawHillBookCompany,1943
3)Fine,[Link]:HandbookonMaterialsandEnergyBalanceCalculationsin
MetallurgicalProcesses
