Professional Documents
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METALLURGY
Q.
Name the four ores of iron with their chemical formula and
composition
Ores of iron
i
Haematite
Chemical
formula
(Fe2O3)
ii
Magnetite
(Fe3 O4)
72 % Fe
iii
Limonite
(2Fe2O3.3H2O)
60% Fe
iv
Siderite
( FeCO3)
Composition
70 % Fe
40 to 45% Fe
Q.
Q.
Ans:
Pig iron: It is used for stoves, lamp posts, drainage covers, pipes,
railing etc
Slag: It is used for road building, cement manufacturing and as
fertilizers
Flue gases: Used as fuel
1
Q.
Gangue or Matrix: the unwanted impurities like sand, clay, rocks etc.
associated with the ores are called as gangue or matrix.
Ex: In Hematite (Fe2O3) ore, silica is gangue.
Flux: The substance used during extraction of metal to remove gangue is
known as flux.
Ex: For removal of gangue like silica (SiO2), calcium oxide (CaO) is used as
flux
Slag: The fusible substance formed by combination of added flux & gangue
present in ore is known as slag.
SiO2 + CaO CaSiO3
2
Q.
Ans:
Q.
Ans:
Explain with justification coke and limestone are added during the
extraction of iron. OR What is function of coke and limestone in
extraction of iron by the blast furnace
During the extraction of iron from its ore smelting is done in blast furnace.
During the process of smelting coke is added as reducing agent and
limestone as flux to remove impurities. Coke reduces haematite ore to
metallic iron. Lime stone (CaCO3) decomposes to lime which combines
with impurities of silica to form calcium silicate which is removed as slag.
Q.
Ans: Metallurgy: It is a process of extraction of metal from its ore economically and
profitably.
Mineral is a naturally occurring substance present in earths crust which
contains metal in free state or combined state.
Ore is a mineral from which the metal can be extacted economically. All ores
are minerals but all minerals are not ore.
Q.
What are the commercial forms of iron.
Ans: Commercial forms of iron are
i) Pig iron or cast iron
ii) Wrought iron
iii)Steel
3
Q.
Ans: Steel is an alloy of iron and carbon, hence it is called plain carbon steel.
Properties of steel:
a)
b)
c)
d)
e)
Applications: Steel is used for making girders, bridges, machinery parts, bar
magnets, razors, springs and other constructional works etc.
Q.
Ans. Steels which contains small quantity of chromium, nickel, carbon, vanadium,
tungsten, cobalt, molybdenum, manganese, silicon etc. to improve the desired
properties are known as alloy steels.
Alloy steel: Different types of alloy steels are as follows
1.
2.
3.
4.
5.
6.
Q.
Q.
Ans: Wrought iron is the purest form of iron containing 0.12 to 0.25% carbon and
traces of S, P and Mn etc.
Properties:
1.
2.
3.
4.
It is soft, fibrous, grey in colour, tough and having medium tensile strength
Its melting point is highest, 15000C
It can be magnetised but not permanently
It is very malleable and ductile and can also be forged, extruded and welded
Applications:
Wrought iron is mostly used for making small size water pipes and fittings,
corrugated sheets, ornamental sheets, metal works, wires, anchors, chains, bolts,
nails etc.
It is also used in making cores of electromagnets and in making hard steel.
Q.
Ans: Heat treatment: It is a process of heating the iron or steel to a certain high
temperature and then cooling at a suitable and controlled rate to change the
physical properties of it, without changing chemical properties.
Purposes:
1.
2.
3.
4.
5.
6.
7.
To improve machinability
To improve hardness and strength
To change the grain size of steel
To increases the resistance to heat and corrosion
To remove the trapped gases
To change the structure of steel
To increase surface hardness
5
Q.
Define an alloy.
Ans: Alloy can be defined as a homogeneous mixture of two or more elements, out
of which at least one element must be metal.
Ex.: Steel (Fe+C), Brass (Cu+Zn),
Bronze (Cu+Sn) etc
Q.
What is binary alloy.
Ans: The alloy which contains only two components is known as binary alloy
Ex.: Brass- It contains only copper and zinc
Ex.: Bronze- It contains only copper and tin
Q.
Write the chemical reactions taking place in the zone of reduction.
Ans: Following reactions take place in the temperature range 3000-8000 C i.e. Zone of
reduction.
1. At the top of the furnace the charge is heated between 3000C to 5000C, Fe2O3 is
converted into Fe2O4
3Fe2O3 +CO
2Fe3O4 + CO2 .
Ferroso ferric oxide (stable upto 6500C)
Ferric oxide
3FeO + CO2
Fe + CO2
CaO + CO2
Q.
Write the chemical reactions takes place in the zone of heat of absorption.
Ans: Zone of heat absorption has temperature range 800-12000C. In this temperature
zone following reactions takes place.
1. Any oxide of iron which is not reduced in the zone of reduction is reduced by
red hot carbon and also carbon dioxide is reduced by red hot carbon to carbon
monoxide by the absorption of heat.
Fe2O3 + 3C
CO2 + C
2. The hot iron meets the carbon monoxide to form carbon which is absorbed by
hot iron.
2CO
CO2 + C
3. The lime obtained in the zone of reduction by decomposition of lime stone
combines with silica and forms calcium silicate i.e. slag.
CaO + SiO2
CaSiO3
4. At about 12000C ,non metallic and metallic oxide are reduced by coke to
respective elements
SO2 + 2C
S + 2CO
P2O5 + 5C
2P + 5CO
MnO2 + 2C
Mn + 2CO
SiO2 + 2C
Si + 2CO
Q.
Ans: Cast iron: The molten metal poured into moulds of desired shape and the iron
obtained is known as cast iron.
It is most impure form of iron containing highest percentage of carbon (2-5 %)
which makes it hard and brittle hence it is not used directly in industry
Composition of Pig iron (Cast iron)
Fe
Carbon
Silicon
Phosphorus
Manganese
Sulphur
:
:
:
:
:
:
92 to 95%
2.5 to 4.5%
0.7 to 3%
0.5 to 1%
0.2 to 1%
0.1 to 0.3%
Properties:
1.
2.
3.
4.
5.
Uses: Cast iron is widely used in casting various types of articles like stoves,
radiators, toys, cooking ranges, water pipes, drain pipes, agricultural
instruments. It is also used in railway sleepers, lamp posts, drainage covers,
railing and fire gates. Mostly, it is used in manufacturing wrought iron and steel.
Q.
:
8
15%
Properties:
It is fusible chemical substance consisting of silicate of calcium and aluminium,
with small amounts of MgO, MnO, FeO and CaS.
Uses:
1. It is used for road building, cement manufacturing and used as fertilizers
2. The slag is used as ballast (filler) for rail roads
Q.
Ans: Flue gases: Gases removed from blast furnace through flue are called flue
gases.
Composition of flue gases:
Carbon monoxide
Carbon dioxide
Nitrogen
Hydrogen
:
:
:
:
25-28%
12-15%
60%
3-4%
Properties:
It is hot, which has calorific value 750Kcal/m3
Uses:
As it has considerable calorific value it is used as fuel
Q.
How steels are classified on the basis of percentage of carbon? Write two
properties and two applications of each of them.
Ans: Steel is an alloy of iron and carbon therefore it is called as plain carbon steel.
Steels are classified on the basis of percentage of carbon as
9
A) Low carbon steel (0.05 to 0.3% carbon): It is also called as mild steel (MS)
Properties:
1.
2.
3.
4.
5.
6.
Applications:
1. These are used for making nuts, nails, bolts, screws
2. These are used for soft wires, wires for ropes etc
3. These are also used for chains, tubes, fan blades etc
Applications:
1.
2.
3.
4.
Applications:
1. These are used for making wood working tools such as chisels, hammers,
saws, drills, punches etc
2. These are also used for making metal cutting tools for lathes, cutters, knives,
blades, razors etc
Q.
To increase hardness
To increase the resistance to wear and abrasion
To improve the ability to cut other metals
To increase the strength
11
Q.
Q.
Purposes of normalizing:
1.
2.
3.
4.
5.
Advantages of normalizing:
1.
2.
3.
4.
Q.
Annealing
1 It is the process of heating the steel at a
temperature (760-9250C)& cooling it
slowly in the furnace at a
controlled & slow rate.
2 Due to annealing, steel have less
hardness, tensile strength and
toughness.
3 Internal stresses are least
Normalising
It is the process of heating the steel at
a temperature of 500C above the
critical temperature (7250C) &
cooling it freely in air at a rate 50C/sec.
Due to normalising steel have slightly
more hardness, tensile strength and
toughness.
Internal stresses are slightly more
5 Fuel consumption or electric power for Fuel consumption or electric power for
heating is more
heating is less.
13
Q.
State the effects of addition of following alloying elements on steelCr, Ni, W, V, Si, C,Mo.
Ans:
a) Addition of chromium (Cr)
1. Cr forms hard carbide and increases hardness and improves resistance to
wear and abrasion
2. It increases oxidation resistance and corrosion resistance of steel
b)
1.
2.
3.
Addition of Nickel(Ni)
It increases tensile strength of steel as well as ductility
It lowers critical temperature of steel
It improves corrosion and heat resistance, elasticity, toughness etc
c)
1.
2.
3.
d) Addition of Vanadium(V)
1. It is powerful deoxidizer and degasifier
2. Up to 0.2% V in steel increases tensile strength, hardness, wear and shock
resistance
3. It is very strong carbide former
4. It increases air-hardening and cutting quality
e)
1.
2.
3.
Addition of silicon(Si)
It acts as deoxidizer
It increases high electrical resistance
It improves heat resistance and acid resistance of steel
f) Addition of carbon( C)
1. Carbon increases tensile strength and hardness of steel
2. It decreases ductility and malleability of steel
14
g) Addition of molybdenum(Mo)
It improves corrosion and abrasion resistance and strength even at elevated
temperature.
Q.
Describe basic oxygen process for preparation of steel from pig iron.
Ans: Basic oxygen process for manufacturing of steel:
Process:
The process occurs in a furnace which is a specially designed steel vessel that
may be rotated through 360 in a vertical plane.
The vessels are lined with heat resistant (refractory) materials e.g.Dolomite
(MgCO3/CaCO3) and magnetite (entirely MgCO3).
1. Scrap steel is placed in the vessel followed by molten iron directly from a
blast furnace.
2. The vessel is stood upright and a water-cooled lance is lowered from above
and oxygen is blown onto the surface at high speed. Carbon in the iron is
oxidized to CO and CO2
C(S) + O2 (g)
CO2 (g)
15
2CO (g)
2CO2 (g)
SiO2
CaSiO3
16
Wrought iron
Carbon 0.25 - 0.5%
It is soft
Steel
Carbon 0.05 - 1.5%
Harder than wrought iron
and brittle
Highest tensile strength
It can be forged but not
easily
Malleable and ductile
when % of carbon is low
Between 12000-15000C
Ans:
17
Chapter 2
CORROSION
Q.
Define corrosion.
Q.
Q.
Q.
Ans: The corrosion of metal which take place in presence of liquid (Solution)
through ionic reaction when two dissimilar (different) metals are in contact
with each other is called as electrochemical/wet/immersed corrosion.
Q.
Q.
Q.
Name the oxide film which is corrosive against corrosion. Give one
example
Q.
Name the oxide film which is protective against corrosion. Give one
example
Q.
Q.
Ans: In any structure, two dissimilar metals should not be allowed to come in
contact with each other because galvanic corrosion takes place as a result the
metal in electrochemical series undergoes corrosion
Example: Refer- Electrochemical corrosion using Daniel cell
Q.
Q. Compare the rate of corrosion of iron when it is in contact with zinc and
copper
Ans. When iron come in contact with zinc, zinc protects the iron from corrosion a
it is more electropositive than iron and does not allow iron to pass into the
solution. When iron comes in contact with copper iron undergoes corrosion
as it is more electropositive than copper
Q.
Q.
2M + O 2
2MO
Metal
Metal oxide
2. Then the electrons from metal are transferred to oxygen and oxide ion is
formed.
3. Then the metallic ion and oxide ion combine together to form metal
oxide.
4. The mechanism of oxide film formation can be represented by the
following equation,
M
+
O + 2e-
M++ + O- -
M+ O
Metal Oxygen
Metallic
ion
Q.
O--
MO (Metal oxide)
Oxide
ion
Ans: The factors which affect the rate of atmospheric corrosion are
1. Impurities in the atmosphere
2. Moisture in the atmosphere
22
Q.
Working: The EMF is developed due to two separate reactions taking place
at the two electrodes.
At anode:
Zn(s)
b. The liberated electrons move along metallic conductor and are accepted
by copper which acts cathode.
At cathode:
Cu++(aq)+ 2e-
Cu(s) (reduction)
Thus, zinc goes into the solution (get dissolved) and corroded, while copper
is deposited at cathode and get protected.
24
Q.
Explain
the
factors
which
affect
the
rate
of
A. Nature of environment
1. PH value of the solution:
PH value of solution indicates the acidity or alkalinity of solution. Acidic
solutions are more corrosive to metals than neutral or alkaline solution;
hence solution with PH value less than 7 causes more corrosion.
B. Nature of metal
1. Position of metal in electrochemical series:
In electrochemical series, elements are arranged in the order of their
decreasing activity. Therefore top elements are more active than that of
bottom element. So top elements are easily oxidized and get corroded
easily.
25
Ans: When metal comes in contact with atmospheric oxygen then a thin film of
oxide is formed on the surface of metal. The oxide film which is formed can
be classified into three types.
1. Stable
2. Unstable
3. Volatile
1. Stable oxide film:
Stable film (consist of fine grains in its structure) is tightly adhering and
impervious in nature. Stable oxide film may be porous or non porous.
Therefore this oxide layer faces stress and strain and produces crack or
pores in its structure.
These porous oxide layers allow free access of O2 to fresh metal surface
and corrosion continues.
2MO
2M
Metal oxide
Metal
O2
Oxygen
Q.
28
Mechanism:
Consider a steel (Fe) tank which contains acidic solution (waste) and a
small piece of copper. As copper and iron come in contact and surrounded
by acidic solution, then galvanic cell is formed. Then large steel tank (Fe)
becomes anode and small copper becomes cathode.
Working:
1. At anode: Electrons flow through the metal from anode to cathode
Fe
2H+ + 2e-
H2
(reduction)
Fe++ + H2
Q.
29
Mechanism:
Consider a steel (Fe) surface exposed to atmosphere, after a course of time
iron oxide layer is formed on the surface of steel (Fe) plate. If there is a
small crack developed in iron oxide layer and a drop of water (moisture) is
collected in crack, then
a. Water acts as electrolyte
b. Small crack acts as anode
c. Iron oxide covered steel surface acts as cathode.
Working:
At anode: The liberated electrons flow through anodic area to cathodic area.
2Fe
2H2 O + O2 + 4e-
4OH- (reduction)
30
2Fe++ + 4OH-
31
Q.
Q.
Ans: Cementation is the process in which base metal is heated with a powder of
protective metal.
The types of Cementation are: Chromizing, Colorizing and Sheradizing
Q.
Ans: Cathodic protection is a method in which the base metal to be protected from
corrosion is made to acts as cathodic by attaching more active anodic metal
to it. e.g.: Protection of underground pipelines
Q.
Ans: The process in which superior metal (like Silver, gold, nickel, chromium)
deposited on base metal by passing electric current is called as
electroplating.
Purposes: Decoration, Protection of metal from corrosion, Repairing worn
out machinery parts.
32
Q.
Applications:
1. It is used for protection of ships and boats
2. It is used for protection of underground pipeline, cables from soil
corrosion
33
Q.
Ans: In this method the corroding metal is converted from anode to cathode by
applying impressed current to the metal to be protected and is itself used as
cathode.. This can be done by applying amount of direct current from D-C
source to an anode
Method: In this method
1. The negative terminal of battery is connected to the metal
2. The positive terminal of battery is connected to an inert anode
3. The inert anode used is graphite platinized titanium
4. Then the anode is buried in a back fill to provide electrical contact.
5. Then oxidation reaction is taking place at the cathode electrode and
electrons are liberated, which are repelled by the cathode electrode.
6. As result, the anode electrode destruct and has to replaced time to time
7. Thus cathode electrode protected from corrosion
Q.
Applications:
This method is used for roofing sheets, water pipes, bars, rods, fencing wires
etc.
35
Q.
Why Galvanized containers are not useful for storing food and food
stuff (material).
Ans: Galvanized containers are not useful for storing or preparation of food stuff
because galvanized containers have a coating of zinc. This zinc metal reacts
with the acids present in food stuff and forms highly poisonous compounds
which are harmful for human consumption
Q.
Ans: Tinning: It is the process of coating of tin metal on the surface of iron
(steel) by hot dipping method to prevent it from corrosion is called as
tinning.
3. Then the sheet dipped in bath containing ammonium chloride and zinc
chloride flux and then it is dipped in molten tin
4. Finally it is dipped in palm oil to prevent oxidation of tin
5. Then the metal sheet is passed through a series of rollers to remove
excess of tin & to get uniform coating
Q.
Ans: In tinning base metal iron is coated with thin layer of tin (Sn). Tin (Sn) is
less electropositive than iron, hence it is more resistant to chemical attack
and thus protects the base metal. Due to its non-toxic nature and resistance
to chemical attack tinned articles are used for storing food stuff.
Q.
Tinning
called as galvanizing.
is called as tinning.
protected.
corroding.
large.
small.
Stuff.
Q.
Name and describe the method used for coating odd (large) and
irregular shaped surfaces for the protection of metal OR
Describe metal spraying method. Write its advantages and applications.
Ans: Metal spraying: The method used for coating odd (large) and irregular
shaped articles to protect from corrosion is called as metal spraying.
It is carried out by using spraying gun.
38
Advantages:
1. Large and irregular surface can be protected from corrosion by this
method.
2. Non metallic surfaces can be coated
3. The thickness of coating can be controlled
39
Applications:
1. It can be applied to non metallic bases made of wood, plastic and glass
2. Coating can be applied to fabricated structure
3. Worn out machine parts can be reclaimed
4. Coating of metals like Al, Zn,Ni,Sn,Pb is made by this method
Q.
Ans: Sheradizing: The method used for coating small iron and steel articles
like bolts, nuts, screws, nails etc by zinc dust to protect from corrosion is
called as sheradizing.
4. Then zinc dust gets diffused into the iron surface and Fe Zn alloy is
formed at the surface which protect iron surface from corrosion
Applications: This method is used for protecting small steel articles like
bolts, screws, nuts, threaded parts, washers, valves, gauge, tools
Q.
Ans: Sheradizing process is used to protect small iron articles. Because the
coating is uniform even if the surface has depressions and there is practically
no change in dimension of articles
Q.
41
2. This sheet is then passed through two heavy rollers under high
temperature and pressure.
3. The coated metal is cathodic with respect to base metal so that
electrolytic protection is provided.
Ex. The cladding of duralumin by aluminium.
Applications (Advantages) :
1. This methods widely used in aircraft industry where alclad sheets are
used in which a plate of duralumin is cladded between two layers of 99.5%
pure Al
2. To develop surface properties like corrosion resistant in steel sheets.
3. The cladding metal provides electrolytic protection to the base metal
Disadvantages:
1. By metal cladding only plain surface can be protected
2. Corrosion cannot be absolutely prevented by this method because
irregular surfaces provides the galvanic cell action in presence of
moisture
Q.
Metal cladding is done for plain surfaces only. Give reason. OR Rough
surfaces corrode faster than smooth surface
Ans: Irregular (Rough) surfaces provides the galvanic cell action in presence of
moisture, hence corrosion cannot be prevented by this method. Due to above
reason metal cladding is done for plain surfaces only
42
Q.
Iron nails used to join copper sheets rust more. Give reason
Ans: Iron nails used to join copper sheets rust more because iron is more
electropositive than copper
Q.
2. Drying oil
3. Thinner
4. Drier
5. Extenders
6. Plasticizers
43
44
CHAPTER 3
WATER
Q.
Q.
Q.
Write the names of the processes which are used to remove impurities
present in natural water.
Ans:
S.No.
1
2
3
4
Q.
IMPURITY
Suspended
Colloidal
Dissolved
Biological
PROCESS
Sedimentation
Sedimentation with coagulation, filtration
Ion exchange, Zeolite, Limesoda
Sterilization
Q.
Distinguish between hard water and soft water. OR Define hard water
& soft water.
Ans: Hard water: Water which contains chlorides, sulphates and bicarbonates
of calcium and magnesium called as hard water. Such water does not
produce lather with soap. Hard water cannot use for boilers or for cooking or
washing purposes.
Soft water: Water which is free from any salts of calcium and magnesium
is called as soft water. Soft water easily produces lather with soap and can
be safely used for boilers and for other household and industrial purposes.
46
Q.
Name the salts which are responsible for temporary and permanent
hardness of water with chemical formula.
Q.
Clark =
French =
47
PPM =
10 Clark = 1.430 French = 14.3PPM.
Q.
Q.
Dissolved impurities
ii)
Suspended impurities
iii)
iv)
Organic matter.
1. Dissolved impurities.
The soluble salt impurities present in water included salts of Ca, Mg, Na in
various soluble salt forms oxides of Mn, Fe, Pb &Ar may also present in
water.
48
2. Suspended impurities.
Suspended impurities are the dispersion of solid particles. Which can be
removed by filtration or settling.
They are of 2 types:Inorganic: It includes clay silica, Oxides of Fe & Mn etc.
Organic: Includes wood pieces. Disintegrated particles of dead
animals,
Q.
H2 O + CO2
H2CO3
Water Carbonic acid
49
2. When this water flows over rock containing calcium & magnesium
carbonates.
3. These reacts with carbonic acid present in water to form calcium
bicarbonate and magnesium bicarbonate which are highly soluble in
water.
H2CO3 + CaCO3
H2CO3 + MgCO3
Ca(HCO3)2
Mg (HCO3)2
4. There are chlorides & sulphates of calcium & magnesium present on the
surface layer which also dissolve in water.
5. When this water flow on the earth surface,these salt enter in water.In this
way chlorides, sulphates & bicarbonate of calcium and magnesium are
dissolved in water and making it hard.
Q.
Write the ill (bad) effect of using hard water in following industries. OR
What are the disadvantages of hard water in 1) Paper industry 2)
Dyeing in industry 3) Textile industry 4) Sugar industry.
C) These changes the shades of the dies & unwanted coloures are produced.
Iron produces yellow stains (spots) on clothes
Hence hard water should not be used in dyeing industry.
3. Textile industry:
A) If hard water is used in textile industry then a large quantity of soap as
well as water is wasted during washing the yarn because calcium &
magnesium salts do not allow formation of lather with soap.
B) They react with soap (sodium or potassium salt of fatty acid) to form
curdy precipitate which sticks to the fabric making it weak & brittle. Iron
& manganese present in hard water produces spots ( stains) on fabrics
therefore water used in textile industry should be free from calcium,
magnesium, iron & manganese salts.
4. Sugar industry:
If hard & impure water is used in sugar industry for refining of sugar the
impurities like sulphates nitrates, alkali carbonate & bacteria present in it
causes difficulties in the crystallization of sugar. The sugar so formed
may be deliquescent (become watery) & get decomposed during storage.
Q.
What are the disadvantages or ill (bad) effect of using hard water in 1)
Washing 2) Cooking 3) Bathing 4) Drinking OR
Why hard water is not suitable for 1) Washing 2) Cooking 3) Bathing 4)
Drinking
Ans: 1.Washing:
Hard water consist of soluble sulphate, chlorides & bicarbonates of calcium
& magnesium
If hard water is used for washing, then the Ca & Mg salts react with soap &
produces curdy precipitate of Ca of Mg salts of fatty acid
51
In this way large quantity of soap is wasted & the precipitate stick to the
cloth making it weak & brittle.
Secondly if iron is present in hard water it forms spots (stains) on clothes
2. Cooking:
The presence of impurities in water also increases the boiling point of water.
Hence vegetables may not cook well, so more time and more fuel required if
hard water is used.
The life of cooking utensils also decreases due to overheating
Hence hard water should not be used for cooking.
3. Bathing:
If hard water is used for bathing then
a) Wastage of soap takes place as hard water does not form good lather
b) Insoluble residue is formed with soap which is adsorbed on our body,
due to which our skin become dry & dark
4. Drinking:
If hard water is used for drinking then impurities in hard water causes bad
effect on digestion process and also kidney stone may formed due to
accumulation of calcium oxalate crystals
Q.
What are the causes of boiler corrosion? Explain the causes of boiler
corrosion.
2. Dissolved salts
3. Acidity or alkalinity of water
1. Dissolved gases:
Among the dissolved gases oxygen has most corroding effect on boiler
Water contains about 8ml of oxygen per litre at 100C
Dissolve oxygen in presence of water under high temperature attacks the
boiler material
4Fe + 4H2O + 2O2
4Fe (OH)2 + O2
4Fe (OH)2
2 ( Fe 2O3. 2 H2O)
Ferrous hydroxide
Rust
H2 CO3
2. Dissolved salts:
If hard water contains chlorides of calcium & magnesium; they get
hydrolyses & produces hydrochloric acid
MgCl2+2H2O
Mg (OH)2 + 2HCl
This liberated hydrochloric acid react with iron material of the boiler like a
chain reaction producing hydrochloric acid again & again
Fe + 2HCl
FeCl2 + 2H2O
FeCl2 + H2
Fe(OH)2 + 2HCl
Q.
Define scales & sludge OR What are scales and sludge in boiler? Write
prevention (control) measures
Scales: The hard and adherent coating formed on inner walls of the boiler is
called as boiler scales. They stick very firmly on to the inner wall surface
and are difficult to remove with chisel and hammer.
Prevention:
Methods of prevention of scales
54
Ans: The main causes of scale & sludge formation in boiler are
1. Chemical decomposition OR Presence of Ca (HCO3)2 & Mg (HCO3)2
2. Decrease in solubility of salts
1. Chemical decomposition OR Presence of Ca (HCO3)2 & Mg (HCO3)2
If water contains soluble bicarbonate of calcium & magnesium then under
high temperature & pressure inside the boiler, it decomposes to give calcium
carbonate precipitate (insoluble) which forms scales.
This effect is observed in low pressure boiler.
In high pressure boilers CaCO3 forms soluble Ca (OH)2.
Ca (HCO3)2
CaCO3 + H2 O + CO2
55
Q.
Ans: The disadvantages of scale & sludge formation in boiler are as follow.
1. Wastage of fuel:
Scales deposited on the inner wall of the boiler are poor conductor of heat.
Hence to get the steady supply of steam; overheating of boiler is needed.
Most of the heat is wasted in heating the scales & in this way there is
wastage of fuel.
It is estimated that for 25mm thick scale, nearly 60% of the fuel is wasted.
3. Danger of explosion:
a) When scales crack due to uneven expansion of scale & boiler material,
the water comes suddenly in contact with overheated iron plate of boiler
56
b) This causes the formation of a large amount of steam suddenly inside the
boiler
c) Hence sudden high pressure is developed which may causes explosion of
boiler
4. Decrease in efficiency:
Scales may sometimes deposits in the valves of condensers of the boiler &
choke them. These results in decrease of efficiency of boiler
Q.
Ans: During the process of softening of hard water, the soluble calcium and
magnesium salts are converted into insoluble salts. These insoluble salts can
be removed by filtration and soft water can be obtained
Q.
Ans:
1
2
3
4
5
6
Scale
When the precipitated matter forms a
hard adherent coating on the inner
surface of the boiler is called boiler
scales.
Scales are hard and adherent
It cannot be removed by mechanical
means
Scales are bad conductor of heat
Scales are formed throughout the
metal surface in contact with water
Scales lead to bursting or explosion
of metal tube
Sludge
When the precipitated matter forms a
soft, loose, slimy deposits inside the
boiler which do not stick to the boiler
permanently are called boiler sludge.
Sludges are soft
Sludges can be removed by mechanical
means
Sludges are poor conductor of heat
Sludges are formed at comparatively
cooler parts of the boiler
Sludge lead to check up problems
57
Q.
Ans:
1. Zeolite: Zeolite are complex of silicates and aluminates of metallic and
non metallic oxides. For softening of water, generally sodium zeolite is
used. It has crystalline structure with a chemical formula.
Na2Al2 Si2O8.6 H2O
It is represented as Na2Z or Na2P
Principle: When zeolite come in contact with hard water, sodium ions in
zeolite are replaced by calcium and magnesium to form insoluble
calcium and magnesium zeolite
2. Working: When zeolites come in contact with hard water, sodium ions
in zeolites are replaced by calcium and magnesium ions to form insoluble
calcium and magnesium zeolites.
58
3. Chemical Reactions:
For temporary hardness
Ca(HCO3)2+ Na2P
CaP + 2NaHCO3
Mg(HCO 3)2+Na2P
MgP +2 NaHCO3
CaP +2 NaCl
MgCl2+ Na2P
MgP +2 NaCl
CaSO4+Na2P
CaP +Na2SO4
MgSO4 +Na2P
MgP +Na2SO4
4. Regeneration: After some time all the Na+ ions from zeolite (permutit)
completely gets converted into calcium and gets exhausted. At this stage,
supply of hard water is stopped. The exhausted zeolite is regenerated
or reactivated by passing 10% Brine solution( NaCl) through it
CaP + 2NaCl
Na2P+CaCl2
Brine Solution
MgP + 2 NaCl
Na2P + MgCl2
The washings containing CaCl2 and MgCl2 are passed to drain and the
regenerated zeolite is used again. Water softened by zeolite is almost of
zero hardness.
59
Q.
Ans: Process: It consists of three cylindrical towers. First tower consists of cation
exchanger (RH2) and second tower consists of anion and alkali tanks for
regeneration of the exhausted resins.
Third tower is a degasifier.
1. Hard water is first passed through the cation exchanger. It removes all the
cations like Ca++, Mg2+ and releases H+ ions.
RH2 + CaCl2
RCa + 2HCl
RH2 + MgSO4
RMg + H2 SO4
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2. The acidic water is then passed through anion exchanger where acids are
converted into water.
R-(OH)2 + 2HCl
RCl2+2H2O
R-(OH)2 + H2SO4
R- SO4 + 2H2O
3. Thus water is free from all cations and anions. Finally water is made free
from dissolved gases like CO2, O2 by passing it through third tower of
degsifier.
Regeneration: When the cation exchanger resins get exhausted, they are
regenerated by passing the solution of dill. HCl or H2SO4 through first
tower.
R-Ca + 2HCl
RH2 + CaCl2
R-Mg + H2SO4
RH2+ MgSO4
R(OH)2 + 2NaCl
RSO 4 + 2NaOH
R(OH)2 + Na2SO4
61
This process can be used for purifying highly acidic or alkaline water
Water of zero hardness is obtained
Small space occupying equipment and portable
Water totally free from any ionic impurity is obtained
Treated water contains negligible amount of total dissolved solid i.e. up
to 5 mg/lit
6. Method of self adjusts with water of all types and different hardness
Limitations/Disadvantages:
1. Initial investment is high (low running cost)
2. Turbidity may clog the pores of resins and reduce the output of process
3. Method cannot be used for getting deionized water on large scale
Q.
Ans: Water which is fit for human consumption and safe to drink is known as
drinking water or potable water.
Requirement (Characteristics/Parameters) for potable water:
1. It should be colourless, odourless and clear
2. It should be totally free from disease producing microorganisms like
germs and bacteria
3. Water should be soft and pleasant in taste
4. The turbidity of water should be less than 10 ppm
5. If water has a colour then it should be less than 20ppm
6. If water dissolve any solid then it should be less than 500ppm
7. It should be free from dissolved gases like hydrogen sulphate
62
Q.
Ans:
1. Screening:
Screening is the process of removing floating materials from water. To
remove the floating matter, mainly this method is used.
The water is allowed to pass through screens having a large number of
pores. Thus, only floating material remains on the screen.
2. Sedimentation:
Sedimentation is the process of removing suspended impurities by allowing
the water to stay undisturbed for some time in large tanks when most of the
suspended particles settle down due to the force of gravity.
The process of sedimentation is generally carried out in continuous flow
type tanks in which water flows continuously in a horizontal or vertical
direction at a slow and uniform speed. Due to gravitational force, the
suspended particles get settled down at the bottom of the tank, form where
they can be removed periodically. Sediment water is taken out continuously.
3. Coagulation:
Coagulation is the process of removing colloidal (or fine size) particles
from water by the addition of certain chemicals known as coagulants before
sedimentation. This process is usually carried out along with
sedimentation.
The commonly used coagulants are the salts of iron and aluminium e.g. alum
[K2SO4. Al2(SO4)3. 24H2O], ferrous sulphate (FeSO4.7H2O) etc.
These coagulants react with bicarbonates present in water, and form bulky
gelatinous precipitate called flock. As these flocks descend through water,
63
they absorb or catch suspended fine particles from water and forming bigger
flocks, which settle down quickly.
The addition of coagulants to water also removes colour, odour and
improves its taste.
Al2(SO4)3 + 3 Ca (HCO3)2
(Coagulant)
Calcium
Bicarbonate
FeSO4 + Mg(HCO3)2
(Coagulant)
Magnesium
Bicarbonate
4 Fe (OH)2 + 2H2O + O2
(Dissolved oxygen)
Q.
4 Fe (OH)3
Ferric hydroxide
(Heavy flock)
Defing Filtration. Explain Gravity sand filtration process with the help
of a figure.
Construction:
It consists of a large shallow rectangular tank made of concrete
At the bottom of the tank, there is a channel of bricks through which filtered
water goes out. Over this channel, a layer of coarse and fine gravels (about
30cm thick) and then a layer of coarse sand (about 20cm thick) and finally a
layer of fine sand (about 50cm thick) are placed
64
Working:
Sediment water enters the sand filter from the top. As the water percolates
through the sand bed, fine suspended particles, most of the germs and
bacteria are retained by the top sand layer. Clean filtered water is collected
in the under drain channel, from where it is drawn out.
Cleaning:
1. The rate of filtration, after 24 hours of use becomes slow due to clogging
of pores or the top sand layer by the impurities retained in the pores
2. Therefore, the portion of the top fine sand layer is scrapped off and
replaced by a new sand layer. The filter is put to use again.
Q.
HOCl + HCl
(Hypochlorous acid)
HOCl
HCl + [O]
(Nascent Oxygen)
Germs + [O]
Ca(OH)2 + Cl2
HOCl + HCl
HCl + [O]
(Nascent oxygen)
3. The nascent oxygen liberated, oxidizes germs and other harmful bacteria.
66
By using chloramines(ClNH2):
ClNH2 + H2O
HOCl
HOCl + NH3
Advantages of chloramination:
1. It removes irritating smell due to excess of chlorine
2. It imparts good taste to water
3. It checks the dissipation of chlorine (by stabilizing chlorine) when
water is exposed to atmosphere, especially to sunlight
Q.
Ans: Principle of reverse osmosis: In reverse osmosis the flow of solvent take
place in reverse direction i.e. from higher concentration solution to lower
concentration solution through a semi permeable membrane (SPM).
67
Process:
1. Sea water is filled in reverse osmosis cell. A pressure of 200-800 psi is
applied on it to force the solvent to pass through semi permeable
membrane.
2. The membrane consists of a polymeric material film made of proper
porosity, from materials like acrylics, polyamides, barmaids etc.
Q.
Principle:
EDTA stands for Ethylene Diamine Tetra Acetic acid. As it is insoluble in
water, we use its disodium salt.
68
Structure of EDTA:
When EDTA is titrated against the complex, EDTA replaces all the
EBT and forms a stable Ca/Mg-EDTA complex. The liberated EBT
indicates the end point as steel blue.
[Ca/Mg EDTA] + EBT
[Ca/Mg-EBT] + EDTA
(Wine red/unstable)
(Stable)
(Steel blue)
So, the end point is the colour change from wine red to steel blue.
Procedure:
Determination of total hardness:
1. Pipette out 50 ml of the given hard water sample into 250 ml conical
flask.
2. Add 5 ml of buffer solution to increase the pH to about 10.
3. Add 3-4 drops of Eriochrome Black- T indicator.
4. The solution turns wine red.
5. Titrate the hard water sample slowly with 0.01M EDTA until the colour
changes to blue (end point).
69
Q.
(carbonate)
and
permanent
CHAPTER 4
CEMENT AND LIME
CEMENT
Q.
Define cement.
Q.
Ans: It is finely ground grayish mixture of calcium silicates and aluminates with a
small amount of gypsum which are capable of setting and hardening by
chemical reaction with water.
Q.
Q.
Ans:
1
2
3
4
5
6
7
8
Q.
Oxides
Lime (CaO)
Silica (SiO2)
Alumina(Al2O3)
Iron Oxides(Fe2O3)
Magnesia (MgO)
Sulphur trioxide
Soda and Potash(Na2O+K2O)
Gypsum (CaSO4.2H2O)
Percentage
60-70%
17-25%
3-8%
0.5-6%
0.1-4%
1-2%
0.5-1.3%
3-4%
2) Function of Silica:
It is one of the active constituent of cement. If Silica percentage is high it
prolongs setting time but increases the strength.
3) Functions of Alumina:
Alumina makes the cement quick setting. Excess alumina, however weakens
the cement.
Q.
Ans: After adding water to cement, the initial setting occurs within short time (30
min). We get jelly like paste which is quite plastic. As the time passes the
mixture loses its plasticity. Before the time of initial set, the paste can be
mixed and put in different sections of structure. Once the solid mass is
formed it should not be disturbed. After initial setting there is final setting
followed by hardening of cement.
Q.
Ans: The setting and hardening of cement is due to hydration and hydrolysis
reaction taking place between various constituents of cement and water.
Anhydrous compounds undergo hydration forming insoluble gels and
crystalline products.
Setting: It is defined as stiffening of original plastic mass due to initial gel
formation.
Hardening: It is the development of strength due to crystallisation.
The chemical reactions taking place during setting and hardening of cement
are as follows
73
1. Hydrolysis:
C3S + (x+1) H2O
C4AF+7 H2O
2. Hydration:
C3S + xH2O
C3A.6H2O(crystals)+C.F.H2O(gel)
C3A + 6H2O
Q.
C2S.xH2O(gel) + C.H2O(crystals)
Q.
Write composition properties and uses of super sulphate cement.
Ans:
Composition: It contains
1. Granulated slag
2. Anhydride
3. Portland cement
= 80-85%
= 10-12%
= 5-6%
Properties:
1. It is highly resistant to marine water and sulphate bearing soil.
2. Low heat is librated during setting.
74
Uses:
1. It is used for mass concrete job
2. It is suitable where concrete is exposed to sea water and sulphate bearing
soil.
Q.
75
Q.
Why are calcium soaps and aluminium soaps used in making water
proof cement?
Ans: Calcium soaps and aluminium soaps are chemically inactive agents. They
also act as a pore blocking agents and increase the resistance to penetration
of moisture. Therefore calcium soaps and aluminium soaps are used in
making water proof cement.
Q.
Ans: Some important specifications for ordinary Portland cement as per. Indian
standard are given below:
A) Chemical Requirements:
1. Lime saturation factors 0.66 to 1.02
2. (Al2O3) Alumina :
Not lesser than 0.66
(Fe2O3)Iron oxide
3. Insoluble residue- Not more than 2%
4. MgO: Not more than 6%
5. SO3 : Not more than 2.75%
6. Loss on ignition: Not more than 4%
B) Physical Requirements:
1. Initial setting time - Not less than 30 Minutes.
2. Final setting time - Not more than 60 Minutes.
3. Compressive strength 3 days : Not less than 1.6 kgf/mm2 (1 kgf =9.807
newton)
4. Soundness method
By Le chatiler method Unaerated cement: max 10 mm.
Aerated cement: max 5 mm.
5. Finess
As specific surface (Not less than 215 m2/kg)
By Blain permeability method:
76
Q.
Ans: Plaster of paris [CaSO4. H2O] is produced by heating fairly pure gypsum to
a temperature of about 120-1600C
1200C
CaSO4.2H2O
(gypsum)
CaSO4.2H2O
orthorhombic
2000C
CaSO4. H2O
CaSO4
plaster of Paris
dihydrate
Q.
Ans: When plaster of Paris is mixed with water, the powder forms a plastic mass,
which quickly sets to a hard mass like stone. This supports the cracked
bones. Then recovery of fractured bones is faster, hence POP is used for
plastering fractured bones.
Q.
77
LIME
Q.
What is lime?
Ans: Calcium oxide (CaO) is called as lime. It is also known as quick lime or
common lime.
On calcinations of CaCO3 in the form of limestone, chalk, marble etc. quick
lime is obtained.
CaCO3
Heated
Q.
CaO+CO2
(Lime)
Ans: The action of water on quick lime is known as slaking of lime. When lime is
mixed with water (3:1) it absorbs water, begins to burst and swell with
evolution of heat. This heat brings entire mass to boil with hissing sound and
the solid lime crumbles into fine dry white powder resulting in a suspension
of finally divided calcium hydroxide in water called slaked lime.
The process is called slaking of lime.
CaO + H2O
Ca(OH)2 + (15.9) Kcal
(Quick lime) (Slaked lime) (Heat)
Q.
Ans: If little amount of water is added to quick lime we get fine white powder
called hydrated lime.
Advantages:
1.
2.
3.
4.
Q.
A) Fat Lime:
Composition:
It is purest form of lime containing CaO 92-95%. Other impurities like
Alumina, Silica and iron oxide are less than 2% and remaining consist of
MgO,H2O,CO2
Properties:
1.
2.
3.
4.
5.
Uses:
1.
2.
3.
4.
79
Uses:
1. White washing
2. Plastering
3. In the form of mortar for inferior type structures
C) Hydraulic Lime:
Composition:
It is like inferior grade natural cement. It contains about 70 to 80% of CaO
and 5-20% Silica and Alumina and very small quantity of Fe2O3 and MgO.
Depending on the proportion of Silica and Alumina Hydraulic Lime is
classified as
1. Feebly Hydraulic Lime
2. Moderately Hydraulic Lime
3. Eminently Hydraulic Lime
Properties:
Hydraulic Lime slakes slowly with water with less evolution of heat. It
possesses the Hydraulic property of setting under water.
80
Uses:
1. Feebly Hydraulic Lime containing 5 to 15% of Silica and Alumina has
poor hydraulic property and used in ordinary machinery and plastering
2. Moderately Hydraulic Lime containing 15 to 25% of Silica and Alumina
has better hydraulic property and used as mortars in superior machinery
work
3. Eminently Hydraulic Lime containing 25 to 30% of Silica and Alumina
has high hydraulic property, and sets under water therefore used for
foundation work under water
D) Dolomite Lime:
It is obtained by calcinations of dolomite (CaCO3.MgCO3) at 17000C.
Dolomite Lime thus obtained contain 30 to 40% of MgO, 60-70% CaO and
very small percentage of clay.
Properties:
1.
2.
3.
4.
Uses:
1. It is used in metallurgy as flux
2. It repairing basic refractories
3. It is used for preparing special slag
81
82