Calcium Carbide - Definition and How to Make it?, Uses of ...

Calcium Carbide

Calcium carbide is a chemical compound also known as calcium acetylide. It is primarily used in industries for production purposes. However, calcium carbide is harmful for human consumption.

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Structure of Calcium Carbide

Calcium carbide, or calcium acetylide, has a chemical formula of CaC2, which consists of one calcium atom and two carbon atoms.

This compound is mainly utilized in the production of acetylene and calcium cyanamide. Notably, when exposed to moisture, technical-grade calcium carbide emits an unpleasant garlic-like odor.

Furthermore, when calcium carbide reacts with water, it generates acetylene gas, which is essential for cutting torches and welding applications.

According to the Hong Kong Trade Development Council (HKTDC), calcium carbide is a crucial component in the production of most PVC (Polyvinyl Chloride) in China.

Historically, calcium carbide has been produced in a furnace using lime and coal. However, the United States Environmental Protection Agency (EPA) has reported that particulate matter and other byproducts are released into the environment during its production.

Despite this, the hydrocarbon emissions produced during calcium carbide manufacturing are minimal. Its pure form appears as a colorless, crystalline solid resembling rock salt and generates higher flames that exceed normal flame temperatures.

How to Make Calcium Carbide?

Producing calcium carbide is a complex process that requires specific equipment and materials. You will need a furnace, lime, and coal for the production.

This method demands a high temperature that cannot be achieved with traditional furnaces; therefore, an electrical arc furnace is necessary.

The production process cannot utilize conventional combustion methods to reach the required temperatures. The end product consists of approximately 80% calcium carbide.

• First Step: Load lime and coal into an arc furnace.
• Second Step: Heat the furnace to a minimum temperature of 3,632 degrees Fahrenheit (2,000 degrees Celsius), ensuring it does not exceed 3,812 degrees Fahrenheit (2,100 degrees Celsius).
• Third Step: Place the electrode paste close to the electric arc within the furnace to bake.
• Fourth Step: Introduce the baked electrode into the furnace as it acts as a catalyst for the lime and coal reaction.
• Fifth Step: Once baking is completed, transfer the molten calcium carbide to a cooling mechanism to allow solidification.
• Sixth Step: Crush the solidified calcium carbide into the desired size using suitable tools or equipment.

Uses of Calcium Carbide

Calcium carbide has numerous applications. Its primary use is in the manufacturing of acetylene gas, which is essential for generating light in carbide lamps.

Additionally, it is used in producing chemicals for fertilizers and plays a vital role in steelmaking and hardening processes. Historically, acetylene solutions were utilized in street lighting as well.

When calcium carbide reacts with nitrogen, it produces calcium cyanamide, commonly referred to as nitro lime, which is utilized as a fertilizer.

Moreover, calcium carbide acts as a ripening agent for food. In industrial applications, it is also employed in toy and bamboo cannons.

Furthermore, it is used alongside calcium phosphide in floating, self-igniting solar flares.

Solved Question for You

Question: Which of the following is not used in the production of calcium carbide?

A. Calcium
B. Limestone
C. Coal
D. Carbon

Answer: The correct answer is option A. Calcium is not directly used in the production of calcium carbide; rather, its role is fulfilled by limestone.

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Acetylene is a combustible gas characterized by its distinctive odor. It serves as a raw material for producing various organic chemicals and as a fuel source in metal cutting and oxy-acetylene welding. Nowadays, acetylene is also used in producing several plastics. Typically, acetylene is generated through one of the following methods:

1. Initiating a reaction between calcium carbide and water in the acetylene generator.
2. Utilizing different types of hydrocarbons.

The choice of method depends entirely on the user, as each has its advantages. This post will elaborate on the production of acetylene using calcium carbide in the acetylene generator.

Introduction to Acetylene Generation Process Using Calcium Carbide

In industrial settings, acetylene generation begins in acetylene-producing generators. These devices are available in various capacities, ranging from 8 m³ to over 200 m³ per hour. Calcium carbide is introduced at the top of the generator shell into the water. The chemical reaction can be expressed as follows:

CaC2 + 2 H2O → C2H2 + Ca(OH)2

This reaction must only occur under carefully controlled conditions. The process unit should be equipped with pressure and temperature sensors as well as non-return valves to ensure safety.

Acetylene Generator and Acetylene Production Using Calcium Carbide

The components of the acetylene generation plant and their respective roles are outlined below:

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1. Generator: Calcium carbide is combined with a substantial amount of water to produce acetylene gas. The generator is equipped with several accessories, including:

   • Automatic control sensors
   • Feeder
   • Hopper(s)
   • Agitator
   • Arrestor

2. Condenser: This device cools down the acetylene gas generated in the generator.

3. Ammonia Scrubber: This vessel removes ammonia from the acetylene stream before purification.

4. Medium Pressure Drier: As the name suggests, this unit dries the acetylene gas and regulates the moisture content. It uses anhydrous calcium chloride for this purpose.

5. Purifier: This unit contains purifying material that separates phosphine and hydrogen sulfide produced during acetylene generation.

6. Purifier Scrubber: This component prevents any purifying material from entering the compressor.

7. Compressor: Due to its flammability, acetylene requires a compressor that uses water for cooling after each compression stage.

Safety Guidelines for Handling Calcium Carbide during Acetylene Generation

Adhere to the following guidelines while handling calcium carbide during acetylene generation:

1. The maximum allowable size and weight of the carbide for a single charge must comply with the equipment manufacturer's specifications.
2. Store calcium carbide in airtight metal containers, clearly labeled “Calcium Carbide – Dangerous If Not Dry.”
3. Do not exceed 250 kg of calcium carbide in drums and ensure they are stored in water-free environments. Regularly inspect containers for water ingress.
4. Open calcium carbide drums only when filling hoppers.
5. Do not charge carbide with over 15% dust concentration into the generator.
6. Dispose of carbide-water residue responsibly and do not discharge it directly into the environment.

Best Sizes for Gas Yield of Calcium Carbide

The size of calcium carbide is crucial when it comes to gas production. The following data provides insights into the optimal grades:

Grade Size

The aforementioned data regarding optimal sizes for gas yield is compiled from various industrial studies. For expert advice tailored to your application needs, consider consulting a specialist such as Rexarc, which manufactures industry-grade acetylene plants with diverse specifications and dimensions. Yield may vary between different manufacturers.

For more information about a calcium carbide manufacturer, please feel free to contact us.