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Industrial Chemical - Coggle Diagram
Industrial Chemical
Solvay Process (Formation of Sodium Carbonate)
Characteristic
Sodium carbonate dissolves in water to form an alkaline solution.
Used as a base, sodium carbonate is cheaper and safer than sodium hydroxide.
Applications
NaOH production for soap and detergent.
Glass making.
Baking soda production.
Steps in Solvay Process
1) Brine Preparation and Purification.
2) Formation of Sodium Bicarbonate (NaHCO3)
3) Formation of Sodium carbonate (Na2CO3)
4) Ammonia Recovery
Schematic diagram
Waste & Management
Calcium chloride, CaCl.
It uses is limited (drying agent in industry, de-icing roads, an additive in soil treatment and concrete)
The rest must be disposed of either by pumping out to sea, or by evaporating to dryness and
Other solid wastes include unburnt calcium carbonate, sand and clay from the kiln.
It is possible that these could be used to make bricks, landfill or road base
Environmental problem
AIR POLLUTION:
Ammonia: Lost during the Solvay Process and is a toxic atmospheric pollutant
THERMAL POLLUTION:
Exothermic Process; Cooling Water Release (Near the Ocean & Inland Plants)
HABER PROCESS (FORMATION OF AMMONIA)
Characteristics
High Pressure:
Around150-200 atmospheres (atm). High pressure shifts the equilibrium towards ammonia production according to Le Chatelier's principle.
High Temperature
Usually conducted at temperatures between 400-500°C.
While high temperatures favor the reverse reaction (decomposition of ammonia), they are necessary to achieve a reasonable reaction rate.
Catalyst
Promoters such as potassium and aluminum oxides are added to enhance the efficiency of the iron catalyst.
Exothermic reaction
The synthesis of ammonia is exothermic, meaning it releases heat.The released heat needs to be managed to prevent the catalyst from becoming too hot and losing efficiency
Large-scale production
It enables the production of millions of tons of ammonia annually, which is essential for global agriculture and various industries.
Schematic Diagram
Applications
The production of fertilizers such as ammonium nitrate, urea, and ammonium sulfate.
Nitric acid is used in fertilizers, explosives, and as an industrial oxidizing agent.
Ammonia is used to manufacture explosives like ammonium nitrate, which is a component of many industrial explosives.
Ammonia is used in the textile industry for treating fibers and as a component in dyeing and finishing processes.
Ammonia is used in water treatment processes to form chloramine, a disinfectant used to treat drinking water.
Waste
Carbon Dioxide (CO₂)
Unreacted Gases:Unreacted gases are typically recycled back into the process, but there can still be some losses.
The exothermic nature of the ammonia synthesis reaction releases significant amounts of heat, which needs to be managed to maintain optimal reaction conditions.
The iron catalyst used in the process eventually degrades and needs to be replaced, generating spent catalyst waste.
Management strategies
CO₂ produced during hydrogen production can be captured and stored underground or used in other industrial processes.
Implementing heat exchangers allows for the recovery and reuse of excess heat generated during the reaction, improving overall energy efficiency.
Improving the efficiency of the Haber Process can reduce the amount of unreacted gases and overall energy consumption.
Spent catalysts can be recycled and regenerated to reduce waste and lower the environmental impact of catalyst production.
Environmental problems
Greenhouse gas emissions, that can contribute to global warming
Requires high temperatures and pressures, consuming significant fossil fuel energy and increasing the carbon footprint.
Potent greenhouse gas released during fertilizer production and use.
Ammonia volatilizes into the atmosphere, contributing to particulate matter and air quality issues.
Contact Process (Formation of Sulfuric Acid)
Applications
Production of titanium (IV) oxide from titanium minerals.
Sulfuric acid is used to remove the oxide layer from iron or steel before galvanisation.
Organic chemical Industry: Production of plastics, synthetic fibers.
Catalyst for various reactions in petroleum industry.
Manufacture fertilizers such as ammonium sulfate and superphosphate.
Production of detergents and paints.
Waste Management
Waste
Very energy efficient and produce little waste.
Waste produce are SO2, H2SO4 mist and vanadium.
Management
SO2 - double absorption processes.
H2SO4 mist - controlling absorber temperature, gas flow rate and concentration.
Vanadium - disposed in landfill area.
Characteristics
Dehydrating Properties
Used as a drying agent for air & gasses.
Cannot be used to dry alkaline bases such as ammonia.
Displays a strong affinity of water.
Used to remove hydrogen/oxygen atoms.
Oxidising Properties
Concentrated acid acts as a strong oxidant, especially when hot.
Metals are oxidized to their sulfates/sulfides.
Hot acid oxidizes a number of non metal species, eg: sulfur, carbon & phosphorus.
Acidic Properties of Sulfuric Acid
A diprotic acid in dilute solution.
In the presence of a strong base, the conversion of bisulfate ions to sulfate ions to virtually complete.
Environmental Problems
Emission of Sulfur Dioxide.
Air pollution: lead to formation of acid rain, which harms ecosystems, aquatic life, vegetation and buildings.
Human health: Cause respiratory problems
Sulfur Trioxide and Acid Mist.
Acid Mist Formation: cause corrosion and have detrimental effects.
Environmental Damage: can settle on vegetation and water bodies, causing acidification and harm to plants and aquatic life.
Steps in Contact Process
OSTWALD PROCESS (MANUFACTURING OF NITRIC ACID)
USES OF NITRIC ACID
Manufacture of fertilizer
Ammonium nitrate
Used to make explosives
Calcium ammonium nitrate
Make intermediate in the polymer industry
Manufacture of hexanedioic acid (adipic acid) to make polyamides.
Manufacture of methylbenzene diisocyanate and dinitrobenzene to make polyurethanes.
Nitrobenzene is used to make aniline, key reagent for making dyes.
Steps in the Ostwald Process
Catalytic Oxidation of Ammonia
Oxidation of ammonia is carried out in a catalyst chamber
The catalyst used is 90% platinum alloyed with 10% rhodium (for increased strength) gauzes.
Air is preheated and mixed with ammonia.
Nitrous oxide, nitrogen and water are also simultaneously formed in this step
Oxidation of Nitrogen Monoxide
Nitrogen monoxide is oxidised to nitrogen dioxide
The oxygen consumed in this step may be added from an external source
The gases are then passed through a cooling chamber
Any condensed water is transferred to the absorption tower.
Absorption of Nitrogen Dioxide
Water is mixed with the nitrogen dioxide gas in absorption towers to form dilute solutions of nitric acid.
The towers contain large number of inert plates packed with inert granular materials designed to increase the contact between the gases and water.
The conversion is favoured by low temperatures and significant reaction occurs until the gases leave the towers.
Waste & Managements
Ostwald process is very energy efficient and produces little waste
Generating sufficient heat energy to meet the energy needs of the rest of the plant
NO and NO2 contribute to photochemical smog and are significant greenhouse gases and some can react with water to form acid rain
Using natural gas, naphtha or hydrogen, over a catalyst, to reduced NO, NO2 and N2 O gases to N2 .
