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Chemical Process Industries

This document discusses several key chemical process industries: 1. Chlor-alkali industries, which produce soda ash, caustic soda, and chlorine via the Solvay process or LeBlanc process. 2. Electrolytic industries, which use electrical energy to power chemical processes and generate heat. 3. Sulfuric acid production, which produces sulfuric acid via reacting sulfur with oxygen and water in series of reactions. Key processes discussed are the Frasch process and contact process. 4. Fertilizer production, which involves organic and chemical fertilizers that supply essential nutrients like nitrogen, phosphorus, and potassium to plants.

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Dean Joyce Alboroto
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68 views3 pages

Chemical Process Industries

This document discusses several key chemical process industries: 1. Chlor-alkali industries, which produce soda ash, caustic soda, and chlorine via the Solvay process or LeBlanc process. 2. Electrolytic industries, which use electrical energy to power chemical processes and generate heat. 3. Sulfuric acid production, which produces sulfuric acid via reacting sulfur with oxygen and water in series of reactions. Key processes discussed are the Frasch process and contact process. 4. Fertilizer production, which involves organic and chemical fertilizers that supply essential nutrients like nitrogen, phosphorus, and potassium to plants.

Uploaded by

Dean Joyce Alboroto
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© © All Rights Reserved
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CHEMICAL PROCESS INDUSTRIES

Chemical Process Industries 1. CHLOR-ALKALI INDUSTRIES: Soda Ash, Caustic Soda


- Chemical processing of raw materials into & Chlorine, Baking Soda
useful and profitable products
- About ¼ of the total chemical output is LeBlanc Process (Old Process)
utilized in the manufacture of other
- Based on roasting salt cake with carbon and
chemicals
limestone in a rotary furnace and
subsequent leaching of the product with
𝑅𝑎𝑤 𝑚𝑎𝑡 → 𝑀𝑎𝑛𝑢𝑓𝑎𝑐𝑡𝑢𝑟𝑖𝑛𝑔 𝑃𝑟𝑜𝑐𝑒𝑠𝑠 → 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 water
- Black ash – the crude product of the reaction
1. Unit Operations – physical operations - None of LeBlanc Process is now operated in
Ex. Heat transfer, fluid flow, distillation the world
2. Unit Processes – chemical reactions Solvay Process (Present Synthetic Process)
Ex. Nitration, sulfonation, oxidation - Developed by Ernest Solvay
- Solvay began developing the ammonia-soda
process
Types of Questions - Reduced the price of soda ash almost 1/3
1. Identify the industrial process given a reaction
2. Provide products for a given industrial reaction
3. Identify industry given raw materials or Manufacturing of
equipment 1. Soda Ash (Na2CO3)
4. Identify scientist who discovered the chemical 2. Caustic Soda (NaOH) & Chlorine
process given the industrial product 3. Baking Soda (NaHCO3)
5. Problem Solving
a. Chemical Engineering Calculations I. Soda Ash (Na2CO3)
i. Mass Balance for Industrial - Lightweight solid
Stoichiometry - Moderately soluble in water
ii. Must know the process - Usually containing 99.3% Na2CO3
iii. Familiar the common name - Sold on the basis of Sodium Oxide content,
which is 58%
Industries II. Pure Caustic Soda (NaOH)
1. Chlor-Alkali - Brittle white solid that readily absorbs
moisture and carbon dioxide from the air
2. Electrolytic
3. Sulfuric Acid Production - Sold on the basis of Na2O content, usually
4. Fertilizers contains 76% Na2O equivalent to 98% NaOH
5. Sugar - Corrosive to skin
6. Pulp & Paper - Uses: soap, textiles, petroleum refining
- Between the products NaOH and Cl2, NaOH
7. Metallurgical
8. Water Conditioning is in strong demand
9. Petrochemical III. Chlorine
10. Fermentation - Used for bleaching
11. Ceramics - Use in the synthesis of organic chemicals
12. Glass - Metallurgical uses: extraction of copper,
lead, gold, and etc., beneficiation of ores and
13. Rubber
fluxing
14. Industrial Gas
15. Fats & Oils - End products: clothing, jewelry, paints,
16. Plastic foods, paper, tires, and toys
17. Dyes IV. Baking Soda (NaHCO3)
18. Inorganic and Organic Chemicals - About 99.9% pure
- Uses: Food Industry, making rubber, antacid
in Pharmaceutical, fire extinguishers, soap,
animal feeds, textiles, leather and paper
making
Two Process: 3. SULFURIC ACID PRODUCTION
- Common way of producing Sulfuric Acid (H2SO4)
1. Solvay Process
- Used for manufacturing Soda Ash (Na2CO3) Sulfur
- Raw materials: - Examples of Sulfur combined in ores
1. Limestone or Calcite (CaCO3) o Pyrite (FeS2)
2. Table Salt (NaCl) o Sphalerite (ZnS)
o Chalcopyrite (CuFeS2)
- Constituents of petroleum and natural gas (as
𝑁𝑎𝐶𝑙 + 𝐶𝑎𝐶𝑂3 → 𝐶𝑎𝐶𝑙2 + 𝑁𝑎2 𝐶𝑂3
H2S)
(Table Salt) (Limestone) (Soda Ash)

Frasch Process
2. Lime Soda Process
- Used for manufacturing Caustic Soda - Developed by Herman Frasch
(NaOH) - A method of extracting sulfur from
underground deposits
Calcium Oxide:
Reaction of forming Sulfuric Acid
𝐶𝑎𝑂 + 𝐻2 𝑂 → 𝐶𝑎(𝑂𝐻)2
(Lime or Quicklime) (Limewater) 𝑆(𝑙) + 𝑂2(𝑔) → 𝑆𝑂2(𝑔)
𝐶𝑎(𝑂𝐻)2 + 𝑁𝑎2 𝐶𝑂3 → 𝐶𝑎𝐶𝑂3 + 2𝑁𝑎𝑂𝐻 1
𝑆𝑂2(𝑔) + 𝑂2(𝑔) → 𝑆𝑂3(𝑔)
(Limewater) (Soda ash) (Limestone) (Caustic Soda) 2
𝑆𝑂3(𝑔) + 𝐻2 𝑂(𝑙) → 𝐻2 𝑆𝑂4(𝑙)
NOTE: Limewater is Ca(OH)2(aq) (Sulfuric Acid)
Slaked lime is Ca(OH)2 *Excess SO3 react with H2SO4 that forms to oleum
𝑆𝑂3(𝑔) + 𝐻2 𝑆𝑂4(𝑙) → 𝐻2 𝑆2 𝑂7(𝑙)
Magnesium Oxide: (Oleum, Disulfuric Acid or Pyrosulfuric Acid)
𝑀𝑔𝑂 + 𝐻2 𝑂 → 𝑀𝑔(𝑂𝐻)2  98% H2SO4
(Magnesia or Periclase) (Milk of Magnesia) o 98% H2SO4
𝑀𝑔(𝑂𝐻)2 + 𝑁𝑎2 𝐶𝑂3 → 𝑀𝑔𝐶𝑂3 + 2𝑁𝑎𝑂𝐻 o 2% Water
(Milk of Magnesia) (Caustic Soda)  20% Oleum
o 20% SO3
o 80% H2SO4
NOTE: Milk of magnesia is MgOH2(aq)
In equilibrium:
𝐻2 𝑆2 𝑂7(𝑙) + 𝐻2 𝑂(𝑙) → 2𝐻2 𝑆𝑂4(𝑙)
3. Manufacture of Baking Soda (NaHCO3)
- Made by treating a saturated solution of (Oleum) (Sulfuric Acid)
soda ash with CO2 in a contacting tower at
about 40◦C 4. FERTILIZERS
- any material of natural or synthetic origin
that is applied to soils or to plant tissues to
2. ELECTROLYTIC INDUSTRIES
supply nutrients to the plants that are
- Electrical energy is extensively consumed by the
essentials for their growth
chemical process industries, not only to furnish
power through electric motors, but to give rise Two Types of Fertilizers
to the elevated temperatures and directly to 1. Organic – low nutrients despite of its low toxicity
cause chemical change. (CHONPK)
- Heat produced by electricity is the source of the 2. Chemical – (NPK)
high temperature required in the electrothermal a. Nitrogen (N) – required to promote
industries. development of stems and leaves
- Industries that heavily rely on REDOX reactions. b. Phosphorus (P) – stimulates growth and
accelerates fruit and seed formation
Two Types c. Potassium (K) – essential to the
1. Energy Requiring (non-spontaneous) development of starches, sugars, and
fibers and helps to prevent disease and
Ex. Electrolytic cell, Production of metal from salt
lessens the effects of excessive nitrogen
solution, production of gases
application
2. Energy Producing
Composition of Commercial Mixes expressed in the ratio
Ex. Batteries
of 30:12:6
1. Total Nitrogen (30%)
2. Available Phosphate (12%) as (P2O5 – equivalent
to 5.23% P)
3. Soluble Potassium (6%) as (K2O – equivalent to
5% K)
*Most industries in the Philippines are downstream. 18. INORGANIC AND ORGANIC CHEMICALS

Upstream Processes:
Nitrogen (N)
Haber-Bosch Process
𝑁2 ( 𝑎𝑖𝑟) + 3𝐻2 → 2𝑁𝐻3
Phosphorus (P)
- From phosphate rock
𝑃 → 𝐻3 𝑃𝑂4
Potassium (K)
- From rock/salts

5. SUGAR
6. PULP & PAPER

7. METALLURGICAL
8. WATER CONDITIONING
9. PETROCHEMICAL
10. FERMENTATION
11. CERAMICS
12. GLASS
13. RUBBER
14. INDUSTRIAL GAS
15. FATS & OILS

16. PLASTIC

Thermoplastic / Thermoset

Seven (7) Standard Classifications for Plastics


1. PET or PETE (Polyethylene Terephthalate)
Ex. Soft drink & water bottles, fruit juice
container, cooking oil
2. HDPE or PE-HD (High-density Polyethylene)
Ex. Milk jugs, cleaning agents, laundry
detergents, shampoo & laundry detergents
bottles
3. PVC or V (Polyvinyl Chloride)
Ex. Trays for sweets, fruit plastic packing (bubble
foil), food foils to wrap the foodstuff
4. LDPE or PE-LD (Low-density Polyethylene)
Ex. Crushed bottles, shopping bags, highly
resistant sack and most of the wrappings, cloth
bags
5. PP (Polypropylene)
Ex. Furniture, luggage, toys, car bumpers, car
parts, pails
6. PS (Polystyrene)
Ex. Toys, hard packing, refrigerator trays,
cosmetic bags, CD cases, vending cups,
styrofoams
7. Others or O
Ex. Acrylic, polycarbonate, polyactic fibers,
nylon, fiberglass, baby feeding bottle

17. DYES

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