an Introduction to Industrial Chemistry Also edited by C. A. Heaton The Chemical Industry (a complementary volume) Contents: Editorial introduction C. A. Heaton. Polymers J. P. Candlin. Dyestuffs E. N. Abrahart. The chlor-alkali, sulphur, nitrogen and phosphorus industries D. R. Browning. The pharmaceutical industry C. W Thornber. Agrochemicals C. A. Heaton. Biological catalysis and biotechnology M. K. Turner. The future C. A. Heaton. References. Index. an introduction to Industrial Chemistry Second Edition Edited by (R Heaton Senior Lecturer and Industrial Chemistry Subject Tutor School of Natural Sciences Liverpool Polytechnic BLACKIE ACADEMIC &. PROFESSIONAL An Imprint of Chapman & Hall London . Glasgow· New York . Tokyo . Melbourne· Madras Published by Blackie Academic & Professional, an imprint of Chapman & Hall, Wester Cleddens Road, Bishopbriggs, Glasgow G64 2NZ, UK Chapman & Hall, 2-6 Boundary Row, London SE1 8HN, UK Blackie Academic & Professional, Wester Cleddens Road, Bishopbriggs, Glasgow G64 2NZ, UK Chapman & Hall Inc., One Penn Plaza, 41 st Floor, New York NY10119,USA Chapman & Hall Japan, Thomson Publishing Japan, Hirakawacho Nemoto Building, 6F, 1-7-11 Hirakawa-cho, Chiyoda-ku, Tokyo 102, Japan DA Book (Aust.) Pty Ltd, 648 Whitehorse Road, Mitcham 3132, Victoria, Australia Chapman & Hall India, R. Seshadri, 32 Second Main Road, CIT East, Madras 600 035, India First edition 1984 Reprinted 1991, 1992, 1994 © 1991 Blackie & Son Ltd. Typeset by Thomson Press (India) Limited, New Delhi Edmunds, Suffolk ISBN-13: 978-0-7514-0113-4 e-ISBN-13: 978-1-4615-6438-6 001: 10.1007/978-1-4615-6438-6 Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the UK Copyright Designs and Patents Act, 1988, this publication may not be reproduced, stored, or transmitted, in any form or by any means, without the prior permission in writing of the publishers, or in the case of reprographic reproduction only in accordance with the terms of the licences issued by the Copyright Licensing Agency in the UK, or in accordance with the terms of licences issued by the appropriate Reproduction Rights Organization outside the UK. Enquiries concerning reproduction outside the terms stated here should be sent to the publishers at the London address printed on this page. The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made. A catalogue record for this book is available from the British Library Preface to First Edition The chemical industry is a major, growing influence on all our lives, encompassing household commodities and utensils, industrial materials and components, medicines and drugs, and the production of chemicals has become an essential factor in the economy of any industrialized nation. The scientists and engineers responsible for the efficient operation of the industry must have a sound knowledge not only ofthe physical and chemical principles, but also of the economic and environmental aspects and the cost-effective use of energy. This book provides an introduction to these topics and includes detailed discussion of catalysis and petrochemicals. It is written as a basis from which students of chemistry and chemical engineering will be able to build an understanding and appreciation of the industry. Acknowledgements An undertaking of this nature requires teamwork and it is a pleasure to acknowledge the efforts and cooperation of the contributors. Thanks are also due to the publishers for their help and advice at all times. Finally, I wish to thank my wife Joy for typing part of the MS and for the support which she and our children, Susan and Simon, have given. C.A.H. v Preface to Second Edition The first edition of this book has been very well received and the few minor criticisms made by reviewers were largely answered by the publication of the complementary book-The Chemical Industry by C. A. Heaton (referred to as Volume 2}-which was in preparation at the time. This covers each of the major sectors of the chemical industry. They are designed to be used as a two volume set and the contents of Volume 2 are listed on page ii of this volume. We have, however, taken the opportunity in this second edition to add two new chapters: Chapter 1, Introduction to the chemical industry which gives both an overview of the industry and a lead into other chapters, and Chapter 9, Chlor-alkali products which provides a balance on the inorganic side to the Petrochemicals chapter on the organic side, plus leading into Chapter 3 of Volume 2 (The chlor-alkali, sulphur, nitrogen and phosphorus industries). Almost all statistics and tables have been updated as have references and bibliographies, where appropriate, and it is a pleasure to record thal this has been done by the original team of authors. The new edition also reflects the changed situation of the industry which is currently riding high, in contrast to the recession when the first edition was written. Issues which have become more topical during the last few years, mostly environmental concerns, are also given increased coverage. We hope you enjoy reading this new edition and find it both informative and interesting. C.A.H. Note Where reference is made to West Germany this is because no figures were available for the newly combined Germany at the time of printing. VI Contributors D. G. Bew Formerly of ICI Petrochemicals and Plastics Division, Wilton, Middlesbrough C. A. Heaton School of Natural Sciences, Liverpool Polytechnic S. F. Kelham ICI Chemicals and Polymers Ltd., Runcorn, Cheshire J. McIntyre Department of Chemistry, University of York 1. Pennington Formerly of BP Chemicals Ltd, Hull K. V. Scott Consultant, Worthing, West Sussex R. Szczepanski Infochem Computer Services Ltd., London vii Conversion factors Mass 1 tonne (metric ton) = 1000 kilograms = 2205 pounds = 0·984 tons 1 ton = 1016 kilograms = 2240 pounds = 1·016 tonnes Volume 1 litre = 0·220 gallons (U.K. or Imperial) = 1 cubic metre 1 gallon = 4·546 lit res 1 gallon = 1·200 U.S. gallons = 0·00455 cubic metres 1 barrel = 42 U.S. gallons = 35 gallons = 0·159 cubic metres (Densities of crude oil vary, but 7·5 barrels per tonne is an accepted average figure.) 1 cubic metre = 35·31 cubic feet 1 cubic foot = 0·02832 cubic metres Pressure 1 atmosphere = 1·013 bar = 14·696 pounds per square inch = 1· 013 x 105 newtons per square metre = 1·013 x 10 5 pascal Temperature Degrees Centigrade = 0·556 (degrees Fahrenheit - 32) Degrees Fahrenheit = 1·80 (degrees Centigrade) + 32 Degrees Kelvin = degrees Centigrade + 273 Energy 1 therm = 100000 British thermal units 1 British thermal unit = 0·252 kilocalories = 1·055 kilojoules 1 kilocalorie = 4·184 kilojoules 1 kilowatt hour = 3600 kilojoules = 859·8 kilocalories = 3412 British thermal units. Vlll CONVERSION FACTORS IX Power 1 horsepower = 0·746 kilowatts 1 kilowatt = 1·34 horsepower