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Industrial Chemistry Prepared by Helen Njeri NJENGA African Virtual university Université Virtuelle Africaine Universidade Virtual Africana African Virtual University Notice This document is published under the conditions of the Creative Commons http://en.wikipedia.org/wiki/Creative_Commons Attribution http://creativecommons.org/licenses/by/2.5/ License (abbreviated “cc-by”), Version 2.5. African Virtual University Table of ConTenTs I. Industrial Chemistry ________________________________________3 II. Prerequisite Course or Knowledge _____________________________3 III. Time ____________________________________________________3 IV. Materials _________________________________________________4 V. Module Rationale __________________________________________4 VI. Content __________________________________________________5 6.1 Overview ___________________________________________5 6.2 Outline _____________________________________________5 6.3 Graphic Organizer _____________________________________7 VII. General Objective(s) ________________________________________8 VIII. Specific Learning Activities ___________________________________8 IX. Pre-assessment __________________________________________11 X. Compiled List of all Key Concepts (Glossary) ____________________14 XI. Compiled List of Compulsory Readings ________________________15 XII. Compiled List of Resources _________________________________16 XIII. Compiled List of Useful Links ________________________________17 XIV. Learning Activities _________________________________________20 XV. Synthesis of the Module ___________________________________162 XVI. Summative Evaluation ____________________________________163 XVII. References _____________________________________________165 XVIII. Student records _________________________________________166 XIX. Main Author of the Module _________________________________166 XX. File Structure _____________________________________________167 African Virtual University I. Industrial Chemistry By Dr. Helen Njeri Njenga, University of Nairobi and William Wanasolo II. Prerequisite Courses or Knowledge Module 5 Unit I Basic Organic Chemistry Unit II Hydrocarbons Unit III Alkyl halides Unit IV Amines Module 6 Unit I Alcohols and ethers Unit III Carboxylic acids and their derivatives Module 7 Unit I Benzene and its derivatives Unit III Heterocyclic compounds Module 9 Thermodynamics Chemical principles of variable constituents III. Time This unit will require 120 hours • Unit I Introduction to industrial chemistry and the chemical industry (15 hrs) • Unit 2. Unit Operations and Unit Processes (20 hrs) • Unit 3. Industrial Inorganic Chemistry I (Extractive Metallurgy) (10 hrs) • Unit 4. Industrial Inorganic Chemistry II (Chlor-alkali, Ammonia, Sulphuric Acid, Fertilizer and Cement) (20 hrs) • Unit 5. Industrial Organic Chemistry I (Petroleum, Petrochemicals and Po- lymers) (25 hrs) • Unit 6. Industrial Organic Chemistry II (Fermentation, Ethanol, Pharmaceu- ticals, Soaps and Detergents) (25 hrs) African Virtual University IV. Materials You will require the following tools and resources for completing the module: Computer, CD-ROM, and e-library • To access this module, exams and other relevant material • To access other suggested reference materials • For interactive discussions/chat sessions Recommended textbooks and reference materials • To assist learning and further understanding of topics in the module V. Module Rationale Industrial chemistry deals with commercial production of chemicals and related products from natural raw materials and their derivatives. It enables humanity to experience the benefits of chemistry when we apply it in the exploitation of materials and energy. When we apply chemistry in the transformation of materials and energy to make useable products, this results in growth and improvement in areas such as food production, health and hygiene, shelter and clothing. The economic growth of industrialized countries relies on the manufacturing industry for finished products. The goal of studying industrial chemistry at university is to try and bridge the gap between classical chemistry and chemistry is applied in industry. The chemical industry is highly globalized and produces thousands of chemicals from a wide variety of raw materials by means of varied technologies for varied end uses. It is therefore important to base the study of industrial chemistry on an understanding of the structure of the industry and the unit operations and unit processes that make up the chemical processes. On the basis of natural raw materials sources and the chemistry involved, we find it easier to study industrial inorganic and industrial organic chemistry separately, Through the electrolysis of brine, we obtain chlorine and sodium hydroxide both of which are important reactants in organic synthesis of products such as petrochemicals and detergents respectively. By fixing nitrogen, we obtain ammonia, from which we can make fertilizers. From sulphur, we get sulphuric acid, which we use, in the manufacture of phosphate fertilizers. Mineral ores as well as being raw materials for basic chemicals are the source of pure metals, which we use elsewhere in building and construction, manufacture of equipment, machines and jewellery. Turning now to organic chemical industry, we use petroleum as the source of petrochemicals and synthetic polymers. Fermentation enables us to convert natural organic materials into chemicals, some like penicillin being pharmaceutical ingredients. From natural oils and fats, we obtain soaps and detergents. African Virtual University VI. Content 6.1 Overview This module starts by defining industrial chemistry and then gives a view of the chemical industry, its position in the general economy, and its classification in terms of the chemical processes that characterize it. To enable the study of selected chemical processes, unit operations and unit processes, especially those that are relevant in later learning actvities, are then covered in Unit 2. With this background, it will be easy to study industrial inorganic and organic chemical industries. The study of extractive metallurgy in Unit 3 draws on the knowledge of size reduction and separation unit operations learnt earlier, as well as chemical conversions that take place during pyroprocessing. The extractive metallugy of iron, copper and aluminium is included. In Unit 4, we focus our attention on some basic inorganic industrial processes that synthesize products from a variety of raw materials derived from the natural environment. They include manufacture of chlorine and sodium hydroxide from brine, ammonia from methane and nitrogen, sulphuric acid from sulphur, fertilizer and cement from mineral ores. The study of organic industrial chemistry then starts with petroleum refining followed by the manufacture of selected petrochemicals and polymers. The module closes with the study of ethanol, pharmaceuticals, soaps and detergents. These are high value-added products, some of which are produced through the fermentation route. 6.2 Outline Unit 1: Introduction to Industrial Chemistry (15 hours) • Introduction to industrial chemistry • Classification of the chemical industry • Raw materials for the chemical industry • Unit operations and unit processes that make up chemical processes • Flow diagrams • Material and energy balances Unit 2: Unit operations and unit processes (20 Hours) • Size reduction and size enlargement • Magnetic and electrostatic separation • Froth flotation • Fractional distillation • Unit processes African Virtual University Unit 3: Inorganic Industrial Chemical Industries Part I: Extractive metallurgy (10 Hours) • Mineral ores • Ore dressing • Pyroprocessing • Refining • Extractive metallurgy of iron • Extractive metallurgy of aluminium • Extractive metallurgy of copper Unit 4 : Inorganic Chemical industries Part II: Chlor-alkali, Ammonia, Sulphuric Acid, Fertilizer, Cement (25 hours) • Sodium hydroxide and Chlorine • Ammonia • Sulphuric acid • Fertilizer • Cement Unit 5: Organic Chemical IndustriesI : Petroleum, Petrochemicals and Polymers (25 hours) • Petroleum processing • Petrochemicals • Polymers Unit 6: Organic Chemical Industries II Fermentation, Ethanol, Pharmaceuticals, Soaps and Detergents (25 hours) • Fermentation • Ethanol • Pharmaceuticals • Soaps and detergents African Virtual University 6.3 Graphic Organizer Industrial Chemistry General Industrial Industrial Industrial Inorganic Organic Chemistry Chemistry chemistry Introduction to industrial chemistryand Fermentation, chemical ethanol, industry pharmaceuticals, Unit operations soaps and and unit detergents processes Petroleum, petrochemicals Extractive and polymers metallurgy Chlor-alkali, ammonia, sulphuric acid, fertilizer, cement 6 African Virtual University VII. General objective(s) At the end of this module you should be able to: i. Classify the chemical industry in terms of products, raw materials, scale and types of transformations. ii. Describe the operation principles of selected unit operations and unit processes. iii. Describe metal extraction in general and the extractive metallurgy of iron, aluminium and copper in particular. iv. Discuss with the help of relevant flow diagrams, equations, operating conditions and equipment principles, the manufacture of chlorine, sodium hydroxide, ammonia, sulphuric acid, fertilizer and cement. v. Explain using flow diagrams and equations, how crude oil is refined, and how some petrochemicals and polymers are synthesized. vi. Discuss fermentation theory and its application in ethanol manufacture, the production of some pharmaceuticals, soaps and detergents. VIII. specific learning objectives (Instructional objectives) Unit 1: Introduction to Industrial Chemistry and the Chemical Industry At the end of this unit, you should be able to: a. Distinguish between classical and industrial chemistry b. Classify the chemical industry in terms of scale, raw materials, end use and value addition c. Distinguish between unit operations and unit processes d. Describe chemical processes by means of flow diagrams e. Carry out material balances for a simple process Unit 2: Unit Operations and Unit Processes At the end of this unit you should be able to: a. List the various reasons for undertaking size reduction and enlargement in the chemical industry b. Describe the operation principles of some size reduction equipment and size enlargement equipment African Virtual University c. Explain how industrial materials can be separated on the basis of their magnetic, electrostatic, hydrophobic and volatility differences respectively d. Discuss various organic unit processes including polymerization, alkylation, hydrolysis and their application in the chemical industry. Unit 3: Inorganic Chemical Industries Part I: Extractive Metallurgy At the end of this unit you should be able to: a. Describe the various stages mineral ores go through in a typical mineral ore dressing process. b. Write equations to describe calcination and roasting c. Explain what happens during smelting d. Describe the extractive metallurgy of iron e. Describe the extractive metallurgy of aluminium f. Describe the extractive metallurgy of copper Unit 4: Inorganic chemical Industries Part II: Chlor-alkali, Ammonia, Sulphuric Acid, Fertilizer, Cement At the end of this unit you should be able to a. Describe using equations and diagrams, the electrolytic process for the production of sodium hydroxide and chlorine using mercury, diaphram and membrane cells b. Explain how ammonia is manufactured from methane and air by the Haber process c. Describe the Contact process for the manufacture of sulphuric acid d. Discuss the various types of fertlizers and the manufacture of phosphate fertilizer e. Describe using diagrams, equations and unit operations, for the manufacture of Portland cement. Unit 5: Organic Chemical Industries Part I: Petroleum, Petrochemicals and Polymers At the end of this unit you should be able to: a. Discuss the occurrence and extraction of petroleum b. Explain the purposes and application of fractional distillation, catalytic crac- king and catalytic reforming during petroleum processing c. Describe using equations and flow diagrams, the manufacture of some petrochemicals, namely, phthalic anhydride and adipic acid