Test tasks on chemical technology: educational manual

284 Pages·2020·1.202 MB·English

by  Аубакиров Е.А.

AL-FARABI KAZAKH NATIONAL UNIVERSITY

TEST TASKS ON
CHEMICAL TECHNOLOGY

Educational manual

Almaty
«Qazaq University»
2020

1
UDC 66. 0 (075)
BBC 35.11я73
Т 38

Recommended for publication by the decision of the Academic
Council of the Faculty of Chemistry and Chemical Technology and
Editorial and Publishing Council of al-Farabi KazNU
(Protocol No.3 dated 13.03.2020)

Reviewer
Doctor of Chemistry, Professor S.M. Tazhibayeva

Т 38 Test tasks on chemical technology: educational manual /
Y.A. Aubakirov, Zh.Kh. Tashmukhambetova, L.R. Sassykova,
[et al.]. – Almaty: Qazaq University, 2020. – 284 p.
ISBN 978-601-04-4588-8

The manual contains test tasks for the main sections of the course «Ge-
neral Chemical Technology» for the Specialty «5В072000 – Chemical Tech-
nology of Inorganic Substances». The educational manual is intended for the
organization of independent work of students. The educational manual con-
tains a very detailed glossary, questions for self-control to each chapter. It
can be useful for bachelors, masters of chemical and technological special-
ties of higher educational institutions and for engineering and technical wor-
kers in the chemical and allied industries.

UDC 66. 0 (075)
BBC 35.11я73

ISBN 978-601-04-4588-8 © Aubakirov Y.A., Tashmukhambetova Zh.Kh.,
Sassykova L.R., [et al.]., 2020
© Al-Farabi KazNU, 2020

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PREFACE

The basic discipline «General Chemical Technology» is aimed at
generalizing and consolidating the fundamental theoretical knowledge in
the most important areas of chemistry, deepening this knowledge with
examples of practical implementation in the form of existing and promi-
sing chemical technologies. This is intended to contribute to the comple-
tion of university training in the chosen direction of chemical education.
In accordance with the current main program of the specialty,
the discipline includes the study of the theoretical foundations of che-
mical technology and their practical implementation by the example of
learning the most important industrial technologies of inorganic pro-
duction.
Training of specialists in the field of chemical technology of
inorganic substances and materials has its own specifics. First, the
problem of studying the theoretical foundations of chemical techno-
logy is solved: the physicochemical laws of chemical technological
processes, the fundamentals of economics, the organization and plan-
ning of the chemical industry, etc. Secondly, an attempt is being ma-
de to integrate theoretical concepts of the natural science and funda-
mental chemical disciplines with the practical aspects of implementa-
tion of modern industrial technologies of inorganic production based
on the relevant requirements for raw materials, energy resources and
the economy of processes.
The purpose of the course «General Chemical Technology» is to
provide students of the specialty «5В072000 – Chemical Technology
of Inorganic Substances» of chemical faculties of universities with
knowledge on general techniques of using the laws of chemical, phy-
sical and technological sciences to solve the final problems of tech-
nology applied to mass industrial production of inorganic substances
and organization of modern industrial production and its economy.
In this regard, the course of chemical technology of inorganic
substances should:
– provide basic information on the current development trends
and the relationship of chemical production processes, integrated use
of raw materials and energy, creation of non-waste production and
use of the most important types of chemical products;
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– provide basic information on the main methods of transition
from experimental study of the process to industrial production, met-
hods of physical and mathematical modeling of chemical-technologi-
cal processes, as well as their optimization;
– provide basic information on the main issues of labor protec-
tion and environmental protection from harmful wastes of chemical
plants (when considering each specific technological process);
– provide basic information on the main technological prob-
lems of chemical and related industries, including the Republic of
Kazakhstan in terms of future economic development.
The main task of the «Test tasks on chemical technology» is to
form practical skills and competencies of students. Along with know-
ledge of the basics of the theory of chemical technological produc-
tion, the principles of rational use of raw materials, fuel and energy
resources, environmental protection, students should fully master the
development and implementation of technological processes, design,
construction and operation of chemical equipment and many other
practical problems of chemical technology.
The following questions must be included in the mandatory mi-
nimum content of tests in the educational program of the university
course «General Chemical Technology» for specialty 5В072000 –
Chemical Technology of Inorganic Substances:
– chemical production: hierarchical organization of processes
in chemical production; criteria for evaluating production efficiency;
general laws of chemical processes; industrial catalysis;
– chemical reactors: basic mathematical models of processes in
chemical reactors; isothermal and non-isothermal processes in che-
mical reactors; industrial chemical reactors;
– chemical process systems (CPS): structure and description of
CPS; CPS synthesis and analysis; raw materials and energy subsys-
tems CPS;
– energy in chemical production: the most important industrial
chemical production.
This manual contains test tasks according to the main sections of
the course «General Chemical Technology» and is intended for the
organization of independent work of students and its educational and
methodological support.
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1. INTRODUCTION TO GENERAL
CHEMICAL TECHNOLOGY

1.1. General questions of chemical technology

The essence of the subject «General Chemical Technology».
The history of the development of Chemical Technology. Chemical
Industry of the Republic of Kazakhstan. The most important tech-
nological concepts and definitions. Classification of technological
processes on the basis of phase

Modern chemical production is based on the achievements of
science and technology.
The basis of chemical production is chemical technology.
From the Greek language, the term «technology» is translated as
the science of the ability to do or create (technos – art, craft; logos –
science, teaching).
The object of chemical technology is substances and systems of
substances involved in chemical production, or chemical production
itself.
The processes of chemical technology are a combination of va-
rious operations carried out in the course of production in order to
transform one substance into another.
General chemical technology is a science studying the most eco-
nomic chemical ways of processing of raw materials into target pro-
ducts and means of production.
General Chemical Technology is divided into Mechanical Tech-
nology, which studies the processes associated with changes in size,
shape, state of aggregation, the crystalline structure of substances,
and Chemical Technology. Chemical technology considers not only
methods of chemical processing, but also a variety of physical, che-
mical and mechanical processes. Chemical technology studies the
processsing reactions that are associated with changes in the compo-
sition, structure and properties of substances, that is, with their che-
mical transformation into other substances.
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The subject of study of chemical technology is chemical produc-
tion, as a method of processing initial materials (raw materials) into
useful products.
The purpose of the study of chemical technology is to create ap-
propriate ways to produce the necessary human products.
Chemical technology is divided by industry into two groups:
inorganic and organic.

History
The basis of foundations of chemical technology was laid back
in antiquity, mainly in ancient China, the states of the Ancient East,
America, and later in Europe, Russia and other countries. But as an
independent scientific direction, chemical technology was formed by
the middle of the 20th century, although the prerequisites for this we-
re the achievements of scientists beginning in the 8th century and the
succeeding centuries.
Modern chemical production begins with the invention of the
French chemist Leblanc of the technology of soda production in
1789. This led scientists to the need to develop new technologies for
the production of sulfuric and hydrochloric acids, mineral fertilizers,
ammonia and nitric acid, later synthetic rubber, synthetic dyes, cata-
lytic raw materials, etc., which became the basis for the further deve-
lopment of industrial production.
In Russia, chemical technology was separated from theoretical
chemistry and became an independent science in the 1800s, when the
first Department of Chemical Technology was established at the
Academy of Sciences, the first «Technological Journal» and text-
books were published, the St. Petersburg Practical Technology Insti-
tute was organized and for the first time general courses in chemical
technology began to be read.
Later in the works of eminent chemists D.I. Mendeleev, N.N. Zinin,
N.D. Zelinsky, I.N. Kablukov, N.N. Vorozhtsov, A.G. Kasatkin, S.I. Wolf-
kovich, P.M. Lukyanov, P.T. Romankov and others scientific foundations
of chemical technology were laid. Only by 1914 in Russia there were
more than 70 chemical plants. The organization of a number of scienti-
fic institutions of the corresponding chemical technology profile, the de-
velopment of basic research on chemical technology, the publication of
textbooks and a chemical technology journal played a significant role in
the development of the science of chemical technology.
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In Kazakhstan, chemical production as a technology, unlike Rus-
sia, was developed much later – only at the end of the 19th century
(1885 – industrial production of wormwood for the production of the
drug santonin).
The development of the chemical industry in Kazakhstan was
closely and directly connected with the study of natural resources.
During this period the main attention was paid to the geological and
geochemical research connected with specification of geological re-
serves and search for new mineral deposits. In 1928-1930 the Com-
mittee on Chemicalization of Kazakhstan was organized. Studying of
raw material resources of the republic and training of chemists was
its main direction. The most important practical problems were cove-
red: study of mineral resources, development of advanced technolo-
gy of enrichment and smelting of metals, production of refractories
and building materials, etc.
It is necessary to refer to works of geochemists, geologists-mi-
neralogists V.I. Vernadsky and A.E. Fersman to number the most im-
portant in this area.
In 1930 the Aktyubinsk chemical plant for the production of mi-
neral fertilizers was built. In 1932, construction began on the Aral-
sulfat processing plant in the Kyzylorda region based on proven re-
serves of mirabilite and tenardite, from which anhydrous sodium sul-
fate was obtained for glass plants, production of sodium chloride,
magnesium chloride, etc.
In 1935, the domestic production of boron compounds from po-
tassium-boron ore deposits Inder (work of academician A.B. Bektu-
rov) was organized. In the post-war period (1945) the Kazakh metal-
lurgical plant was built, the capacity of Aktobe ferroalloys plant in-
creased, the first stage of Karatau mining and chemical plant was put
into operation. Since 1958, the construction of new facilities of the
chemical industry has been widely developed. The main direction
was the production of mineral fertilizers.
The development of Karatau phosphorites resolved the issue of
supplying phosphate fertilizers throughout Central Asia. Phosphorite
processing has allowed Kazakhstan to create powerful enterprises for
obtaining elemental yellow phosphorus using an electrothermal pro-
cess. It was decided to construct the Dzhambul double superpho-
sphate plant. The production of sodium silicofluoride was mastered.
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A workshop for the production of ammophos was put into operation.
The technology of extraction of phosphoric acid by anhydride met-
hod was developed. In Chimkent hydrolysis and tire repair plants
began to operate.
In the 1960s due to the pronounced raw material orientation of
the economy of the republic, extractive industries received priority
development. In 1961-1965 years, 729 large industrial enterprises
and 535 workshops were put into operation. In the second half of the
1960s, 445 large enterprises and workshops were put into operation,
hundreds of factories and plants were reconstructed and technically
re-equipped.
The ferrous and non-ferrous metallurgy, oil and gas, chemical
and petrochemical industries were accelerated, a number of new in-
dustries for the production of titanium, magnesium, alumina, cast
iron, coke, synthetic rubber, cranes, electric motors, new drawing
mills and forging machines, asbestos, etc. appeared.
During these years, construction of the Aktyubinsk chemical
plant in the city of Alga, for the production of precipitate, started. For
processing of phosphate ores, a special technological enrichment sche-
me was developed to obtain standardized flotation concentrate.
In 1963, the second phase of the Aktyubinsk plant of chromium
compounds, the Karaganda synthetic rubber plant, and the Guryev
chemical plant were commissioned. Tire-repair plants were built in
Tselinograd, Kustanai, Karaganda, and Pavlodar. Sulfuric acid
workshops were launched at the Balkhash Mining and Metallurgical
Combine and at the Chimkent Lead Plant. At the Karaganda Metal-
lurgical Plant, coke-chemical production was developed.
In 1964, for processing of Karatau ores, the gravity enrichment
method was used in heavy suspensions to produce final products in
the form of concentrate and waste, as well as intermediate products –
objects for flotation or roasting.
The process is based on the technology developed by scientists
L.I. Stremovsky and M.I. Baskakova. For the first time, the flotation
separation of phosphates from magnesium carbonates was carried out
by sequentially separating of first carbonates into the foam in an aci-
dic medium, and then phosphate from the chamber product in an al-
kaline medium. The process of enrichment of Karatau carbonate ores
using roasting was also developed.
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In 1965, there were five plants in Karaganda, Aktyubinsk, Semi-
palatinsk, Ust-Kamenogorsk and Chimkent. The Karaganda and Se-
mipalatinsk plants for asbestos-cement products and the Chimkent
plant for asbestos-cement constructions were commissioned.
In the 1970s capacities for production of mineral fertilizers at
the Dzhambul superphosphate plant, where new workshops on pro-
duction of sulfonated coal and defluorinated fodder phosphates were
commissioned, considerably increased. Production by the method of
melting of natural phosphates and defluorinatings in the cyclonic
furnace was first developed. The company began to produce ammo-
niated superphosphate – a fertilizer with better physical and agroche-
mical properties than simple superphosphate. During these years,
Kazakhstan produced in the country most of the yellow phosphorus,
40% of chromite salts, 20% of low-pressure polyethylene, over 10% of
sulfuric acid. The power industry was successfully developing in the
republic. The coal industry has gained significant development. In the
Karaganda and Ekibastuz basins, coal production reached 61 million tons
per year, of which 41% was mined in the most progressive, open, way.
One of the leading industries was the steel industry. At the Soko-
lov-Sarbai mining and processing plant, ore enrichment and indus-
trial production of high-quality iron ore pellets were established. The
Karaganda Iron and Steel Combine became the largest enterprise
with a full metallurgical cycle on production of special profiles of a hire,
high-quality steel and cast iron. The first stage of the Ermakovsky plant
of ferroalloys with production of ferrosilicium was commissioned.
All this led to a significant increase in the share of Kazakhstan
in the all-Union production of ferrous metals. The republic ranked
first in the country in the extraction of chromite ores, the third in the
production of iron and manganese ores; the role of the republic in the
production of steel, rolled products, and ferroalloys increased.
Non-ferrous metallurgy was further developed. Tishinsky mine
and zinc plant at Leninogorsk polymetallic plant, the largest in the
country mines of Dzhezkazgan mining and metallurgical complex
were put into operation; the complex of alumina production of Pav-
lodar aluminum plant, Ust-Kamenogorsk titanium-magnesium plant
reached initial design capacities. The production capacities of the
Ust-Kamenogorsk Lead-Zinc and Balkhash Mining and Metallurgi-
cal Complex were expanded. The oil industry also developed at an
acelerated pace.
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All this created the necessary basis for the development of che-
mical technology in Kazakhstan and necessitated training of required
engineering and technical personnel.

Schemes of the movement of material and power flows. Perio-
dic, semi-continuous and continuous processes. Essence and met-
hods of drawing up and presentation of material and power balan-
ces. Definition of product yield and coefficient of useful energy ap-
plication. Determination of power, productivity and intensity of
production. The economic requirements imposed to rational pro-
duction

The economic efficiency of chemical production is one of its
most important criteria. It depends on the scientific and technical le-
vel and production capacity.
The level of chemical production is determined by a set of tech-
nical and economic indicators (TEI): the yield of the target product,
the degree of conversion of raw materials, productivity, intensity of
the apparatus, expenditure ratios for raw materials and energy, pro-
cess selectivity, product quality, labor productivity, cost of produc-
tion.
They depend on a number of factors that characterize the state of
production: the age of the enterprise, the technical condition of the
equipment, the degree of automation of production, the qualifications
of personnel, the level of work organization, the progressiveness of
the technologies used, etc.
Technical and economic indicators characterize the possibility of
production of products of a given nomenclature and quality and are
the criteria for assessing its economic feasibility and profitability.
They are used to assess the status, plan and update production.
The yield of the target product (η) is the ratio of the mass (qu-
antity) of the obtained product to the mass of raw materials spent on
its production.
For a one-step process, A → B, the yield is:

η = m /m .
B B A

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