manufacture of substance in industry

8/8/2019 Manufacture of Substance in Industry

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Maktab Rendah Sains

Mara

Kubang Pasu

2010

Manufacture Substance

In Industry

Name :Mohamad Aniff Bin Mohamad Najib

No. Matrix: 10696


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Content.


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Sulphuric Acid.

Use

1.Fertilisers2.Paint Pigment

3.Detergents

4.Synthetic Fibre

5.Electrolyte in carbetteries

6.Cleaningmetals

7.Plastics

Manufacture

Stage 1

Sulphur to Sulphur Dioxide

Burningmetal sulphides

Mixedwith excess air anddried.Then,purified to remove impurities.

S(s)+O2(g)SO2(g)

Stage 2

Sulphur Dioxide to Sulphur TrioxidePast through the mixture a converter.

2SO2(g)+O2(g)2SO3(g)

Optimumcondition use 450C, 1 atm, Catalyse-Vanadium(V) oxide.

Produce 95% Sulphur Trioxide.

Stage 3

Sulphur Dioxide to Sulphuric Acid

Sulphur Trioxide is dissolvedin concentration sulphuric acid to produce oleum.

SO3(g)+H2SO4(l)H2S2O7(l)Oleum

H2S2O7(l)+ H2O(l)2H2SO4(aq)Dilute the oleum with water to produce concentrated ofsulphuric acid ofabout 98% inthe diluter


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Environmental Pollution

~Sources:- i) Contact Process

ii) Metal Extraction

iii) Burning ofFossil Fuel

iv) Volcanic Eruption

~ Way to Prevent:- i) Use low-sulphurfuels

ii) Remove sulphurdioxide from the waste

gas before emittedinto the atmosphere.

iii) Neutralise the acidic soil and waterby

treating them withcalcium oxide,

calciumhydroxide andcalciumcarbonate


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Ammonia and Its Salts

Use

1. To manufacture nitrogenous fertilizers.

2. Cooling agent in refrigerators.

3. To produce ammoniumchloride use in electrolyte in drycell.

4. To prevent the coagulation oflatex.

5. To make syntheticfibres.

6. As smelling salts to revive people who have fainted.

7. Making ofexplosives.

Chemicalpropertiesa)Ammonia gas dissolves in water to form a weak alkali.

NH3(g) + H2O(l) NH4+(aq) + OH-(aq)

b)The presence of hydroxide icon causes the aqueous solution to become

alkaline. Thus aqueous ammonia solution:

i.Turns redlitmus paperblue.

ii.Reacts with acid to form only salt and waterin neutralization reaction.

NH3(aq) + HCI(aq) NH4CI(aq)

2NH3 + H2SO4(aq) (NH4)2SO4(aq)

iii.Reacts with solution ofmetalliccations to produce precipitates.

Fe+(aq) + 2OH-(aq) Fe (OH)2(s)

(Form ammonia solution) Dirtygreen precipitate

Physicals Properties

Colourless GasLess dense than

airAlkaline gas

Pungent smellVery soluble in

water


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Manufacture ofAmmonia in Industry.

Haber Process

1. Ammonia is manufacture on a large scale in industry through the haberprocess. In this process,

ammonia is formedformdirect combination ofnitrogen andhydrogen gas in the volume ratio 1:3.2. The gas nitrogen obtain form the fractionaldistillation ofliquefied air. The hydrogen gas is obtained

form the cracking ofpetroleum orfrom the catalysedreaction ofnaturalgas, CH4, with steam.

CH4(g) + H2O(g) CO(g) + 3H2(g)

2.The mixture ofnitrogen andhydrogen gases is passed over an iron catalyst undercontrolled optimum

condition as below to form ammonia gas.

i.Temperature: 450-500C

ii.Pressure: 200-500 atmospheres

iii.Catalyst used: Iron fillings

N2(g) + 3H2(g) 2NH3(g)

3.Under these control optimum condition, only 15% of the gas mixture turn into ammonia gas. The

nitrogen andhydrogen that have not reacted are then flow back over the catalyst again in the reactor

chamber.

4.The ammonia product is then cooled at a low temperature so that it condenses into a liquid in the

coolingchamber.

AMMONIUM FERTILIZERS

1. Nitrogen is required in large amount byplant to make proteins which are necessary forgrowthandcellrepair.

2. Most plant are not able to get a nitrogen supplydirectlyfrom the air although it is abundant inthe air(78%). Plants can only absorb soluble nitrogen compounds from soil through theirroots.

3. The nitrogen compounds are usually soluble nitric salt, ammonia and ammonia salt which aremanufacture as chemicalfertilizer.

4. Reactions ofammonia with acids produce ammoniumfertilizers.


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Alloys

Definition

~ A mixture oftwo ormore elements with a certain fixedcomposition in which

the majorcomponent in a metal.

Physical Properties

1.Ductile- can be drawn into fine wire

2.Malleable- can be beaten into thin sheets without cracking

3.Lustrous- becomes shiny when polished

4.Highdensity

5.Highmelting angboilingpoint

6.Goodconductor ofelectric andheat

Force

Metals are ductile

ForceThe shape of the

metal change

Matel are malleable


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Aim ofmaking Alloy

1.To increase the strength andhardness ofa pure metal

~During alloying, small amount ofothermetalis addedinto the molten pure

metal. When alloybecome solid, the otherparticle is replace the pure metal

partical.(disrupts the orderly arrangement ofatom)

~This reduce the layers ofatoms from sliding over one another andmaking

Alloys harder ang stronger than pure metals.

2.To increase the resistance to corrosion ofpure metal

~Most metalcorrode readily when exposed to air. This is because theyreact

with oxygen and water vaporin air.(prevent metals fromcorrosion)

3.To improve the appearance ofa pure metal

~Metals have lustrous surface prevent fromformation ofoxide layers.


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Composition, properties anduses ofalloys.

Alloy Composition Properties Uses

High carbon steel 99% iron

1% carbon

Strong,hard and

high wearresistance

yMaking ofcutting tools,hammers and

chisels

Stainless steel 80.6% iron

0.4% carbon

18%chromium

1% nickel

Do not rust and

tarnish, strong

and durable

yMaking ofsurgical

instrument,

knives forks and

spoons

Brass 70% copper

30% zinc

Hard, do not rust,

bright appearance

yMaking of

ornaments,electrical wiring

and plug.

Bronze 90% copper

10% tin

Hard, do not

corrode easily

and durable

yFor castingbells, medals,

swords and

statues

Pewter 90% tin

2.5% copper

0.5% antimony

Ductile and

malleable, white

silveryappearance

yMaking ofornaments,

souvenirs andmugs

Duralumin 95% aluminium

4% copper

1%magnesium

Light, strong and

durableyMaking part of

aircrafts and

racing cars

Cupronickel 75%copper

25%nickel

Attractive, silvery

appearance, hard

and tough

yMaking of silvercoins

Composition, properties and uses of alloys


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Synthetic Polymers

Definition

Polymers =Longchainedmolecules formedby joiningupmanyidenticalrepeating

sub-units calledmonomers.

Polymerisation =Process by which the monomers are joining togetherinto chain-

Like bigmolecules knows as polymers.

How are syntheticpolymers made?

1. Addition polymerisation

~ Involve monomer withcarbon-carbon double between the carbon atoms

2. Condensation polymerization

~ Joining the monomers with the formation ofother smaller and simple

Molecules

Exist in living things

in nature.Natural

Polymers

Man-made inlaboratory throughchemicalprocess

SyntheticPolymers


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Some Common Addition Polymers

Name(s) Formula Monomer Properties Uses

Polyethylene

low density(LDPE)(CH2-CH2)n

ethylene

CH2=CH2soft, waxy solid

film wrap,

plastic

bags

Polyethylene

highdensity(HDPE)(CH2-CH2)n

ethylene

CH2=CH2rigid, translucent solid

electrical

insulation

bottles,

toys

Polypropylene

(PP) different grades

[CH2-

CH(CH3)]n

propylene

CH2=CHCH3

atactic: soft, elastic solid

isotactic: hard, strong

solid

similar to

LDPE

carpet,

upholster

y

Poly(vinyl chloride)

(PVC)(CH2-CHCl)n

vinylchloride

CH2=CHClstrongrigid solid

pipes,

siding,

flooring

Poly(vinylidene

chloride)

(Saran A)

(CH2-CCl2)nvinylidene chloride

CH2=CCl2dense, high-melting solid

seat

covers,

films

Polystyrene

(PS)

[CH2-

CH(C6H5)]n

styrene

CH2=CHC6H5

hard, rigid, clear solid

soluble in organic

solvents

toys,

cabinets

packaging

(foamed)

Polytetrafluoroethylen

e

(PTFE, Teflon)

(CF2-CF2)n

tetrafluoroethylen

e

CF2=CF2

resistant, smooth solid

non-stick

surfaces

electrical

insulation

Poly(methyl

methacrylate)

(PMMA, Lucite,

Plexiglas)

[CH2-

C(CH3)CO2CH3]n

methyl

methacrylate

CH2=C(CH3)CO2CH3

hard, transparent solid

lighting

covers,

signs

skylights

Uses of synthetic polymers


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SYNTHETIC POLYMERS IN DAILY LIFE

1. Syntheticpolymers have many advantages over other type ofmaterials:

a. They are cheap, light-weight and translucent.

b. They are easilycoloured, easilymoulded and shaped.

c. They are non-corrosive, waterproofandgoodinsulator.d. They are durable and long lasting because they are resistant to decay,

rusting andchemical attacks.

2. There are disadvantage using syntheticpolymer:

a. Most of the syntheticpolymer are flammable. When a syntheticpolymer

materialcatches fire, poisonous fumes are produce causing airpollution.

b. Synthetic polymers are non-biodegradable. When there are discharge,

theycause litterproblem andpollute the environment.

c. Plastic container that are left aside in an open area collect rainwater

whichbecomes the breedinggroundformosquitoes.

d. There are limitation in recycle have to be separated out as the addition of

non-recyclable polymers in the mixture affect the properties of the

recycledpolymers.


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Glass and Ceramics

WHAT ARE GLASS

1. Glass is one of the most usefulbut inexpensive materials in the world. Manyproducts are made fromglass because ofits specials properties.

2. Glass is:

a. Transparent, hardbut brittle.

b. A heat and electricinsulator.

c. Resistant to corrosion.

d. Chemical not reaction and therefore resistant to chemical attack.

e. Easy to maintain.

Type of glass Composition Properties Uses

Fused glass SiO2: 100% yTransparent

yHigh melting point

yGood heatinsulator

yLens

yTelescope mirrors

yLaboratoryapparatus

Soda-lime glass SiO2: 75%Na2O:15%

CaO: 9%Other:1%

yLow melting point,easily molded intodesired shape and

size

yLow resistant tochemical attacks

yBrittle

yDrinking glass,bottles

yElectric bulbs

yWindow glass

Borosilicate glass SiO2: 78%

B2O3: 12%Na2O: 5%

CaO: 3%Al2O3:2%

yResistant chemicalattack and durable

yHigh melting point

yGood insulator toheat

yCooking utensils

yLaboratoryglassware such as

conical flaks andboiling tube

Lead crystal glass

(flint glass)

SiO2: 70%

Pbo/PbO2:20%Na2O: 10%

yHigh refractiveindex

yHigh density

y

Attractiveglittering

appearance

yLenses and prisms

yDecorativeglassware and art

objectyImation jewellery


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CERAMICS

1. Traditional silicate ceramics are made byheating aluminosilicate clay such as

kaolin to a varyhigh temperature.

2. Ceramics have many specialproperties that make them one ofthe most useful

materials in our everydaylife. That:

a. Are hard, strongbut brittle

b. Have highmeltingpoint andremain stable at high temperature

c. Are heat and electricinstrument

d. Are resistant to corrosion and wear

e. Are chemically not reactive

f. Do not readilydeformunder stress

3. Ceramicplayimportant role in ourdailylife. They are uses as

a. Construction materials

i.Ceramic are strong andhard, uses to make rooftiles, bricks cement, sinks,

and toilet bowls.

ii.They are also used to make refractory bricks because high resistant to

heat.

b. Decorative items

i.To make pottery, china plates, and porcelain vases since they do not

tarnish easily and are durable.

ii.They are used to make bathroomfixture such as floor and wall tiles.

c. Electricalinsulator

i.Ceramic are used to make electrical insulator in electrical items such as

toasters, fridges and electricalplug.

Materials Melting point/C

Density/G cm-3 Elastic

modulus/ GPa

Hardness/ mohs

Oxide ceramic

Alumina,AL2O3Beryllia, BeO

Zirconia, ZiO

20542574

2710

3.973.01

5.68

380370

210

98

8

Non-oxideceramicsBoron

carbide,B4C3Silicon nitride,

Si3, n4

2350

2830

1900

2.50

3.16

3.17

280

400

310

9

9

9

Metals

AluminiumSteel

6601515

2.707.86

70205

35


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Composite Materials

WHAT ARE COMPOSITE MATERIALS

1. A composite materials (orcomposite) is a structure ofmaterials that is formed

by two or more different substances such as metal, glass, ceramic and

polymer.

2. Some common composite materials are:

a. Reinforces concrete

b. Superconductor

c. Fibre optic

d. Fibre glass

e. Photochromicglass

REINFORCES CONCRETE

1. Concrete is hard, fireproof, waterproof, comparatively cheap and easy to

maintain. It is more important construction materials.

2. The reinforces is a combination ofconcrete and steel.

SUPERCONDUCTOR

1. Metal such as copper and aluminium are good conductor of electricity, but

20% ofthe electric energyis lost in the form ofheat during transmission.

2. Superconductor are materials that have no resistance to the flow ofelectricity

at a particular temperature. Hence, 100% electricity transmission is possible.

3. One of the most dramatic properties of a superconductor is its ability to

levitate a magnet. Superconductor are used to buildmagneticallylevitate high-

speed train (at about 552 km/h).

4. Superconductor are used to make chips for smaller andfaster supercomputer.

Superconductor also play an important role in high speeddata processing in

internet communication.


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FIBRE OPTIC

1. Fibre optic is a composite material that in used to transmit signals for light

wave.

2. Fibre opticis usedin

a. Telecommunicate where the telephone substation are likedbyfibre opticcables.

b. Domesticcable television network

c. Closedcircuit television security system.

3. Fibre optic also used in medical fields. It is used in a number of instrument

which enable the investigation for internal body part without having to

perform surgery.

FIBRE GLASS

1. Fibre glass is glass in the form of fine threads. Molten gas is dropped onto a

refractoryratingdisc when the glass flies offthe discglass to formfibre.

2. Fibre glass is strong than steel, do not burnt, stretch orrot, resistant to fire and

waterbut is brittle.

3. When fibre glass added to a plastic, a new composite material fibre glass

reinforces plasticis formed.

4. Fibr

egl

assreinforc

espl

astic

h

asm

ore s

uperi

orpr

op

erties t

han

glass an

dplastic. It is

a. Extremely strong

b. Light weigh

c. Resistant to fire and water

d. Can be molded, shaped and twisted

PHOTOCHROMIC GLASS

1. When 0.01 to 0.1% of silverchloride (a type ofphotochromic substances) and

a small amount of copper (II) chloride are added to molten silicon dioxide,

photochromicglass is formed.

2. The photochromic glass has a specialproperties. It darken when exposed to

strong sunlight orultraviolet.

3. Photochromicglass is suitable formaking sunglasses.


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manufacture of substance in industry

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