option 1 a chemical industry
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Option 1A.1
Industrial Chemistry
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Contribution of Chemistry to Society
1. Provides chemicals, pharmaceuticals, fuels, medicines, agrochemicals etc.
2. Provides materials such as plastics, semi-conductors, synthetic fibres etc.
3. Provides stable well paid employment and contributes to the knowledge economy.
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James Muspratt
Born August 12, 1793Dublin, Ireland
Died May 4, 1886Lancashire, England
Nationality Irish
Field Chemist, industrialist“Father of the
modern chemical industry”
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Principles of Industrial Chemistry
Batch process: reactants/feedstock are
allowed to react for a fixed time with each
other inside a vessel known as a batch
reactor, under controlled conditions of
temperature and pressure. When the
reaction is complete the product is isolated.
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Principles of Industrial Chemistry
Continuous process: feedstock continually
fed in at one end of the plant and the product
is continually removed at the other end. All
the case studies are continuous.
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Principles of Industrial Chemistry
Semi-continuous process: is a combination of
a batch process and continuous process. The
first stage involves a batch process to make the
product, and the second stage involves a
continuous process where the product is
purified using feed from various batch reactors.
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Batch Process
Advantages Disadvantages
1. Low capital costs 1. Time consuming and labour intensive
2. Same vessel used 2. Contamination more likely
3. Easier to cater for slow reactions
3. Difficult to control exothermic reactions
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Continuous Process
Advantages Disadvantages
1. Low labour costs due to computer automation
1. High capital costs
2. Low risk of contamination since only one product is being made
2. Less flexibility as plant is tailor-made for a specific product
3. Long periods of use without stopping for maintenance
3. Not cost effective unless run at full capacity
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Characteristics of an Industrial Chemical Process
Raw materials: Limestone from a local quarry and seawater from the Boyne estuary.
Feedstock: Calcium hydroxide and purified seawater.
The reactants are called feedstock and produced from the raw materials.
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Reaction Rate
The main reaction is fast.
MgCl2 + Ca(OH)2 Mg(OH)2 + CaCl2
So to slow the process down for the formation of large crystals the incoming seawater is diluted with spent seawater.
The reaction mixture is seeded with Mg(OH)2. A high temperature of 900oC speeds up the loss of water to form MgO.
Mg(OH)2 MgO + H2O
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Products
Co-products: are other products made along
with the main product – in this case CaCl2.
By-products: are products made from side
reactions, which reduce the yield of the main
product – no by-products in this case.
Product yield: 2g MgO from a litre of seawater.
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Waste disposal and effluent control
Dust is removed by electrostatic precipitators.
Gases are scrubbed to remove SOx and grit.
The used seawater contains Ca(OH)2 which is
alkaline and has to be neutralised to reduce the pH.
It is then filtered to remove suspended solids before
being released back to sea.
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Quality control
Analysis of all reactants and products are
carried out at every stage. Acid-base
titrations are used and X-ray fluorescence is
an instrumentation technique used to test the
purity of the MgO crystals.
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Safety
Ongoing health and safety training
for staff on site.
Personal protective equipment –
helmets, boots, goggles, ear plugs
and clothing.
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Costs
Fixed costs are those that have to paid regardless of the rate of production of the plant e.g. labour, plant depreciation, repayment of loans etc…
Variable costs depend directly on the rate of production of the plant e.g. costs of raw materials, costs of effluent treatment and disposal, distribution costs, plant maintenance, administration etc
Costs can be reduced by recycling and using waste gases for heating.
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Site Location
Plentiful supply of seawater from the Boyne estuary.
Site located near a local limestone quarry with good
road and rail network for easy transport.
Highly skilled workforce available.
Site had suitable equipment already as it was
previously a cement factory.
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Construction materials
Large concrete silos. Kilns and furnaces
lined with refractory bricks. Many of the
buildings are made of steel with outer
cladding. Materials that are un-reactive and
resist corrosion are used.
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The Chemical Industry
Case Study 1A.2
Premier Periclase
www.premierpericlase.com
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Premier Periclase
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Premier Periclase
The manufacture of magnesium oxide is
carried out by Premier Periclase in
Drogheda, Co. Louth.
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Premier Periclase
It is a continuous process. MgO occurs in the
mineral periclase. It has a high melting point
2800oC and used to make refractory bricks,
which are heat resistant for lining furnaces.
The MgO powder is made into pellets and
briquettes.
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Raw materials Feedstock
Limestone CaCO3
Calcium hydroxide Ca(OH)2
Sea water Purified seawater
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Preparation of Raw Materials
CaCO3
LIMESTONE CaO + CO2
LIME
roasting
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Preparation of Raw Materials
CaO + H20 Ca(OH)2
LIME LIMEWATER
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Preparation of Raw Materials
Seawater is degassed to remove dissolved
gases and filtered to remove solids such as
sand and silt hence purifying the seawater.
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Main Reaction
Ca(OH)2 + MgCl2 CaCl2 + Mg(OH)2
MgO
(used to make refractory bricks for lining furnaces)
heat
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