Manufacture of Substance in Industry
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Transcript of 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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