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Chemistry > Option - Industrial Chemistry > Flashcards

Option - Industrial Chemistry Flashcards

(103 cards)

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1
Q

list the three manufacturing processes in which a chemical product might be made

A
  • Batch Process
  • Continuous Process
  • Semi-Continuous Process
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2
Q

Batch process - the ___ _______ are allowed to react for a _____ ______ inside a reactor. Reaction takes place under ________ _________ __ ____ ___ _______ ___ _ _____ ____. When the reaction is complete, the product is _____.

A

Batch process - the raw materials are allowed to react for a fixed time inside a reactor. Reaction takes place under controlled conditions of temp and pressure for a given time. When the reaction is complete, the product is isolated. Used in pharmaceutical industry and manufacture of substances like soap

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3
Q

The raw materials are allowed to react for a fixed time inside a reactor. Reaction takes place under controlled conditions of temp and pressure for a given time. When the reaction is complete, the product is isolated.

A

Batch Process

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4
Q

Batch Process is used ….

A

in pharmaceutical industry and manufacture of substances like soap

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5
Q

Advantages of Batch Process (x3)

A
  • Capital costs are not too high
  • Same reactor can be used for a range of products
  • Easy to cater for slow reactions
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6
Q

Disadvantages of Batch Process (x3)

A
  • Filling and Emptying reactor are time consuming
  • Contamination from batch to batch is more likely
  • May be difficult to control in case of an exothermic reaction.
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7
Q

the raw materials are continually fed in at one end of the plant and the product is continually removed at other end.

A

Continuous process -

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8
Q

Continuous process - the ____ _______ are ________ ___ in at one end of the plant and the product is _______ _______ at other end.

A

the raw materials are continually fed in at one end of the plant and the product is continually removed at other end.

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9
Q

Continuous process is commonly used in…

A

the manufacture of large-scale quantities of materials. e.g ammonia and urea in IFI, Cobh, Co.Cork

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10
Q

Advantages of Continuous Process (x3)

A
  • Very Suitable for large scale production of materials
  • Long periods of usage possible before shutdown is needed for maintenance.
  • Low risk of contamination - only one product is made
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11
Q

Disadvantages of Continuous Process (x3)

A
  • Very high capital costs to build plant
  • Less flexible in terms of products manufactured
  • If plant is not run at full capacity, may not be cost effective to manufacture product.
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12
Q

Semi-continuous Process - Combination of ____ and ________. Product is made using _____ ______ and _____/_______ using _______ _______.

A

Combination of batch and continuous. Product is made using batch process’ and removed/purified using continuous process.

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13
Q

Combination of batch and continuous. Product is made using batch process’ and removed/purified using continuous process.

A

Semi-continuous Process -

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14
Q

Semi-continuous Process is used in…

A

brewing industry, soft-drinks - products made using batch process; bottling in addition of CO2 done using continuous process’

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15
Q

Feedstock

A 
The reactants used in the industrial process
//Feedstock is produced from raw materials. these raw materials may have to be treated to ensure that they are sufficiently pure to be used as feedstock//
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16
Q

The reactants used in the industrial process

A

Feedstock

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17
Q

Rate

A

The best conditions of temp., pressure, catalyst are selected for the process to occur at the optimum rate so the plant can run in the most economical way.

//It is often necessary to compromise when deciding the conditions under which the reaction will occur.//

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18
Q

The best conditions of temp., pressure, catalyst are selected for the process to occur at the optimum rate so the plant can run in the most economical way.

A

Rate

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19
Q

Co-Products

A 
Other products formed along with the main product being manufactured are called co-products . Sometimes unwanted side reactions occur and give rise to unwanted  ~by-products~. 
//Side reactions reduce the yield of the required product.//
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20
Q

Other products formed along with the main product being manufactured are called _________ . Sometimes unwanted side reactions occur and give rise to unwanted ~by-products~.

A

Co-Products

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21
Q

Product-yield

A

The conditions are chosen to ensure a reasonable yield of product in a reasonable amount of time. There has to be compromise between the reaction time and the product-yield.

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22
Q

The conditions are chosen to ensure a reasonable yield of product in a reasonable amount of time. There has to be compromise between the reaction time and the ___________.

A

Product-yield

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23
Q

Waste disposal and Effluent Control

A

co-products which may be hazardous have to be treated before disposal. Costs are incurred by treating waste water of gaseous emissions from a reaction plant. However, some of these products can also be valuable materials and be profitable to the company.

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24
Q

co-products which may be hazardous have to be treated before disposal. Costs are incurred by treating waste water of gaseous emissions from a reaction plant. However, some of these products can also be valuable materials and be profitable to the company.

A

Waste disposal and Effluent Control

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25
Quality Control
The quality of feedstock and other products are continually monitored to ensure they meet required specifications.
26
The quality of feedstock and other products are continually monitored to ensure they meet required specifications.
Quality Control
27
Safety
Chemical plants must comply with legislation covering all aspects of health and safety. There is on-going training of staff and continuous monitoring of potential hazards.
28
Chemical plants must comply with legislation covering all aspects of health and safety. There is on-going training of staff and continuous monitoring of potential hazards.
Safety
29
Costs
Fixed costs include labour, plant depreciation repayment of loans. Variable costs include the cost of raw materials, cost of effluent treatment and disposal, distribution cost, plant maintenance.
30
Fixed costs include labour, plant depreciation repayment of loans. Variable costs include the cost of raw materials, cost of effluent treatment and disposal, distribution cost, plant maintenance.
Costs
31
Ways of reducing costs...
- Recycling unreacted feedstock - using catalysts - selling useful co-products and by-products - using heat exchangers to transfer heat generated in one part to another part where heat is needed
32
Site Location
Needs to have access to good transport for movement of feedstock and products; large water supply (for cooling); skilled workforce; facilities for treatment and disposal of waste.
33
- Recycling unreacted feedstock - using catalysts - selling useful co-products and by-products - using heat exchangers to transfer heat generated in one part to another part where heat is needed
Ways of reducing costs...
34
Needs to have access to good transport for movement of feedstock and products; large water supply (for cooling); skilled workforce; facilities for treatment and disposal of waste.
Site Location
35
Plant Construction materials
Generally unreactive and resistant to corrosion e.g. glass lined vessels, stainless steel.
36
Generally unreactive and resistant to corrosion e.g. glass lined vessels, stainless steel.
Plant Construction materials
37
The two "chemicals" produced by IFI, Cobh, Co.Cork are
ammonia and urea
38
Ammonia is the basic ingredient of all _______ containing ______ compounds
Ammonia is the basic ingredient of all fertilisers containing nitrogen compounds
39
Ammonia is manufactured by ....this process is called the
passing hydrogen and nitrogen over an iron catalyst | Haber-Bosch process
40
The Haber-Bosch Process was developed by
the Chemist Fritz Haber and the chemical engineer Carl Bosch.
41
Haber-Bosch process is the
the production of Ammonia by passing hydrogen and nitrogen over an iron catalyst
42
Give the Equation for the Haber-Bosch Process
Fe | N2 + 3H2 ⇌ 2NH3
43
Fe N2 + 3H2 ⇌ 2NH3 : Is the Equation for what?
the Haber-Bosch process
44
The process was developed in Germany prior to WW1 to ensure that
Germany would be able to manufacture fertilisers and explosives
45
Who, why, where and when was the Haber-Bosch process created?
Who? Fritz Haber & Carl Bosch Why? To ensure Germany would be able to manufacture fertilisers and explosives Where? Germany When? before WW1
46
What is the ratio of Hydrogen to Nitrogen (H:N)?
1:3
47
how many atmospheres are the gases compressed to in the production of ammonia?
200atm
48
What temp. are the gases heated to in the production of ammonia?
500°C
49
What happens to the unreacted hydrogen and nitrogen in the production of ammonia?
they are sent back and passed over the catalyst again
50
what type of catalyst is used?
iron
51
Where does the hydrogen come from?
The hydrogen is obtained from natural gas in a process called methane - steam reforming
52
What does the methane - steam reforming reaction consist of? a.k.a what happens in the reaction?
``` Natural gas (methane) is reacted with steam at a high temperature to form carbon monoxide and hydrogen as a by-product. CH4 + H2O ⇌ CO + 3H2 The carbon monoxide then reacts with more steam to produce Carbon Dioxide and more hydrogen CO + H2O ⇌ CO2 + H2 ```
53
What type of reaction is this? | The carbon monoxide then reacts with more steam to produce Carbon Dioxide and more hydrogen CO + H2O ⇌ CO2 + H2
= The shift reaction
54
Why is it necessary to remove the carbon monoxide?
it poisons the catalyst, i.e. would be adsorbed on the iron catalyst
55
Overall what is the % yield of ammonia?
~70% (comes from the two reactions)
56
How is the nitrogen gas formed?
The nitrogen is formed by burning the unreacted methane (from the methane steam reforming stage) in air that is injected into the reactor. Burning the methane in air forms carbon dioxide and steam CH4 + 2O2 ⇌ CO2 + 2H2O This reaction is called secondary reforming. Thus, the oxygen in the air is removed and this leaves almost pure nitrogen. This nitrogen is later used to synthesise ammonia.
57
1:3 is....
the ratio of nitrogen to hydrogen used in the production of ammonia
58
200atm is....
the pressure the gases are compressed under
59
Haber-Bosch Process - __________ is reacted with steam at a high temperature to form ________ _______ and _________ as a by-product. The ______ ________ then reacts with more______ to produce ________ and more ______.
``` Natural gas (methane) is reacted with steam at a high temperature to form carbon monoxide and hydrogen as a by-product. CH4 + H2O ⇌ CO2 + 3H2 The carbon monoxide then reacts with more steam to produce Carbon Dioxide and more hydrogen CO + H2O ⇌ CO2 + H2 ```
60
The shift reaction =
The carbon monoxide then reacts with more steam to produce Carbon Dioxide and more hydrogen CO + H2O ⇌ CO2 + H2
61
~70% =
Overall % yield of ammonia
62
Comment on the rate of the production of ammonia
A high pressure of about 200atm and a temp. of around 500°C give a satisfactory rate. Also by keeping the particle size of the iron catalyst small, the rate of reaction is increased.
63
Comment on La Chateliers Principal and the production of ammonia.
According to La Chateliers Principle this reaction would favour a low temp. but the reaction would take too long for the temp do be of benefit. So an accommodation of 500°C was reached.
64
Comment on the Product yield in relation to the production of ammonia
The yield in the ammonia-synthesis reactor is about 17%. On leaving the reactor, ammonia is liquefied by refrigeration. The unchanged reactants are re-circulated. The typical ammonia plant produces 20,000 tonnes of ammonia each day
65
On average how much ammonia does a plant produce each day?
~20,000 tonnes
66
How is the ammonia liquefied?
by refrigeration
67
What is the & Yield of ammonia in the ammonia-synthesis reactor?
~17%
68
Why are there no co-products formed from the Haber-Bosch process?
Since the Haber-Bosch process involves the formation of only one product
69
What useful by-product is formed during the secondary reforming reaction?
Carbon Dioxide
70
Why is CO2 a useful by-product? (2xReasons)
(i) to manufacture urea in another part of the plant and | (ii) to be sold to soft drinks manufacturers and breweries to carbonate drinks.
71
How is a potassium hydrogencarbonate solution formed?
after the shift reaction has taken place, the CO2 is removed by reacting it with a Potassium Carbonate (K2CO3) solution.
72
What is formed when the CO2 is removed by reacting it with a Potassium Carbonate (K2CO3) solution.
potassium hydrogencarbonate solution
73
The following are two reasons why ______ is a useful by-product: (i) to manufacture urea in another part of the plant and (ii) to be sold to soft drinks manufacturers and breweries to carbonate drinks.
CO2
74
Equation for the formation of potassium hyrogencarbonate =
CO2 + H2O + K2CO3 → 2KHCO3
75
CO2 + H2O + K2CO3 → 2KHCO3 =
the equation for the formation of potassium hydrogencarbonate
76
Where is the potassium hydrogencarbonate pumped?
to the urea plant where the pressure on the solution is reduced and the hydrogencarbonate dissociates back into carbon dioxide and potassium carbonate.
77
What is urea?
Urea is an excellent fertiliser since its nitrogen content is so high (>46%)
78
What is Urea's nitrogen content in %?
>46%
79
Give the structural formula for urea
----------0 II H2N = C - NH2
80
Urea is manufactured by
the combination of ammonia with carbon dioxide
81
Give the chemical formula for the following equation Ammonia + Carbon Dioxide -> ammonium carbamate -> Urea + H2O
2NH3 + CO2 -> NH2COONH4 -> NH2CONH2 + H2O overall, 2NH3 + CO2 -> NH2CONH2 +H2O
82
What does EPA stand for?
Environmental Protection Agency
83
All emissions and effluents from the plant are monitored for the presence of substances like ____ or ____ from ____
ammonia or dust from urea
84
Why are the emission levels low?
as the substances are recycled back into the production process.
85
sensors are used to monitor variables like...
temp. pressure, pH, flow rate of gases etc.
86
Give two methods which are used during quality control.
Chromatography and infra-red spectrometry
87
What safety measures have IFI, Cobh, Co. Cork taken?
All staff have undertaken training courses in safety and a fire-fighting team is on standby at all times.
88
Give examples of costs endured by the plant
Purchase of natural gas - (variable); electricity - the plant has a high electrical consumption to drive the turbines- (variable); purchase of large quantities of fresh water for cooling - (variable); waged for workers - (fixed)
89
Give the four reasons why the site at Cobh was chosen;
(i) Near a railway line (ii) Deep water harbour for easy export of ammonia and urea (iii) Close to Kinsale which is a good location of natural gas (iv) Skilled workers as it is located close to Cork City which has a university and an Institute of Technology
90
Comment on the Plant Construction Materials used throughout the plant
Stainless Steel, specifically designed and custom made for the plant. this ensures that corrosion is kept at a minimum.
91
State the (approximate) optimal industrial conditions of temperature and pressure for the Haber process.
500°C and 200atm
92
Write a balanced equation to show how the hydrogen feedstock is obtained.
CH4 + H2O → 3H2 + CO
93
Explain how the nitrogen feedstock is obtained.
secondary reforming of methane (burning methane in air, removing combustion products to leave nitrogen)
94
Write a balanced equation to describe the formation of urea from ammonia
2NH3 + CO2 → NH2CONH2 + H2O
95
Give two uses of Nitrogen
(i) packaging food to prevent oxidation (keep food fresh) and (ii) for the removal of skin cancers (warts)
96
Name two components of the air feedstock that are removed prior to fractional distillation.
carbon dioxide // water vapour // dust
97
Explain how the air intake is liquefied prior to fractional distillation.
cooled // | compressed (placed under pressure)
98
Distinguish between the terms feedstock and raw materials in the chemical industry.
raw materials: used to produce feedstock while feedstock: materials (reagents, chemicals, substances) used in the process (reaction) / used to make the industrial product
99
Explain whether labour costs are a fixed cost or a variable cost.
fixed costs must be paid regardless of level of production
100
Why are glass and steel widely used as the materials for the reaction vessels in the chemical industry?
they are chemically unreactive (inert, stable, resistant to corrosion)
101
Give one advantage of a batch process and one advantage of a continuous process.
batch: versatile (usable for diff. processes / usable to make diff. products) contin: can run for long periods
102
Effluent refers to
liquid waste
103
__-________ are formed in unwanted side reactions; __-________ are accounted for in the chemical equations
By-products are formed in unwanted side reactions; co-products are accounted for in the chemical equations

Chemistry (3 decks)

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