Option – Part 1 Industrial Chemistry Leaving Certificate Chemistry

Benefits of Chemical Industries Produces 1.necessary medicines 2.Chemicals for food industry - increases food output 3.health and hygiene products Benefits of Chemical Industries

Chemical Industry in Ireland James Muspratt 1793 – 1886 Muspratt is credited with the beginning of the Irish Chemical Industry with the setting up of a plant in 1818 to manufacture chemical products such as hydrochloric and acetic acids and turpentine

Modern Industry in Ireland Pfizer Pharmaceuticals Co. Cork

Industrial Manufacturing Processes Manufacturing Processes BatchContinuous Industrial Chemical Reactions take place in reactors for a set period of time to make product. Process repeated for a new batch. Advantage overall costs to the pharmaceutical plant kept to a minimum. Disadvantage Contamination of the batch reactor – must be cleaned after each batch Industrial Chemical Reactions continuously take place with the raw materials fed in at one end and the product coming out at the other Advantage Very suitable for large scale production. Disadvantage Very high costs to build plants.

Semi-Continuous Process A combination of batch and continuous processes. Part of the operation is a batch process, usually the reaction step, and the separation stage might be run continuously using materials from several batch reactors.

Learning check... What does batch processing mean? Give one advantage and one disadvantage of batch processing. What is an advantage of continuous processing? Name a difference between batch and continuous processing?

The Manufacture of Ammonia and urea Nitrogen (N 2 ) Hydrogen (3H 2 )+ Ammonia (2NH 3 ) Haber-Bosch Process Iron Catalyst 400 o C High Pressure: 200 atm

Haber process – continuous flow

Why manufacture Ammonia?

The Manufacture of Ammonia and urea

Raw Materials Methane (CH 4 )Air

The Manufacture of Ammonia and urea Raw Materials give us our feedstock Methane (CH 4 ) Methane (CH 4 ) is reacted with steam to give hydrogen Steam Reforming CH4CH4 +H2OH2O3H23H2 +CO

The Manufacture of Ammonia and urea Raw Materials give us our feedstock(reactants) Air Methane (CH 4 ) is reacted with oxygen to remove it from the air leaving mostly nitrogen Secondary steam reforming CH4CH4 +2O 2 2H2O2H2O+CO 2

The Manufacture of Ammonia and urea Rate (Speed) of Reaction A finely divided iron catalyst increases the rate of reaction

The Manufacture of Ammonia and urea Product yield Some of the ammonia is used to form urea – an excellent fertiliser Nitrogen (N 2 ) Hydrogen (3H 2 )+ Ammonia (2NH 3 ) 17 %

What is a co- product? A co- product is a product that is made alongside the principal product during the process. The Manufacture of Ammonia and urea

Co-products Air The carbon dioxide produced could be sold to the beverages industry to put the “fizz” into drinks Secondary steam reforming CH4CH4 +2O 2 2H2O2H2O+CO 2

The Manufacture of Ammonia and urea Co-products Air The carbon dioxide is removed on reaction with potassium carbonate solution Secondary steam reforming CH4CH4 +2O 2 2H2O2H2O+CO 2 CO 2 + H 2 O + K 2 CO 3  2KHCO 3

The Manufacture of Ammonia and urea Co-products Air Urea is formed when ammonia reacts with carbon dioxide Secondary steam reforming CH4CH4 +2O 2 2H2O2H2O+CO 2 CO 2 + 2NH 3  NH 2 COONH 4 Ammonium Carbonate Dehydration gives urea +

The Manufacture of Ammonia and urea Waste disposal & effluent control The discharge of ammonia or carbon dioxide could lead to pollution

The Manufacture of Ammonia and urea Quality control A QC control room sensors are available to monitor variables like temperature, pressure, pH, flow rates of gases

Fixed costs vs Variable costs Fixed cost – doesn’t depend on amount of product made Variable cost –depends on how much product is made The Manufacture of Ammonia and urea Costs

The Manufacture of Ammonia and urea Costs Wages for employees Electricity costs Purchase of methane for process

The Manufacture of Ammonia and urea Site location – Cobh Cork Natural gas produced nearby Railway line nearby to transport products elsewhere Port nearby to transport products elsewhere