- INDUSTRIAL HEAVY CHEMICALS -

Chemistry is a branch of science which deals with the study of matter

w.r.t. their properties , composition, structure and uses such study is
called as “ Chemistry .”

Industrial chemistry is the branch of chemistry which deals with the

preparation of various chemicals on a large scale in industry is called as
“Industrial Chemistry”.

The rate of chemical reaction is totally depends upon the temperature ,

pressure ,concentration and catalyst. Some of the reaction or processes
occur’s spontaneously with desired products while some of the reaction
requires longer periods hence such reactions may required proper
conditions.

The study of kinetics and energetic of a chemical reaction is to be

studied for the better yield.

The chemicals which are manufactured and consumed on commercial

scale in the market is called as “ Heavy Chemicals”.

This topic deals with the study of industrial chemistry of two heavy
chemicals .these are viz . Sulphuric acid and ammonia. Each chemical is
studied with respect to their 1) Physico-chemical principle 2) It’s Plant
and process.

A simple balanced chemical reaction cannot give’s any idea about the
optimum conditions of the reaction. Hence it becomes essential to
study the reaction with physico-chemical principles.( Means conditions
for getting the good yield ).

SULPHURIC ACID ( H2SO4) :

Sulphuric acid is king of chemicals which is most important commercial
product, Not a single industry can be run without the use of Sulphuric
acid. It plays an important role in the manufacture of number of
substances like cellulose , acids , fertilizers , dyes ,drugs , industrial
explosives , in leather industry , paints and pigments , in plastics, rayon
,textile ,coal-tar products and what not !

It is used in electroplating , refining of oils , in paper industry , in

purification of petroleum ,and in metallurgical processes. It also used in
nitration , esterification and in sulphonation of organic compounds.

Sulphuric acid is one of the powerful oxidising as well as dehydrating

agent . The technical development of country is totally depends upon
the manufacture and consumption of sulphuric acid. The country which
manufacture and consumed the sulphuric acid on large scale such
country is richest country in the world. Commercially , sulphuric acid is
consumed in countless industries.

There are two different methods used for manufacture of sulphuric

acid .these methods are –

1. The Lead Chamber Process ( Old method) ,

2. The Contact Process ( Modern method).

The Lead Chamber process is old and today is out of dated. Hence the
Contact process is the most advanced ,economical and almost
automatic today near about 80% of the Sulphuric acid is manufactured
by the contact Process.
MANUFACTURE OF H2SO4 BY CONTACT PROCESS :-

A) Theory : IN the manufacture of Sulphuric acid by contact

process involves the following reactions :-
1. Sulphur or sulphur containing compounds like iron pyrites
when burnt in air it produce sulphurdioxide.
S + O2 SO2
4FeS2 +11O2 8SO2 + 2Fe2O3
2. Sulphur dioxide is oxidised to Sulphur trioxide by atmospheric
oxygen in presence of suitable catalyst.
2SO2 + O2 V2O5 / Pt 2 SO3

3. Sulphur trioxide is absorbed in concentrated H2SO4 (98%) .It

gives oleum i.e. pyrosulphuric acid or may called as fuming
sulphuric acid.
SO3 + H2SO4 H2S2O7 ( Oleum )
4. This oleum is diluted with water or with dilute sulphuric acid .it
form any desired strength of H2SO4.

H2S2O7 + H2O 2H2SO4.

In a nut shell :
S oxidation SO2 oxidation SO3 Conc.H2SO4 H2S2O7
Pt/v2O5
(Oleum) water 2H2SO4.
The main step in this process is the catalytic conversion of SO2
into SO3. This is heterogeneous catalytic reaction because the
reactant SO2 , O2 and product SO3 are in gaseous phase while
catalyst Pt / V2O5 are in solid phase.
 These reacting gases are come in contact over the surface of solid
catalyst Pt or V2O5. Hence the name of process becomes “Contact
Process”.

PHYSICO-CHEMICAL PRINCIPLES :

( Conditions to get good yield of SO3) :-

The main reaction of contact process is catalytic oxidation of SO2 into

SO3 by atmospheric oxygen. The reaction may be represented as –

2SO2 (g) + O2(g) Pt/ V2O5 2SO3(g) + 189 kJ/ Mole

2vol 1 vol. 2 vol.

The reaction is reversible and forward reaction is exothermic once the

reaction is started further heating is not necessary. Reaction proceeds
with decrease in volume of products.

Hence for getting the good yield of SO3 reaction should be studied with
conditions like temperature, pressure , concentration and catalyst.
a) Effect of Temperature : -
The key reaction of this process is –
2 SO2 + O2 Pt/V2O5 2 SO3 + 189 kcal .
2vol + 1 vol 2vol
The above reaction is reversible and forward reaction is
exothermic .one’s the reaction is started further heating is not
necessary. Reaction proceeds with decrease in volume of the
products. ( From 3 vol of reactant to 2 vol of product) .
Therefore this reaction should be carried out at 4500c. for the
better yield of SO3.
Below and above to this particular temperature 4500c the catalyst
Pt or vanadium pentaoxide V2O5 becomes inactive .
 It’s conversion efficiency goes on decreasing with decrease in
yield of product.

Fig- 3.4

From the table 3.3 fig 3.3 and fig. 3.4 it clearly shows that, the
oxidation of SO2 to SO3 is 100% at 4000c ( 673 K ). But it goes on
decreasing with rise in temp.
 On the other hand from table 3.4 it is found that the rate of
reaction increases with rise in temperature.
The reacting gases are passed over a part of the catalyst at 5500c
(823 K) Where rate of reaction is very high it convert 80% of SO2
to SO3 then gaseous mixture is cooled down at 4500c (723 K) by
passing through heat exchanger and then pass over the surface of
catalyst it form 97% of SO3 continuously.
b) Effect of Pressure :-

The key reaction of this process is –

2 SO2 + O2 Pt/V2O5 2 SO3 + 189 kcal .

2vol + 1vol 2vol

The above reaction is reversible and forward reaction is
exothermic .one’s the reaction is started further heating is not
necessary reaction proceeds with decrease in volume of the
products. ( From 3 vol of reactant to 2 vol of product) .
Therefore this reaction should be carried out at 1.5 to 1.7 atm
pressure for the better yield of SO3. Below and above to this
particular pressure 1.5 to 1.7 atm. the catalyst Pt or vanadium
pentoxide (V2O5 ) becomes inactive its conversion efficiency goes on
decreasing with decrease in yield of product. When we applied the
law of mass action to the above equation in terms of partial
pressure it gives the relation :-

K p = p2 SO3/ P2SO2. PO2

At higher pressure SO3 get strongly adsorbed over the surface of
catalyst. Hence reacting gases diffused over the surface of catalyst
and becomes inactive. Decrease the yield of SO3.
 At high pressure plant easily get corrode. Plant cannot be stand at
high pressure therefore this reaction should be carried out at
optimum pressure 1.5 to 1.7 atm .

c) Effect of concentration :-

The key reaction of this process is –

2 SO2 + O2 Pt/V2O5 2 SO3 + 189 kcal .

2vol + 1vol 2vol

The above reaction is reversible and forward reaction is
exothermic .one’s the reaction is started further heating is not
necessary reaction proceeds with decrease in volume of the
products. ( From 3 vol of reactant to 2 vol of product) .
Therefore this reaction should be carried out at concentration of
reactant SO2 :O2 must be 1:3 Proportion by volume.
If we apply the law of mass action and Le- Chatelier’s principle to
the above reaction in terms of concentration as-

Kc = [SO3]2 / [SO2]2.[O2]

Where K c is concentration constant.

Concentration of sulphur trioxide is increased by increasing the
concentration of either SO2 or O2.
From the equation it is observed that the ratio of [SO3] to [SO2] is
propotional to the square root of concentration of oxygen thus
concentration of oxygen is increased four times , the yield of
product SO3 is increased only two times.
If the concentration of oxygen is increased nine times, the yield of
product SO3 is increased simply three times. Oxygen is always used
from Linde’s or Claude liquid air mixed with SO2 .Hence
Concentration of reacting gases SO2 : O2. Must be 1:3
d) Effect of Catalyst :

The key reaction of this process is –

2 SO2 + O2 Pt/V2O5 2 SO3 + 189 kcal .

2vol + 1vol 2vol
The above reaction is reversible and forward reaction is
exothermic .one’s the reaction is started further heating is not
necessary reaction proceeds with decrease in volume of the
products. ( From 3 vol of reactant to 2 vol of product) .

Reaction if carried out at low temp. but rate of reaction is

becomes very slow therefore for increasing the rate of reaction,
suitable catalyst must be used.

On trial basis number of catalyst is used in this process but most

commonly used are platinum and vanadium pentoxide (V2O5). The
reacting gas SO2 is produced by burning the sulphur containing
compounds like Iron pyrites it contains Arsenic oxide (As2O3) it
becomes poison of catalyst Pt. it’s conversion efficiency goes on
decreasing with decrease in yield of product reacting gases must be
free from impurities .when pt is used as catalyst. But Platinum is
costly.

Therefore vanadium pentoxide (V2O5) is used as better

catalyst for the conversion of SO2 to SO3. Because it is cheapest and
are resistant to poisoning or to the impurities present in the reacting
gases. Hence optimum conditions for better yield of SO3 are as –

1. Temp. must be 400-4500c ( 673-723 K).

 2. Pressure must be 1.5 to 1.7 atm.
3. Concentration of SO2:O2 must be 1:3
4. Suitable Catalyst is Pt or V2O5.

Plant and Process [ Working of Contact Process]:

The Contact plant Consist of the following parts:-

1. Iron Pyrites Burner or Burning Chamber

2. Purification Unit
i) Dusting Tower or chamber
ii) Cooling Pipe
iii) Washing Chamber or Scrubber
iv) Drying Chamber or tower
v) Arsenic Purifier
vi) Asbestos Filter
vii) Testing Box or Tyndal Box
3. Contact Converter or Tower
 4. Absorption Tower
The manufacture of Sulphuric acid by Contact Process is carried
out in Four step :-
1. Production of SO2
2. Purification of reacting gases ( if iron pyrites used)
3. Conversion of SO2 to SO3 And
4. Absorption of SO3 in conc. H2SO4.

Working of Plant:-

1. Production of SO2:-

Sulphur or sulphur containing compounds like iron pyrites when

burnt in air it produce sulphurdioxide.

S + O2 SO2
4FeS2 +11O2 8SO2 + 2Fe2O3

2. Purification Of Gases:-

If sulphur is used as raw material and is burnt in the atmospheric

oxygen it forms SO2 here purification of reacting gases is not required.
But if the sulphur containing compounds like Iron Pyrites is used as raw
material for the formation of SO2. Then purification of reacting gases
must be carried out.

The burning gases contains reacting gases SO2 and excess of oxygen
along with large amount of impurities like moisture dust particles,
chlorine , nitrogen ,CO2, sulphur and pyrite dust, arsenic oxide ,
sulphuric acid fog and so on. Therefore for getting the good yield of
H2SO4. The reacting gases must be purified before passing over the
surface of catalyst Platinum because it easily get poison with arsenic
oxide (As2O3). Hence these gases must be purified by passing towards
purification unit.

i.Dusting Tower or Chamber :-

The reacting gases SO2and O2 are taken from burning chamber into
dusting chamber where there these gases contains the impurity that
are removed by passing the steam from top of the tower.

Steam get condensed over the surface of dust particles then particles
becomes heavier and settle down at the bottom of the chamber
according to the ‘ “gravitational force”. Then reacting gases becomes
very hot then pass towards cooling pipe.

ii. Lead cooling pipe:- The hot gases from dusting tower are then pass
through the lead cooling pipe where there gases are cooled down at
1000c (373 K) .

iii.Washing chamber or Scrubber :

The reacting gases SO2 and O2 are taken into washing chamber for
washing purposes. This chamber is fitted with quartz on which these
gases are washed with water coming from the top of tower as like
trickling (shower) system. The reacting gas SO2 not get dissolve in water
because its solubility is nil at higher temperature. Due to washing,
reacting gases becomes “ wet” hence are passed towards drying
chamber.

iv.Drying Tower or Chamber:

These reacting gases are dried up by using the conc. H2SO4 as drying
agent pass over the gases from top of the tower by shower system here
tower is packed with quartz pieces and remove the moisture in reacting
gases. Then these reacting gases are taken towards arsenic purifier.

v.Arsenic Purifier:

If the iron pyrites used as raw material in the production of SO2 gas it
contains arsenic after burning Arsenic get oxidized into arsenic oxide
(As2O3). It becomes poison of catalyst Platinum. Hence it must be
removed.

This tower is made up from the steel constructed with horizontal plate
on which freshly prepared precipitate of Ferric hydroxide [ Fe(OH)3] is
kept. When the reacting gases move though the tower the impurity of
arsenic oxide is get incorporated by ppt. of ferric hydroxide and gases
becomes free from impurity.

vi.Asbestos Filter:

The reacting gases SO2 and O2 free from arsenic oxide are then pass
through asbestos filter which contains the layer of asbestos fiber that
removes the trace amount of dust particles and mist.

vii.Tyndal or Testing Box :

The reacting gases from asbestos filter are taken into tyndal box for
testing the presence of arsenic oxide and other impurity with the help
of powerful beam of light.

“ When a powerful beam of light is pass through the reacting gases in

testing box. It detect or ensure the presence of dust particles .if any
particles are present, it easily get illuminated by light such effect is
called as “Tyndal effect” ( In which particles scatter the light ,if they are
illuminated by light at right angles to their propogation and viewed
from top.) When the gases are free from impurities , then they pass
towards contact converter.

8.Pre heater: After tyndal test ,the reacting gases SO2 and O2 are get
cooled. Hence before passing towards the contact converter reacting
gases are pre heated to 4000c then and then pass towards the contact
converter.

3. Contact converter (Conversion of SO2 to SO3.):

The preheated reacting gases are passed into contact converter. it
is heart of contact process. Where there it is made from steel
having height 25-30 meter and width of 10 meter fitted with
vertical iron pipes packed with suitable catalyst Pt or Vanadium
pentoxide ( V2O5) .
 In modern plants, first few pipes are heated to 5500c (823K) once the
reaction is started further heating is not necessary because reaction is
exothermic heat produced that increase the temperature of remaining
pipes to 4500c.

These reacting gases are passes upwards around the vertical pipes and
then downwards through the pipes at that time all the SO2 gas is
catalytically oxidized into SO3. (80 % of SO2 oxidised at high
temperature 5500c and 17 % of SO2 get oxidized to SO3 at 4500c .

“The two reacting gases SO2 and O2 come in contact over the surface
of solid catalyst pt. or V2O5 hence derived the name to the process is
“Contact Process”.

Then this resulting SO3 is cooled down and pass towards absorption
tower.

4. Absorption Tower :

The well cooled SO3 from the contact converter pass towards
absorption tower. Which is packed with acid resisting stone where the
98 % conc. H2SO4 is pass from the top of chamber in trickling system.
The gaseous SO3 is react with conc. H2SO4 and is absorbed and forms
the “oleum”. It may also called as “fuming sulphuric acid” or “pyro
sulphuric acid”.

SO3 + H2SO4 H2S2O7 ( oleum)

Along with oleum some tri sulphuric acid ( H2S3O10 ) is also
formed.

Then oleum mixed into water and prepared any desired strength of
H2SO4.
 H2S2O7 + H2O 2 H2SO4

H2S3O10 + H2O 3 H2SO4

Here it should be noted that, the gaseous SO3 have great affinity about
water and forms dense fog ( a mist of sulphuric acid droplets) instead of
formation of H2SO4 hence It is rather difficult to condense in H2SO4
therefore it cannot be absorbed directly into the water.

Merits and Demerits of Contact Process:

Merits :

i ) Pure and 98 % highly concentrated sulphuric acid is obtained.

ii) The process is most advanced and almost automatic.

iii) Any desired strength of sulphuric acid is manufactured directly.

Iv ) The plant is erected anywhere .

v) The process is easier than Lead chamber process and cheaper on

unit cost basis.

Demerits :

i) The Process requires expert supervision in the purification unit.

ii) The Process becomes costly if Platinum used as catalyst.
iii) Highley pure gases is used because of catalyst Platinum.
iv) Initial cost of plant is high .
Distinction between Platinum and Vanadium Catalysts :

Platinum Catalyst Vanadium catalyst

1. Initial cost of plant becomes high.1. Initial cost of plant becomes low
2. Easily get poisoned by arsenic 2. Resistant to poisioning.
3. Work at lower temp. 3. Works at higher temp.
4. It recovered 100% . 4. It Cannot be recovered.
5. High cost. 5. Low cost.
6. 189 g of Pt is required per day 6. 14 Kg required per day
for per tonne. for per tonne.
7. Cost of pre heating is low. 7. Cost of pre heating is high.

Ammonia:

It is third most important heavy chemical next to sulphuric acid and

soda ash it plays an important role in the present civilization as a
fundamental material. Ammonia is the starting material of so many
nitrogenous compounds and fertilizers.

Not a single industry can be run without the use of ammonia. Used in
military explosive, nylon , plastic ,rubber , dyes , nitric acid ,soda ash ,
lacqueres and fertilizers viz. ammonium sulphate , ammonium
phosphate, ammonium nitrate ,ammoniated superphosphate, urea
,calcium nitrate ,sodium nitrate ,

Trace of ammonia is present in spring waters and in the atmosphere it

released during slow decomposition of animal and plant. It occurs in
combined state in the form of ammonium chloride and ammonium
sulphate.
It prepared in laboratory by heating the ammonium salt with an alkali .

NH4+ + OH- Heat NH3 + H2O

Ammonia is gas having great industrial importance. It is manufactured

by different methods like -

1. The Haber- Bosch process

2. The Claude process
3. The American Process
4. The Casale process,
5. The Mont Cenis process.
But today 90 % of ammonia is manufactured by Haber process.

Manufactured of Ammonia By Haber Process :

This process was discovered by Fritz Haber and Carl Bosch during
the period 1904-08 in Germany hence the process is called as “Haber
- Bosch Process.”

Fritz Haber discovered the direct combination between N2 and H2 in

laboratory While Carl Bosch was a chemical engineer discovered the
plant for the production of Ammonia.

Hence Haber was awarded with Nobel Prize for their significant work
on the reaction of direct combination of nitrogen and hydrogen for
Chemistry in 1918. While Bosch was awarded with Nobel prize for the
discovery of plant in Chemistry in 1931 .

This process is based on direct combination of nitrogen and hydrogen

to produce ammonia.
Physico -chemical principles: [ Technical conditions] :

The Main reaction of this process is

N2 (g) + 3H2 (g) Fe2O3 + Mo 2NH3 (g) + 112 kJ /mole

1 vol. 3 Vol. 2 Vol.

The above reaction is reversible and forward reaction is exothermic,

once the reaction is started further heating is not necessary, reaction
proceeds with decrease in volume of products ( 4 volumes of reactants
get converted into 2 volumes of products ) reaction is never be
completed. Hence for the better yield of ammonia this reaction be
studied on trial basis w .r .t. the several factors like-

1. Effect of temperature – [500-5500c]

The Main reaction of this process is
N2 (g) + 3H2 (g) Fe2O3 + Mo 2 NH3 (g) + 112 kJ /mole
1 vol. 3 Vol. 2 Vol.

The above reaction is reversible and forward reaction is exothermic,

once the reaction is started further heating is not necessary, reaction
proceeds with decrease in volume of products ( 4 volumes of reactants
get converted into 2 volumes of products ) reaction is never be
completed.

The reaction is carried out at 500- 5500c for the better yield of ammonia
because below and above to that particular temperature Catalyst Iron
oxide with promoter Molybdenum becomes inactive its conversion
efficiency goes on decreasing with decrease in yield of product .
 Table : Effect of temperature on yield of ammonia

Temperature % of NH3 Kp % of NH3 Kp

at 10 atm. at 10 atm.
10.1 x105 50.5 x 105
Pa Pa
3500c(623K) 7.35 0.0266 25.11 0.0278
4000c(673 K) 3.85 0.0129 15.11 0.0130
4500c 2.04 0.0066 9.17 0.0069

2. Effect of Pressure:
The Main reaction of this process is
N2 (g) + 3H2 (g) Fe2O3 + Mo 2 NH3 (g) + 112 kJ /mole
1 vol. 3 Vol. 2 Vol.

The above reaction is reversible and forward reaction is exothermic,

once the reaction is started further heating is not necessary, reaction
proceeds with decrease in volume of products ( 4 volumes of reactants
get converted into 2 volumes of products ) reaction is never be
completed .According to Le- Chatelier’s principles high pressure
favours forward reaction.

Temp. Pressure
00c K 1 atm. 50atm. 100atm. 200atm. 1000atm.
 400 673 0.44 15.11 25.10 36.30 80.00
450 723 0.24 9.50 16.20 26.00 70.00
500 773 0.13 5.70 10.40 17.60 57.50
550 823 0.08 3.70 6.90 12.00 41.00

At any pressure, increase in temperature causes a decrease in the yield

of ammonia but at given temp, increase in pressure increase the yield
of ammonia this reaction should be carried out at 200 atm.(202 x
105pa).

The lower temperature and higher pressure increase the yield of

ammonia.

3. Effect of concentration :
The Main reaction of this process is

N2 (g) + 3H2 (g) Fe2O3 + Mo 2 NH3 (g) + 112 kJ /mole

1 vol. 3 Vol. 2 Vol.

The above reaction is reversible and forward reaction is exothermic,

once the reaction is started further heating is not necessary, reaction
proceeds with decrease in volume of products ( 4 volumes of reactants
get converted into 2 volumes of products ) reaction is never be
completed.

By applying the law of mass action to the above reaction in terms of

concentration,

Kc= [NH3]2

[N2] [H2]3

K c remains constant, for the better yield of ammonia, the

concentration of both N2 and H2 must be increased. But the
concentration of H2 is with third power and is at denominator,its
concentration is far higher than that of nitrogen. Hence concentration
of nitrogen to hydrogen should be 1:3.

4. Effect of Catalyst :

The main reaction of Haber process is reversible and forward reaction is

exothermic, the good yield of ammonia is expected at lower
temperature but at lower temp the reaction rate is very low because
heat of dissociation of nitrogen molecule is very high 945 kJ/mole and
to that of H2 is 435 kJ/mole. The thermal energy of molecule is
insufficient to break the bond between nitrogen atoms. Hence rate of
reaction becomes negligible. If temp .increases reaction rate becomes
very slow. This opposite trends suggest that the catalyst in this process
must be used positive such catalyst lowers the activation energy of
nitrogen then that react with hydrogen to form the ammonia.

Catalyst should not have the strong affinity for nitrogen to form the
nitrides
The finely divided catalyst iron acts as better but it loses its activity at
temp 5000c hence it mixed with a small amount of promoter either
Molybdenum or mixture of Al2O3 and K2O.

Catalyst is prepared as – Pure Iron is burnt in oxygen it form Fe3O4. It is

fused in electric furnace with Al2O3 and K2O. the solid mass is crushed
and ground to smaller particle size.

This catalyst placed in the converter where iron oxide is reduced to iron
by the passage of N2 and H2 where promoter is not reduced. This
reduced porous iron mix with Al2O3. It acts as better catalyst.

5. Time of contact or ( Space Velocity) :

If the space velocity increase , the time of reacting gases decreases If

the amount of ammonia per unit volume of catalyst per hour increases
large amounts of un reacted gases is passed on with small amount of
ammonia.

If the time of contact is low , the amount of conversion of ammonia is

also low. This indicates that, un reacted reacting gases should be re
circulated over and over and large number of operation are carried out
in a day for better yield of ammonia Space velocity is differ from plant
to plant mostly it is in between 600-1200 m3.

Hence following are the good condition for better yield of ammonia by
Haber process are -

1. Effect of pressure- 202 x 105 Pa or 200 atm.

2. Effect of concentration- N2:H2 = 1:3

3. Use of Catalyst- Fe2O3 + Mo Or [Fe2O3 + Al2O3 + K2O].

4. Time of contact i.e. [Space velocity ]– 600- 1200 m3.

Plant and Process:

The Haber process contains following units –

I) Main Compressor ,
II) Purifier and Drier ,
III) Catalytic Chamber And Heat exchanger ,
IV) Condenser ,
V) Recirculation pump
The Haber process is carried out in the following steps –
a) Preparation and Purification of the reacting gases ,
b) Conversion of reacting gases into ammonia and
c) Liquefaction and separation of ammonia from the un reacted
gases.
Working :

a.Production of reacting gases:

Nitrogen and hydrogen are basic raw materials of Haber process can be
obtained from water gas ( CO + H2) or from decomposition of steam or
by electrolysis of acidified water or from natural gas. While nitrogen is
obtained from producer gas ( Co + N2). Or it obtained by fractional
distillation of liquid air or from air.

H2 is obtained by electrolysis of water but is much more expensive.

Now a days it obtained from natural gas.

CH4 + H2O CO + 3 H2.

CH4 +2H2O CO2 + 4 H2.

Nitrogen is obtained from producer gas

( 4N2 + O2) + 2H2 4N2 + 2H2O

The reacting gases must be free from impurities like S,P,CO etc.

Carbon monoxide reacts with steam it form hydrogen and carbon

dioxide.

CO + H2O Fe2O3 + Mo H2 + CO2 + 42kJ.

450-5000c

Un reacted carbon monoxide is removed by passing the gas through

sodium hydroxide under pressure.

CO + NaOH HCOONa ( Sodium formate)

The resulting gas mixture is passed through lime.
CaO + H2O Ca(OH)2.
Concentration of reacting gases N2 to H2 must be 1:3.
 b.Conversion to Ammonia :

The pure and dry gaseous mixture of nitrogen and hydrogen is

taken as 1:3 and passed through main compressor and
compressed it at 200 atm. then passed towards converter.

The converter is made of chrome steel. It is 10 m in height and has 1

m width packed with finely divided iron with little Al2O3+K2O as
promoter. The catalyst is heated electrically to 500-5500c.

N2 + 3H2 2NH3 + 112kJ

The reaction is exothermic , hence temperature is automatically

maintained by controlling the rate of entering gases.

Finally gases are taken into heat exchanger where they transfer their
heat energy to the incoming fresh gases.

c.Liquefaction of Ammonia :

8 to 12 % of ammonia is obtained in one cycle then unreacted reacting

gases nitrogen ahd hydrogen is circulated towards the main
compressor where these un reacted gases are again compressed in
main compressor with incoming fresh gases .then transfer towards
converter then towards heat exchanger and finally into condenser
Where there gaseous ammonia is condensed into liquid ammonia.
Condenser is immersed in brine solution cooled to about -10 to -200c
cycles are repeated again and again and again with formation of
ammonia 8-12 %, un reacted N2 and H2 again pass towards main
compressor with fresh incoming N2 and H2.
This ammonia is stored in vessels made from either steel ,or polythene ,
or aluminium , or rubber .and transported in steel cylinder that
withstand vapour pressure of ammonia.

Merits:

1. With no loss 8-12% of ammonia is produced in each cycle by

Haber process.
2. Highly pure and concentrated ammonia is obtained.
3. Plant and process carried out at any place.
4. Process is cheap and economical on cost basis.
World production of ammonia was 1 million tones per year
in 1950. It rise to 98 millions at 1988. The ammonia
producing countries are Russia 27% China 21%, USA 18 %,
Canada 4% Romania 4%.