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U2M3 chem. Factors influencing the site of an industrial plant & Al production 2 of 4
Industrial plant site location of sodium hydroxide, NaOH, at 175 °C. This converts the alumina to
Industrial plants are manufactured for the sole purpose of producing materials aluminium hydroxide, Al(OH)3, which dissolves in the hydroxide solution
and items either used directly or indirectly in our everyday lives. However, the according to the chemical equation:
question that first arises is where to build this industrial plant ? Near a school, Al2O3 + 2 OH− + 3 H2O → 2 [Al(OH)4]−
near a beach, an airport, away from everything and everybody? A place only The other components of bauxite which are not amphoteric like aluminium
accessible by helicopter? WHERE? oxide do not dissolve. However the silica is weakly acidic and dissolves to form
silicate ions as well. The mixture is then filtered to remove the solid impurities.
Some factors which influence a plant site The mixture of solid impurities is called red mud, and presents a disposal
1. Proximity to raw materials problem. Next, the hydroxide solution is cooled, and a “seed” of aluminum
2. Easily accessible to the workforce hydroxide is added and it results in large amounts of aluminium hydroxide
3. Proximity to good infrastructure (seaport, railway, airport, roads) precipitating out of solution to form a white, fluffy solid. NB In some cases,
4. Type of terrain (flat, rugged or slightly rolling hills) carbon dioxide gas is bubbled through the aluminate and silicate solution to
5. Distance from general populace form the solid aluminium hydroxide Then, when heated to 1050°C, the
aluminium hydroxide decomposes to alumina, giving off water vapor in the
Checkpoint A process: 2 Al(OH)3 → Al2O3 + 3 H2O
Think of the cement factory in St. Lucy, which of the factors listed above The pure alumina so produced is then subsequently electrolysed in the Hall–
would be the most important in relation to the location of the plant site and Héroult process in order to produce aluminium.
give reasons why.
……………………………………………………………………………………
In the case of St. Lucy’s cement factory, the most important factor in relation to the location Below is the Hall-Heroult electrolytic cell
……………………………………………………………………………………
of the plant site could be the availability of raw materials. This is because cement production
requires large quantities of raw materials such as limestone, clay and sand. St. Lucy is known
……………………………………………………………………………………
for its limestone deposits which could have been a major factor in the decision to locate t
……………………………………………………………………………………
he cement factory there
Checkpoint B
Compare a cement plant to a petroleum refinery plant. Which safety
requirements would be the most critical for each and why?
……………………………………………………………………………………
In terms of which safety requirements would be most critical for each facility, it would
……………………………………………………………………………………
depend on the specific operations being carried out at each facility. However, some of
the most critical safety requirements for cement plants include ensuring proper ventilation
……………………………………………………………………………………
and fire prevention measures. For petroleum refineries, some of the most critical safety Cryolite (Na3AlF6) is added to molten alumina to become the electrolyte as its
……………………………………………………………………………………
requirements include ensuring proper ventilation systems and fire prevention measures. melting temperature is reduced from 2050 ° to 950 °C. Aluminium is formed at
the cathode Al3+ + 3e- Al and oxygen at the anode 2O2- -4e- O2. Since the
Production of aluminium anode is made of carbon, the oxygen gas causes the anode to be eroded because
Bauxite, the most important ore of aluminium, contains only 30-54% alumina, of carbon dioxide gas produced. This process requires a lot of energy and thus
Al2O3, the rest being a mixture of silica, various iron oxides, and titanium should be located next to a hydroelectric power plant. Aluminium metal can
dioxide. The alumina must be purified before it can be refined to aluminium also be recycled without any loss of properties or quality. Only 5% of the
metal. In the Bayer process, bauxite is digested by washing with a hot solution initial energy needed for aluminium production is used in the recycling process.
U2M3 chem. Factors influencing the site of an industrial plant & Al production 3 of 4 U2M3 chem. Factors influencing the site of an industrial plant & Al production 4 of 4
Properties and related uses of Aluminium metal
Property Uses
Low density Used in aerospace and transport
High corrosion resistance
industries i.e. manufacture of car parts
and aircraft frames
High corrosion An oxide layer forms on the surface of
resistance the metal and prevents any further High reflective nature
corrosion. This allows it to be used for
car parts, packaging material and
cooking utensils.
High electrical conductivity
High electrical Allows for use as overhead electric
conductivity cables
High reflective Reflects infra-red radiation and visible
nature light very well, so can be used in
firefighter suits
Checkpoint C
Bayer process
Al2O3 + 2 OHAl2O3 + 2 OH
+ 3 H2O + (OH)4]
2 [Al 3 H2O 2 [Al(OH)4]
Some fractions are in heavier demand than other, for example the
fractions diesel and petrol are required in extremely large amounts while
the heavier fraction are not in such high demand. A process called
cracking is then used to fragment the large molecules into smaller
molecules (forming even more diesel and petrol fractions).
Checkpoint A
Checkpoint B
Unit 2 Mod 3 Haber Process & Ethanol Production & consumption page 1 of 6 Unit 2 Mod 3 Haber Process & Ethanol Production & consumption page 2 of 6
HABER PROCESS Checkpoint A
The Haber Process combines nitrogen from the air with hydrogen 1. State how the following conditions would cause a shift in the position
derived mainly from natural gas (methane) into ammonia. The reaction is of equilibrium (left, right or no change)
reversible and the production of ammonia is exothermic.
a) increase in temperature ………………………
A flow scheme for the Haber Process looks like this: b) decrease in pressure …………………………
c) a catalyst…………………………….
Uses of ammonia
Yeast is added to a sugar source e.g. sugarcane, molasses, grapes etc with
various nutrients and the correct temperature and pH and in the absence
of oxygen. Sugar is first broken down into glucose and fructose by the
enzyme sucrase. Eventually glucose molecules are respired
anaerobically to produce ethanol and carbon dioxide gas by the enzyme
zymase.
The ethanol content rises as high as 12% before the yeast cells are killed.
Practice Problems
Unit 2 mod 3 chlorine production & Contact Process Mar 6 2010 page 1 of 4 Unit 2 mod 3 chlorine production & Contact Process Mar 6 2010 page 2 of 4
CHLORINE PRODUCTION Economic disadvantages
Very dilute sodium hydroxide produced (12%) and industry requires
In diaphragm cell electrolysis, an asbestos (or polymer-fiber) diaphragm 50%. Large amounts of steam is required to concentrate the alkali.
separates a cathode and an anode, preventing the chlorine forming at the The chlorine produced is usually not very pure and requires purification
anode from re-mixing with the sodium hydroxide and the hydrogen
formed at the cathode. Chlorine can also be produced via the flowing mercury cathode cell
The salt solution (brine) is continuously fed to the anode compartment The cathode is a thin layer of mercury and graphite is the anode.
and flows through the diaphragm to the cathode compartment, where the The electrode reactions are:-
caustic alkali is produced and the brine is partially depleted. At cathode Na+ + e- Na At anode 2Cl- -2e- Cl2
As a result, diaphragm methods produce alkali that is quite dilute (about
12%) and of lower purity than do mercury cell methods. But diaphragm However the sodium undergoes further reactions
cells are not burdened with the problem of preventing mercury discharge a) Na + Hg Na/Hg
into the environment. They also operate at a lower voltage, resulting in b) 2Na/Hg + 2H2O 2NaOH + H2 + 2Hg
an energy savings over the mercury cell method, but large amounts of
steam are required if the caustic has to be evaporated to the commercial The product is chlorine and by-products are sodium hydroxide and
concentration of 50%. hydrogen gas.
Practice Question
Economic advantages
1. Less energy used because it operates at a lower voltage
2. No risk of releasing mercury into environment (i.e. less cost
involved in expensive recovery methods)
Unit 2 mod 3 chlorine production & Contact Process Mar 6 2010 page 3 of 4 Unit 2 mod 3 chlorine production & Contact Process Mar 6 2010 page 4 of 4
What is the ratio of moles of NaCl used to moles of Cl2 produced? Importance of compounds of sulphur in industry
Use this ratio to determine mass of NaCl in kg required to produce 2.5 x 1010 kg 1. SO2
of Cl2 Used as a food preservative in juices and jams. It creates an acidic and
oxidising medium which prevents the growth of any microbes.
2. Sulphuric acid
Used in the manufacture of fertilisers, manufacture of detergents, production
of phosphoric acid, used to help manufacture fabrics e.g. nylon, in petroleum
refining, to manufacture dyes and as the battery acid in car batteries.
To conserve energy, the mixture is heated by exhaust gases from the catalytic Practice Questions
converter by heat exchangers.
Sulphur dioxide and oxygen then react in the manner as follows:
2 SO2(g) + O2(g) ⇌ 2 SO3(g) : ΔH = −197 kJ mol−1
To increase the reaction rate, high temperatures (450 °C), medium pressures (1-
2 atm), and vanadium(V) oxide (V2O5) are used to ensure a 96% conversion.
Hot sulfur trioxide passes through the heat exchanger and is dissolved in
concentrated H2SO4 in the absorption tower to form oleum:
H2SO4(l) + SO3(g) → H2S2O7(l)
Note that directly dissolving SO3 in water is impractical due to the highly
exothermic nature of the reaction. Acidic vapour or mists are formed instead of a
liquid.
Sedimentation
The water, after coagulation, is left in settling basin further for sufficient period to
allow sedimentation of remaining materials. Sedimentation however considerably
reduces microbial population of the water aside from removing most of the
suspended particles.
Filtration
After sedimentation, water is subjected to sand filters to remove flocks of living
organisms. The process of filtration is highly critical and important as it can remove
Water cycle is essential for the continued supply of water on the earth’s protozoan cysts and also about 98-99% of bacteria from water. The water may also
surface. Our bodies are made of about 65% water and thus all metabolic be filtered through activated charcoal to remove potentially toxic organic
activities require water to be present. We cannot easily make MORE water, compounds and organic compounds that impart undesirable colour and/or taste to
so we must depend on the water cycle for our present supply of it. the water.
Troposphere
The troposphere begins at the surface and extends to between 7 km (23,000 ft) at These four equations are the Chapman reactions which regulate the
the poles and 17 km (56,000 ft) at the equator, with some variation due to concentration of ozone in the stratosphere. Note that hv represents uv light.
weather. The lowest part of the troposphere is warmest and temperature
decreases with altitude. The tropopause is the boundary between the troposphere (1) Photodissociation causes the oxygen molecule to dissociate, (2) each oxygen
and stratosphere. atom then can combine with an oxygen molecule to form ozone.
(3) Ozone molecules dissociate when in contact with uv rays reforming an
Stratosphere oxygen molecule and oxygen atom. (4) An ozone molecule and oxygen atom
The stratosphere extends from the tropopause to about 51 km (32 mi; combine to form 2 oxygen molecules.
170,000 ft). Temperature increases with height, which restricts turbulence and
mixing. The stratopause, which is the boundary between the stratosphere and Significance of CFCs in ozone layer
mesosphere. CFCs and other contributory substances are commonly referred to as
ozone-depleting substances (ODS). Since the ozone layer prevents most
Mesosphere
The mesosphere extends from the stratopause to 80–85 km (50–53 mi; 260,000– harmful UVB wavelengths (270–315 nm) of ultraviolet light (UV light)
280,000 ft). It is the layer where most meteors burn up upon entering the from passing through the Earth's atmosphere, observed and projected
atmosphere. Temperature decreases with height in the mesosphere. decreases in ozone have generated worldwide concern leading to
adoption of the Montreal Protocol that bans the production of CFCs and
Thermosphere halons (halogenoalkane) as well as related ozone depleting chemicals
Temperature increases with height in the thermosphere from the mesopause up such as carbon tetrachloride and trichloroethane. It is suspected that a
to the thermopause, then is constant with height. The top of the thermosphere is variety of biological consequences such as increases in skin cancer,
the bottom of the exosphere, called the exobase. cataracts, damage to plants, and reduction of plankton populations in the
ocean's photic zone may result from the increased UV exposure due to
Exosphere
ozone depletion. Ozone is also a very powerful oxidising agent.
The outermost layer of Earth's atmosphere extends from the exobase upward.
Here the particles are so far apart that they can travel hundreds of km without
colliding with one another. CFCs are non-toxic, low boiling, inert compounds and thus diffuse to the
stratosphere where it undergoes fission by uv light. An example of the
reactions are shown below
b) Tropospheric ozone
The majority of tropospheric ozone formation occurs when nitrogen oxides
(NOx), carbon monoxide (CO) and volatile organic compounds (VOCs), such as
xylene, react in the atmosphere in the presence of sunlight. NOx, CO, and VOCs
are called ozone precursors. Motor vehicle exhaust, industrial emissions, and
chemical solvents are the major anthropogenic (man-made) sources of these
chemicals.
Once NOx is in the atmosphere, their concentrations can be affected by For small particles:- Electrostatic precipitators are
precipitation resulting in acid rain. That is the reaction of NOx and water used, these exploit the fact that particles are
forming dilute solutions of nitric acid. usually charged and by passing “dirty” air through
charged plates, the particles are attracted to the
The formation of acid rain, the Haber Process and use of fertilisers also oppositely charged plate and the air comes out
affects the nitrogen cycle, the amount of nitrates present in the soil. clean
Gases Scrubbers (wet)
A wet scrubber uses an anti parallel flow of water
against the flow of gas (gas travelling upward and
water flowing downward). Note the water is in
very fine droplets to increase surface area. The
pollutant then dissolves or reacts with the water,
allowing the air to become “clean”.
Checkpoint C
Unit 2 Module 3 Topic Solid Waste Management Impact of solid waste on the terrestrial environment
Plastic
All plastics have a resin code which represents the type of chemical
processing required for recycling purposes. Thus all plastics must be
cleaned, all labels removed and then sorted into their different resin
codes. Some plastics are merely heated while others undergo a type of
reverse polymerisation and then the melt is shaped into new plastics.
Aluminium
Aluminium metal is very good for recycling as 95% of the energy used
to make virgin aluminium is saved. The metal is melted and then easily
reshaped into new objects.
Paper
Paper is first sorted for suitable use for recycling and then it is easily
mixed with water to form a paste and then rolled into large sheets. Paper
is not infinitely recyclable.
Steel is one of the most recycled materials in the world. Roughly 75% of
the energy is saved when steel is recycled. Again it is a process of
melting the scrap metal and reshaping it for future uses.