CHEMISTRY FORM 4:

MANUFACTURE SUBSTANCES IN

INDUSTRY

NAME : EZZA JASMIN KAUTHAR BINTI BAHARI

FORM : 4 BETA (2010)

TEACHER :PN OZIAH

 OBJECTIVES

Understand the manufacture of sulphuric acid

Synthesis the manufacture of ammoniaand its salts

Understand alloys

Evaluate the uses of synthetic polymer

Apply the uses of ceramixs and glass

Evaluate the uses of composites material

Appreciate various synthetic industrial material

 SULPHURIC ACID
Uses of sulphuric acid
1.Sulphuric acid is used to produce chemical fertilizer such as ammonium sulphate
and potassium sulphate,which are highly soluble in water and can easily
obsorbed by plant.

2. Car batteries contain sulphuric acid which is used as the electrolyte.

3. Sulphuric acid also used in the making of artificial silk-like fibres and rayon.

4. Chemical like paints, dyes and drug use sulphuric acid as one of their
component material.

Manufacture of sulphuric acid

1. Sulphuric acid is manufactured in industry though contact process

2. The process contain three stage

STAGE1: Production Of Sulphur Dioxide From Sulphur
i. Combustion of sulphur or sulphide ores in the air produce sulphur
dioxide SO2

S(s)+O2(g)->SO2(g)
ii. sulphur dioxide is dried and purified.
 STAGE2: Production Of Sulphur Trioxide From Sulphur Dioxide

i. The purified sulphur dioxide SO2 and excess air are passed over
vanadium (V) oxide V2O5 at controlled condition optimum condition
to produce sulphur trioxide SO3
2SO2(g)+O2(g) 2SO3(g)

ii. The optimum used are

a) Temperature:450-500°C
b) Pressure: 2-3 atmospheres
c) Catalyst: Vanadium(V) oxide

iii.Under controlled optimum conditions, 98% conversion is possible. Sulphur

dioxide and oxygen that have not reacted are allowed to flow back again over

the catalyst in the converter.

STAGE 3: Conversion Of Trioxide To Sulphuric Acid

i.Sulphur trioxide SO2 is dissolved in concentrated sulphuric acid H2SO4 to form

oleum H2S2O7 which is then diluted with water to form sulphuric acid H2SO4.

SO3(g)+H2SO4(l)-> H2S2O7(l)

Oleum

H2S2O7(l)+ H2O(l)->2H2SO4(aq)

ii. The two reactions in stage3 are equivalent to adding sulphur trioxide
directly into water.

SO3(g)+H2O(l)->H2SO4(aq)

iii. The addition of sulphur trioxide directly into is not carried out
because the reaction is vary vigorous,a lot of heat is given of.As a
result,a large cloud of sulphuric acid fumes is produced,which is
corrosive and causes severe air pollution.
Sulphur Dioxide And Poluttion

1.Sulphur dioxide is one of the by-product of contact process. It is a colourless

and poisonous gas with a vary pungent smell.

2.Sulphur dioxide which escape into the air causes air pollution.
3.Sulphur dioxide is an acidic which dissolves in water to form sulphurous acidic,

H2SO3.In the atmosphere, sulphur dioxide dissolve in water droplets to form

sulphurous acidic.

SO2(g) + H2O(l)->H2SO3(aq)

4.Oxidation of sulphur acid by oxygen produce sulphuric acid, H2SO4, which falls

to the earth as acid rain. Sulphur trioxide is also easily oxidised in the air to form

sulphur trioxide. Sulphur trioxide dissolve in rainwater to produce sulphuric

acid.

SO3(g) + H2O(l)-> H2SO4(aq)

 AMMONIUM AND ITS SALTS

USES OF AMMONIA
1.Ammonia that is produce commercially has many uses.

2.It uses:

i.In the manufacture of chemical fertilizers such as ammonium sulphate, ammonia nitric,
ammonia phosphate

and urea.
ii.To manufacture nitric acid and explosive.
iii.In the making of synthetic fibre and nylon.
iv.As a degreasing agent in aqueous form to remove greasy stains in the kitchen.

PROPERTIES OF AMMONIA GAS

1.The physical properties of ammonia gas include the following:
i.It colourless and has a pungent odour.
ii.It is vary soluble in water and form a weak alkaline solution.
iii.It less dense then water.
iv.It easily liquified (at about 35.5°C) when cool

2.The chemical properties of ammonia gas:

a) 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 red litmus paper blue.

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 of metallic cations to produce precipitates.

Fe²+(aq) + 2OH(aq)-> Fe (OH)2(s)

MANUFACTURE OF AMMONIA IN INDUSTRY

1. Ammonia is manufacture on a large scale in industry through the haber process. In this process,
ammonia is formed form direct combination of nitrogen and hydrogen gas in the volume ratio
1:3.

2. The gas nitrogen obtain form the fractional distillation of liquefied air. The hydrogen gas is
obtained form the cracking of petroleum or from the catalysed reaction of natural gas, CH4, with
steam.

CH4(g) + H2O(g)-> CO(g) + 3H2(g)

3.The mixture of nitrogen and hydrogen gases is passed over an iron catalyst under controlled

optimum condition as below to form ammonia gas.

i.Temperature: 450-500°C
ii.Pressure: 200-500 atmospheres
iii.Catalyst used: Iron fillings

N2(g) + 3H2(g) ->2NH3(g)

4.Under these control optimum condition, only 15% of the gas mixture turn into ammonia gas. The
nitrogen and hydrogen that have not reacted are then flow back over the catalyst again in the
reactor chamber.

5.The ammonia product is then cooled at a low temperature so that it condenses into a liquid in

the cooling chamber.

AMMONIUM FERTILIZERS
1. Nitrogen is required in large amount by plant to make proteins which are necessary for

growth and cell repair.

2. Most plant are not able to get a nitrogen supply directly from the air although it is abundant in
the air (78%). Plants can only absorb soluble nitrogen compounds from soil through their roots.

3. The nitrogen compounds are usually soluble nitric salt, ammonia and ammonia salt

which are manufacture as chemical fertilizer.

4. Reactions of ammonia with acids produce ammonium fertilizers.

NH3(aq) + HNO3(aq)-> NH4NO3(aq)

3NH3(aq) + H3PO4(aq)->(NH4)3PO4(aq)

2NH3(aq) +H2SO4(aq)-> (NH4)2SO4(aq)

 ALLOYS

ARRANGEMENT OF ATOMS IN MATELS

1. The atom of pure metals are packed together closely. This causes the metal to have a

hight density

2. The forces of attraction between atoms (metallic bonds) are strong. More heat energy is
needed to overcome the metallic bond so that the atoms are further apart during the melting. This
is why metals usually have hight melting point.

3. Heat energy can be transferred easily from one atom to the next by vibration. This

make metal good conduct of heat.

4. The freely moving outermost electrons within the metal’s structure are able to conduct

electricity. Metal are, therefore, good electrical conductors.

5. Since atoms of pure metal are of the same size, they are arranged orderly in a regular layered
pattern. When a force is applied to metal, layer of atom slide easily over one another. This make
pure metals soft, malleable and ductile.
What Are Alloys

1. Pure metal are usually too soft for most uses. They also have a low resistance to
corrosion. They rush and tarnish easily.
2. To improve the physical properties of metal, a small amount of another element
(usually metal) is added to form another an alloy.
3. An alloy is a mixture of two or more metals (something non-metal) in a specific proportion.
For example:
a. Bronze (90% of copper and 10% of tin)
b. Steel (99% of iron and 1% of carbon)
4.The purposes of making alloys include the following:
a) Increase the strength

i. Pure iron is soft and vary malleable. When a small amount of carbon is added to
iron, an alloy, steal is
formed. The more carbon is added, the stronger the steel becomes.

ii. Pure aluminium is light but not strong. With a small amount of copper and
magnesium are added to
aluminium, a strong, light and durable alloy call duralumin is produced.

b) Improving the resistance to corrosion

i. Iron rust easily but stainless steel which contains 80.6% of iron, 0.4% of carbon, 18% of
chromium and 1% of

nickel does not rush. These properties make stainless steel suitable for making surgical
instrument and cutlery.
 ii. Pure copper tarnish easily. When zinc (30%) is added, the yellow alloy which is
known as brass develops a high resistance to corrosion.
c) Enhancing the appearance
i. Pewter, an alloy of tin (97%), antimony and copper is not only hard but also has
a more beautiful white silvery appearance.

iii. When copper is mixed with nickel to form cupronickel, an alloy that has an attractive
silvery, bright appearance is formed which is suitable for making coins.

Alloy Composition Properties Uses

High carbon steel 99% iron Strong,hard and high Making of cutting
1% carbon wear resistance tools,hammers and
chisels
Stainless steel 80.6% iron Do not rust and Making of surgical
o.4% carbon tarnish, strong and instrument,knives
18% choromium durable forks and spoon
1% nickel
Brass 70% copper Hard, do not rust, Making of
30% zinc bright appearance ornaments,
electrical wiring
and plug.

Bronze 90% copper Hard,do not corrode For casting

10% tin easily and durable bells,medals,sword
and statues
Pewter 90% tin Ductile and Making of
25% copper malleable,white ornaments,souvernirs
0.5 % antimony silvery appearance and mugs
Duralumin 95% alluminium Light,strong and Making part of
4% copper durable aircrafts and racing
1% magnesium cars
Cupronickle 75% copper Attractive,silvery Making of silver coins
25% nickel appeareance,hard and
tough
 SYNTHETIC POLYMER

WHAT ARE POLYMER

1.Molecule that consist of a large number of small identical or similar units joined together

repeatedly are called polymer.

2.The smaller molecules that make up the repeating unit in polymer are caller monomer.

3.The process of joining together a large number of monomers to form a long chain

polymer is called polymerisation.

4.Polymer can be naturally occurring or man-made (synthetic). Natural polymer are found in plant

and in animals for example of natural polymers are starch cellulose, protein and rubber.

5.Two type of polymerisation in producing synthetic polymer are additional polymerisation.

6.Double bonds between two carbon atoms usually undergo addition polymerisation.

SOME COMMON ADDITION POLYMERS

NAME(S) FORMULA MONOMER PROPERTIES USES

Polyethylene –(CH2-CH2)n– ethylene Soft,waxy solid Film wrap,plastic bags
low density CH2=CH2
(LDPE)

Polyethylene –(CH2-CH2)n– ethylene Rigid,translucen Electrical insulation

high density CH2=CH2 t solid bottles,toys
(HDPE)

Poly(vinyl –[CH2- propylene atactic: soft, similar to LDPE

chloride) CH(CH3)]n– CH2=CHCH3 elastic carpet,
(PVC) solid upholstery
isotactic: hard,
strong solid
Poly(vinylidene –(CH2- vinyl chloride Strong rigid Pipes,siding,flooring
chloride) CHCl)n– CH2=CHCl solid
(Saran A)

Polystyrene –(CH2- vinylidene Dense,high- Seats covers,films

(PS CCl2)n– chloride melting,solid
CH2=CCl2
Polyacrylonitrile –[CH2- styrene hard, rigid, Toys,cabinets,packagin
(PAN, Orlon, CH(C6H5)]n CH2=CHC6H clear g (foamed)
Acrilan) – 5 solid
soluble in
organic
solvents
Polytetrafluoroet –(CH2- acrylonitrile high-melting Rugs,blankets,clothing
h CHCN)n– CH2=CHCN solid
ylene soluble in
(PTFE, Teflon organic
solvents
Polytetrafluoroet –(CF2-CF2)n– tetrafluoroethyl Resistance, non-stick
h ene smooth solid surfaces
ylene CF2=CF2 electrical
(PTFE, Teflon) insulation

Poly(methyl –[CH2- methyl Hard lighting covers,

methacrylate) C(CH3)CO2C methacrylate transparent signs
(PMMA, Lucite, H3]n– CH2=C(CH3)C solid skylights
Plexiglas) O2CH3

Poly(vinyl –(CH2- vinyl acetate Soft latex paints,

acetate) CHOCOCH3) CH2=CHOCOC Sticky solid adhesives
(PVAc) n– H3

cis-Polyisoprene –[CH2- isoprene Soft requires

natural rubber CH=C(CH3)- CH2=CH- Sticky solid vulcanization
C(CH3)=CH2 for practical use

CH2]n–

Polychloroprene –[CH2- chloroprene Taugh synthetic rubber

 (cis + trans) CH=CCl- CH2=CH- Rubbery solid oil resistant
(Neoprene) CH2]n– CCl=CH2

SYNTHETIC POLYMERS IN DAILY LIFE

1.Synthetic polymers have many advantages over other type of materials:

i) They are cheap, light-weight and translucent.
ii) They are easily coloured, easily moulded and shaped.
iii) They are non-corrosive, waterproof and good insulator.

iv) They are durable and long lasting because they are resistant to decay, rusting and chemical
attacks.

2.There are disadvantage using synthetic polymer:

i) Most of the synthetic polymer are flammable. When a synthetic polymer material catches
fire, poisonous

fumes are produce causing air pollution.

ii) Synthetic polymers are non-biodegradable. When there are discharge, they cause litter
problem and pollute

the environment.

iii) Plastic container that are left aside in an open area collect rainwater which becomes the
breeding ground

for mosquitoes.

Iv) 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 recycled polymers.

WHAT ARE GLASS
1.Glass is one of the most useful but inexpensive materials in the world. Many
products are

made from glass because of its specials properties.

2.Glass is:
a. Transparent, hard but brittle.
b. A heat and electric insulator.
c. Resistant to corrosion.
d. Chemical not reaction and therefore resistant to chemical attack.
e. Easy to maintain.

Type of glass Compositions Properties Uses

Fused glass SiO2: 100%  Lens
• Transparent
 Telescope mirrors
• High melting point
 Laboratory
• Good heat apparatus

insulator

Soda-lime glass SiO2: 75% • Low melting point,  Drinking glass

Na2O:15% Bottle
CaO: 9% easily molded into
Other:1% desired shape and  Electric bulbs
size
 Window glass
• Low resistant to
chemical attacks
• Brittle

Borosilicate glass SiO2: 78% • Resistant chemical  Cooking utensils

B2O3: 12% attack and durable • Laboratory
Na2O: 5% • High melting point
CaO: 3% • Good insulator to glassware such as
heat conical flaks and
Al2O3:2%
boiling tube
 Lead crystal glass SiO2: 70% • High refractive • Lenses and prisms
Pbo/PbO2:20% index • Decorative
(flint glass) Na2O: 10% • High density glassware and art
• Attractive object
glittering • Imation jewellery1
appearance

CERAMICS
1. Traditional silicate ceramics are made by heating aluminosilicate clay such as kaolin to a vary
high temperature.

2. Ceramics have many special properties that make them one of the most useful materials in
our everyday life. That:
a. Are hard, strong but brittle
b. Have high melting point and remain stable at high temperature
c. Are heat and electric instrument
d. Are resistant to corrosion and wear
e. Are chemically not reactive
f. Do not readily deform under stress

3. Ceramic play important role in our daily life. They are uses as

a. Construction materials

i. Ceramic are strong and hard, uses to make roof tiles, 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 bathroom fixture such as floor and wall tiles.

c. Electrical insulator
 i. Ceramic are used to make electrical insulator in electrical items such as toasters, fridges
and electrical plug.

Materials Melting points/c Density /Gcm^3 Elastic Hardness/mohs

modulus/GPa
Oxide ceramic

Alumina,AL2O3 2054 3.97 380 9

Beryllia, BeO
Zirconia, ZiO 2574 3.01 370 8

2710 5.68 210 9

Non-oxide
ceramics
2350 280 9
Boron 2.50
carbide,B4C3 2830 3.16 400 9
Silicon nitride, 3.17
1900 310 9
Si3, n4

Metals
Aluminium
Steel 660 2.70 70 3

1515 7.86 205 5

 COMPOSITE MATERIALS

WHAT ARE COMPOSITE MATERIALS

1. A composite materials (or composite) is a structure of materials 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. Photochromic glass

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 of concrete and steel.

SUPERCONDUCTOR
1. Metal such as copper and aluminium are good conductor of electricity, but 20% of the
electric energy is lost in the
form of heat during transmission.

2. Super conductor are materials that have no resistance to the flow of electricity 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 build magnetically levitate high-speed train (at about 552 km/h).
4. Superconductor are used to make chips for smaller and faster supercomputer.
Superconductor also play an
important role in high speed data processing in internet communication.

FIBRE OPTIC
1. Fibre optic is a composite material that in used to transmit signals for light wave.

2. Fibre optic is used in

a. Telecommunicate where the telephone substation are liked by fibre optic cables.
b. Domestic cable television network
c. Closed circuit television security system.

2. 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 refractory
rating disc when the
glass flies off the disc glass to form fibre.

2. Fibre glass is strong than steel, do not burnt, stretch or rot, resistant to fire and water but is
brittle.

3. When fibre glass added to a plastic, a new composite material fibre glass reinforces plastic
is formed.

4. Fibre glass reinforces plastic has more superior properties than glass and plastic. 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 silver chloride (a type of photochromic substances) and a small
amount of copper (II)
chloride are added to molten silicon dioxide, photochromic glass is formed.

2. The photochromic glass has a special properties. It darken when exposed to strong sunlight
or ultraviolet.

3. Photochromic glass is suitable for making sunglasses.