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Chemistry (Tara) > Additional industrial chemistry > Flashcards

Additional industrial chemistry Flashcards

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1
Q

3 ways to organise the operation of a chemical manufacturing process

A

batch process
continuous process
semi-continuous process

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2
Q

batch process

A

raw materials place into a vessel (batch reactor) and allowed to react together, conditions are monitored. when reaction finished, products are isolated and process repeated with fresh batch of raw materials

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3
Q

continuous process

A

raw materials fed in at one end of processing plant and product is continuously removed at other end

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4
Q

example of continuous process

A

the manufacture of ammonia

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5
Q

semi-continuous process

A

combination of batch and continuous processes. first part is a batch process to make the product, second stage involves continuous process where product is purified using materials from several batch reactors

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6
Q

example of semi-continuous process

A

soft drink industry, soft drink is produced in a batch process and the addition of carbon dioxide and bottling is continuous

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7
Q

advantage of batch processing

A

more effective for smaller quantities of materials and the same vessel can be used for a range of products

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8
Q

disadvantage of batch processing

A

they require larger workforces and contamination can occur from batch to batch

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9
Q

advantage of continuous processing

A

better suited to larger quantities, low risk of contamination and can run for long periods of time with low labour needs

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10
Q

disadvantage of continuous processing

A

the plant is expensive to build, is not flexible for other products and hence may not be cost effective

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11
Q

feedstock

A

reactants used - produced from the raw materials

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12
Q

rate

A

conditions involved chosen for optimum rate

real conditions may not be necessarily the ideal, compromises must be made to ensure that it is cost effective

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13
Q

production yield

A

conditions chosen to produce a reasonable yield of product in reasonable time - compromises must be made

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14
Q

co-products

A

other products made alongside the main product

can be sold or separated and disposed of appropriately

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15
Q

waste disposal and effluent control

A

contaminated water may contain hazardous material and has to be treated before it is released - some gases can be dangerous (produce acid rain or damage ozone layer), must be purified and monitored

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16
Q

quality control

A

the quality of the feedstocks and products are constantly checked in laboratories so that they are of a required standard

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17
Q

safety

A

staff trained on site and continuous monitoring of hazards - safety features incorporated e.g safety glasses, first aid etc.

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18
Q

3 costs

A

capital costs
fixed costs
variable costs

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19
Q

capital costs

A

cost involved in setting up the plant

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20
Q

fixed costs

A

salaries, repayments of loans, plant depreciation

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21
Q

variable costs

A

raw materials, waste disposal, plant maintenance

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22
Q

ways of reducing costs

A

recycling of unreacted feedstocks, use of heat exchanger selling of co-products, essential equipment

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23
Q

sit location

A

access to roads, ports etc. for transport
available cheap energy and water
available skilled workforce
tax incentives etc.

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24
Q

suitable materials for construction of chemical plant

A

do not react with feedstocks, catalysts or solvents
resistant to corrosion, long-lasting
withstand temperatures and pressures used

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25
Q

process for manufacture of ammonia

A

continuous process

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26
Q

manufacture of ammonia by

A

IFI in Cobh, Co.Cork

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27
Q

manufacture of ammonia

feedstock

A

raw materials compressed of air, natural gas and water
nitrogen - compressed air
hydrogen - natural gas and water

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28
Q

manufacture of ammonia

do to air first

A

filtered to remove dust

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29
Q

manufacture of ammonia

do to water first

A

passes through ion exchange resins to deionise it

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30
Q

manufacture of ammonia

natural gas first

A

methane coming from Kinsale gas field, piped underwater to Inch beach in East Cork and supplied underground to IFI in cork, mercaptans added to ensure it has an odour

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31
Q

manufacture of ammonia

how do they ensure that the catalyst is not poisoned

A

first the sufur compunds are removed from naturl gas by mixing incoming gas with hydrogen and passing it over a cobalt/nickel/alumina catalyst
hydrogen sulfide is formed and then removed

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32
Q

manufacture of ammonia

where does the hydrogen come from

A

recycled from later on in the process

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33
Q

manufacture of ammonia

primary steam reforming

A

methane gas heated with steam in the presence of a catalyst to produce hydrogen
90% of methane consumed, reaction occurs in a reforming furnace, which contains 520 catalyst filled tubes

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34
Q

manufacture of ammonia

equation of primary steam reforming

A

CH4 + H2O ⇌ CO2 + 3H2

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35
Q

manufacture of ammonia

heat change of forward reaction in primary steam reforming

A

endothermic

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36
Q

manufacture of ammonia

secondary reforming

A

remaining 10% of methane

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37
Q

manufacture of ammonia

equation for secondary reforming

A

CH4 + 2O2 -> CO2 + 2H2O

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38
Q

manufacture of ammonia

removal of carbon monoxide equation

A

CO + H2O ⇌CO2 + H2

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39
Q

manufacture of ammonia

heat change of forward reaction in secondary steam reforming

A

exothermic

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40
Q

manufacture of ammonia

name of reaction of secondary steam reforming

A

shift reaction

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41
Q

manufacture of ammonia

significance of secondary steam reforming being exothermic

A

allows for heat recovery which emphasises the thermal efficiency of the ammonia process

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42
Q

manufacture of ammonia

explain the removal of carbon dioxide

A

the gas is scrubbed with a hot potassium carbonate under high pressure and temperature to form potassium hydrogen carbonate, it is then removed from the system

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43
Q

manufacture of ammonia

equation for removal of carbon dioxide

A

CO2 + K2CO2 + H2O -> 2KHCO3

44
Q

manufacture of ammonia

methanation

A

the gas is hydrogenated using a catalyst to convert remaining CO and CO2 into methane, as traces of these gases could poison the catalyst in the manufacture of NH3

45
Q

manufacture of ammonia

equation for methanation

A

CO + 3H2 -> CH4 + H2O

46
Q

manufacture of ammonia

heat change of methanation

A

exothermic

47
Q

manufacture of ammonia

feedstock

A

nitrogen and hydrogen

48
Q

manufacture of ammonia

according to Le Chatelier’s Principle, what are the ideal conditions?

A

low temperature and high pressure

49
Q

manufacture of ammonia

low temperature

A

slow reaction

50
Q

manufacture of ammonia

high pressure

A

expensive vessel

51
Q

manufacture of ammonia

actual conditions

A

high pressure of 200 atm and temperature of 500ºC

52
Q

manufacture of ammonia

catalyst

A

divided iron

53
Q

manufacture of ammonia

promoter

A

aluminium oxide

54
Q

manufacture of ammonia

how much of the nitrogen and hydrogen react to form ammonia

A

about 17%

55
Q

manufacture of ammonia

what is done to the ammonia

A

liquified and stored at -33ºC at atmospheric pressure, or sent directly to urea plant

56
Q

manufacture of ammonia

co-product

A

carbon dioxide

57
Q

manufacture of ammonia

how is the carbon dioxide released

A

can be released from potassium hydrogencarbonate by heating it and reducing the pressure

58
Q

manufacture of ammonia

what is done with the CO2 made?

A

used in the manufacture of urea on site and can also be sold to soft drink companies and breweries

59
Q

manufacture of ammonia

what do they treat the effluent with?

A

the plant effluent is treated with ion exchange resins to facilitate the recycling of ammonia and carbon dioixed back into the production steam

60
Q

manufacture of ammonia

rate of treatment

A

225 m3 per hour of water recovered

61
Q

manufacture of ammonia

what are air emissions monitored for?

A

the presence of ammonia, oxides and nitrogen

62
Q

manufacture of ammonia

CO2

A

emitted to atmosphere

63
Q

manufacture of ammonia

steam

A

emitted to atmosphere

64
Q

manufacture of ammonia

ammonia

A

flamed and emitted as nitrogen

65
Q

manufacture of ammonia

2 other products

A

nitrous oxides

water

66
Q

manufacture of ammonia

2 procedures to analyse the gas mixtures at all stages of the ammonia production

A

gas chromatography

infra red spectroscopy

67
Q

manufacture of ammonia

safety

A

2 alarm systems, fire alarm and alarm to indicate gas release
workforce trained in first aid and fire fighting
site designed to allow fire engines into central parts

68
Q

manufacture of ammonia

fixed costs

A

labour costs, plant depreciation and repayment of loans

69
Q

manufacture of ammonia

variable costs

A

raw materials, heat and electricity and waste disposal

70
Q

manufacture of ammonia

cost of natural gas

A

increased as running out in Kinsale, is now obtained from the North Sea - more expensive due to transport costs

71
Q

manufacture of ammonia

who supplies water and how much

A

supplied by local council - 4.5 million L per day

72
Q

what reduces the cost

A

recycling and sale of the co-product
heat exchangers in the exothermic reactions
use of catalyst to allow lower temperatures

73
Q

manufacture of ammonia

site location

A

marino point in Cobh, Co.Cork

74
Q

manufacture of ammonia

4 reasons for location

A

natural gas nearby
skilled personnel in Cork area
seawater available for cooling
rail and sea available for transport of products

75
Q

manufacture of ammonia

construction materials

A

mild steel on a deep concrete foundation

stainless steel for reaction chambers and compressors - low rate of corrosion

76
Q

3 uses of ammonia

A

manufacture of urea
manufacture of nitric acid
manufacture of fertilisers

77
Q

manufacture of urea

where?

A

by IFI in Cobh, Co.Cork

78
Q

manufacture of urea

type of process

A

continuous process

79
Q

manufacture of urea

raw materials and where do they come from

A

anhydrous ammonia and potassium hydrogen carbonate

produced by IFI

80
Q

manufacture of urea

what is done to the potassium hydrogen carbonate

A

heat and pressure reduced to produce carbon dioxide

81
Q

manufacture of urea

equation for producing carbon dioxide

A

2KHCO3 -> CO2 + H2O + K2CO3

82
Q

manufacture of urea

feedstock

A

ammonia and carbon dioxide

83
Q

manufacture of urea

first step

A

ammonia and carbon dioxide reacted together to form ammonium carbamate

84
Q

manufacture of urea

equation for reaction with ammonia and carbon dioxide

A

CO2 + 2NH3 ⇌ NH2COONH4

85
Q

manufacture of urea

heat change in forward reaction of ammonia and carbon dioxide

A

exothermic

86
Q

manufacture of urea

ideal conditions

A

carried out at high temperature to favour the forward reaction and heat produced in removed immediately to ensure completion of reaction

87
Q

manufacture of urea

what happens to ammonium carbamate

A

ammonium carbamate loses water to form urea n a carbamate condenser

88
Q

manufacture of urea

equation for when ammonium carbamate loses water

A

NH2COONH4 ⇌ CO(NH2)2 + H2O

89
Q

manufacture of urea

heat change when ammonium carbamate loses water

A

endothermic

90
Q

manufacture of urea

speed of reaction when ammonium carbamate loses water

A

slow but sped up with high temperature

91
Q

manufacture of urea

left over ammonium carbamate

A

decomposed to form ammonia and carbon dioxide and these gases are recycled to the condenser to react

92
Q

manufacture of urea

what is done to the urea

A

changed into molten urea in an evaporator, then prilled

93
Q

manufacture of urea

prilling

A

process that involves spraying the molten urea downward from the top of a tall prill tower against an upward flow of air, causes urea to solidify into small spherical particles called prills

94
Q

manufacture of urea

co-products

A

there are no co-products

95
Q

manufacture of urea

waste disposal and effluent control

A

treated with steam to hydrolyse urea to ammonia and carbon dioxide which is recycled
air emissions monitored for the presence of urea dust

96
Q

manufacture of urea

quality control

A

gas chromatography and infra red spectroscopy are carried out to analyse the gas mixtures at all stages of the ammonia production

97
Q

manufacture of urea

safety

A

2 alarm systems, fire alarm and alarm to indicate gas release
workforce trained in first aid and fire fighting
site designed to allow fire engines into central parts

98
Q

manufacture of urea

fixed costs

A

labour costs, plant depreciation and repayment of loans

99
Q

variable costs

A

raw materials, heat and electricity and waste disposal

100
Q

manufacture of urea

reduce costs

A

recycling and sale of the co-product
heat exchangers in the exothermic reactions
use of catalyst to allow lower temperatures

101
Q

manufacture of urea

site location

A

marino point in Cobh, Co.Cork

102
Q

manufacture of urea

why that location?

A

natural gas nearby
skilled personnel in Cork area
seawater available for cooling
rail and sea available for transport of products

103
Q

manufacture of urea

construction materials

A

mild steel on a deep concrete foundation is used in some areas of the plant
stainless steel is used in parts of the plant - reaction chambers and compressors, low rate of corrosion

104
Q

3 uses of urea

A

as a fertiliser
on runways as a non-corrosive de-icer
manufacture of MDF (medium density fibreboard)

105
Q

2 other important chemicals produced in Ireland

A

Nitric acid

magnesium dioxide

106
Q

where is nitric acid produced?

A

from ammonia by IFI in Arklow, Co.Wicklow

107
Q

where is magnesium dioxide produced?

A

from seawater by Premier Periclase in Drogheda

Chemistry (Tara) (50 decks)

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