Program: B.Sc. Chemical Engineering Technology Semester: 3rd Lecturer: Engr. Babar Saeed

Program: B.Sc.
Chemical Engineering Technology
Semester: 3rd
Lecturer: Engr. Babar Saeed

Introduction
 Chemical Process Industries
 Abbreviated as CPI
 in which the raw materials undergo chemical conversion during
their processing into finished products, as well as the physical
conversions common to industry in general. In the chemical
process industry the products differ chemically from the raw
materials as a result of undergoing one or more chemical
reactions during the manufacturing process.
 The chemical process industries broadly include the traditional
chemical industries, both organic and inorganic; the petroleum
industry; the petrochemical industry, which produces the
majority of plastics, synthetic fibers, and synthetic rubber from
petroleum and natural-gas raw materials; and a series of allied
industries in which chemical processing plays a substantial part.
2
Recommended Books
 “Shreve’s Chemical Process Industries” by Austin George T.
 Chemical Process Technology by Jacob A. Moulijin, Michiel

Makkee & Annelies Van Diepen
 Unit Processes in Organic Synthesis by Groggins P. H.
 A Text Book of Chemical Technology by Pandey G. N.
3
Course Outline
1) Acid & Alkali Industries
2) Glass & Ceramic Industries
3) Paint & Varnishes Industries
4) Oil & Fat Industries
5) Cosmetic Industry
6) Industrial Detergents
7) Insecticides & Pesticides Industries
8) Explosives Industry
4
Acids & Alkali Industries
 Acid
 (PH < 7)
 Alkali
 (PH > 7)
 Acids
 Sulfuric Acid (H2SO4)
 Nitric Acid (HNO3)
 Hydrochloric Acid (HCl)
5
Sulfuric Acid (H2SO4 )
• Justus von Liebig was a German chemist in the 1800s who is
considered by many the founder of organic chemistry. He once
said “the commercial prosperity of a nation can be measured
by the amount of sulfuric acid it consumes”.
• One of the oldest industrially applied processes. Discovered by
a Persian alchemist Jaber Bin Hayan in the tenth century.
• Saltpeter and sulfur were mixed in a glass container and
burned in a moist atmosphere. Acid was collected from the
condensed vapors.
• In England, 1746, the lead chamber reactor was invented. This
invention allowed for higher production rates (<78%).
6
H2SO4 - Properties
 The chemical formula of sulfuric acid is H2SO4
 its molecular weight is 98.079 g/mol
 H2SO4 is a colorless or slightly yellow viscous liquid with a
pungent odor
 It has a density of 1.84 g/mL, boiling point of 337 °C, and
melting point of 10 °C
 It is a powerful oxidizing agent and reacts with many metals at
high temperatures
 Concentrated H2SO4 is also a strong dehydrating agent.
 Addition of water to concentrated sulfuric acid is a very
exothermic reaction and can lead to explosions
7
Manufacturing of Sulfuric Acid
Three Step Process
1) S + O2 SO2
2) SO2 + 1/2O2 SO3
3) SO3 + H2O H2SO4
• Manufacturing Methods
• Chamber Process
• Contact Process
H2SO4 -Process Flow Diagram
9
Chamber Process
 When sulfur is burned in air, sulfur dioxide is formed, and this,
when combined with water, gives sulfurous acid.
 To form sulfuric acid, the dioxide is combined with oxygen to
form the trioxide, which is then combined with water. A
technique to form the trioxide, called the chamber process,
developed in the early days of the operation of the Leblanc
process.
 In this technique the reaction between sulfur dioxide and
oxygen takes place in the presence of water and of oxides of
nitrogen. Because the reaction is rather slow, sufficient
residence time must be provided for the mixed gases to react.
 This gaseous mixture is highly corrosive, and the reaction must
be carried out in containers made of lead
10
Chamber Process
 Lead is a material awkward to use in construction, and the
process cannot deliver acid more concentrated than about 78
percent without special treatment.
 Therefore, the chamber process has been largely replaced by
the contact process, in which the reaction takes place in a hot
reactor, over a platinum or vanadium compound catalyst, a
substance that increases the speed of the reaction without
becoming chemically involved
11
Contact Process
 Current method of producing sulfuric acid in the high
concentrations needed for industrial processes.
 Platinum used to be the catalyst for this reaction; however, as it
is susceptible to reacting with arsenic impurities in the sulfur
feedstock, vanadium(V) oxide (V2O5) is now preferred.
 This process was patented in 1831 by British vinegar merchant
Peregrine Phillips. In addition to being a far more economical
process for producing concentrated sulfuric acid than the
previous lead chamber process, the contact process also
produces sulfur trioxide and oleum.
12
Contact Process
 The process can be divided into five stages:
 Combining of sulfur and oxygen (O2) to form sulfur dioxide
 Purifying the sulfur dioxide in a purification unit
 Adding an excess of oxygen to sulfur dioxide in the presence of the
catalyst vanadium pentoxide at 450 °C and 1-2 atm
 The sulfur trioxide formed is added to sulfuric acid which gives rise
to oleum (disulfuric acid)
 The oleum is then added to water to form sulfuric acid which is
very concentrated.
13
Contact Process
14
Uses of H2SO4
• The fertilizer market is the largest use for sulfuric acid and
consumes 50-65 percent of all produced.
• Second is the organic chemical industry. Production of plastics
and synthetic fibers are examples.
• Production of TiO2 consumes large quantities of sulfuric acid.
TiO2 is a white pigment used in paints and plastics.
• In the metal industry, sulfuric acid is used for pickling ferrous
and non-ferrous materials and in the recovery of copper, nickel,
and zinc from low-grade ores.
• Finally, the petroleum industry uses acid as a catalyst for various
reactions.
15
Associated Uses of H2SO4
Percent
H2SO4 Uses
35.67 Storage batteries, electric utilities
62.18
Normal superphosphate and other fertilizers
69.65
Normal superphosphate and other fertilizers,
77.67
isopropyl and sec-butyl alcohols
80.00 Copper leaching
Phosphoric acid, tianium dioxide, steel pickling,
93.19
regenerating ion exchange resins of utilities
98-99 Chlorine drying, alkylation, boric acid
104.50
Surfactants, nitrations, hydrofluoric acid
106.75
109.00 Explosives
111.25
Reagent manufacture, organic sulfonations,
113.50
blending with weaker acids
114.63
16
H2SO4 Production in Pakistan
17
Sulfuric Acid Producers in Pakistan
18

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Program: B.Sc. Chemical Engineering Technology Semester: 3rd Lecturer: Engr. Babar Saeed

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Program: B.Sc.

Chemical Engineering Technology

Lecturer: Engr. Babar Saeed

 Chemical Process Technology by Jacob A. Moulijin, Michiel

 Unit Processes in Organic Synthesis by Groggins P. H.

 A Text Book of Chemical Technology by Pandey G. N.

2) Glass & Ceramic Industries

3) Paint & Varnishes Industries

4) Oil & Fat Industries

7) Insecticides & Pesticides Industries

2) SO2 + 1/2O2 SO3

3) SO3 + H2O H2SO4

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