Industrial Chemistry

[BOOK DESCRIPTION]

Industrial Chemistry is a book that brings the subject matter of a chemistry curriculum to life. It examines the major chemistry performed by industry and looks at how such chemical processes affect our lives. In addition, as each process is presented and examined, there is a significant discussion dedicated on the by-products, pollution, necessary waste generated, and attempts to make each process more ecologically friendly, or "greener." It bridges the divide between the basic chemistry that students learn in the undergraduate curriculum, and the broader chemical processes that are used in real life.

[TABLE OF CONTENTS]

Preface V
1 Overview and Introduction to the Chemical Industry 1
1.1 Introduction  1
1.2 Listing of U.S. Top 50 Chemical Producers  1
1.3 List of Top Chemical Producers Worldwide  3
1.4 Employment  5
1.5 Recycling  5
2 Sulfuric Acid 7
2.1 Introduction  7
2.2 Methods of Production, Sulfur  7
2.3 Methods of Production, Sulfuric Acid  8
2.3.1 The Contact Process  8
2.3.2 The Wet Sulfuric Acid Process  9
2.4 Volume of Production and Sales  9
2.5 Uses  10
2.5.1 Production of Phosphoric Acid  10
2.5.2 Production of Aluminum Sulfate  10
2.6 Recycling  11
3 Major Industrial Gases 13
3.1 Introduction, Air Liquefaction  13
3.2 Helium  13
3.3 Helium Uses  13
3.4 Air Liquefaction  14
3.5 Oxygen  15
3.5.1 Storage and Uses  15
3.6 Nitrogen  16
3.6.1 Major Uses  16
3.7 Argon  16
3.7.1 Major Uses  16
3.8 Carbon Dioxide  16
3.8.1 Carbon Dioxide Uses  16
3.9 Pollution, Recycling, By-Product Uses  17
4 Nitrogen Compounds 19
4.1 Inorganic Nitrogen Compounds  19
4.2 Ammonia  19
4.2.1 Introduction and History  19
4.2.2 Sources of Starting Materials  19
4.2.3 Reaction Chemistry  19
4.2.4 Uses  20
4.3 Nitric Acid  20
4.4 Ammonium Nitrate  21
4.5 Adipic Acid  21
4.6 Urea  21
4.7 Ammonium Sulfate  22
4.7.1 Pollution  22
4.7.2 Recycling Possibilities  22
5 Chemicals from Limestone 25
5.1 Introduction  25
5.2 Lime  26
5.3 Sodium Carbonate  26
5.3.1 Soda Ash Uses  27
5.3.2 Sodium Bicarbonate Uses  27
5.4 Calcium Chloride  28
5.4.1 Uses  28
5.5 Pollution and Recycling  29
6 Sodium Chloride 31
6.1 Introduction  31
6.2 Methods of Recovery, Production, and Extraction  31
6.2.1 Evaporation  33
6.2.2 Mining  33
6.2.3 Uses  33
6.3 Chemicals Produced From Sodium Chloride  34
6.3.1 Sodium Hydroxide Production  34
6.3.2 The Mercury Cell  34
6.3.3 The Diaphragm Cell  34
6.3.4 The Membrane Cell  35
6.3.5 Production Statistics  35
6.4 Uses of NaOH  36
6.5 Chlorine  36
6.5.1 Uses of Chlorine  37
6.6 Hydrochloric Acid  37
6.6.1 Production of Hydrochloric Acid  37
6.6.2 Uses of Hydrochloric Acid  38
6.7 Titanium Dioxide  38
6.7.1 Production of Titanium Dioxide  38
6.7.2 Uses of Titanium Dioxide  39
6.8 Recycling  40
7 Further Inorganics 41
7.1 Carbon black  41
7.2 Producers  41
7.3 Production Methods  42
7.4 Uses  43
7.5 Recycling  44
7.6 Potash  44
7.6.1 Producers  44
7.7 Production by Country  46
7.8 Recycling  46
7.9 Sodium Tri-Poly-Phosphate  47
7.10 Producers  47
7.11 Production  47
7.12 Uses  48
7.13 Recycling  48
8 Water 51
8.1 Introduction, Sources  51
8.2 Purification Techniques  51
8.2.1 Desalination  51
8.2.2 Sewage Treatment  53
8.3 Uses, Residential  54
8.4 Uses, Industrial  54
8.5 High Purity Water, Uses  55
8.6 Recycling  55
8.7 Further  56
9 Simple Organics from Petroleum 57
9.1 Introduction and History  57
9.2 Sources, Geographically  57
9.3 Extractive Techniques  59
9.3.1 Offshore  59
9.3.2 Onshore  60
9.4 Refining and Distillation  62
9.4.1 Simple De-Salting  62
9.4.2 Distillation  62
9.4.3 Hydrotreating or Hydroprocessing  62
9.4.4 Cracking or Hydrocracking  62
9.4.5 Coking  63
9.4.6 Visbreaking  63
9.4.7 Steamcracking  63
9.4.8 Catalytic Reformers  63
9.4.9 Alkylation  63
9.4.10 Removal of the C1 or Natural Gas Fraction  63
9.4.11 Sulfur Recovery  64
9.5 Pollution  64
9.6 Recycling and By-Product Uses  64
10 The C1 Fraction 65
10.1 Methane  65
10.2 Methanol  65
10.2.1 Production  65
10.2.2 Uses  66
10.3 Other Oxygenated C1 Chemicals  67
10.3.1 Production  67
10.3.2 Uses  67
10.4 CFCs and HFCs  68
10.4.1 Production  68
10.4.2 Nomenclature  69
10.5 Elemental Hydrogen Production from Methane  69
10.6 Pollution and Recycling  70
11 The C2 Fraction and Ethylene Chemistry 71
11.1 Introduction  71
11.2 Ethane  72
11.3 Ethylene  72
11.3.1 Acetaldehyde and Acetic Acid  73
11.3.2 Ethylene Dichloride (also, Ethylene Chloride,
or 1,2-Dichloroethane)  74
11.3.3 Vinyl Chloride  75
11.3.4 Ethylene Oxide and Ethylene Glycol  75
11.3.5 Vinyl Acetate  76
11.3.6 Ethanol  76
11.3.7 Acetylene  77
11.4 Recycling  77
12 C3 and C4 Fraction Chemistry 79
12.1 Introduction  79
12.2 Propane  79
12.3 Propylene  80
12.4 Acrylonitrile  80
12.5 Propylene Oxide and Propylene Chlorohydrin  81
12.6 Isopropanol  82
12.7 Cumene  83
12.8 Acetone and Phenol  83
12.9 Butane  84
12.10 The 1,3-Butadiene Isomers  84
12.11 Recycling Possibilities  85
13 Liquid Organic Fuels 87
13.1 Gasoline  87
13.2 Octane Number  87
13.3 Additives  88
13.4 Jet Fuels  89
13.5 Diesel  90
13.6 Liquefied Petroleum Gas  90
13.7 Biofuels, Pollution, and Recycling  91
14 Aromatics and Their Derivatives 93
14.1 Benzene  93
14.1.1 Catalytic Reforming or Steam Cracking  94
14.1.2 Toluene Hydrodealkylation  94
14.1.3 Toluene Disproportionation  94
14.2 Ethylbenzene  94
14.3 Cyclohexane  95
14.4 Nitrobenzene  95
14.5 Toluene  97
14.5.1 Caprolactam  97
14.5.2 Trinitrotoluene  97
14.5.3 Toluene Diisocyanate  98
14.6 Xylene  99
14.7 Pollution and Recycling  100
15 Polymers 101
15.1 Introduction  101
15.2 Resin Identification Codes, RIC 1–6  101
15.3 Thermoplastics  102
15.4 Thermosets  102
15.5 Polyethylene Terephthalate (PETE)  103
15.6 Low Density Polyethylene and High Density Polyethylene (LDPE and
HDPE)  104
15.7 Polypropylene (PP)  105
15.8 Polyvinyl Chloride (PVC)  106
15.9 Polystyrene (PS)  107
15.10 Pollution, Recycling Possibilities, and By-Product Uses  107
15.10.1 PETE  107
15.10.2 Polyethylene, Polypropylene, and Polyvinyl Chloride  108
15.10.3 Polystyrene  108
16 Coatings and Adhesives 109
16.1 Introduction  109
16.2 Coating Types  109
16.3 Adhesives and Binders  109
16.4 Fillers  110
16.5 Pigments  111
16.5.1 Recycling  113
17 Fertilizers and Pesticides 115
17.1 Introduction  115
17.2 Nitrogen-Containing Materials  115
17.3 Phosphorus-Containing Materials  115
17.4 Potassium Containing Materials  116
17.5 Mixed Fertilizers  116
17.5.1 Production of Mixed Fertilizers  117
17.6 Pesticides  117
17.6.1 Herbicides  117
17.6.2 Insecticides  119
17.7 Pollution and Recycling  120
18 The Paper Industry 123
18.1 Introduction: The Chemical Composition of Wood  123
18.1.1 Cellulose  123
18.1.2 Hemicellulose  124
18.1.3 Lignin  124
18.2 Virgin Papers  124
18.3 Kraft Process (a.k.a. the Sulfate Process)  124
18.3.1 By-Product, Lignin  126
18.3.2 Tall Oil  126
18.4 High Quality Papers – Acid Sulfite Process  126
18.5 Steps in Paper Manufacturing  127
18.6 Paper Uses  128
18.7 Paper Re-Cycling  128
18.8 Low Grade Papers  128
19 Pharmaceuticals 131
19.1 Introduction  131
19.2 The Top 100 Prescription Medicines Sold  131
19.3 Over the Counter Drugs  136
19.4 Drug Synthesis  137
19.4.1 Synthesis of Common Medicines  137
19.5 Recycling  139
20 Surfactants and Detergents 141
20.1 Introduction and Historical Production  141
20.2 Current Syntheses  143
20.2.1 Anionic Surfactants  144
20.2.2 Cationic Surfactants  144
20.2.3 Zwitterionic or Di-Ionic Surfactants  145
20.2.4 Non-Ionic Surfactants  145
20.3 Function of Surfactants  145
20.4 Additives  146
20.5 Artisanal Soap Making  147
20.6 Recycling  148
21 Rubber 149
21.1 Introduction  149
21.2 Sources  149
21.2.1 Natural Rubber  149
21.2.2 Synthetic Rubber  150
21.2.3 Vulcanization  150
21.3 Major Uses  151
21.3.1 Synthetic Isoprene Rubber  151
21.3.2 Poly-Butadiene Rubber  152
21.4 Other Elastomers  152
21.5 Recycling  152
22 Silicon 155
22.1 Introduction, Purification of Silicon  155
22.1.1 Ferrosilicon  156
22.2 High purity Silicon, Uses  157
22.3 Silicones  157
22.3.1 Production of Silicones  157
22.3.2 Uses and Features of Silicones  158
22.4 Silicon Dioxide  159
22.5 Recycling  160
22.5.1 Recycling of Silicon  160
22.5.2 Recycling of Silicones  160
22.5.3 Recycling of Silica  160
23 Iron and Steel 163
23.1 Introduction and Historical Production  163
23.2 Ore sources  163
23.3 Current Iron Production  165
23.3.1 Blast Furnace  165
23.4 Steel Production  167
23.5 By-Products  168
23.6 Recycling  168
24 Aluminum 171
24.1 Introduction and History  171
24.2 Bauxite Sources  172
24.3 Production Methods  173
24.4 Major Industrial Uses  174
24.5 By-Products  175
24.6 Recycling  175
25 Copper 177
25.1 History  177
25.2 Ore Sources  177
25.3 Producers  177
25.4 Production Methods  178
25.5 Major Industrial Uses  179
25.5.1 Wire, Piping, Machinery, and Alloys  179
25.5.2 Coinage  179
25.6 Brass  180
25.7 Bronze  181
25.8 Recycling  181
26 Other Major Metals for Industrial Use 183
26.1 Titanium  183
26.1.1 Sources  183
26.1.2 Worldwide Production  183
26.1.3 Extraction Chemistry, Reactions  184
26.1.4 Volume Produced Annually  185
26.1.5 Major Uses  185
26.2 Chromium  186
26.2.1 Sources  186
26.2.2 Extraction Chemistry, Reactions  187
26.2.3 Major Uses  187
26.3 Mercury  188
26.3.1 Sources  188
26.3.2 Volume Produced Annually  188
26.3.3 Major Uses  188
26.4 Gold  189
26.4.1 Introduction  189
26.4.2 Sources  189
26.4.3 Extraction Chemistry  190
26.4.4 Major Uses  191
26.5 Silver  192
26.5.1 Introduction  192
26.5.2 Sources  192
26.5.3 Extraction Chemistry  192
26.5.4 Major Uses  193
26.6 Platinum Group Metals (PGM)  194
26.6.1 Introduction  194
26.6.2 Sources  194
26.6.3 Extraction Chemistry  195
26.6.4 Major Uses  196
26.7 Uranium  196
26.7.1 Introduction and History  196
26.7.2 Sources  196
26.7.3 Major Uses  197
26.7.4 Recycling  197
27 Materials 199
27.1 Introduction, Silicates  199
27.2 Enamel  199
27.2.1 Introduction  199
27.2.2 Production  199
27.2.3 Uses of Enamel  200
27.3 Ceramics  200
27.3.1 Introduction and Classifications  200
27.3.2 Production  200
27.3.3 Major Uses  201
27.4 Metal Foams  201
27.4.1 Production  201
27.4.2 Uses  202
27.5 Carbon Materials  202
27.5.1 Introduction  202
27.5.2 Bucky Ball Fullerenes  202
27.5.3 Tubular Fullerenes  203
27.5.4 Major Uses  203
27.6 Pollution, Recycling, and By-Product Uses  203
Index 205