MANUFACTURED

SUBTANCES

IN

INDUSTRY
INTRODUCTION:
What is manufactured subtances in industry? Almost everything we see is a manufactured products.

Industrial products are manufactured for our comfort. Spoons, forks, pots are industrial products used in

the kitchen. Bucket, bottles, plastic, plates and bowls are example of synthetic polymer normally used in

our daily life.

SULPHURIC

ACID
OBJECTIVES:

1. List the uses of sulphuric acid.

2. Explain the industrial process involved in the manufacture of sulphuric acid.

3. Explain that sulphur dioxide causes environmental pollution.

1. Uses of Sulphuric Acid
: manufacture of fertilizers.
: manufacture of electrolyte in lead acid accumulators.
: manufacture of soaps and detergents.
: manufacture of pesticides.
: manufacture of plastic items such as rayon and nylon.
: manufacture of paints.
: Leather tanning.

Manufacture of car batteries Manufacture of detergents Manufacture of detergents

Manufacture of paints Manufacture of plastic items Leather tanning

Manufacture of pesticides
2. Manufacture of Sulphuric Acid

Sulphuric acid, H2SO4, is manufactured in industry through the Contact Procces. The manufacture of

sulphuric acid, H2SO4, is called Contact Procces because sulphur dioxide, SO2, reacts with oxygen in

contact with the catalyst in several times. Catalysts are normally made from transition elements to

speed up the rate of reaction. The raw materials used are sulphur, air and water.The manufacturing of

sulphuric acid, H2SO4, in industry involve three stages.

The manufacture of sulphuric acid, H2SO4 in the Contact Process

The three stages involved in the Contact Process.

1. > Molten sulphur is burnt in the furnace in dry air to produce sulphur dioxide, SO2.

> The gas produced is purified and cooled.

S(1) + O2 (g) → SO2 (g)

2. > SO2 with excess oxygen are passed through a converter. SO2 is converter. SO2 is converted into

sulphur trioxide, SO3 with the presence of vanadium(V) oxide, V2O5 as a catalyst, a temperature

of 450°C - 550°C and a pressure of 1 atmosphere.

2SO2 (g) + O2(g) ↔ 2SO3 (g)

> The conversion efficiency is about 98%

3. a) SO2 is released with concentrated sulphuric acid, H2SO4 to dorm oleum, H2S2O7.

SO3 (g) + H2SO4 (1) → H2S2O7

b)Oleum, H2S2O7 is diluted with water to produce concentrated sulphuric acid, H2SO4 in large

quantities.

H2S2O7 + H2O(1) → 2H2SO4 (1)

c)SO3 is not dissolved directly in water to produce sulphuric acid (SO3 + H2O → H2SO4) because:

∙ solubility of sulphur trioxide, SO3 in water is slow.

∙ SO3 reacts too slow violently with water to produce a lot of heat and fumes.
3. Environmental Pollution Causes by Sulphur Dioxide.

Sulphur dioxide, SO2 is one of the by-products of the Contact Process. It can cause environmental

pollution. Almost all sulphur dioxides, SO2 in the air comes from the burning of fossil fuels such as

petrol containing sulphur. Below are the environmental pollution causes by sulphur dioxide :
AMMONIA

AND ITS

SALTS
OBJECTIVE:

1. List the uses of ammonia.

2. State the properties of ammonia.

3. Explain the industrial process in the manufacture of ammonia.

4. Design an activity to prepare ammonium fertiliser.

1. Uses of Ammonia

: Manufacture of fertilisers

: Manufacture of nitric acid , HNO3, through the Ostwald Process

: Manufacture of electrolytes in dry cells

: Manufacture of cleaning agents such as washing powder and detergents

: Maufacture of explosives such as trinitroluene (TNT)

: Manufacture of dyes
2. Properties of Ammonia
3. Manufacture of Ammonia

Ammonnia, NH3 is manufactured on a large scale in factories through the Haber Process. There are

three main stages in the manufacture of ammonia. The Haber process is the third stage and uses a

catalyst.

The manufacture of ammonia,NH3 through the Haber Process.

1. Gases mixed and scrubbed

Haber process combines N2 gas from the air with H2 gas from natural gas to form NH3. the two

gases are mixed. The mixture is scrubbed to get rid of impurities.

2. Compressor

One volume of N2 gas and three volume of H2 gas is compressed to a pressure of 200 – 500 atm.

N2 (g) + 3H2 (g) ↔ 2NH3 (g)

3. Converter

Then, it goes to the converter. It is then passed through layers of iron catalyst with aluminium oxide

as a promoter at a temperature of 450°C – 550°C.

4. Cooler

A mixture of three gases leaves the converter. It is cooled until the ammonia condenses. The

nitrogen and hydrogen are pumped back to the converter for another chance to react.

5. Storage tanks

NH3 is formed and the liquefy and separated to get a better yield. The NH3 is run into tanks and

stored as a liquid under perssure.

4. Preparation of ammonium fertiliser.

Aim
To prepare ammonium sulphate, (NH4)2SO4, salts

Materials
Ammonia solution, NH3, 1 mol dm-3, sulphuric acid, H2SO4, 1 mol dm-3, red litmus paper

Apparatus
250 cm3 beaker, glass rod, tripod stand, Bunsen burner, wire gauge, filter funnel, filter paper, measuring

cylinder, dropper, asbestos tile

Preparation of ammonium sulphate, (NH4)2SO4, salts

Procedure

1. 50 cm3 of sulphuric acid, H2SO4, 1 mol dm-3 is measured with a measuring cylinder and poured into a

250 cm3 beaker.

2. While stirring, ammonia solution, (NH4)2SO4, 1 mol dm-3, is added drop by drop from a dropper into

the sulphuric acid, H2SO4, until an excess amount is used (when ammonia, NH4, can be smelled)

3. The mixture is then poured into an evaporating dish.

4. The mixture is boiled until it evaporates to form a saturated solution.

5. The saturated solution is then cooled to room temperature until crystals salts is formed.

6. The crystals are then filtered and rinsed with a little cold distilled water.

7. The salt crytals are then dried on filter paper.

Analysis

Neutaralisation occur between sulphuric acid, H2SO4, and ammonia solution or ammonia hydroxide,

NH4OH, and can be represented by the chemical equation below :

H2SO4 + 2NH4OH (NH4)2SO4 + 2H2O

Conclusion

Ammonium sulphate, (NH4)2SO4, salt can be prepared from the reaction between sulphuric acid, H2SO4,

and ammonia solution NH3.

Dicussion

The mixture formed in the beaker is tested from time to time with red litmus paper. The adding of

ammonia solution, NH3, drops are stopped when the red litmus paper turns blue.
ALLOYS
OBJECTIVE:
1. The arrangement of atoms in metals.

2. The arrangement of atoms in alloy.

3. Meaning of alloy.

4. Examples of alloy, its compositions and properties.

5. Properties of alloys and their uses.

1. Arrangement of Atom in Metals

o When force is applied to pure metals, the atoms slide along one another easily. This property causes

pure metal to be ductile, that is, it can be stretched into wire.

Metals are ductile

o When knocked or hammered, metal atoms slide along one another to fill spaces between the metal

atoms. This property causes pure metal to be malleable, that is, it can be knocked or pressed into

various desired shapes.

Metals are malleable

2. Arrangement of Atom in Alloys

A mixture of two or more elements with a certain fixed composition; the major component is a metal.

The formation of alloy

3. Alloys

Two soft metals can be mixed together to make stronger metal called alloy. An alloy is

a mixture of two or more elements with a certain fixed composition on which the

major component is a metal. Most pure metals are weak and soft. The properties of pure

metals can be improved by making them into alloys. The aim of making alloys is to

make them into alloys. The process of mixing atoms of impurities with atoms of pure

metal by melting is called alloying.

4. Composition and Properties of Alloy

ALLOY COMPOSITION PROPERTIES

Steel o 99% iron o Hard and strong
o 1% carbon o Withstand corrosion
Bronze o 90% copper o Hard and strong
o 10% tin o Withstand corrosion
o Has shiny surface
Brass o 70% copper o Strong
o 30% zinc o Shiny
o Harder than copper
Stainless steel o 74% iron o Shiny
o 8% carbon o Strong
o 18% chromium o Does not rust
Duralumin o 93% aluminium o Light
o 3% copper o Strong
o 3% magnesium o Withsand corrosion
o 1% manganese
Pewter o 96% tin o Lustre
o 3% copper o Smooth and shiny
o 1% antimony surface
o Strong
o Withstand corrosion
Copper nickel o 75% copper o Strong
o 25% nickel o Shiny silver colour
5. Uses of Alloys
Properties of alloys and their uses.
SYNTHETIC

POLYMERS
OBJECTIVE:

1. State the meaning of polymers.

2. List naturally occurring polymers.

3. List synthetic polymers and their uses.

4. Identify the monomers in the synthetic polymers.

5. Justify uses synthetic polymers in daily life.

1. Meaning of Polymers

Polymers are long chains of molecules made from combination of many small molecules. Small

molecules that combine together by covalent bond to form polymers are called monomers.

Polymerisation is a process of combining monomers to form a long chain of molecules.

Formation of polymer

2. Natural Polymer

A natural polymer is a polymer that occurs naturally. Naturals polymer are normally made by living

organism.

NATURAL POLYMER MONOMER (small molecules)

Rubber Isoprene
Cellulose Glucose
Starch Glucose
Protein Amino acid
Fat Fatty acid and glycerol
Nucleic acid Nucleotides

Examples of natural polymers and their monomers

3. Synthetic Polymers

Synthetic polymers are man-made polymers that are produced from chemical compunds through

polymerisation. Plastic, synthetic fibres and synthetic rubbers are three examples of synthetic

polymers.

There are two types of polymerisation:

a) Additon polymerisation

b) Condensation polymerisation

Addition polymerisation

Unsaturated monomers that contain double bonds between two carbon atoms undergo addition

polymerisation.

Condesation polymerisation

Small molecules such as water, H2O, and ammonia, NH3, are released in condensation polymerisation.

Examples of synthetic polymers (products of condensation polymerisation, with their monomers)

MONOMER POLYMER
a) Adipic acid and hexanediamine Nylon
b) 1,4-dicarboxylbenzene and ethene-1,2diol Terylene
4. Monomers in the synthetic polymers

SYNTHETIC MONOMER
POLYMER
Polythene Ethene
Polyvinyl chloride Chloroethene (Vinylchloride)
(PVC)
Polypropene Propene
Perspex Methyl-2-methylpropenoate
(Methyl metacrylate)
Polystyrene Styrene
Nylon Adipic acid and hexanediamine
Terylene 1,4-dicarboxylbenzene and ethene-1,2diol

5. Uses of synthetic polymers in daily life

TYPE OF POLYMER USE

Polythene a) Make buckets
b) Make plastic bags
c) Make raincoats
d) Make films
e) Make rubbish bins
Polyvinyl chloride (PVC) a) Make water pipes
b) Make electric cables
c) Make mats
d) Make vinyl records
e) Make clothes hangers
Polypropene a) Make ropes
b) Make bottles
c) Make chairs
d) Make drink cans
e) Make carpets
Perspex a) Make car windows
b) Make plane windows
c) Make spectacle lenses (optical instruments)
Nylon a) Make ropes
b) Make curtains
c) Make stockings
d) Make clothes
Polystyrene a) Make packing boxes
b) Make buttons
c) Make noticeboards
Terylene a) Make textile items such as clothes and cloths
 GLASS

AND

CERAMICS
OBJECTIVE:

1. List the uses of glass.

2. List the uses of ceramics.

3. List type of glass and their properties.

4. State properties of ceramics.

1. Uses of Glass

TYPE OF GLASS USES

Fused silica glass Lenses, spectacles, laboratory glassware, ultraviolet
column.
Soda-lime glass Bottles, glass containers, mirrors, electrical bulbs,
glass windows
Borosilicate glass Bowls, plates, saucers, pots and laboratory glassware
such as test tubes, beakers and flasks
Lead crystal glass Lenses, prisms, glasses and ornamental items
(crystals)

2. Uses of Ceramics.

> Manufacture of computer microchips

> Make porcelaine vase and ornamental items

> Make plates, bowls and pots

> Make dentures – enamel

> Used in the manufacturing of car engines, spacecraft, superconductors and nuclear reactors

> Make construction materials such as bricks, cement, tiles, underground piping or roof tiles.
3. Types of glasses and their properties

TYPE OF GLASSES PROPERTIES

Fused silica glass o Very high melting point
o Not easy to change its shape
o Does not easily expand or shrink with changes of
temperature

o Transparent to ultraviolet ray

Soda-lime glass o Transparent
o Low melting point
o Easily to be shaped
o Easily broken

o Cannot withstand heat and chemical reactions

Borosilicate glass o Withstand heat and chemical reactions
o High melting point
o Transparent to light and infrared ray but not to
ultraviolet ray

o Expand and shrink very little and only when

temperature changes
Lead crystal glass o Very transparent
o Shiny
o High refractive index

o High density
4. Properties of ceramics

> Brittle > Crack when temperature changes drastically

> Extremely hard > Inert to chemicals ( withstand corrosion)

> High melting point > Good insulator of heat and electricity

> Withstand compression

COMPOSITE

MATERIALS
OBJECTIVE:

1. Describe the needs to produce new materials for specific purposes.

2. State the meaning of composite materials.

3. List examples of composite materials and their components.

4. Compare and contrast the properties of composite materials with those of their original

components.

5. Justify the use of composite materials.

6. Generate ideas to produce advanced materials to fulfill specific needs.

1. The Needs to Produce New Materials for Specific Purposes.

Since the old days, human beings have been using clay, wood, stones or metals as building

materials. These substances either corrode or decay easily. Otherwise, they are too heavy, bulky

or difficult to be shaped or carved.

Many of our modern technologies require materials with unusual combinations of properties that

cannot be met by the conventional metal alloys, ceramics and polymeric materials. Therefore,

continuous research and development have been done in search of new structural materials.

Today, many of such materials are created and used for various fields. New materials are needed

today to supply high demand for the new industries.

To fulfil the needs, these building materials must have properties like:

> Low density > Able to withstand high pressure

> Strong > Easier and more convenient to use

> Resistance to heat and corrosion > Last longer

2. Meaning of Composite Materials.

A composite material is a structural material that is formed by combining two or more different

substances such as metal, alloys, glass, ceramics and polymers. The different materials work together to

give composite unique properties. The resulting material has properties that are superior than those of

original components. Composite materials are created for specific application.

Composite exist in nature. A piece of wood is a composite, with long fibres of cellulose (a very

complex form of starch) held together by a much weaker substances called lignin. Cellulose is also

found in cotton and linen, but it is the binding power of the lignin that make a piece of timber much

stronger than bundle of cotton fibres.

3. Examples of Composite Materials and Their Components.

COMPOSITE MATERIALS COMPONENTS

Mixture of :

• Cement
• Gravel
Reinforced concrete • Sand
• Water
• Iron

• Steel
• Yttrium oxide
• Barium carbonate
Superconductor
• Copper (II) oxide
• Silica
• Sodium carbonate
Fibre optic
• Calcium oxide
Fibre glass • Glass fibre
 • Polyester (a type of plastic)
• Glass
Photochromic glass
• Silver chloride or silver bromide

4. Comparison the Properties of Composite Materials and Their Original Components.

ORIGINAL COMPONENTS COMPOSITE MATERIALS

Concrete Reinforced Very strong

Low tensile
concrete
strength

Yttrium oxide,
Non- Barium carbonate, Superconductor Very good
conductor Copper (II) oxide conductor
electric

Silica,
Sodium
Non carbonate, Fibre optic
Transparent
transparent Calcium oxide

Transparent Glass
but not Transparent
sensitive to but sensitive
the intensity Photochromic to the
of light rays glass intensity of
light rays
Sensitive to
the intensity Silver chloride
of light rays
5. Uses of Composite Materials

COMPOSITE MATERIALS USES

Reinforced concrete Construction of large structures like
o Highways
o High-rise buildings
o Bridges
o Oil platforms
o Airport runners
o Dams
Superconductor o Transportation
o Telecommunication
o Astronomy
o Industry
o Medical fields
Fibre optic o Used in medical field to observe internal
organs (endoscope)
o Transmit data, voice, images in a digital
format
Fibre glass o Water storage tanks
o Badminton rackets
o Small boats
o Skis
o Helmets
o Used to make protective apparel for
astronauts and firefighters.
Photochromic glass o To make optical lenses
o Glass windows (windshields) of vehicles
o Lens in camera
o Information display panels
o Optical switches
o Light intensity meters
6. Ideas to Produce Advanced Materials to Fulfil Specific Needs.

Bridge are is used to reinfrorced concrete Magnetic resonance imaging, MRI in hospitals
A helmet that is made from fibre glass A fibre optic cable

ADVANCED

MATERIALS

AND THE
 FUTURE
1. Importance of doing research and development continuously

The phrase research and development (also R and D or, more often, R&D), according to the

Organization for Economic Co-operation and Development, refers to "creative work undertaken on a

systematic basis in order to increase the stock of knowledge, including knowledge of human, culture and

society, and the use of this stock of knowledge to devise new applications.

2. Handling synthetic materials and their wastes

Recycling involves processing used materials into new products in order to prevent waste of potentially

useful materials, reduce the consumption of fresh raw materials, reduce energy usage, reduce air

pollution (from incineration) and water pollution (from landfilling) by reducing the need for

"conventional" waste disposal, and lower greenhouse gas emissions as compared to virgin production.

Recycling is a key component of modern waste management and is the third component of the "Reduce,

Reuse, Recycle" waste hierarchy.

Recyclable materials include many kinds of glass, paper, metal, plastic, textiles, and electronics.

Although similar in effect, the composting or other reuse of biodegradable waste – such as food or

garden waste – is not typically considered recycling. Materials to be recycled are either brought to a

collection center or picked up from the curbside, then sorted, cleaned, and reprocessed into new

materials bound for manufacturing.

In a strict sense, recycling of a material would produce a fresh supply of the same material, for example

used office paper to more office paper, or used foamed polystyrene to more polystyrene. However, this

is often difficult or too expensive (compared with producing the same product from raw materials or

other sources), so "recycling" of many products or materials involves their reuse in producing different

materials (e.g., cardboard) instead. Another form of recycling is the salvage of certain materials from

complex products, either due to their intrinsic value (e.g., lead from car batteries, or gold from computer

components), or due to their hazardous nature (e.g., removal and reuse of mercury from various items).

Critics of recycling claim that it often wastes more resources than it saves, especially in cases where it is

mandated by the government. Note here that municipal recycling may nevertheless still be worthwhile if

the net cost is less than the landfill or other disposal costs for the same amount of material.

3. Importance of synthetic materials in daily life

Materials science plays a pivotal role in determining and improving economic performance and the

quality of life, particularly in the following areas:

Living Environment: Because of pressing environmental concerns more efficient use of material and

energy resources is urgently required. Materials science is helping to develop new energy generation

technologies, more energy efficient devices, and easily recyclable, less toxic materials.

Health: Overcoming disease and providing worldwide medical care are high priorities. Materials

science, in conjunction with biotechnology, can meet this challenge by, e.g., developing artificial bones

and organ implants, safe drug delivery systems, water filtration systems, etc.
Communication: The increasing interconnectedness of our world requires faster and more reliable

means of communication. The information and associated computer revolutions closely depend on

advances made by scientists working on new electronic, optical, and magnetic materials.

Consumer Goods: Consumers have come to expect global products/services that are delivered rapidly

at reasonable prices. Materials science can improve not only the products but also the way they are

handled (e.g., packaging), resulting in faster production and delivery times and higher quality goods.

Transport: Whether for business, holidays, or space exploration, materials science is needed to provide

durable, high-performance materials that make traveling faster, safer, and more comfortable. Examples

are the development of light-weight aluminium bodies for automobiles, brake systems for high-speed

trains, quieter aircrafts, and insulation tiles for re-entry spacecrafts.

CONCLUSION
Sulphuric acid H2SO4, is used to make fertiliser, the electrolyte in car batteries, paint and detergent.

Sullphuric acid, H2SO4, is made in industry through the Contact process. The burning of fossil fuels

such as petrol and products made from sulphuric acid, H2SO4, will produce sulphur dioxide, SO2,

which pullutes the environment. Sulphur dioxide can caused acid rain which harmful for human and

nature.

The main use of ammonia, NH3, is in the manufacture of nitrogenous fertilers. Ammonia NH3, is

mass produced in factories through the Haber process. Examples of ammonium salts that can be used as

fertiliser are ammonium nitrate, NH4NO3, ammonium sulphate, (NH4)2SO4, and ammonium

phosphate, (NH4)3PO4.

An alloy is a compound formed by mixing metals with other elements. The process of mixing atoms

of pure metals and atoms of impurities such as metals or non-metals by melting is called alloying.

Alloying aims to increase the strength and hardness of metals, prevent metal corrosion and to improve

the appearance of metals so that they are more attractive.

A polymer is a long-chained molecule made from the combination of many small molecules

(monomers). Polymerisation is the process of combining monomers to form a long-chained polymer.

There are two types of polymers; natural polymer and synthetic polymer. A natural polymer is a
polymer that occurs naturally, such as starch and cellulose. A synthetic (artificial) polymer is a man-

made polymer that is formed from chemical compounds through polymerisation.

The main component of glass is silica or silicon dioxide, SiO2. Glass is brittle, hard, transparent and

chemically inert. Types of glass include fused silica glass, soda-lime glass, borosilicate glass and lead

crystals glass. Ceramics are items made from clay that have been heated at high temperature. The main

properties of ceramics include being brittle, a good insulator of heat and electricity, very hard, having a

very high melting point and being heat resistance.

Composite materials are compound that are formed from combinations of two or more different

compounds. The new subtance has the properties that are superior to those of the original components.

Examples of composite materials are reinforced concrete, composite plastics, fibre optics, fibre glass and

photochromic.
REFERENCES
1. Form 4 Chemistry Text Book (KBSM)

2. Reference Text Series Chemistry (Pearson Longman)

3. www.wikipedia.org/wiki/sulfuric_acid

4. www.epa.gov/air/urbanair/so2/hlth1.html

5. www.portal.unesco.org/education

6. www.answers.com/topic/sulfuric-acid

7. http://education.yahoo.com/reference/encyclopedia/entry?id=45647

8. www.ibchem.com/IB/ibnotes/full/ope_htm/sulphuricacid.htm

9. www.wikipedia.org/wiki/ammonia

10. SPM CHEMISTRY (Learning Through Diagram)