MANUFACTURED SUBSTANCES IN INDUSTRY

MUHAMAD ARIF BIN AHMAD 4 CITA

TABLE OF CONTENT
9.1 SULPHURIC ACID 9.1.1 Uses of Sulphuric acid 9.1.2 The manufacture of Sulphuric acid 9.1.3 Sulphur Dioxide and environmental pollution 9.2 AMMONIA AND ITS SALT 9.2.1 Uses of Ammonia 9.2.2 Properties of Ammonia 9.2.3 Manufacture of Ammonia 9.2.4 Preparation of Ammonia in laboratory 9.3 ALLOY 9.3.1 Relation between arrangement of atoms in metals to their properties 9.3.2 Meaning of Alloy 9.3.3 Aim of making Alloy

9.3.4 Examples of Alloy 9.3.5 Composition and properties of Alloy 9.3.6 Relation between properties of Alloy to their uses 9.3.7 Relation between arrangement of atoms in Alloy to their strength and hardness 9.4 SYNTHETIC POLYMERS 9.4.1 Meaning of polymers 9.4.2 Naturally occuring polymers 9.4.3 Synthetic polymers and their uses 9.4.4 Monomers in the Synthetic polymers 9.4.5 Justification of Synthetic polymers in daily life 9.5 GLASS AND CERAMIC 9.5.1 Type of Glass and their properties 9.5.2 Uses of Glass

9.5.3 Properties of Ceramics 9.5.4 Uses of Ceramics 9.6 COMPOSITE MATERIALS 9.6.1 Meaning of Composite materials 9.6.2 Composite materials and their components 9.6.3 Comparisons and contrast of properties of Composite materials with their original component 9.6.4 Justification of uses of Composite materials 9.7 APPRECIATION IN VARIOUS SYNTHETIC INDUSTRIAL MATERIALS 9.7.1 Justification of importance of doing research and development continuously 9.7.2 The importance of synthetic

materials in daily life

9.1 SULPHURIC ACID, H2SO4 9.1.1 Uses of H2SO4 a) manufacture of detergent

b) manufacture of fertiliser

c) manufacture of artificial fibres

d) manufacture of paint

e) manufacture of leather products

f) as electrolyte in battery

g) to removed Sulphur compound in crude oil h) to produced other metals i) removed oxides from the surface of metals (metallurgy)

9.1.2 The manufacture of H2SO4 a) through Contact Process b) compose of three raw materials : i Sulphur ii Air iii Water, H2O

Figure 9.1

Stage 1 In the furnace, molten sulphur is burnt in dry air to produce sulphur dioxide, SO2. The gas produced is purified and cooled. S(l) + O2(g) Stage 2 In the converter, sulphur dioxide, SO2 and excess oxygen gas, O2 are passed over a few plates of vanadium(V) oxide, V2O5 catalyst at 450 oC to produce sulphur trioxide, SO3. 2SO2(g) + O2(g) 2SO3(g) SO2(g)

About 99.5 of the sulphur dioxide, SO2 is converted into sulphur trioxide, SO3 through this reversible reaction. Stage 3 In the absorber,the sulphur trioxide, SO3 is first reacted with concentrated sulphuric acid, H2SO4 to form a product called oleum, H2S2O7. SO3(g) + H2SO4(l) H2S2O7(l)

The oleum, H2S2O7 is then diluted with water to produce concentrated sulphuric acid, H2SO4 in large quantities. H2S2O7(l) + H2O(l) 2H2SO4(l)

The two reactions in the third stage are equivalent to adding sulphur trioxide, SO3 directly to water. SO3(g) + H2O(l) H2SO4(l) However,this is not done in industry because sulphur trioxide,SO3 reacts too violently with water.this produces a lot of heat and a large cloud of sulphuric acid,H2SO4 mist.The mist is corrosive,pollutes the air and is difficult to condense.

9.1.3 Sulphur Dioxide and environmental pollution

a) can cause acid rain. b) occurs when pH of rain exceed between 2.4 and 5.0. c) due to reaction of sulphur dioxide, SO2 with rainwater : SO2(g) + H2O(l) 2H2SO4(aq)

Science Titbits Inhaling SO2 can cause coughing, chest pain, shortness of breath, bronchitis, and lung diseases.

9.2 Ammonia and its salt 9.2.1 Uses of ammonia a) manufacture of fertiliser

b) manufacture of synthetic fibres

c) manufacture of explosives

d) manufacture of wood pulp, paints, varnishes, laquers and rocket propellant.

9.2.2 Properties of ammonia Ammonia, NH3 a) is an alkaline. b) is a colourless gas. c) has a pungent smell. d) is less dense than air. e) burns in oxygen gas,O2 not in the air. f) very soluble in water. g) gives a white fume when reacted with hydrogen chloride gas, HCl.

9.2.3 Manufacture of ammonia a) through Haber Process. b) derived from natural gas(N2 and H2)

Figure 9.2

a) ratio volume of nitrogen gas to hydrogen gas is 1:3 is passed through the reactor. b) the mixture is compressed to high pressure of 200 atm in 4500C. c) iron catalyst is used to speed up the reaction : N2(g) + 3H2(g) 2NH3(g)

d) the product is then liquefied and separated. e) production of ammonia, NH3 gives out heat. f) the process is reversible.

9.2.4 Preparation of ammonia in laboratory In laboratory : a) ammonia can be prepared to produced ammonium fertilisers. b) examples of ammonium fertilisers is ammonium sulphate, (NH4)2SO4. c) other examples of ammonium fertilisers is ammonium phosphate, (NH4)3PO3 , ammonium nitrate, NH4NO3 and etc.

9.3 Alloy 9.3.1 Relation between arrangement of atoms in metals to their properties a) most metals are solid. b) arrangement of atoms in metals gives it ductile and malleable properties. c) metals are ductile when layers of atoms slide on one another when force is applied. d) this due to an orderly arrangement of atoms in metals. e) metals also malleable when atoms slide to filled the empty spaces between the atoms. f) this due to an imperfections in the orderly arrangement of atoms in metals.

Figure 9.3a

Figure 9.3b

9.3.2 Meaning of alloy Alloy is a mixture of two or more elements with a certain fixed composition in which major components is a metal.

9.3.3 Aim of making alloy Aim : a) stronger. b) harder furnish. e) lustre. c) resistant to corrosion. d) have a better

9.3.4 Examples of alloy

a) bronze. b) brass. c) steel. d) stainless steel. e) duralumin . f) pewter. g) the uses of alloy varies depends on its properties.

9.3.5 Composition and properties of alloys Table 9.3 Alloy Bronze Composition Properties Uses 90% Cu Hard & Building of strong statues or 10% Sn monuments Does not corrode Making easily medals, swords & Shiny artistic surface materials 70% Cu Harder Making of than Cu musical 30% Zn instruments & kitchenware 99% Fe Hard Construction of buildings 1% C Strong & bridge Building of the body of cars & railway tracks

Brass

Steel

Stainless 74% Fe steel 8% C 18% Cr Duralumin Pewter 93% Al 3% Cu 3% Mg 1% Mn 96% Sn 3% Cu 1% Sb

Shiny Strong Does not rust Light Strong Lustre Shiny Strong

Making of culery Making of surgical instrument Building of the body of aeroplanes & bullet trains Making of souvenirs

9.3.6 Relation between arrangement of atoms in alloys to their strength and hardness a) alloy is made up of two different type of metals b) the presence of atoms of another metals that are differ in sizes disturb the orderly arrangement of atoms in the metal. c) this reduces the layer of atoms from sliding. d) thus, an alloy is stronger and harder than its pure metal.

9.4 Synthetic polymers 9.4.1 Meaning of polymers Polymers are large molecules made up of many identical repeating sub-units called monomers which are joined together by covalent bonds. Monomers are joined into chains by a process of repeated linking known as polymerisation.

Figure 9.4

9.4.2 Naturally occuring polymers Examples : a) starch b) cellulose c) wool d) protein e) silk f) natural rubber

9.4.3 Synthetic polymers and their uses

Table 9.4 Uses Plastic bags, shopping bags, plastic containers and insulation for electrical wiring Polypropene Piping bottle crates, carpets, car batteries and rope Polyvinyl chloride, PVC Artificial leather, water pipes and records Perspex Safety glass, reflectors, traffic sign and lens Terylene Clothing, sails and ropes Nylon Ropes, clothing and carpets Synthetic polymer Polythene

9.4.4 Monomers in the synthetic polymers Polythene : - ethene Polypropene : - propene Polyvinyl chloride, PVC : - Chloroethene Perpex : - Methylmethacrylate Terylene : - Hexane-1,6-diol - Benzene-1,4-dicarboxylic acid Nylon : - Hexane-1.6-diamine - Hexane-1,6-dioic acid

9.4.5 Justification of synthetic polymers in daily life a) synthetic polymers can give great advantages such as that they can be made to have special properties required for their uses. b) synthetic polymers are very stable and do not corrode or decay(difficult to dispose). c) they are not easily biodegradable. d) they mat cause pollution, blockage of drainage systems and flash floods. e) they give out harmful and poisonous gases which have a pungent smell when burnt. f) We can still continue using synthetic polymer but in a wiser manner. g) we should reduce, reuse and recycle them.

9.5 Glass and ceramics 9.5.1 Types of glass and their properties a) there are four types of glasses which are : - fused glass - soda-lime glass - borosilicate glass - lead crystal glass b) mainly composed of silica,SiO2. 1. Fused glass - mainly silica, SiO2 - simplest glass - high heat-resistant - great purity - optical transparency - high temperature

- chemical durability - thermal shock resistant 2. Soda-lime glass - made by heating sand with limestone, CaCO3 or sodium carbonate, Na2CO3 can be melted at low temperature malleable good chemical durability high thermal expansion coefficient

3. Borosilicate glass - addition of boron oxide, B2o3 to soda-lime glass - lower thermal expansion coefficient - greater chemical durability(less alkali content) - thermal shock resistance

4. Lead crystal glass - made by substituting PbO for CaO and often for part of the silica used in soda-lime glass soft and easy to melt optically transparent contains much more lead expensive than soda-lime glass

9.5.2 Uses of glass 1. Fused glass - used as laboratory glassware, lenses, telescope mirrors and optical fibres 2. Soda-lime glass - used to make flat glass, electrical bulb, mirrors and all kind of glass container 3. Borosilicate glass - used in cookware, laboratory glassware, automobile headlights, glass pipeline applications which require superior resistance to thermal shock and greater chemical durability

4. Lead crystal glass - used for finest tableware, lead crystal glassware and art objects

9.5.3 Properties of ceramics Ceramics can withstand high temperature do not melt easily very hard brittle chemically inert do not corrode have a very high melting point good insulator of electricity and heat

9.5.4 Uses of ceramics Ceramics - Used in making abrasive, construction materials, tableware, insulators in electrical equipments and refractories

9.6 Composite materials 9.6.1 Meaning of composite materials A composite materials is a structural material that is formed by combining two or more different substances such as metal, alloys, glass, ceramics and polymers. 9.6.2 Composite materials and their component a) there five main composite materials which is : Concrete Superconductors Fibre optics Glass fibre Photochromic glass

1. Reinforced concrete - mixture of stones, chips and sand bound together by cement - strong but brittle and weak in tension - can be reinforced with steel wires, steel bars or any polymer fibres 2. Superconductors - alloy of metal compounds or ceramics of metal oxides - capable of conducting electricity without any electrical resistance when they are cooled to extremely low temperature 3. Fibre optic - consist of a bundle of glass or plastic thread that are surrounded by a glass cladding - low material cost - high transmission capacity

- chemical stability - less susceptible to interference 4. Fibre glass - made by reinforced plastic with glass fibres - high tensile strength - can be easily coloured - low in density - very strong eventhough in thin layers - easily moulded and shaped 5. Photochromic glass - produced by embedding photochromic substances like silver chloride in glass or transparent polymers

9.6.3 Comparison and contrast of properties of composite materials and their components a) composite materials is an improvement from their components. b) therefore, their properties is differ and improved from the properties of their components. c) an example of composite materials and their components is fibre glass that is made from plastic reinforced with glass fibre. d) refer table 9.6 for more details.

Table 9.6 example of comparisons and contrast of composite material with their components Composite material Fibre glass Strong even in thin layers Properties Materials Hardness Components Glass fibre and plastic Glass fibre: - strong plastic: - not as strong as fibre glass Glass fibre: - High density Plastic: - Low density

Low density

Density

Contrast Have quite the same strength of materials with their composite materials

9.6.4 Justification of the use of composite materials Uses of composite materials a) composite materials is essential to fulfil the ever expanding needs. b) to improved our standard of living c) to help a country to achieve a status of developed country and improved their technology.

9.7 Appreciation in various synthetic industrial materials 9.7.1 Justification of importance of doing research and development continuously a) to find an alternative ways to overcome the adverse effect of synthetic materials on human being and environment. b) to improved the quality of the syntheticbased products. c) to ensure the standard of living of human being and environment is taking care.

9.7.2 The importance of synthetic materials in daily life

a) to provide a complete set of our needs in daily life. b) to help in improving our lack in capability and ease our burden. c) to help in systemize our standard of living.