Introduction to Process Technology

1. Introduction to Process Technology Unit 5 Applied Chemistry

2. Agenda • What is Chemistry? • Chemistry in process industry • Organic and Inorganic • Chemical and Physical Properties • Terminology • Reactions • Chemical Formulas, Calculating Mass • Acid, Base, pH • Hydrocarbons • Review

3. Chemistry in the Process Industry • Chemistry – the science that describes matter, its chemical and physical properties, the chemical changes it undergoes, and the energy changes that accompany those processes.

4. Chemistry in the Process Industry • Through chemistry, scientists and process technicians are able to understand various elements and compounds, their properties, and how they interact with one another in the presence of heat, cold, catalyst, and other variables. • By understanding these principles, the process industries are able to produce better products and safer processes.

5. Chemistry in Process Industry • How Chemistry Applies to Process Tech • Turning raw materials into products • Proper management of waste • Understand chemistry concepts that occur during manufacturing process • Understand terminology • Understand concepts to troubleshoot problems and improve quality, efficiency

6. Structure of Matter • Atoms – smallest particle of an element that retains the properties of that element • Protons – positively charged subatomic particle found in the nucleus of an atom • Neutrons – subatomic particle found in the nucleus of an atom that has no charge • Electrons – negatively charged subatomic particle found in orbiting the nucleus of an atom -- Valence Electrons – outermost electrons which provide links for bonding • Molecule – neutral chemically bonded groups of atoms that act as a unit

7. Structure of Matter (Continued) • Atomic Number – the number of protons in the nucleus of an atom of an element • Atomic Mass (Molecular Weight) – weighted average of the masses of the isotopes of an element predominantly from masses of protons & neutrons • Determining Molecular Weight – • Add all masses of each element. Remember to multiply if more than 1 present.

8. The Periodic Table (cont.) (Sodium Atoms)

9. Organic and Inorganic • Chemistry – science that deals with the composition, behavior, and transformation of matter • Organic – carbon based • Hydrocarbon – contains only hydrogen and carbon • Inorganic – no carbons • Such as salts, acids, bases, metals • Many agricultural products

10. Physical Properties • Density – mass (weight) per unit volume • Specific Gravity – comparison of density to that of water for solids and liquids and to air for gases • Hardness – ability of one substance to scratch/mark another • Odor – smell of substance • Color – optical sensation produced by effect of light waves stiking surface

11. Chemical Properties • The ability of a substance to form new substances under given conditions. • A listing of all chemical reactions of a substance and the conditions under which the reactions can occur.

12. Reactivity of a Chemical • The ability of a substance to form new substances under given conditions • A listing of all chemical reactions of a substance and the conditions under which the reactions can occur

13. Types of Bonds • Ionic – metal and non-metal. Electrons are transferred • Covalent – non-metals. Electrons are shared • Metallic – metal to metal. Electrons free flow

14. Terminology • Matter – anything occupying space that has mass • Element – simplest form of matter • Compound – pure substance made up of elements that are chemically combined • Mixture - mixed together, but no chemical reaction • Solution - a homogenous mixture of 2 or more substances in a single phase (usually liquid). Solute and solvent.

15. Terminology (Continued) • Solvent – substance that dissolves • Solute – substance that is dissolved • Solubility : how well solvent dissolves the solute • Freezing Point • Melting Point

16. Terminology (Continued) • Boiling Point • When vapor pressure of liquid equals system pressure • As vapor pressure increases, boiling point decreases • As pressure increases, so does boiling point • The higher the vapor pressure the more easily a material evaporates

17. Terminology (Continued) • Homogenous • Same throughout • Can’t tell one part of mixture from another • Heterogeneous • Different • Equilibrium • Rate of reactants forming products = rate of products forming reactants • Anion – atom or group of atoms with negative charge • Cation - atom or group of atoms with positive charge

18. Chemical Reactions • Chemical Reactions • Endothermic – needs/absorbs heat • Exothermic – gives off heat • Neutralization – acid + base salt + water • Combustion – • fuel + oxygen combustion products + heat + light • Replacement – removes minerals from water

19. Chemical Reactions are Affected By • Heat --- increases molecular activity and reaction rate (rates double with each 10°) • Pressure – slows molecular movement and changes boiling point • Surface Area – solids • Concentration of liquid and gas components • Flow Rates of reactants and products

20. Chemical Reactions • Catalyst • Helps a reaction go at a lower temp or increases rate of reaction • Is not consumed in the reaction

21. Types of Catalysts • Adsorption – solid that attracts and holds reactant molecules so more collisions can occur. Also stretches bonds of reactants making them easier to break, which requires less energy.

22. Types of Catalysts • Intermediate – attaches to reactant molecules and slows it down so collisions can occur • Inhibitor – decreases reaction rate • Poisoned / Spent – no longer functions due to contamination or has been used up • Some can be regenerated

23. Chemical Equations • Like a recipe • Must be balanced (same number of atoms of each element in reactants as products 2H2 + O2 2H2O reactants products

24. Mass Relationships • Allows us to take a balanced equation and use it to determine the actual mass/weight needed for reactants and how much product can be produced

25. Mass Relationships - Steps • Find molecular weight of each element on periodic table (AMUs, but represent grams, pounds, etc.) • Example H = 1.008 O = 16.00 • Multiply by number of atoms (if > 1) • Example H x 2 = 2.016 • Total these up to determine actual weight of entire molecule • Example H2O = 2.016 + 16.00 = 18.016 • Note how reactant mass = product mass

26. Mass Relationships - Steps • Determine how many moles (amounts) of a reactant are needed to produce a set amount of product • Example N2 + 2O2 2NO2 • So you need 1 mole of N2 and 2 moles of O2 to make 2 moles of NO2

27. Mass Relationships - Steps • Determine the relative volume of reactant or product you have • Example if you only have 16 pounds of O, you only have 0.25 volume (16/64) • Multiply the relative volume by the amount of product you can make • Example – 0.25 x 2NO2 = 0.5 volume of NO2

28. Mass Relationships - Steps • Multiple the volume you can make by the molecular weight of material • Example – 0.5 volume x 46 * = 23 kg, lbs, tons N = 14.00 kg, lbs, tons O = 16.00 x 2 = 32.00 kg, lbs, tons * 46.00 kg, lbs, tons

29. Material Balances • Method used to determine the exact amount of reactants needed to produce the specified products in the quantity desired • Steps • Determine the weight of each molecule • Ensure reactant total weight equals product total weight • Determine relative number of reactant atoms or ions

30. Percent by Weight Solutions • Weight of solute (material that is dissolved) is taken in relationship to entire solution • 650 pound barrel has 10% catalyst solution • 650 lb x 0.10 (percent as decimal) = 65 lbs

31. Acid, Base and pH • pH – measurement of hydrogen ions in solution • Acid (pH > 0 and < 7) • Sour taste • Vinegar, Hydrocholoric Acid, Hydrofluoric Acid • Base (pH > 7 and < 14) • Bitter taste, slippery • Alkaline • Caustic –pungent odors • Lye, sodium hydroxide, caustic soda • Neutral – pH = 7 • The stronger the acid or base the more hazardous to body tissue and metal

32. Acids and Bases (cont.)

33. Hydrocarbons • Compound that contains both hydrogen and carbon • Fossil fuels – oil & natural gas, and their refined products (gasoline, ethylene)

34. Hydrocarbons • Major groups • Alkanes – single covalent bond (methane, propane, ethane, etc) • Olefins – not naturally occurring. Produced by cracking oil. At least one double bond (hence the high energy when used) • Alkenes – double bonds (ethylene, propylene) • Alkyne – triple bonds (acetylene – only one used widely) • Cycloalkane – contains a ring or cycle of carbons • Aromatic – contains at least one highly unsaturated six-carbon ring

35. Aromatic Hydrocarbons • Include both hydrocarbons and compounds that cannot be classified as hydrocarbons • Most common - benzene

36. Alcohols • Compounds that contain OH goups connected to an alkyl carbon. • Ethanol – commonly referred to as grain alcohol since often produced from corn, rye, wheat, molasses (from sugar cane), grapes and potatoes. • Becoming popular as gasoline additive or main fuel.

37. Alcohols • Methanol – referred to as wood alcohol, because it was originally derived from wood. • Now produced by subjecting H to CO3 at high temp. in presence of catalyst. • Used as solvent in paints, varnishes, production of formaldehyde, cleaners.

38. Alcohols • Isopropyl Alcohol – most common is rubbing alcohol used externally for cooling skin, disinfect cuts, cosmetic solvent

39. Phenols • Similar to alcohols, but have an OH group connected directly to an aromatic ring. • Used in antiseptics, dyes, aspirin, and at one time throat lozenges

40. Ethylene Glycol • Highly reactive ethylene oxide is reacted with water • Commonly used as antifreeze in vehicle radiators because of unique abiltiy to lower freezing point of water. • Also has higher boiling point than water so better suited to high and low temp. variations due weather extremes. • Because of toxicity when ingested there is a move to switch to less toxic propylene glycol – which many countries in Europe have already done

41. Applied Concepts • Distillation – separation of various fractions in a mixture by individual boiling points • Reactors – designed to break or make chemical bonds which changes reactants into products

42. Applied Concepts • Catalytic Cracking – splits side stream of fractionating column into smaller, more useful molecules – for example, kerosene into hexane and hexene • Hydrocracking – process used to boost gasoline yield • Alkylation – uses a reactor to make one large molecule out of smaller ones. For example isobutane and olefins into high octane alkylates

43. Review • List importance of applied chemistry to process technicians • Re-write all vocabulary words and their definitions • Understand difference between the following: • Organic and inorganic • Endothermic and exothermic • Acids and bases • Define the 4 basic chemical reactions most common to process industry

44. Work • Read CAPT Chapter 11 (pages 158 – 169) • Do questions 1 – 13 on pages 170 & 171) • Read Thomas Chapter 13 (pages 281 – 302 • Do questions 1 – 21 on page 303 • Module 5, Exercise 1 – Chemistry Supplement • Major Grade • In class example worked by group

45. Independent Project • Internet or literature search • Write a paper on the importance of chemistry to 2 different process industries • List raw materials, products • List what chemical reactions, terms apply • Identify associated safety and environmental measures and/or concerns