This document provides an overview of several key chemical processes used in the production of important industrial chemicals and fuels. It discusses the production of sulfuric acid, ammonia, urea, nitric acid, styrene, biofuels, methanol to gasoline, and fuel additives. For each process, it describes the main chemical reactions, process steps, catalysts used, and industrial significance. The document emphasizes the central role of catalysis in efficiently producing chemicals at scale for various industrial sectors.

1. (CHEMICAL PROCESS
INDUSTRIES)
Presented By Submitted to
Sana Parveen Dr. Moina Athar
21PKPM102 (Assistant Professor)
GM6514
Department Of Petroleum Studies
Zakir Husain College of Engineering &
Technology
Aligarh Muslim University
Aligarh, 202002
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2. CONTENT
 Introduction
 Sulfuric acid
 Ammonia synthesis
 Urea production
 Nitric acid
 Styrene production process
 Heterogeneous catalysis
 Bio based fuels
 Types of bio-based fuels
 Bio-based chemicals
 Types of bio-based chemicals
 Methanol to gasoline
 Fuel additives
 Conclusion
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3. INTRODUCTION
 The inorganic chemical industry plays a pivotal role in the modern world, providing the essential
building blocks for a wide array of products and processes.
 Each of these chemicals holds a unique place in the industrial landscape, serving as raw materials
or intermediates in various sectors, from plastics manufacturing to energy production.
 It underscores the significance of optimizing these processes to minimize environmental impact
and maximize economic benefits, reflecting the ever-evolving landscape of industrial chemistry in
the 21st century.
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4. SULFURIC ACID (H₂SO₄)
Sulphuric acid is manufactured commercially by the contact process. The raw materials used source of
sulphur dioxide, air, water and a catalyst.
The Contact Process main stages in this process are:-
1-Production of sulphur dioxide
2. Oxidation of sulphur dioxide to sulphur trioxide
3. Hydration of sulphur trioxide to sulphuric acid
1.PRODUCTION OF SULPHUR-DI-OXIDE
This can be produced by;
 Burning sulphur in an excess of air:
S+ O₂(g) → SO₂(g)
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5. SULFURIC ACID (H₂SO₄)
 Heating sulphide ores like pyrite in an excess of air:
4FeS₂O) + 11O₂(g) → 2Fe₂O3(s) + 8SO₂(g)
 Decomposing calcium sulphate in the presence of coke
2CaSO4(s) + C(s) → 2CaO + CO₂ + 2SO₂(g)
2.Oxidation of sulphur dioxide to sulphur trioxide:
Sulphur dioxide is mixed with excess air and passed through an electrostatic precipitator which
removes dust and impurities. The purified sulphur dioxide combines with oxygen in the presence of a
catalyst, vanadium oxide to form sulphur trioxide, the anhydride of sulphuric acid:
2SO₂(g) + O₂ → 2SO₃(g)
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6.  A Temperature of about 450 °C is
used with the catalyst, producing
a fairly high yield of sulphur
trioxide at an exceptable reaction
rate. It is done close to
atmospheric pressure.
 It must be noted that since the
forward reaction is exothermic
the temperature of the
surrounding system increases
thus the gases are cooled down
by a cooling system which
employs the use of a
cooled water circuit.
SULFURIC ACID
PRODUCTION FLOW
DIAGRAM
Sulfuric acid production flow diagram
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7. 3.HYDRATION OF SULPHUR TRIOXIDE TO SULPHURIC ACID:-
 The sulphur trioxide is first dissolved in concentrated sulphuric acid to form oleum:
H₂SO₄+SO₃(g) → H₂S₂O₇
 It is then diluted with water to produce concentrated sulphuric acid:
H₂S₂O₇ + H₂O → 2H₂SO₄
USES:- Sulfuric acid is a highly corrosive and strong mineral acid. It plays a crucial role in various
industrial processes, including the production of chemicals, fertilizers, and batteries, etc.
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8. AMMONIA SYNTHESIS
 Ammonia synthesis is a crucial chemical process that involves the production of ammonia (NH₃)
from its elements, nitrogen (N₂) and hydrogen (H₂).
 This process is of great industrial significance, as ammonia serves as a fundamental building block
for the production of fertilizers, chemicals, and various other products.
Reaction: -
 The ammonia synthesis reaction is typically represented as follows:
N₂ + 3H₂ ⇌ 2NH₃
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9. PRODUCTION
OF AMMONIA
SYNTHESIS
1. Hydrogen Production: - The
production process often begins
with the generation of hydrogen
(H₂). Hydrogen can be produced
through various methods, such as
steam methane reforming (SMR)
or electrolysis of water.
2. Nitrogen Separation: - Air is
liquefied, and nitrogen (N₂) is
separated from other components
of air using a process called air
separation. Nitrogen is then
stored for further use.
Production of ammonia synthesis flow diagram9

10. AMMONIA SYNTHESIS
3. Ammonia Synthesis: - Ammonia is synthesized through the Haber-Bosch process, which combines
hydrogen and nitrogen in the presence of an iron-based catalyst at high temperature and pressure.
Reaction: N₂ + 3H₂ ⇌ 2NH₃
4. Purification and Recovery: - The resulting ammonia gas often contains impurities. It undergoes a
series of purification steps to remove these impurities, leaving behind high-purity ammonia.
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11. UREA PRODUCTION
The production of urea, a vital nitrogenous fertilizer and chemical
compound, involves a two-step process: synthesis of ammonia (NH₃)
and subsequent reaction of ammonia with carbon dioxide (CO2).
Here's an overview of the production process: -
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12. UREA PRODUCTION
Carbon Dioxide Generation: - Urea production requires carbon dioxide (CO2). In some cases, CO2
is obtained as a byproduct from various industrial processes. Alternatively, it can be produced through
combustion or recovered from flue gases.
Ammonia and Carbon Dioxide Reaction: -The ammonia gas produced in the first step is reacted
with carbon dioxide to produce ammonium carbonate, which is an intermediate in urea production.
Reaction: 2NH₃ + CO₂ + H₂O ⟶ (NH₄)₂CO₃.
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13. UREA PRODUCTION
Urea Formation: - The ammonium carbonate produced is then heated to break down into ammonia
and carbon dioxide, which can be recycled. The remaining ammonia is then reacted with carbon
dioxide in a high-pressure reactor to produce urea.
Reaction: 2NH₃ + CO₂ ⟶ NH₂CONH₂ + H₂O
Urea Concentration and Granulation: - The liquid urea solution is concentrated to increase its urea
content. It's then cooled and granulated to produce urea granules or prills, which are the final products
suitable for storage and distribution.
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14. UREA PRODUCTION.
Prilling or Granulation: - The concentrated urea solution is prilled or
granulated into solid urea particles of a desired size and shape. This process
involves spraying the concentrated solution onto a solid seed material, which
allows the urea to solidify into pellets or granules.
Packaging and Distribution: - The final urea product is packaged into bags
or stored in bulk for distribution to agricultural and industrial customers.
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15. NITRIC ACID (HNO₃)
Nitric acid (HNO₃) is a highly corrosive and strong acid with numerous industrial applications,
including the production of fertilizers, explosives, and various chemicals.
The production of nitric acid involves a multi-step process, primarily consisting of ammonia
oxidation, followed by the absorption of nitrogen dioxide (NO₂) in water.
Step 1: Ammonia Oxidation: -
Ammonia Oxidation: - In the first step, ammonia (NH₃) is oxidized to form nitrogen monoxide (NO)
or nitric oxide.
Reaction: 4NH₃ + 5O₂ ⟶ 4NO + 6H₂O.
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16. NITRIC ACID FLOWSEET
Nitric acid production flow diagram
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17. NITRIC ACID
Formation of Nitrogen Dioxide: - Nitrogen monoxide (NO) reacts further with oxygen (O₂) to
form nitrogen dioxide (NO₂).
Reaction: 2NO + O₂ ⟶ 2NO₂.
Step 2: Absorption of Nitrogen Dioxide (NO₂): -
Absorption in Water: - Nitrogen dioxide (NO₂) is absorbed into water to form nitric acid (HNO₃)
and nitrogen oxide (NO):
Reaction: 3NO₂ + H₂O ⟶ 2HNO₃ + NO.
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18. STYRENE PRODUCTION PROCESS
Styrene is an important industrial chemical used in
the production of various plastics, resins, and
synthetic rubber. Its production typically involves
the dehydrogenation of ethylbenzene. Here's an
overview of the process:
Feedstock Preparation:- The primary feedstock
for styrene production is ethylbenzene (C8H10),
which is typically obtained from the petrochemical
industry through the alkylation of benzene with
ethylene. Ethylbenzene is often stored and
transported as a liquid.
Styrene production of flow diagram 18

19. STYRENE PRODUCTION PROCESS
Dehydrogenation: - The key step in styrene production is the dehydrogenation of ethylbenzene,
which involves the removal of two hydrogen atoms from the ethylbenzene molecule to form styrene.
Reaction: C₈Hₗ₀ ⟶ C₆H₅CH=CH₂ + 2H₂
In this reaction, ethylbenzene is heated to high temperatures (usually around 500-600°C) in the
presence of a suitable catalyst.
Catalyst: - The dehydrogenation reaction is catalysed by a solid catalyst, which is typically a mixture
of iron oxide (Fe₂O₃) and potassium oxide (K₂O) supported on an inert material. This catalyst
facilitates the dehydrogenation reaction and helps increase the yield of styrene.
Product Storage and Distribution: -The purified styrene is then typically stored and transported in
tanks or containers for various industrial applications.
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20. BIO BASED FUELS
 Bio-based fuels are a category of renewable energy sources derived from biological materials.
 These fuels are produced from organic matter such as plants, algae, and waste organic materials,
making them a sustainable alternative to fossil fuels.
TYPES OF BIO-BASED FUELS: -
1. Bio-jet Fuel: - Bio-jet fuels are derived from biomass and can replace conventional aviation fuels,
reducing greenhouse gas emissions in the aviation industry.
2. Biodiesel: - Biodiesel is made from vegetable oils (like soybean, canola, or palm oil) or animal fats
through a process called transesterification. It can be blended with or substituted for diesel fuel in
diesel engines. (Bio-ethanol, Biogas etc)
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21. TYPES OF BIO-BASED CHEMICALS
1. Bio-Based Polymers: - These are biodegradable or non-biodegradable polymers produced from
bio-based feedstocks. Examples include bio-based polyethylene, bio-based polypropylene, and bio-
based polyethylene terephthalate (PET).
2. Bio-Based Solvents: - Environmentally friendly solvents produced from bio-based feedstocks,
often used in applications like coatings, paints, and cleaning products.
3. Bio-Based Platform Chemicals: - Key chemical building blocks derived from biomass, which
serve as precursors for a wide range of chemical products. Examples include bio-based succinic acid,
1,4-butanediol, and lactic acid. 21

22. PRODUCTION OF BULK
CHEMICALS
 The production of bulk chemicals using transition metal catalysts is a significant area of chemical
manufacturing.
 Transition metals and their compounds serve as catalysts in numerous industrial processes due to
their ability to facilitate chemical reactions efficiently.
Transition Metal Catalysts:
 Transition metals, such as iron, nickel, cobalt, platinum, palladium, and others, exhibit unique
catalytic properties due to their electron configuration.
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23. METHANOL TO GASOLINE
Haldor Topsoe and TIGAS are two different technologies for the conversion of methanol into gasoline.
Both processes involve catalytic reactions and are used in the production of liquid transportation fuels.
Haldor Topsoe Methanol-to-Gasoline (MTG): -Haldor Topsoe is a Danish company known for its
expertise in catalysts and process technologies. Their Methanol-to-Gasoline (MTG) process is a
catalytic conversion technology that transforms methanol into high-quality gasoline.
Key Features: -
Zeolite catalyst: - The MTG process employs a zeolite-based catalyst, which is central to the
conversion of methanol into gasoline.
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24. METHANOL TO GASOLINE
Reaction: - The primary reaction in the MTG process involves the conversion of methanol (CH₃OH)
to hydrocarbons (gasoline range) through a series of complex steps, including dehydration,
oligomerization, and hydrocracking.
Gasoline Quality: - MTG produces gasoline with a high-octane rating and low sulphur content,
meeting stringent fuel quality standards.
Efficiency: - The MTG process is designed for high efficiency and selectivity to maximize the yield of
gasoline.
Commercialization: - The Haldor Topsoe MTG technology has been employed in various methanol-
to-gasoline plants worldwide, contributing to the production of gasoline from methanol feedstock.
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25. METHANOL TO GASOLINE
TIGAS- TIGAS is another technology used for the conversion of methanol into gasoline, but it's not
associated with Haldor Topsoe. While Haldor Topsoe is known for its MTG process, TIGAS is
typically associated with Total, the French multinational energy company.
Key Features: -
Catalyst and Process: - The TIGAS process involves the use of specific catalysts and process
conditions to convert methanol feedstock into high-octane gasoline.
High-Quality Gasoline: -TIGAS is designed to produce gasoline with high octane ratings, making it
suitable for use in modern internal combustion engines.
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26. FUEL ADDITIVES
Fuel additives are chemical compounds or products that are introduced into fuels to enhance their
properties, improve combustion, reduce emissions, and protect engines and fuel systems.
Types of Fuel Additives: -
1. Octane Boosters: - These additives increase the octane rating of gasoline, preventing
knocking and improving engine performance.
2. Cetane Improvers: - Cetane improvers raise the cetane number of diesel fuel, improving
ignition quality, reducing diesel knock, and enhancing engine efficiency.
3.Corrosion Inhibitors: - Corrosion inhibitors protect fuel systems from rust and corrosion,
particularly in marine and storage applications.
4. Anti-Knock Agents: - These compounds, such as tetraethyl lead (once used but now phased
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27. CONCLUSION
In this comprehensive exploration of fuel and chemical
production, catalysis emerged as a central theme, highlighting
the crucial role of catalysts in numerous industrial processes.
 Transition metal catalysts, such as those employed by Haldor
Topsoe and Total in methanol-to-gasoline (MTG) and TIGAS
technologies, have revolutionized the production of bulk
chemicals like gasoline.
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28. THANK YOU
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