Industrial Processes

Industrial Processes

Introduction
Since time immemorial, industries have existed where knowledge of production processes was derived from archeological investigation. According to the 2019 Global Competitiveness Report, published by the World Economic Forum, Uganda was the 115th most competitive economy. Overall, Uganda’s industrial sector is still developing, as compared to developed countries. What are some of the industries in
Uganda? What products do they manufacture? What is the importance of industrial processes in improving a country’s economy? In this chapter, you will appreciate the principles behind some industrial processes and the importance of the products formed.

2.1 Main Industries that Produce Useful Chemicals
There is a vast number of natural resources in Uganda, ranging from minerals, to rocks,’ plants and animals. These are a good starting point for manufacturing industries. In Activity 2.7, you will look at the materials that are produced by various industries in Uganda.

Can a New Chemical Industry Help the Environment? Watch the Video below

4. How do the industries relate with each other?
5. Share your findings with the whole class.
   Observation and Analysis
6. What do people in your community do for a living?
7. What are some of the products obtained from these activities?
   Conclusion:
   A variety of products that you need in your daily life are produced by industries that process raw materials and manufacture goods in factories. Examples of such products include, drugs, soap, plastics, cosmetics, flavours, automobiles, fertilisers, and cement.

Common products from industries in Uganda
Industries consist of enterprises and organizations that produce and / or supply goods and services. What are some of the examples of industries found in your area? What products do they produce? What are the uses of these products in daily life?

In Activity 2.7(b), you will identify the common products that are produced by some industries and the uses of these products.

Analysis

1. How useful are the products above?
2. How do the above industries affect human welfare?
   2.2 Processes of Obtaining Useful Chemicals from Rocks
   We are surrounded by rocks and minerals everywhere; on the ground we walk on, at the places we work and live, and even in the food we eat.
   In this section, you will understand the processes for obtaining useful chemicals and minerals from rocks.

Useful chemicals from rocks

There are several useful chemicals found in rocks. These chemicals are obtained by use of different chemical processes.
In Senior One, you learnt that rocks change from time to time, that is, from igneous rocks, to sedimentary and to metamorphic rocks. You also looked at weathering, and you explored how rocks are weathered physically, biologically or chemically and the
factors responsible for each.
Most rocks are composed of naturally occu rring inorganic solids that have a crystalline structure and a distinct chemical composition. These are known as minerals. Some of the elements that make up the minerals found in the Earth’s rocks are given in
Table 2.2.

Activity 2.2(a): Investigating the components in chalk
Work in groups.
What you need:
. vinegar
. water

• small pieces of chalk
• masking tape
• marker or pen
• magnifying glass
• 2 clear plastic cups or glass beaker
  Safety Precaution
• Do not drink the water or vinegar during the experiment.
  Wash your hands when you finish the experiment.
  Wear protective gear.

Observation and Analysis
a) Which piece of chalk changed the most?
b) How did the piece of chalk change after soaking it in vinegar for 10 minutes?
What caused these changes?
c) Compare your observations in (b) with what happens when rainwater falls on rocks.
Conclusion:
How would you test for the presence of limestone in a rock?

Activity 2.2(b): Studying the processes involved in
Work in groups.
What you need:

• Internet
  What to do
  obtaining useful chemicals from rocks
• relevant Chemistry textbooks

1. Collect information about obtaining minerals from rocks.
2. Study the flowchart below about the process involved in obtaining chemicals from rocks.

Discussion Questions

1. Why are sampling and analysis of the rock necessary before mining?
2. State at least two ways in which sampling is done.
3. Compare manual and excavation (machinery) methods of mining.
4. State three properties of the rock which are considered before
   concentration of the rock is done.
5. Outline three ways in which the rock can be concentrated.
6. Identify one metal that can be obtained along this route.
   Complete the table below by giving examples of metals which are extracted by each of the methods indicated:

Activity 2.3(a): How to obtain pure copper from a copper ore
Work in groups.
What you need:

• Internet
  What to do
• relevant Chemistry textbooks
  1.Collect information about copper mining.
  (2)Identify the principal ores of copper in Figure 2.6.
  3. Where in Uganda can such ores be found?
  4.State the main steps involved in extracting copper from its ores.
  5. How does copper mining affect the environment?
  6. State the uses of copper in everyday life.

THE VIDEO BELOW EXPLAINS HOW COPER IS OBTAINED

Activity 2.3(c): Exploring the processes involved in extracting and purifying iron from its ores
Work in groups.
What you need:

• Internet or other resource materials • markers sellotape
  Manila paper or flip charts
  What to do Research about and discuss the following:
  1.Where in Uganda can iron ores be found?
  2.Discuss the steps involved in extracting iron from its ores. In your discussion,
  3.write the chemical equations for the reactions involved.
  4.Explain the processes involved in purifying iron.
  5.State three uses of iron.
  6.Display your findings on Manila paper.

THIS VIDEO EXPLAINS THE PROCESSES INVOLVED IN EXTRACTING AND PURIFYING IRON

Activity 2.4(a): production of nitrates from nitrogen in air
Work in groups.
What you need:
. Internet
What to do

• relevant Chemistry textbooks

1. Research about the importance of nitrogen.
2. Construct a flowchart showing how nitrogen in the air is captured and eventually becomes nitrogen in nitrate fertilizers.

Analysis and Application
a) Explain the difference between nitrogen-fixing and denitrification.
b) Starting from the atmospheric air, describe how nitrates are obtained from nitrogen.
c) Briefly explain how nitrates are converted into fertilisers.

Ammonia
From Biology, you know that your body produces urine on a daily basis. How does urine smell? That smell is due to ammonia vapour residues in urea. Ammonia naturally occurs in many parts of the environment, such as in soil, air, and vegetation. Ammonia is an essential compound of nitrogen and hydrogen. However, ammonia can also be prepared in the laboratory. In Activity 2.5, you will learn how to prepare
ammonia by reacting calcium hydroxide with ammonium chloride.

What to do

1. Mix equal amounts of calcium hydroxide and ammonium chloride.
2. Put the mixture in a round-bottomed flask.
3. Set up the apparatus, as shown in Figure 2.70.
4. Heat the mixture in the flask.
5. Pass the gas produced through calcium oxide.
6. Collect ammonia by upward delivery with the help of corks and delivery tube.
7. Test the ammonia gas collected with moist blue and red litmus paper.
   Observation
   On testing ammonia with litmus paper, what did you observe when you used moist:
   (i) red litmus paper?
   (ii) blue litmus paper?
   Analysis and Application
   a) Write an equation for the formation of ammonia from calcium hydroxide and ammonium chloride.
   b) Explain the role of calcium oxide in the preparation of ammonia.
   c) Why is ammonia gas collected by upward delivery?
   d) How important is ammonia gas?

Most of the ammonia used today is manufactured by reacting nitrogen and hydrogen at temperatures of 400 oc-500 oc and pressure of 200 atmospheres. Finely divided iron is used as the catalyst in the industrial
manufacture of ammonia. This process is known as the haber process.

Ammonia is converted into a variety of fertilisers, such as potassium nitrate, ammonium nitrate, ammonium sulphate and diammonium phosphate (DAP). These fertilisers are known as inorganic fertilizers.

There are various fertilisers; however, some are better than others, depending on their nitrogen composition.

Activity 2.4(c): Preparing ammonium nitrate
Work in groups.
What you need:

• Internet
  What to do
• relevant Chemistry textbooks

1. Research about the process by which ammonium nitrate can be prepared.
2. Share your research findings with the whole class.

Health awareness
Nitrates and nitrites are widespread contaminants of vegetables, fruits, and waters. Fertilizers applied to crops can be washed into rivers and leached into soil and groundwater. The levels of these compounds have increased as a result of wastes from chemical industries, effluents, nitrogenous fertilizers, and herbicides in agriculture. Therefore, determining the nitrate and nitrite levels in biological, food, and environmental samples is important for human health and the environment. Organic fertilizers, such as cow dung, plant materials (humus) and human waste have less harm to the environment and, therefore, can be used in preference to inorganic fertilizers.

2.5 Industrial Processes that Make Use of Natural Resources Obtained in Uganda
Natural resources are essential for the functioning of human societies and economies. You use many different types of natural resources in your daily life. Think about all the resources around you, such as the resources needed to produce the book and pen you are using. Manufacturing paper mainly needs raw materials of wood. The trees that supply the wood require soil and water to grow. The resources we use can be classified as renewable or non-renewable. In your earlier classes, you learnt aboutthe two different types of resources. Distinguish between renewable and non-renewable resources.
List the different examples of renewable and non-renewable resources.

Natural resources are the primary inputs to most production processes, and they supply much energy for transport, light and heat around the world. In Activity 2.5, you will identify the industries that use natural resources as inputs.

Activity 2.5: identifying the industrial processes that make use
of natural resources obtained in Uganda
Work in groups.
What you need:

• relevant Chemistry textbooks
• Internet
  What to do

1. Research and identify four industrial processes that involve the use of natural resources obtained in Uganda.
2. Copy and complete Table 2.3.
   2.3: Industries that use natural resources

Technology and the environment
Technology has improved transport, industry, and communications in everyday life. Technology has also improved the quality of the environment. For example, energy used at home can be generated from different sources, such as the Sun, water and biomass.

2.6 Importance of Industrial Processes in Utilising Natural Resources to Make Useful Chemicals
Raw materials can be converted into new products that we need in our daily lives, using various industrial processes. Without the industrial processes in the chemical industry, you would not be able to have some products.
In Uganda, the advancement in technology has improved the industrial processes in chemical industries during the production of certain products. Are the industrial processes of any importance? In Activity 2.6, you will find out the importance of industrial processes.

Activity 2.6: Finding out the importance of industrial processes in utilising natural resources to make useful chemicals
Work in groups.
What you need

• Internet connection
  Manila paper
  What to do
  . markers
• sellotape
  relevant Chemistry
  textbooks
  As a class, conduct a debate under the motion ” Industrial processes have done
  more good than harm.”
  1.Choose the proposing and opposing sides.
  2.Research using the Internet or available resource materials to get more information and facts about the motion.
  3.Conduct the debate.
  4.Come up with conclusions about the importance of industrial processes in utilising natural resources to make useful chemicals and the dangers they cause.
  5.Write your conclusions on Manila paper and pin them in the study corner.

2.7 Dangers Arising from Industrial Processes and the Steps that May be Taken to Minimise them
Humans interact with their surroundings in many different ways, for example, by cutting down forests to clear land for growing crops and construction of industries.

Different processes involved in the manufacturing of different products in industries affect the environment in various ways.
In Activity 2.7(a), you will describe the dangers of these industrial processes to the
community and the steps that may be taken to minimise these dangers.

Activity 2.7 (a): Exploring the dangers arising from industrial processes and the steps that may be taken to minimise these dangers
Work in groups.
What you need:

• Internet
  What to do
• relevant Chemistry textbook

1. Research on and describe the dangers arising from industrial processes in the
   community.
2. Describe the steps that may be taken to minimise these dangers.
3. Write a report and present it for class discussion.
   Conclusion
   From the uses of natural resources in industries, wastes are produced. Figure 2.12 shows the relationship between human activities, the environment and wastes. Humans do not only affect the environment negatively, but also contribute positively to sustaining it. When we install wastewater treatment plants, protect endangered species, and replant forests, we make a positive impact on our environment.

Activity 2.7(b): Making posters for encouraging recycling of materials
Work in groups.
What you need
Manila paper

• coloured pencils
  . markers
  . sellotape
  What to do

1. Design posters to explain the concept of three R’s, (that is, Reduce, Reuse and Recycle).
2. Use different words, designs and colours to make your message clear and appealing.
3. Share your designed posters with the class and, then, pin them in differnt areas in your school compound.

2.8 Manufacture of Lime and Cement
Lime and cement production has undergone tremendous development since its beginning, some 2000 years ago. Cement is an important chemical in most societies. What are some of the uses of cement and lime, and where are they produced? What processes do you think are involved in their making?
In this section, you will appreciate the process in the manufacture of lime and cement.

Activity 2.8: Describing the process of manufacturing cement
Work in groups.
What you need:
. Internet
What to do

• relevant Chemistry textbooks
  1.Construct a flowchart to indicate the processes involved in the manufacture of cement.
  2.Identify the social benefits of manufacturing lime and cement.
  3.Explain some of the dangers to the community, arising from the manufacture of lime and cement.
  4.Describe the steps taken to minimise the dangers arising from the manufacture of cement.
  5.Present your findings to the rest of the class.

2.9 The Production of Sodium Hydroxide and Chlorine by the Electrolysis of Salt Solution
You previously learnt about alkalis and identified sodium hydroxide as one of them. sodium hydroxide is one of the world’s most widely used alkalis. How can you manufacture sodium chloride in the laboratory?
In Activity2.9, you will learn about the production of sodium hydroxide by electrolysis.

Activity 2.9: Investigating the production of sodium hydroxide and chlorine gas by electrolysis of sodium chloride solution
Work in groups.
What you need:
battery

• electrical wires
  carbon rods
  glass beaker
  spatula
  test tube
  burning splint
  10 M sodium chloride solution
  100 cm3 measuring cylinder
  distilled water

Safety Precaution
Chlorine gas is poisonous; therefore, the experiment should be carried out in a fume cupboard or carried out by the teacher in small amounts. Alkali solution is corrosive and it should be handled with care.

Observation and Analysis
a) What happened to the blue litmus paper when it was brought near the gas produced at the anode? Give reasons for your answer.
b) What happened when a burning splint it was brought towards the gas produced at the cathode.

2.10 Uses of Synthetic Polymers
You have interacted with polymers, ranging from the plastic cups, plastic plates the ropes used to tie animals, such as goats at home, as well as the polythene bag used to carry commodities from the market and other places. This makes polymers common in your daily environment. You previously learnt about polymers. Describe what polymers are using your prior knowledge.
You learnt that there are two broad types of polymers, that is, natural and synthetic polymers. What are some of the examples of natural and synthetic polymers? Distinguish between natural and synthetic polymers.

In Activity 2.70, using your prior knowledge about polymers, you will prepare presentations about natural and synthetic polymers.

Activity 2.10: Identifying the uses of natural and synthentic
Work in groups.
What you need:

• Internet
  What to do
  polymers
• relevant Chemistry textbooks

1. Research and prepare a presentation about:
   a) uses of natural and synthetic polymers.
   b) dangers of synthetic polymers to the environment.
2. Present your report to the rest of the class.

There are various synthetic polymers and they have a variety of applications. However, there are also environmental dangers associated with the use of these synthetic polymers, since they are non-biodegradable.

Chapter Summary
In this chapter, you have learnt that:
Uganda has a large number of natural resources, which can be used in various industrial processes.
Metals can be extracted from their ores.
The method used to extract a metal from an ore depends on the reactivity of the metal.
Metals which are high in the reactivity series are extracted by electrolysis
but those which are averagely reactive are extracted by chemical reduction.
In the extraction of sodium, molten sodium chloride is used as the
electrolyte. Calcium chloride is added to lower its melting point.
The main ore of aluminium is bauxite.
Iron is extracted by heating a mixture of the ore, limestone and coke in a blast furnace.
Copper is extracted from cuprite or malachite. It can be refined by electrolysis
of copper(ll) sulphate using a copper cathode.

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