The chemical manufacturing industry is a key global industry that encompasses many thousands of companies producing a wide range of products, from laboratory analytical reagents, solvents, and custom-made chemicals to pharmaceuticals.
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This industry supplies virtually all manufacturing companies, which use different types of chemicals for different purposes, including cleaning agents, solvents, reactants, and ingredients.
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The global chemical usage can be categorised in terms of amount (volume and weight) and in terms of unit usage.
For example, sulphuric acid (H2SO4) is virtually ubiquitous because of its many applications in manufacturing other products. In fact, it&#;s estimated that the global annual global demand for sulphuric acid will be around 400 metric tonnes by the year . Currently, it is about half that projected global demand.
The chemicals used by industries and end-users can be classified into categories or segments.
According to Statista, in some segments of the chemical industry posted growth, while other segments experienced decline. For example, chemical coatings showed a 2.7% growth, while organics posted a negative growth of -2.2%. Of course, this implies corresponding increase or decrease in the global demands for these products.
Looking forward, it&#;s expected that the global production and corresponding demand for chemical products remains on a similar trend, with a few adjustments and slight differences on the microeconomic level.
Common chemicals can be categorised into various segments or types
Specific chemicals can be ranked into 10 commonly used in the chemical industry
The most common chemicals have various applications, but are commonly used as reactants or precursors to manufacture other chemicals
The top ten chemicals in the world are the basic elements and compounds that are used across various industries in bulk, particularly in chemical manufacturing.
These chemicals are typically simple, react easily with other chemicals, and used to manufacture other chemicals.
Depending on the type of chemical being manufactured, the fundamental chemicals are applied in various ways, such as reagents, solvents, catalysts, precursors, reactants, and ingredients.
Here are the top ten examples of industrial chemicals used worldwide:
Let&#;s look at each of these in a little more detail&#;
Sulfuric acid is the most common chemical used in industry, particularly in the manufacture of fertilisers. It is primarily used as a reactant to manufacture phosphoric acid, which is then used as a precursor.
Nitrogen naturally exists in the atmosphere as diatomic elemental molecules. In fact, about 78% of the atmosphere is nitrogen.
It is industrially converted into ammonia through the Haber&#;Bosch process, and is also used as a blanketing gas to protect oxygen-sensitive products like fruits and vegetables.
Liquid nitrogen is widely used in laboratories to preserve specimens and conduct scientific experiments.
Ethylene is a hydrocarbon that&#;s mainly used as fuel, and is produced in large volumes worldwide. Almost 95% of ethylene produced annually is through the process of steam cracking of petroleum hydrocarbons. Different types of feedstocks, such as ethane, propane, butane, and naphtha, are used in the production of ethylene.
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Just like nitrogen, oxygen exists naturally in the atmosphere as diatomic molecules. About 21% of the atmosphere is composed of oxygen.
In industry, oxygen is one of the three ingredients of combustion (the other two being fuel and heat). Commercially, oxygen is used for oxy-acetylene and oxyhydrogen welding torches, in SCUBA diving, and in healthcare.
As a major oxidant, oxygen is also used in various industrial chemical processes, such as the breakdown of hydrocarbons into simpler hydrocarbons like ethylene and acetylene. These are then used in the production of plastics paints and plastics, as well as other products.
Finally, liquid oxygen, along with liquid hydrogen, is used as cynic propellant. Around 550,000 litres of liquid oxygen is used per space shuttle launch.
There are several products that are manufactured out of propylene. These include polypropylene, which is a versatile plastic material used to make other products, such as material used in packaging, automotive parts, and textiles.
Propylene is also the main feedstock for synthesising other materials, such as acrylic acid. It is essential in manufacturing polyurethane.
Chlorine is one of the most reactive elements. This halogen gas exists as a diatomic molecule, but it is seldom found in nature as an element because of its high reactivity.
It is a powerful oxidising agent that is industrially produced through the electrolysis of sodium chloride brine. It&#;s mainly used for water treatment to kill pathogens, as the active ingredient of bleaches and detergents, and to bleach paper and textiles.
Ethylene dichloride is important in the production of PVC. It&#;s also essential in the synthesis of polystyrene, a type of synthetic polymer. Many consumer goods and packaging materials are made out of polystyrene.
Phosphoric acid is industrially produced from phosphate rocks and is essential in the synthesis of phosphate fertilisers. It&#;s also an important chemical in the pharmaceutical industry as it&#;s used in the manufacture of anti-nausea medicines, mouthwash products, and teeth whitening products. It&#;s also used in the food industry as an additive to cheese, jams, cereals, and carbonated drinks.
Ammonia is manufactured on an industrial scale using the Haber-Bosch process, which involves high heat and pressure and iron metal catalyst. It combines atmospheric nitrogen with hydrogen.
About 70% of industrially produced ammonia is used to manufacture fertilisers. Other applications of ammonia include refrigeration, water purification, manufacturing explosives, plastics, textiles, dyes, and other products.
Sodium hydroxide is a strong alkaline compound mainly used as an ingredient in manufacturing soaps and detergents. It also has a wide range of applications in other industries, such as in the petroleum industry for creating the right pH when drilling in the earth. It&#;s also used in the paper industry for separating the fibres of cellulose in wood.
Chemicals are an integral part of industry, and we are all consumers of various types of chemicals. Some chemicals are fundamentally important because they serve as the basis of manufacturing other chemicals, and some are virtually ubiquitous across industries worldwide.
It isn&#;t easy to comprehend the scale on which the chemical industry must operate to supply the huge amounts of chemicals required in modern industrial societies. Figure \(\PageIndex{1}\) lists the names and formulas of the chemical industry&#;s &#;top 25&#; for &#;the 25 chemicals produced in the largest quantity in the United States that year&#;along with the amounts produced, in billions of pounds. To put these numbers in perspective, consider that the 88.80 billion pounds of sulfuric acid produced in the United States in has a volume of 21.90 million cubic meters (2.19 × 107 m3), enough to fill the Pentagon, probably the largest office building in the world, about 22 times.
Figure \(\PageIndex{1}\) Top 25 Chemicals Produced in the United States in *
According to Figure \(\PageIndex{1}\), 11 of the top 15 compounds produced in the United States are inorganic, and the total mass of inorganic chemicals produced is almost twice the mass of organic chemicals. Yet the diversity of organic compounds used in industry is such that over half of the top 25 compounds (13 out of 25) are organic.
Why are such huge quantities of chemical compounds produced annually? They are used both directly as components of compounds and materials that we encounter on an almost daily basis and indirectly in the production of those compounds and materials. The single largest use of industrial chemicals is in the production of foods: 7 of the top 15 chemicals are either fertilizers (ammonia, urea, and ammonium nitrate) or used primarily in the production of fertilizers (sulfuric acid, nitric acid, nitrogen, and phosphoric acid). Many of the organic chemicals on the list are used primarily as ingredients in the plastics and related materials that are so prevalent in contemporary society. Ethylene and propylene, for example, are used to produce polyethylene and polypropylene, which are made into plastic milk bottles, sandwich bags, indoor-outdoor carpets, and other common items. Vinyl chloride, in the form of polyvinylchloride, is used in everything from pipes to floor tiles to trash bags. Though not listed in Figure \(\PageIndex{1}\), butadiene and carbon black are used in the manufacture of synthetic rubber for tires, and phenol and formaldehyde are ingredients in plywood, fiberglass, and many hard plastic items.
We do not have the space in this text to consider the applications of all these compounds in any detail, but we will return to many of them after we have developed the concepts necessary to understand their underlying chemistry. Instead, we conclude this chapter with a brief discussion of petroleum refining as it relates to gasoline and octane ratings and a look at the production and use of the topmost industrial chemical, sulfuric acid.
The petroleum that is pumped out of the ground at locations around the world is a complex mixture of several thousand organic compounds, including straight-chain alkanes, cycloalkanes, alkenes, and aromatic hydrocarbons with four to several hundred carbon atoms. The identities and relative abundances of the components vary depending on the source. So Texas crude oil is somewhat different from Saudi Arabian crude oil. In fact, the analysis of petroleum from different deposits can produce a &#;fingerprint&#; of each, which is useful in tracking down the sources of spilled crude oil. For example, Texas crude oil is &#;sweet,&#; meaning that it contains a small amount of sulfur-containing molecules, whereas Saudi Arabian crude oil is &#;sour,&#; meaning that it contains a relatively large amount of sulfur-containing molecules.
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