Chemical industries have a major place in the world economy. The industrial revolution, which commenced in the 18 century, was also a materials revolution that started with the large-scale extraction of iron. This continues to the present day with the extraction of other metals, the production of bulk chemicals such as fertilisers, the oil and plastics industries, and the speciality chemicals industry producing medicines, enzymes, catalysts and additives. When teaching this option, emphasise chemical reactions and their relevant equations.

E.1         Initial Overview (2h)

 

E.1.1		Outline the abundance, occurrence and availability of sources of materials. A qualitative picture only is intended. Include minerals (especially metals and their ores), petroleum and biotechnology.
E.1.2		Identify the factors that influence the establishment of a chemical industry in a particular location. Include sources of suitable raw materials, energy supply, transport to and from the site, availability ofinvestment, skills and labour and existence of markets for the product.
E.1.3		Outline the division of the industry into both intermediates and consumer products.
E.1.4		State the increasing importance of biotechnology in chemical manufacture. Examples can be found in the manufacture of insulin and vitamins.

E.2         Principles of Extraction and Production of Metals (2h)

 

E.2.1		Outline the principles used in the physical separation of materials.
E.2.2		Discuss the chemical principles involved in the extraction of metals from their ores. Relate this to chemical reactions based on the reactivity series (see 10.2), but also include factors such as chemical conversion (iron), electrolytic conversion (aluminium) and energy requirements.

E.3         Iron and Aluminium (4h)

 

E.3.1		State the main sources of iron. Include iron ores and scrap (recycled) iron.
E.3.2		Explain the reactions that occur in the blast furnace. Include the role of coke, limestone and the formation of slag. The relevant equations should be considered.
E.3.3		Explain the conversion of iron into steel using the basic oxygen converter.
E.3.4		Describe the properties and uses of steel as an alloy of iron. Consider carbon steels and alloy steels (including stainless steel).
E.3.5		Discuss the production of aluminium by electrolysis of alumina in molten cryolite. Explain the need for cryolite as a solvent because of the very high melting point of Al2O3. Account for the materials used in the construction of the cell and the choice of electrodes.
E.3.6		Describe the main properties and uses of aluminium. Include the properties of the aluminium oxide coating and the resulting resistance to corrosion. Compare with the properties and uses of iron and steel.
E.3.7		Discuss the environmental impact of iron and aluminium production. Include the effects of mining the ore, siting the plant, energy costs and recycling the metals.

E.4         The Oil Industry (4h)

 

E.4.1		Outline the importance of oil as a source of chemical feedstock. Although only about 10% of the refined products of crude oil are used as chemical feedstock, it is still the most significant source of organic chemicals. Compare the use of oil as an energy source and as a chemical feedstock.
E.4.2		Outline the removal of sulphur from crude oil. Refer to the need for this removal and the use of sulphur in the manufacture of sulphuric acid.
E.4.3		Describe the fractional distillation of oil. Compare simple distillation with fractional distillation. Students should understand that the vapour phase is always richer in the more volatile component. No calculations using Raoult's law or Dalton's law are required.
E.4.4		Describe cracking and its products. Include thermal cracking (both steam and catalytic) and hydrocracking.
E.4.5		Describe reforming processes and their products. Include isomerization, cyclization and aromatization. Reforming is important in some countries as a source of hydrogen for the Haber process (see 8.2.5).
E.4.6		State the uses of refinery products as feedstock for the organic chemical industry. Refinery products are used as raw materials in the manufacture of solvents, plastics, pesticides, food additives, pharmaceuticals, detergents, cosmetics and dyes.

E.5           Polymers (3h)

Cross reference with 11.3

 

E.5.1		Describe how the properties of polymers depend on their structural features. Include the : different amounts of branching in low- and high-density polyethene different positions of the methyl groups in isotactic and atactic polypropene formation of cross-links in phenol-methanal plastics (compare thermoplastics and thermosets)
E.5.2		Describe ways of modifying the properties of polymers. Include the use of : plasticizers in polyvinyl chloride. volatile hydrocarbons in the formation of expanded polystyrene air in the manufacture of polyurethane foams.
E.5.3		Discuss the advantages and disadvantages of polymer use. Consider strength, density, insulation, lack of reactivity, use of natural resources, disposal and biodegradability. Use polyethene, polyurethane foams, polyvinyl chloride and phenol-methanal plastics as examples.