Industrial processes

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Industrial processes are procedures involving chemical, physical, electrical or mechanical steps to aid in the manufacturing of an item or items, usually carried out on a very large scale. Industrial processes are the key components of heavy industry.

Video Industrial processes

General processes

These may be applied on their own, or as part of a larger process.

• Liquefaction of gases - for ease of transportation
• Supercritical drying, freeze-drying - removal of excess liquid
• Scrubbing - removal of pollution from exhaust gases

Maps Industrial processes

Chemical processes

• Haber process - chemically binding gaseous nitrogen from the atmosphere to make ammonia
• Smelting - chemically enhancing metals
• Disinfection - chemical treatment to kill bacteria and viruses
• Pyroprocessing - using heat to chemically combine materials, such as in cement.

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Heat processes

• Flash smelting - a refinement on smelting, for sulfur-containing ores (produces copper, nickel and lead)

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Electrolysis

The availability of electricity and its effect on materials gave rise to several processes for plating or separating metals.

• Gilding, electroplating, anodization, electrowinning - depositing a material on an electrode
• Electropolishing - the reverse of electroplating
• Electrofocusing - similar to electroplating, but separating molecules
• Electrolytic process - the generic process of using electrolysis
• Electrophoretic deposition - electrolytic deposition of colloidal particles in a liquid medium
• Electrotyping - using electroplating to produce printing plates
• Metallizing, plating, spin coating - the generic terms for giving non-metals a metallic coating

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Cutting

• Shearing
• Sawing
• Plasma cutting
• Water-jet cutting
• Oxyacetylene cutting
• Electrical discharge machining (EDM)
• Machining - the mechanical cutting and shaping of metal which involves the loss of the material
• Laser cutting

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Physical processes

There are several physical processes for reshaping a material by cutting, folding, joining or polishing, developed on a large scale from workshop techniques.

• Forging - the shaping of metal by use of heat and hammer
• Casting - shaping of a liquid material by pouring it into moulds and letting it solidify
• Progressive stamping - the production of components from a strip or roll
• Stamping
• Hydroforming - a tube of metal is expanded into a mould under pressure
• Sandblasting - cleaning of a surface using sand or other particles
• Soldering, brazing, welding - a process for joining metals
• Tumble polishing - for polishing
• Precipitation hardening - heat treatment used to strengthen malleable materials
• Work hardening - adding strength to metals, alloys, etc.
• Case hardening, differential hardening, shot peening - creating a wear-resistant surface
• Die cutting - A "forme" or "die" is pressed onto a flat material in order to cut, score, punch and otherwise shape the material

Moulding

The physical shaping of materials by forming their liquid form using a mould.

• Casting, sand casting - the shaping of molten metal or plastics using a mould
• Sintering, powder metallurgy - the making of objects from metal or ceramic powder
• Blow moulding as in plastic containers or in the glass container industry - making hollow objects by blowing them into a mould.
• Compression molding

Separation

Many materials exist in an impure form, purification, or separation provides a usable product.

• Comminution - reduces the size of physical particles (it exists between crushing and grinding)
• Froth flotation, flotation process - separating minerals through flotation
• Liquid-liquid extraction - dissolving one substance in another
• Frasch process - for extracting molten sulfur from the ground

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Distillation

• Fractional distillation, steam distillation, vacuum distillation - separating materials by their boiling point
• Batch distillation
• Continuous distillation
• Fractionating column
• Spinning cone

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Additive

• Fused deposition modeling (FDM)
• Stereolithography (SLA)
• Selective laser sintering (SLS)
• Photolithography

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Iron and steel

Early production of iron was from meteorites, or as a by-product of copper refining.

• Smelting - the generic process used in furnaces to produce steel, copper, etc.
• Catalan forge, open hearth furnace, bloomery, Siemens regenerative furnace - produced wrought iron
• Blast furnace - produced cast iron
• Direct Reduction - produced direct reduced iron
• Crucible steel
• Cementation process
• Bessemer process
• Basic oxygen steelmaking, Linz-Donawitz process
• Electric arc furnace

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Petroleum and organic compounds

The nature of an organic molecule means it can be transformed at the molecular level to create a range of products.

• Cracking (chemistry) - the generic term for breaking up the larger molecules
• Alkylation - refining of crude oil
• Burton process - cracking of hydrocarbons
• Cumene process - making phenol and acetone from benzene
• Friedel-Crafts reaction, Kolbe-Schmitt reaction
• Olefin metathesis, thermal depolymerization
• Transesterification - organic chemicals
• Raschig process - part of the process to produce nylon
• Oxo process - Produces aldehydes from alkenes
• Polymerisation

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Others

Organized by product:

• Aluminium - (Deville process, Bayer process, Hall-Héroult process, Wöhler process)
• Ammonia, used in fertilizer & explosives - (Haber process)
• Bromine - (Dow process)
• Chlorine, used in chemicals - (chloralkali process, Weldon process, Hooker process)
• Fat - (rendering)
• Fertilizer - (nitrophosphate process)
• Glass - (Pilkington process)
• Gold - (bacterial oxidation, Parkes process)
• Graphite - (Acheson process)
• Heavy Water, used to refine radioactive products - (Girdler sulfide process)
• Hydrogen - (steam reforming, water gas shift reaction)
• Lead (and Bismuth) - (Betts electrolytic process, Betterton-Kroll process)
• Nickel - (Mond process)
• Nitric acid - (Ostwald process)
• Paper - (pulping, Kraft process, Fourdrinier machine)
• Rubber - (vulcanization)
• Salt - (Alberger process, Grainer evaporation process)
• Semiconductor crystals - (Bridgeman technique, Czochralski process)
• Silver - (Patio process, Parkes process)
• Silicon Carbide - (Acheson process, Lely process)
• Sodium carbonate, used for soap - (Leblanc process, Solvay process, Leblanc-Deacon process)
• Sulfuric acid - (lead chamber process, contact process)
• Titanium - (Hunter process, Kroll process)
• Zirconium - (Hunter process, Kroll process, crystal bar process, iodide process)

A list by process:

• Alberger process, Grainer evaporation process - produces salt from brine
• Bacterial oxidation - used to produce gold
• Bayer process - the extraction of aluminium from ore
• Chloralkali process, Weldon process - for producing chlorine and sodium hydroxide
• Crystal bar process, iodide process - produces zirconium
• Dow process - produces bromine from brine
• FFC Cambridge Process
• Girdler sulfide process - for making heavy water
• Hunter process, Kroll process - produces titanium and zirconium
• Industrial rendering - the separation of fat from bone and protein
• Lead chamber process, contact process - production of sulfuric acid
• Mond process - nickel
• Nitrophosphate process - a number of similar process for producing fertilizer
• Ostwald process - produces nitric acid
• Pidgeon process - produces magnesium, reducing the oxide using silicon
• Steam reforming, water gas shift reaction - produce hydrogen and carbon monoxide from methane or hydrogen and carbon dioxide from water and carbon monoxide
• Vacuum metalising - a finishing process
• Perstorp Formox process - oxidation of methanol to produce formaldehyde

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See also

• Chemical engineering
• Mass production

Source of the article : Wikipedia