Manufacture of compounds and their challenges

When two or more chemicals react together, they produce a new substance– this simple statement makes the basis of the big chemical industries manufacturing tons and tons of compounds every year.

Manufacture of compounds means transforming one form of matter to another using the already designed chemical synthesis schemes. In other words, chemical industries manufacture a new chemical compound using the various chemical reactions and compounds we already have.

For example, burning coal is a chemical reaction, and it produces carbon dioxide. Ammonia is synthesised with hydrogen and nitrogen, and then it is used to manufacture different chemical compounds.

What does the manufacture of compounds involve?

Manufacture of compounds involves pre-synthesised compounds known as reagents or reactants that react to form new chemical compounds known as products under a certain fixed set of conditions like temperature, pressure and a fixed amount of input compounds.

The amount of the product produced through such a reaction is known as the reaction yield. Based on the reaction yield, it is decided whether the reaction process is economical or uneconomical.

Synthesis can be a multi-step or single-step process.

The manufacture of compounds involves chemical reactions involving the making and breaking of bonds. The products are formed after the bonds between the elements break, and new bonds are formed.

Manufacturing is made possible because of the presence of the functional groups that transform (generally in the case of organic compounds).

Approach and evaluation to a synthesis method in the manufacture of compounds

We must consider some important factors for the manufacture of compounds.

1. Cost: The cost is the biggest concern in the case of industrial and large scale manufacture of compounds.

2. Environmental impact of synthesis: With the growing concern towards the environment, producers should always ensure that the reaction does not produce hazardous compounds. The producers must do synthesis using the utmost safe and readily available reagents. They should follow the Green Chemistry principles in such production processes. 

3. Yield: If the synthesis produces a lower yield, then it cannot be done on a large scale as it will not be economical. The producer should then use an alternative process. The process should be 100% atom efficient (atom economy – principle of green chemistry).

4. Easily attainable reaction conditions: The reaction conditions like the temperature and pressure must be easily attainable for the synthesis.

5. Purification: It is important to ensure that the product does not get contaminated due to the presence of any other compounds. Sometimes at each step, purification is required.

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Various challenges in the manufacture of compounds

1. To manufacture compounds, the producers must consider adopting non-traditional ways of chemical reactions rather than relying on traditional methods. For example, use of microwaves technology instead of doing a particular reaction at a very high temperature.

2. There must be a focus on reducing the material, labour and energy costs involved in the production.

3. Minimising waste production is quite important. It is better not to produce waste than discard it after its generation. Waste disposal requires extra time and workforce allocations.

4. Hazard reduction by using safe and non-hazardous reagents and substances used in the manufacturing process.

5. The producers must ensure the high purity of the manufactured compounds. 

6. The sustainability of the manufacturing process is quite crucial at present. The production process should use renewable starting materials or use the materials obtained from renewable sources. For example, instead of using alcohol, water can be used in a manufacturing process as a solvent in certain circumstances.

7. Manufacturing should be done in a way with minimal or almost no harm to the environment.

8. The choice of catalyst can alter the reaction rate and make it faster. Catalysts should be used instead of harsh conditions to make the reaction faster.

9. Nanoscale reactions are the future; adopting them will be helpful.

Some important industrial processes for manufacturing of compounds

1. Haber Process: Production of ammonia from hydrogen and nitrogen in the presence of iron as a catalyst. 

                                      Haber Process

2. Clemmensen Reduction: This process converts aldehydes and ketones to corresponding hydrocarbons in the presence of zinc and HCl as catalysts. It is a reduction reaction.

3. Kolbe Reaction: Carboxylic acids and salts of carboxylic acids are electrolysed to prepare hydrocarbons.

4. Hall Heroult Process: In this process, aluminium is prepared by the electrolysis of aluminium oxide.

Conclusion

Chemical compounds now play a vital role in our day to day life. The manufacture of compounds involves complex processes and pre-synthesised compounds that go through reactions to form the resultant products. It is important to adopt an economical, environmentally non-hazardous and safe approach to manufacture compounds.