Kent and Riegel's HANDBOOK OF INDUSTRIAL CHEMISTRY AND BIOTECHNOLOGY ELEVENTH EDITION Kent and Riegel's HANDBOOK OF INDUSTRIAL CHEMISTRY AND BIOTECHNOLOGY Volume I ELEVENTH EDITION Edited by James A. Kent, Ph.D. ~ Springer JamesA.Kent ProfessorofChemicalEngineeringandDeanofEngineering Kentjamesargaol.com ISBN:978-0-387-27842-1 e-ISBN:978-0-387-27843-8 LibraryofCongressControlNumber:2005938809 ©2007SpringerScience+BusinessMedia,LLC. Allrightsreserved.Thisworkmaynotbetranslatedorcopiedinwholeorinpartwithoutthewrittenpermissionofthepub lisher(SpringerScience+BusinessMedia,LLC,233SpringStreet,NewYork,NY10013,USA),exceptforbriefexcerpts inconnectionwithreviewsorscholarlyanalysis.Useinconnectionwithanyformofinformationstorageand retrieval, electronicadaptation,computersoftware,orbysimilarordissimilarmethodology nowknownorhereafterdevelopedis forbidden. 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Coverillustration:AbigailKent Printedonacid-freepaper 9 8 7 6 5 4 3 2 I springer.com To myWife ANITA Preface The centralaim ofthis book istopresent anup-to-date account ofthe science andengineering and industrial practice whichunderlie majorareas ofthe chemical process industry.It attempts to do so inthe context ofpriorities and concerns which characterize the still early daysofthe new millennium and,perhaps more important, itprovides various tools for dealing with those factors through, for example, anextensive discussion ofgreen engineering and chemistry and related topics.The heart ofthe book is contained in twenty eight chapters covering various areas ofthe chemical process industry.It istobenoted thatthe products and processes associ atedwith aparticularareaarediscussed inthecontext ofthecorrespondingchapter ratherthan inthe isolated manner characteristic ofan encyclopedia. This work, Kent and Riegel's Handbook ofIndustrial Chemistry and Biotechnology, is an outgrowth ofthe well known Riegel's Handbook ofIndustrial Chemistry, the last edition of which, the tenth, was published in 2003. It follows the essential arrangement ofearlier ver sions,i.e.,severalchapters devotedtogeneral or"infrastructure" topics, with most ofthebook being given over to the various areas ofthe chemical process industry. However,this version introduces a wealth of new, timely, and very useful "infrastructure" material, and greatly enhances the process industry content. (The latter ismost noticeable inthis book byincreased emphasis on biotechnology, although all ofthe chapters have been reviewed and updated as necessary by their respective authors.) In keeping with past practice, all ofthe new chapters have been written by individuals having demonstrated expertise in their respective fields. All told,the work may inmany respects be regarded as a sourcebook for practice in the chemical process industries. Concerning the infrastructure or contextual material mentioned above, the Handbook con tains three new chapters which lie inthe area often referred to as "green chemistry".The first andmost comprehensive ofthese istitled Green Engineering:Integration ofGreen Chemistry, Pollution Prevention and Risk Based Considerations.Itprovides an excellent guide forapply ingthemethods ofgreen chemistryandengineeringtoprocess andproduct development activ ities, whether for newproducts and processes, or for upgrading older ones.Written by ateam ofexpertsinthefield,thechapter canbeofenormoushelptoallpracticingchemists andchem ical engineers, as well as to students studying in either discipline. Another new chapter, Industrial Catalysis;APractical Guide, isavaluable adjuncttothe"Green" chapter sincecatal ysisisanimportant aidinthepractice ofGreenChemistry.Thethirdnewchapter inwhatmight be termed the "green" group is Environmental Chemical Determinations. Succinctlyput,greenchemistry,alsotermed sustainablechemistry,isdescribed bythatchap ter's authors, as "the use ofchemistry to reduce pollution at the source, through the design of chemical products andprocesses that reduce oreliminate the use orgeneration ofunwanted or hazardous substances." Green engineering is defined as "the design, commercialization, and vii viii PREFACE use ofprocesses andproducts that are feasible and economical, yetatthe same time minimize 1)generation ofpollution atthesource, and2)risktohuman healthandtheenvironment." Risk assessment methods used in pollution prevention can help quantify the degree ofimpact for individualchemicalsandthus isavaluabletoolforintelligentdesign ofproducts andprocesses by focusing on the most beneficial methods to minimize risk. Even a superficial look at the literature on green chemistry shows that catalysis is regarded as avery important tool.After all, if in the idealized case one can produce desired product B fromA,withnounwanted sidereactions orby-products, bychoosing appropriate reaction con ditions and a suitable catalyst, one will have done a great deal to promote efficiency and pre vent pollution.Therefore, another ofthe new chapters, Industrial Catalysis, a Practical Guide, is ofspecial relevance. Finally,this particularportion ofthe new material is rounded offwith the chapter Environmental Chemical Determinations, which discusses the many complex fac tors involved in detecting, tracking, and measuring chemical species which have found their wayinto the environment. Additional chapters in the grouping broadly referred to as infrastructure include the new Recent History ofthe Chemical Industry: 1973to the Millennium: and anupdate ofthe chap ter titled Economic Aspects ofthe Chemical Industry, in which some ofthe material extends informationprovided inthe former. Rounding outthe infrastructuregroup areyetanother new chapter Nanotechnology: Principles and Applications, together with the earlier ones which cover such diverse and fundamental topics as process safety, emergency preparedness, and applied statistical methods. Biotechnology first appeared in the Riegel's Handbook some time ago as a chapter titled Industrial Fermentation.It has since been updated several times and more recently wasjoined by a chapter on Industrial Cell Culture. Forthis Handbook, the biotechnology content, rather than being updated, has undergone a major reorganization, including revision ofcontent and emphasis. The former fermentation chapter has become two which are titled, respectively, Industrial Biotechnology: Discovery to Delivery, and Industrial Enzymes and Biocatalysis. This revision wasaccomplishedbytwoteams from amajor biotech company andthus reflects that background. It is informative to interpose at this point a statement (edited) bythe authors ofthe first ofthese twochapters.They describe itthus: "The chapter usesanapproach tointe grategene discovery.functionalgenomics,molecularevolution anddesign, metabolicpathway engineering, andproductionprocesses includingformulation ofdelivery systems. Thechapter walks the reader through biomolecule discovery, development and delivery, by startingfrom screening millions ofnatural and designedgene variants in the mountains ofDNA sequences available today.Also included are several state-ofthe-art examples ofpurposeful modifica tionsofcellularmetabolism, anddescriptions ofunitoperations and unitprocesses which link the upstream and downstream technologies to manufacture biochemicals, enzymes, peptides, and other products on an industrial scale. "Commercializing new bioproducts is a complex, time consumingprocess, and therefore an integrated biotechnology approach is necessary. It istheauthors'hopethatthechapterwillhelpreaderslearn howtodesignandproduce biotech nology products rapidly and successfully." Revision ofthe cell culture chapter was accom plished by a team from another biotech company. The new title, Industrial Production of Therapeutic Proteins: Cell Lines, Cell Culture and Purification, reflects its new content and orientation. Also, as might be expected by persons knowledgeable in the field, the chapter Animal and VegetableOils, Fatsand Waxesisrich in related biotechnical content, as is effec tively described inthe chapter's early pages. Finally,addressing an area ofgreat interest in connection with world energy needs, wehave added achapter inarelated area, Biomass Conversion. Written byateam whose primary work lies inthat area,itprovides comprehensive coverageofthe subject frombiomass structure and composition to thermochemical and biological routes for conversion to energy and a host of PREFACE ix chemicals and products including liquid transportation fuels. This chapter defines the oppor tunity for using sustainable sources ofbiomass as feedstock for new refineries that will pro duce fermentable sugars and chemical intermediates from which much needed forms offuels canbe made. As mentioned earlier,the crux ofthe Handbook comprises twenty eight chapters which are devotedtovarious areas ofthe chemical process industry.Thisinformation,together with sup porting "infrastructure" material described above, viz., process safety, emergency prepared ness, statistical methods,green engineeringandchemistry, provides in toto manysophisticated and useful tools to aid in the design ofnewproducts and processes and for study and evalua tion ofolder ones.The handbook should prove useful also to individuals who possess a back ground in chemistry or chemical engineering and work in related areas such as regulatory agencies and environmental organizations. Among other benefits, it will help ensure that the workofsuchindividuals reflects knowledge ofrelevant contemporaryscience andengineering and industry practices. Reflecting new realities inthe world energy situation,this edition also includes a chapter titledThe Nuclear Industry. Individuals whohaveresponsibilities inthe chemical process industries areusually engaged, consciously orotherwise, incontinually reviewing their operations toensure thattheyare safe, efficient, and in compliance with current environmental regulations. They are also, or should be,anticipating future needs. Itishoped that the information contained herein will providethe wherewithal bywhich chemists,chemical engineers,and others who havea peripheral interest in the process industries, for whatever reason, can ensure that they have touched every base, dotted every i,and crossed every t intheir quest to make theprocesses and products for which theyare responsible as environmentally sound, safe, and efficient as possible. Because ofthe scope ofthe book and the large number ofproducts and processes itcovers, some redundancy is inevitable. For example, more than one chapter includes discussions of gasification and hydrogen production. However, there are significant differences in emphasis inthe various discussions.Thus, rather than distract readers by referring them to information inlocations other than the one oftheir primary interest, such topics havebeen left intact inthe context inwhich they are discussed. Asinalltheearlier versions ofthisworkforwhich Ihavebeenprivilegedtoserveasdesigner and editor, I am happy to acknowledge again the unselfish and enthusiastic manner in which the contributing authors have shared their knowledge and insights so that many others may learn and stillothers maybenefit. The picture ofabit ofknowledge, acting like astone tossed into aquiet pond, spreading the result ofthe impact ever more widely,is, Ithink, apt.There is a saying that knowledge is power, and the authors who have contributed their knowledge and expertise tothisworkarepleased tohavehadtheopportunitytoempowerothers.Allhavebeen unstinting intheir efforts to make their contributions as complete and informative aspossible, within the space available, and Iam indeed humbled and honored to have had a part inbring ing itabout. Needless tostate,errors ofomission and shortcomings in organization are mine. Grateful acknowledgement ismade to the publishing houses and technical/scientific organi zations for permission to reproduce copyrighted illustrations, tables, and other materials, and to the many industrial concerns which contributed drawings, photographs, and text material. And finally, Iwish to express mythanks to Springer editor, Dr.Kenneth Howell,for his many helpful suggestions and support along the way, and for leveling several bumps on the road to publication. JamesA. Kent Morgantown, WestVirginia USA Contents Volume I Chapter 1 RecentHistoryoftheChemical Industry* 1973 totheMillenium: TheNewFacts ofWorld Chemicals Since1973 FredAftalion Chapter2 EconomicAspects oftheChemical Industry 63 JosephV.Koleske Chapter3 SafetyConsiderations intheChemical Process Industries 83 StanleyM. Englund Chapter4 Managing anEmergency Preparedness Program 147 ThaddeusH. SpencerandJames WBowman Chapter5 AppliedStatistical Methods andtheChemical Industry 178 StephenVardeman andRobertKasprzyk Chapter 6 GreenEngineering-Integration ofGreenChemistry, PollutionPrevention, andRisk-Based Considerations 210 DavidShonnard,AngelaLindner, NhanNguyen, PalghatA.Ramachandran, DanielFichana, RobertHesketh, C. StewartSlater, andRichardEngler Chapter7 Industrial Catalysis:APractical Guide 271 RobertFarrauto Chapter 8 Environmental Chemical Determinations 305 William L.Budde Chapter9 Nanotechnology:Fundamental Principles andApplications 328 KoodaliT. RanjitandKennethJ Klabunde Chapter 10 Synthetic Organic Chemicals 345 Guo-ShuhJ Lee,JamesH. McCain, and MadanM. Bhasin Chapter 11 Chemistry inthePharmaceutical Industry 404 Graham S. Poindexter, Yadagiri Pendri,LawrenceB.Snyder, JosephP. Yevich,andMilindDeshpande Chapter 12 ManufacturedTextile Fibers 431 BhupenderS. Gupta Chapter 13 DyeApplication, Manufacture ofDyeIntermediates andDyes 499 HaroldFreeman and GaryMock Chapter 14 TheChemistry ofStructuralAdhesives:Epoxy, Urethane, andAcrylicAdhesives 591 DennisJ Zalucha,Ph.D.andKirk. J Abbey,Ph.D. Chapter 15 Synthetic ResinsandPlastics 623 RudolphD.DeaninandJoeyL.Mead Chapter 16 Rubber 689 D.F. Graves Chapter 17 TheAgrochemical Industry 719 A.M. MaltiandA.T. Lilani Chapter 18 Petroleum andItsProducts 801 StephanyRomanow-Garcia andH.L.Hoffman Index I-I xi xii CONTENTS Volume II Chapter 19 CoalTechnologyforPower, LiquidFuels,andChemicals 843 R.D.Srivastava,H. G.McIlvriedIII,,1 C. Winslow, C. P. Maronde, andR.P. Noceti Chapter 20 Natural Gas 907 RobertN. Maddox, MahmoodMoshfeghian,JamesD.Idol,and ArlandH. Johannes Chapter 21 TheNuclear Industry 935 Tom Congedo, EdwardLahoda,RegisMatzie,andKeithTask Chapter22 SyntheticNitrogenProducts 996 GaryR.Maxwell Chapter 23 Phosphorusand Phosphates 1086 G.A. Gruber Chapter 24 FertilizersandFoodProduction 1111 AmitH. Roy Chapter 25 SulfurandSulfuricAcid 1157 GerardE.d'AquinandRobertC. Fell Chapter26 Salt,Chlor-Alkali,andRelatedHeavyChemicals 1183 TilakV.Bommaraju Chapter 27 IndustrialGases 1215 Steven1 Cooke Chapter28 WoodandWoodProducts 1234 RaymondA.Young Chapter 29 Pigments, Paints,PolymerCoatings,Lacquers,and PrintingInks 1294 RoseRyntz Chapter30 IndustrialBiotechnology:Discoveryto Delivery 1311 GopalK. Chotani, Timothy C. Dodge,AlfredL. Gaertner, and MichaelV.Arbige Chapter31 IndustrialEnzymesandBiocatalysis 1375 JosephC. McAuliffe, WolfgangAehle, GregoryM.Whited,and DonaldE. Ward Chapter32 IndustrialProductionofTherapeuticProteins:CellLines, CellCulture,andPurification 1421 MarieM.Zhu,MichaelMollet,andReneS.Hubert Chapter33 BiomassConversion 1499 StephenR.Decker, JohnSheehan, DavidC. Dayton,Joseph1 Bozell, William S.Adney,BonnieHames,StevenR.Thomas,RichardL. Bain, StefanCzernik,MinZhang, andMichaelE. Himmel Chapter34 AnimalandVegetable Fats,Oils,andWaxes 1549 EdmundWLusas Chapter35 SugarandOther Sweeteners 1657 MaryAn Godshall Chapter36 Soap, FattyAcids,andSyntheticDetergents 1694 JanineChupa,AmitSachdev,SteveMisner.and GeorgeA.Smith Chapter37 Chemical Explosivesand RocketPropellants 1742 Walter Sudweeks,Felix F. Chen, andMichaelMcPherson Index I-I Kent and Riegel's HANDBOOK OF INDUSTRIAL CHEMISTRY AND BIOTECHNOLOGY ELEVENTH EDITION