Industrial processes
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.
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
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.
Heat processes
- Flash smelting – a refinement on smelting, for sulfur-containing ores (produces copper, nickel and lead)
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
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
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
- Fractional distillation, steam distillation, vacuum distillation – separating materials by their boiling point
- Batch distillation
- Continuous distillation
- Fractionating column
- Spinning cone
Additive
- Fused deposition modeling (FDM)
- Stereolithography (SLA)
- Selective laser sintering (SLS)
- Photolithography
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
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
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