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| Subtopic |
Key Concepts |
Video Focus Areas |
| 1.1 |
Basic Chemical Data &
Process Fundamentals |
Basic chemical data (molecular
weight, density, etc.). Unit operation vs. Unit process. Batch vs. Continuous
processing. |
| 1.2 |
Process Flow Sheet &
Engineering Aspects |
Process flow diagrams (PFD),
Piping and Instrumentation Diagrams (P&ID). Environment and safety
aspects in plant design. |
| Subtopic |
Key Concepts |
Video Focus Areas |
| 2.1 |
Sulphur Mining &
Manufacturing |
Frasch process for sulphur
mining. Recovery of sulphur from natural gas (Claus process). |
| 2.2 |
Manufacture of Sulphuric Acid:
Contact Process |
Oxidation of SO₂ to SO₃
(catalyst: V₂O₅). Absorption in concentrated H₂SO₄ to form oleum. Dilution to
desired concentration. |
| 2.3 |
Manufacturing Technologies &
Engineering Problems |
Double absorption process. Heat
recovery (waste heat boilers). Materials of construction (corrosion
resistance). |
| Subtopic |
Key Concepts |
Video Focus Areas |
| 3.1 |
Ammonia Manufacturing |
Steam reforming of natural gas
(SMR). Water-gas shift reaction. CO₂ removal. Haber-Bosch synthesis of
ammonia. |
| 3.2 |
Urea Manufacturing |
Urea synthesis from NH₃ and CO₂.
Carbamate formation and dehydration. Prilling and granulation. |
| 3.3 |
Nitric Acid & Phosphoric
Acid |
Ostwald process for nitric acid
(oxidation of NH₃). Wet process for phosphoric acid (attack on phosphate rock
with H₂SO₄). |
| 3.4 |
Phosphate Fertilizers & NPK |
Manufacturing of single
superphosphate (SSP), triple superphosphate (TSP). NPK fertilizer
formulation. Major engineering problems (dust, corrosion). |
| Subtopic |
Key Concepts |
Video Focus Areas |
| 4.1 |
Soda Ash (Sodium Carbonate) |
Solvay process (ammonia-soda
process). Reactions, recovery of ammonia, by-products. |
| 4.2 |
Manufacture of Chlorine &
Caustic Soda |
Electrolysis of brine. Membrane
cell, Mercury cell, and Diaphragm process. |
| 4.3 |
Engineering Problems |
Corrosion, handling of chlorine
(toxic), mercury pollution (in mercury cells). |
| Subtopic |
Key Concepts |
Video Focus Areas |
| 5.1 |
Classification of Dyes |
Classification by constitution
and by application. Disperse dyes, Reactive dyes, Azo dyes, Vat dyes. |
| 5.2 |
Dye Intermediates |
H-acid, Koch acid, Vinyl
sulphone. Their role in dye synthesis. |
| 5.3 |
Paints & Pigments |
Introduction to paints:
Constituents (binder, pigment, solvent, additives). Pigment Volume
Concentration (PVC). |
| 5.4 |
Types of Pigments |
White pigments (TiO₂), Blue
(ultramarine, phthalocyanine), Red (iron oxide), Yellow (lead chromate),
Green, Brown. |
| 5.5 |
Varnishes, Solvents &
Industrial Coatings |
Introduction to varnishes and
solvent/thinners. Industrial coatings (powder coatings, coil coatings). |
| Subtopic |
Key Concepts |
Video Focus Areas |
| 6.1 |
Introduction to Soap &
Detergents |
Chemistry of soap
(saponification of fats/oils). Chemistry of detergents (surfactants).
Differences between soap and detergent. |
| 6.2 |
Soap Manufacturing Process |
Batch vs. Continuous soap
manufacturing. Saponification, salting out, finishing. |
| 6.3 |
Detergent Manufacturing Methods |
Blending of surfactants,
builders (zeolites, phosphates), and additives. Spray drying process. |
| 6.4 |
Manufacture of Glycerine |
Recovery of glycerine from soap
production (spent lye). Purification by distillation. |
| Subtopic |
Key Concepts |
Video Focus Areas |
| 7.1 |
Classification of Drugs &
Pharmaceuticals |
Classification by therapeutic
action (antibiotics, analgesics, vitamins). |
| 7.2 |
Antibiotics & Penicillin
Manufacturing |
Introduction to antibiotics.
Penicillin manufacturing: Fermentation, extraction, purification (HPLC). |
| 7.3 |
Vitamins: Manufacturing of
Vitamin C (Ascorbic acid) |
Introduction to vitamins.
Manufacturing of Vitamin C (Reichstein process). |
| 7.4 |
Aspirin & Vitamin-D/B-12 |
Manufacturing of Aspirin
(acetylation of salicylic acid). Introduction to Vitamin-D and B-12
production. |
| Subtopic |
Key Concepts |
Video Focus Areas |
| 8.1 |
Sugar Manufacturing |
Processing of sugar cane/beet:
Extraction, clarification, evaporation, crystallization, centrifugation. |
| 8.2 |
Fermentation Process &
Industrial Alcohol |
Fermentation of sugars to
ethanol (C₂H₅OH). Distillation for Industrial Alcohol. Rectified spirit,
Absolute Alcohol (dehydration). |
| 8.3 |
Beers, Wines & Liquors |
Fermentation of grains (beer),
grapes (wine), and distillation for liquors. |
| 8.4 |
Citric Acid & Butyl Alcohol
by Fermentation |
Fermentative production of Butyl
Alcohol (ABE fermentation) and Citric acid (using Aspergillus niger). |
| Subtopic |
Key Concepts |
Video Focus Areas |
| 9.1 |
Cement: Types & Raw
Materials |
Types of cement (Portland
cement, blended cements). Limestone beneficiation. |
| 9.2 |
Manufacturing of Portland Cement |
Dry process (preferred). Wet
process. Rotary kiln: Reactions (calcination, clinkerization). Grinding to
cement. |
| 9.3 |
Lime Manufacture |
Calcination of limestone (CaCO₃
→ CaO + CO₂). Hydrated lime (Ca(OH)₂). |
| 9.4 |
Ceramic Industry &
Refractory Bricks |
Introduction to ceramics: Raw
materials (clays, silica, alumina). Manufacturing of Refractory bricks
(firebricks). |
| Subtopic |
Key Concepts |
Video Focus Areas |
| 10.1 |
Pulp Manufacturing (Kraft
Process) |
Kraft (sulphate) pulping:
Digestion of wood chips with NaOH/Na₂S. Washing and screening. |
| 10.2 |
Chemical Recovery & Major
Engineering Problems |
Recovery of chemicals from black
liquor. Evaporation, recovery boiler (smelt), causticizing. Environmental
concerns (odour, wastewater). |
| 10.3 |
Manufacturing of Paper |
Stock preparation (beating,
refining). Forming (Fourdrinier machine). Pressing, drying, calendering, and
finishing. |
| Subtopic |
Key Concepts |
Video Focus Areas |
| 11.1 |
Importance of Cryogenics |
Cryogenic air separation (Linde
process). Fractional distillation of liquid air. |
| 11.2 |
Production of Oxygen &
Nitrogen |
Cryogenic distillation of air.
Membrane separation. Pressure Swing Adsorption (PSA). |
| 11.3 |
Production of CO₂, Hydrogen
& Acetylene |
CO₂ recovery from flue gases or
fermentation. Hydrogen production (steam reforming). Acetylene production
(calcium carbide route). |
| 11.4 |
Introduction to Rare Gases
(Helium, Argon) |
Recovery of rare gases from air
(argon) and natural gas (helium). |