20/02/2026
UNIT PROCESSES — The Core Chemical Reactions Behind Every Industry
In chemical engineering, Unit Processes represent the chemical transformations that convert raw materials into valuable products.
From pharmaceuticals to polymers, detergents to dyes — every industrial product is built on these fundamental reactions.
The major Unit Processes with real-world visualizations:
1️⃣ Oxidation (O₂ / ↑ Oxygen Addition)
A reaction where oxygen is added or hydrogen is removed.
✔ Used in: producing aldehydes, ketones, organic acids, dyestuff intermediates.
✔ Industrial example: oxidation of toluene → benzoic acid.
2️⃣ Reduction (H₂ / ↓ Oxygen Removal)
Opposite of oxidation — removes oxygen or adds hydrogen.
✔ Used in: metal extraction, refining, hydrogenation processes.
✔ Industrial example: reduction of nitrobenzene → aniline.
3️⃣ Nitration (NO₂ Addition)
Introduction of nitro groups using nitric acid or mixed acids.
✔ Used in: explosives (TNT), dyes, pharmaceuticals, intermediates.
✔ Highly exothermic — requires strict temperature control.
4️⃣ Sulfonation (–SO₃H Group Introduction)
Reaction where sulfonic acid groups are added to organic compounds.
✔ Used in: detergents, surfactants, dyes, sulfa drugs.
✔ Critical for improving solubility and reactivity.
5️⃣ Hydrolysis (H₂O Splitting Reaction)
Breaks chemical bonds using water.
✔ Used in: esters → alcohol + acid, polymer depolymerization, biochemical conversions.
✔ Common in food, pharma, polymer recycling industries.
6️⃣ Polymerization (Monomers → Polymers)
Small molecules (monomers) join to form long chains (polymers).
✔ Used in: plastics (PVC, PE, PP), fibers (nylon, polyester), rubbers.
✔ Foundation of the global materials industry.
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