The Weldon process is a process developed in 1866 by Walter Weldon for recovering manganese dioxide for re-use in chlorine manufacture. Commercial operations started at the Gamble works in St. Helens in 1869. The process is described in considerable detail in the book, The Alkali Industry, by J.R. Partington,D.Sc.
The common method to manufacture chlorine at the time, was to react manganese dioxide (and related oxides) with hydrochloric acid to give chlorine:
Weldon's contribution was to develop a process to recycle the manganese. The waste manganese(II) chloride solution is treated with lime, steam and oxygen, producing calcium manganite(IV):
The resulting calcium manganite can be reacted with HCl as in related processes:
The manganese(II) chloride can be recycled, while the calcium chloride is a waste byproduct.[ citation needed ]
The Weldon process was first replaced by the Deacon process and later by the Chloralkali process.
Chlorine is a chemical element; it has symbol Cl and atomic number 17. The second-lightest of the halogens, it appears between fluorine and bromine in the periodic table and its properties are mostly intermediate between them. Chlorine is a yellow-green gas at room temperature. It is an extremely reactive element and a strong oxidising agent: among the elements, it has the highest electron affinity and the third-highest electronegativity on the revised Pauling scale, behind only oxygen and fluorine.
Sodium carbonate is the inorganic compound with the formula Na2CO3 and its various hydrates. All forms are white, odourless, water-soluble salts that yield alkaline solutions in water. Historically, it was extracted from the ashes of plants grown in sodium-rich soils, and because the ashes of these sodium-rich plants were noticeably different from ashes of wood, sodium carbonate became known as "soda ash". It is produced in large quantities from sodium chloride and limestone by the Solvay process, as well as by carbonating sodium hydroxide which is made using the Chlor-alkali process.
Sodium hypochlorite is an alkaline inorganic chemical compound with the formula NaOCl. It is commonly known in a dilute aqueous solution as bleach or chlorine bleach. It is the sodium salt of hypochlorous acid, consisting of sodium cations and hypochlorite anions.
Manganese dioxide is the inorganic compound with the formula MnO
2. This blackish or brown solid occurs naturally as the mineral pyrolusite, which is the main ore of manganese and a component of manganese nodules. The principal use for MnO
2 is for dry-cell batteries, such as the alkaline battery and the zinc–carbon battery. MnO
2 is also used as a pigment and as a precursor to other manganese compounds, such as KMnO
4. It is used as a reagent in organic synthesis, for example, for the oxidation of allylic alcohols. MnO
2 has an α-polymorph that can incorporate a variety of atoms in the "tunnels" or "channels" between the manganese oxide octahedra. There is considerable interest in α-MnO
2 as a possible cathode for lithium-ion batteries.
The Solvay process or ammonia–soda process is the major industrial process for the production of sodium carbonate (soda ash, Na2CO3). The ammonia–soda process was developed into its modern form by the Belgian chemist Ernest Solvay during the 1860s. The ingredients for this are readily available and inexpensive: salt brine (from inland sources or from the sea) and limestone (from quarries). The worldwide production of soda ash in 2005 was estimated at 42 million tonnes, which is more than six kilograms (13 lb) per year for each person on Earth. Solvay-based chemical plants now produce roughly three-quarters of this supply, with the remaining being mined from natural deposits. This method superseded the Leblanc process.
An alkaline battery is a type of primary battery where the electrolyte has a pH value above 7. Typically these batteries derive energy from the reaction between zinc metal and manganese dioxide.
In chemistry, hypochlorite, or chloroxide is an anion with the chemical formula ClO−. It combines with a number of cations to form hypochlorite salts. Common examples include sodium hypochlorite and calcium hypochlorite. The Cl-O distance in ClO− is 1.69 Å.
The Deacon process, invented by Henry Deacon, is a process used during the manufacture of alkalis by the Leblanc process. Hydrogen chloride gas was converted to chlorine gas, which was then used to manufacture a commercially valuable bleaching powder, and at the same time the emission of waste hydrochloric acid was curtailed. To some extent this technically sophisticated process superseded the earlier manganese dioxide process.
The chloralkali process is an industrial process for the electrolysis of sodium chloride (NaCl) solutions. It is the technology used to produce chlorine and sodium hydroxide, which are commodity chemicals required by industry. Thirty five million tons of chlorine were prepared by this process in 1987. The chlorine and sodium hydroxide produced in this process are widely used in the chemical industry.
Barium chloride is an inorganic compound with the formula BaCl2. It is one of the most common water-soluble salts of barium. Like most other water-soluble barium salts, it is a white powder, highly toxic, and imparts a yellow-green coloration to a flame. It is also hygroscopic, converting to the dihydrate BaCl2·2H2O, which are colourless crystals with a bitter salty taste. It has limited use in the laboratory and industry.
Manganese(II) chloride is the dichloride salt of manganese, MnCl2. This inorganic chemical exists in the anhydrous form, as well as the dihydrate (MnCl2·2H2O) and tetrahydrate (MnCl2·4H2O), with the tetrahydrate being the most common form. Like many Mn(II) species, these salts are pink, with the paleness of the color being characteristic of transition metal complexes with high spin d5 configurations.
A single-displacement reaction, also known as single replacement reaction or exchange reaction, is an archaic concept in chemistry. It describes the stoichiometry of some chemical reactions in which one element or ligand is replaced by atom or group.
Calcium sulfide is the chemical compound with the formula CaS. This white material crystallizes in cubes like rock salt. CaS has been studied as a component in a process that would recycle gypsum, a product of flue-gas desulfurization. Like many salts containing sulfide ions, CaS typically has an odour of H2S, which results from small amount of this gas formed by hydrolysis of the salt.
A zinc–carbon battery (or carbon zinc battery in U.S. English) is a dry cell primary battery that provides direct electric current from the electrochemical reaction between zinc (Zn) and manganese dioxide (MnO2) in the presence of an ammonium chloride (NH4Cl) electrolyte. It produces a voltage of about 1.5 volts between the zinc anode, which is typically constructed as a cylindrical container for the battery cell, and a carbon rod surrounded by a compound with a higher Standard electrode potential (positive polarity), known as the cathode, that collects the current from the manganese dioxide electrode. The name "zinc-carbon" is slightly misleading as it implies that carbon is acting as the oxidizing agent rather than the manganese dioxide.
Calcium hypochlorite is an inorganic compound with chemical formula Ca(ClO)2, also written as Ca(OCl)2. It is a white solid, although commercial samples appear yellow. It strongly smells of chlorine, owing to its slow decomposition in moist air. This compound is relatively stable as a solid and solution and has greater available chlorine than sodium hypochlorite. "Pure" samples have 99.2% active chlorine. Given common industrial purity, an active chlorine content of 65-70% is typical. It is the main active ingredient of commercial products called bleaching powder, used for water treatment and as a bleaching agent.
Calcium chlorate is the calcium salt of chloric acid, with the chemical formula Ca(ClO3)2. Like other chlorates, it is a strong oxidizer.
Walter Weldon FRS FRSE was a 19th-century English industrial chemist and journalist. He was President of the Society of Chemical Industry from 1883-84.
Chlorine gas can be produced by extracting from natural materials, including the electrolysis of a sodium chloride solution (brine) and other ways.
Hydrochloric acid, also known as muriatic acid or spirits of salt, is an aqueous solution of hydrogen chloride (HCl). It is a colorless solution with a distinctive pungent smell. It is classified as a strong acid. It is a component of the gastric acid in the digestive systems of most animal species, including humans. Hydrochloric acid is an important laboratory reagent and industrial chemical.
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