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Industrial processes are procedures involving chemical or mechanical steps to aid in the manufacture of an item or items, usually carried out on a very large scale.
Industrial processes are the key components of heavy industry.
Most processes make the production of an otherwise rare material vastly cheaper, thus changing it into a commodity; i.e. the process makes it economically feasible for society to use the material on a large scales, in machinery, or a substantial amount of raw materials, in comparison to batch or craft processes. Production of a specific material may involve more than one type of process. Mhost industrial processes result in both a desired product(s) and by-products, many of which are toxic, hazardous, or hard to deal with. Very, very few processes are self-contained.
Contents
1 General processes
2 Chemical processes
2.1 Electrolysis
3 Physical processes
3.1 Moulding
3.2 Separation
4 Iron and steel
5 Petroleum and organic compounds
6 Others
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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
Scrubber - removing of pollution from exhaust gases
Chemical processes
Smelting - chemically enhancing metals
Disinfection - chemical treatment to kill bacteria and viruses
Pyroprocessing - using heat to chemically combine materials, such as in cement.
Electrolysis
Main article: 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 particals in a liquid medium
Electrotyping - using electroplating to produce printing plates
Metallizing, Plating, Spin coating - the generic term for giving non-metals a metallic coating
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
Machining - the mechanical cutting and shaping of metal
Progressive stamping - the production of components from a strip or roll
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 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.
Separation
Many materials exist in an impure form, purification, or separation provides a usable product.
Froth flotation, flotation process - separating minerals through floatation
Fractional distillation, Vacuum distillation - separating materials by their boiling point
Solvent extraction - dissolving one substance in another
Frasch process - for extracting molten sulfur from the ground
Iron and steel
Early production of iron was from meteorites, or as a by-product of copper refining. Heating iron ore and carbon in a crucible at 1000 K produces wrought iron. This process gained popularity during the Iron Age. Temperatures of 1300 K were produced around the 8th century by blowing air through the heated mixture in a bloomery or blast furnace (12th century); producing a strong but brittle cast iron. Furnaces were growing bigger, producing greater quantities; a factor contributing to the Industrial Revolution. In 1740 the temperature and carbon content could be controlled sufficiently to consistently produce steel; very strong and very...(and so on)

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