Inquiry Question 3: How, and why, are chemical reactions used to produce particular products?
Evaluate how the industrial synthesis of ammonia (the Haber process) and of sulfuric acid (the contact process) balance the equilibrium and rate demands of an exothermic, gas-phase reversible reaction to optimise the yield and rate of a commercial product
A focused answer to the HSC Chemistry Module 8 dot point on the Haber and contact processes. How Le Chatelier's principle and collision theory are balanced against each other to set industrial temperature, pressure and catalyst choices, worked equilibrium and yield calculations, and graded HSC-style practice questions.
Reviewed by: AI editorial process; not yet individually human-reviewed
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What this dot point is asking
NESA wants you to evaluate why the industrial conditions chosen for the Haber process (ammonia) and the contact process (sulfuric acid) are a deliberate COMPROMISE between two competing demands: Le Chatelier's principle (which sets what happens to the equilibrium YIELD as conditions change) and collision theory (which sets the RATE at which that equilibrium is reached). Full marks require you to apply both frameworks to the SAME set of industrial conditions and explain why neither framework alone determines the final design choice.
The answer
Two exothermic, gas-phase, reversible reactions
Both processes are reversible, gas-phase, exothermic syntheses, and both face the identical design tension: cooling the system would raise the equilibrium yield, but it would also make the reaction too slow to be commercially useful.
The Haber process makes ammonia from nitrogen and hydrogen:
The contact process makes sulfuric acid, via sulfur trioxide, from sulfur dioxide and oxygen:
is then absorbed into concentrated to form oleum, which is diluted with water:
is not absorbed directly into water because the reaction is violent and produces an uncontrollable corrosive acid mist; going via oleum keeps the process safe and controllable.
Why not just use the temperature that maximises yield?
For an exothermic reaction, Le Chatelier's principle says lower temperature always increases the equilibrium yield of product. So why not run both processes at, say, 50 degrees C?
Collision theory answers this. At a much lower temperature, the average kinetic energy of the reacting molecules is far lower, so a far smaller fraction of collisions have energy exceeding the activation energy , even with a catalyst present to lower that barrier. The reaction would take an uneconomically long time to approach its (admittedly higher) equilibrium yield. A chemical plant needs both high yield AND a fast throughput; the industrial temperature is the point where the catalysed rate becomes commercially workable, accepting a somewhat lower equilibrium yield in exchange.
Pressure: why the two processes differ
Pressure is chosen by the same Le Chatelier logic, applied to the change in the total number of moles of gas across each reaction.
| Process | Gas mole change | Industrial pressure | Reasoning |
|---|---|---|---|
| Haber process | 4 mol to 2 mol (large decrease) | 200 to 250 atm (high) | A large mole decrease means high pressure gives a large yield benefit, worth the cost of thick-walled reactors and heavy compressors. |
| Contact process | 3 mol to 2 mol (smaller decrease) | 1 to 2 atm (near atmospheric) | A smaller mole decrease means high pressure gives only a modest extra yield, which does not justify the large extra capital cost when yield is already 95%+ without it. |
Catalysts: fast, not different
A catalyst changes ONLY the rate, never the position of equilibrium. Iron in the Haber process and in the contact process each provide an alternative reaction pathway with a lower activation energy, so a larger fraction of molecular collisions succeed at a given temperature. This lets both processes run at their compromise temperature with an economically useful rate, without changing or the equilibrium yield that temperature and pressure alone would produce.
Examples in context
Example 1. Incitec Pivot's Gibson Island ammonia plant. Incitec Pivot's (former) Gibson Island ammonia plant in Brisbane ran a Haber process synthesis loop at conditions consistent with the HSC model: high pressure to favour the low-gas-mole ammonia side, a compromise temperature to keep the iron catalyst working at a commercially useful rate, and a recycle loop returning unreacted / to the reactor after liquid ammonia was condensed out. The plant's economics depended on exactly the trade-off this dot point tests: pushing temperature down to chase equilibrium yield would have made the reaction too slow to supply the fertiliser market at the required rate.
Example 2. Sulfuric acid production for the Australian fertiliser industry. Australian sulfuric acid manufacturers (supplying phosphate fertiliser production) run the contact process at close to atmospheric pressure because the smaller gas-mole change of means the yield gain from extra pressure would not repay the capital cost of pressurised vessels, unlike the Haber process. is used industry-wide instead of platinum specifically because feed gas from sulfur burning or ore roasting carries trace impurities that would poison a platinum catalyst far more readily.
Try this
Q1. For the Haber process, state the direction of the equilibrium yield shift (or "no change") caused by: (a) increasing pressure; (b) decreasing temperature; (c) adding a catalyst. [3 marks]
- Cue. (a) Yield increases (fewer gas moles on the product side). (b) Yield increases (exothermic forward reaction favoured by cooling). (c) No change (catalyst affects rate only).
Q2. Explain, using both Le Chatelier's principle and collision theory, why the contact process is run at 450 degrees C rather than 50 degrees C. [4 marks]
- Cue. Le Chatelier: lower T would give a higher equilibrium yield of (exothermic). Collision theory: at 50 degrees C, far fewer collisions exceed , so the rate would be uneconomically slow even with ; 450 degrees C is the workable rate-yield compromise.
Q3. A Haber reactor is fed 4.00 mol of with excess , achieving 15.0% single-pass conversion. Calculate the moles, then the mass, of produced. [3 marks]
- Cue. ; ; .
Practice questions
Original practice questions graded from foundation to exam level, each with a full worked solution. Try them before revealing the solution.
foundation3 marksFor the Haber process, , , state and justify the effect on the equilibrium YIELD of ammonia of (a) increasing pressure, (b) increasing temperature, (c) adding the iron catalyst.Show worked solution →
A 3-mark identify-and-justify needs a direction (or "no change") AND a Le Chatelier or catalyst reason for each.
- (a) Increasing pressure
- Yield increases. The forward reaction reduces gas moles (4 mol to 2 mol), so increasing pressure shifts the equilibrium position toward the side with fewer moles of gas, the ammonia side.
- (b) Increasing temperature
- Yield decreases. The forward reaction is exothermic, so by Le Chatelier's principle increasing temperature shifts the equilibrium position toward the endothermic (reverse) direction, reducing the equilibrium proportion of ammonia.
- (c) Adding the iron catalyst
- No change to yield. A catalyst lowers the activation energy of both the forward and reverse reactions equally, so equilibrium is reached faster, but the position of equilibrium (and ) is unaffected.
Marking criteria: 1 mark per part for the correct direction (or "no change") with a reason that correctly names the relevant principle (Le Chatelier gas-mole shift, Le Chatelier exothermic/temperature shift, catalyst effect on rate not position).
foundation3 marksExplain why the industrial temperature chosen for the Haber process (400 to 450 degrees C) is a compromise, rather than the lowest possible temperature that would maximise equilibrium yield.Show worked solution →
- The yield argument for low temperature
- Because the forward reaction is exothermic, Le Chatelier's principle predicts that a lower temperature would shift the equilibrium further toward ammonia, giving a higher equilibrium yield in principle.
- The rate argument against low temperature
- By collision theory, a much lower temperature gives molecules far less kinetic energy, so a far smaller fraction of collisions between and would have energy exceeding the activation energy. The reaction would be too slow to be commercially viable, even with the iron catalyst, because it would take an uneconomically long time to approach that higher equilibrium yield.
- The compromise
- 400 to 450 degrees C is chosen because it gives an acceptable reaction rate (aided by the iron catalyst lowering the activation energy) while still retaining a usable, if reduced, equilibrium yield, which is then improved further by removing ammonia as it forms and recycling unreacted gas.
Marking criteria: 1 mark for the yield/Le Chatelier argument for a lower temperature, 1 mark for the rate/collision theory argument against too low a temperature, 1 mark for explicitly naming the choice as a compromise between rate and yield (not just describing each effect separately).
core5 marksAn industrial Haber reactor is fed 8.40 kg of (with excess ) per batch. At the operating equilibrium, 14.0% of the is converted to in a single pass. Calculate the mass of produced per pass, to 3 significant figures. (, .)Show worked solution →
Step 1: write the balanced equation and identify the mole ratio.
1 mol reacted produces 2 mol .
Step 2: moles of fed to the reactor.
Step 3: moles of actually converted (14.0% single-pass conversion).
Step 4: moles of produced (1:2 ratio from the equation).
Step 5: mass of produced.
Step 6: round to 3 significant figures (matching the 3 s.f. of 8.40 kg and 14.0%).
Marking criteria: 1 mark for correct moles of fed, 1 mark for correctly applying the 14.0% single-pass conversion, 1 mark for the correct 1:2 mole ratio, 1 mark for the mass calculation, 1 mark for the correct final answer to 3 significant figures with units. Note this is the low single-pass yield that is why unreacted and are recycled industrially rather than discarded.
core5 marksThe graph below is an owned illustrative curve showing the percentage yield of at equilibrium in the contact process, , , plotted against temperature at a fixed pressure. (a) Describe the trend shown by the curve. (b) Explain this trend using Le Chatelier's principle. (c) Explain why the industrial operating point marked on the graph (about 450 degrees C) is chosen despite not giving the maximum yield shown.Show worked solution →
- (a) Description
- The percentage yield of is high (above 95%) at low temperature and falls steadily and continuously as temperature increases, dropping to well below 50% at the highest temperatures shown on the graph.
- (b) Le Chatelier explanation
- The forward reaction is exothermic (), so increasing temperature adds energy to the system; by Le Chatelier's principle the equilibrium position shifts in the endothermic (reverse) direction to absorb some of that added energy, converting some back to and and lowering the equilibrium percentage yield of as temperature rises.
- (c) Why 450 degrees C, not the maximum-yield temperature
- The maximum yield on the graph occurs at the lowest temperatures shown, but at those temperatures the rate of reaction (by collision theory, fewer molecules have kinetic energy exceeding the activation energy) is too slow to be commercially viable even with the catalyst. 450 degrees C is the industrial compromise: the catalyst lowers the activation energy enough that a fast, economically useful rate is reached at this temperature, while the equilibrium yield lost compared with a lower temperature (still around 95 to 98% at 450 degrees C for this reaction) remains commercially acceptable.
Marking criteria: (a) 1 mark for correctly describing the falling trend with temperature. (b) 1 mark for citing the exothermic forward reaction, 1 mark for correctly applying Le Chatelier's principle to explain the falling yield. (c) 1 mark for identifying the rate/collision theory reason low temperature is avoided, 1 mark for explicitly naming 450 degrees C as a rate-yield compromise (not simply restating that yield is lower there).
core6 marksCompare the Haber process and the contact process in terms of (a) the change in total gas moles from reactants to products, and (b) the industrial pressure chosen, explaining how these two facts are connected.Show worked solution →
(a) Change in gas moles.
Haber process: . Total gas moles fall from 4 mol (1 + 3) to 2 mol, a decrease of 2 mol of gas per 2 mol of ammonia formed.
Contact process (key step): . Total gas moles fall from 3 mol (2 + 1) to 2 mol, a smaller decrease of 1 mol of gas per 2 mol of formed.
(b) Industrial pressure chosen.
The Haber process uses high pressure, approximately 200 to 250 atm, whereas the contact process uses close to atmospheric pressure, approximately 1 to 2 atm.
(c) The connection. By Le Chatelier's principle, increasing pressure shifts a gas-phase equilibrium toward the side with fewer moles of gas. The Haber process has a LARGER mole decrease (4 to 2), so raising pressure produces a substantial extra shift toward ammonia, which is worth the very high capital and energy cost of thick-walled, high-pressure reactors and compressors. The contact process has a SMALLER mole decrease (3 to 2), so raising pressure would give only a modest extra yield improvement; because already forms in high yield (95%+) at ordinary temperature without high pressure, the extra equipment cost of high pressure is not economically justified for the contact process, so it is run near atmospheric pressure instead.
Marking criteria: 1 mark for the correct Haber mole change, 1 mark for the correct contact process mole change, 1 mark for correctly stating the industrial pressure used in each process, 1 mark for correctly applying Le Chatelier's principle to link mole change to pressure benefit, 1 mark for explicitly comparing the SIZE of the mole change between the two processes, 1 mark for a cost/benefit conclusion linking the smaller contact process mole change to its lower operating pressure.
exam8 marksAssess the claim that industrial equilibrium processes such as the Haber and contact processes are designed to maximise equilibrium yield above all other considerations, referring to BOTH processes and to the role of catalysts, recycling and economic factors.Show worked solution →
This is an 8-mark ASSESS: markers reward a judgement backed by a worked comparison across both named processes, not just a description of each process.
Band 6 PLAN.
- Thesis: the claim is false; both processes are deliberately operated BELOW their maximum possible equilibrium yield because rate, catalyst behaviour, capital cost and energy cost are weighed jointly against yield, with the shortfall recovered through catalysis, product removal and recycling rather than through pushing temperature and pressure to their yield-maximising extremes.
- Haber process evidence: maximum yield would favour LOW temperature (exothermic forward reaction, Le Chatelier) and very HIGH pressure (4 mol to 2 mol gas change), yet the industrial choice of 400 to 450 degrees C and 200 to 250 atm sacrifices potential yield for an economically workable rate (collision theory: too low a temperature makes the reaction too slow even with the iron catalyst) and for equipment cost (pressure far beyond about 250 atm needs disproportionately expensive reactors for a small further yield gain). Single-pass conversion is low (about 10 to 20%); the process compensates by liquefying ammonia out of the gas stream (Le Chatelier product removal) and recycling unreacted /, not by forcing near-total single-pass conversion.
- Contact process evidence: maximum yield would also favour low temperature, yet 450 degrees C is chosen with the catalyst for a workable rate; because the mole change (3 to 2) is smaller than the Haber process, pressure is kept near atmospheric rather than raised, since the incremental yield gain from higher pressure would not repay the extra capital cost. is chosen over the more catalytically active platinum on cost and poison-resistance grounds, a clear case of an economic factor overriding a purely rate/yield-maximising catalyst choice.
- Cross-process pattern: in both processes, a catalyst is used to raise RATE (not equilibrium position or yield, since a catalyst affects both directions equally and leaves unchanged), and yield lost to a rate/cost compromise temperature is recovered by non-equilibrium engineering steps (continuous product removal, recycling of unreacted feed) rather than by further raising temperature toward the yield-maximising extreme.
- Judgement: real industrial equilibrium design optimises an overall rate-yield-cost package, not equilibrium yield in isolation; the claim should be rejected, though yield remains one of the most heavily weighted factors in both cases.
Model paragraph (excerpt). The claim that yield is maximised above all else does not hold for either the Haber or the contact process. Both reactions are exothermic, so Le Chatelier's principle predicts that the highest equilibrium yield would occur at the lowest practicable temperature; yet both processes are run at temperatures of 400 to 450 degrees C specifically because collision theory shows that a lower temperature would make the rate commercially unworkable, even with an efficient catalyst. The two processes also diverge sensibly on pressure: the Haber process, with its larger four-to-two mole reduction, justifies costly high-pressure engineering, while the contact process's smaller three-to-two mole reduction does not, so it is run near atmospheric pressure instead. In both cases, the resulting shortfall in single-pass yield is not clawed back by pushing conditions further toward the yield-maximising extreme, but by removing product as it forms and recycling unreacted feed, evidence that plant designers are optimising a joint rate-yield-cost function rather than yield alone.
Marker's note: top-band answers (1) apply BOTH Le Chatelier's principle (yield/position) and collision theory (rate) explicitly to BOTH named processes, (2) use the Haber-versus-contact pressure contrast as concrete comparative evidence, (3) explain the catalyst's role correctly as a rate effect only, not a yield effect, and (4) close with an explicit judgement rather than a neutral summary. Answers describing only one process, or omitting the catalyst-does-not-affect-yield point, cap out in the mid-range bands.
