Skip to main content
ExamExplained
NSW · Chemistry
Chemistry study scene
§-Syllabus dot point
NSWChemistrySyllabus dot point

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

Have a quick question? Jump to the Q&A page

Jump to a section
  1. What this dot point is asking
  2. The answer
  3. Examples in context
  4. Try this

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:

N2(g)+3H2(g)2NH3(g)ΔH=92 kJ mol1N_{2(g)} + 3H_{2(g)} \rightleftharpoons 2NH_{3(g)} \qquad \Delta H = -92\ \text{kJ mol}^{-1}

The contact process makes sulfuric acid, via sulfur trioxide, from sulfur dioxide and oxygen:

2SO2(g)+O2(g)2SO3(g)ΔH=198 kJ mol12SO_{2(g)} + O_{2(g)} \rightleftharpoons 2SO_{3(g)} \qquad \Delta H = -198\ \text{kJ mol}^{-1}

SO3SO_3 is then absorbed into concentrated H2SO4H_2SO_4 to form oleum, which is diluted with water:

SO3(g)+H2SO4(l)H2S2O7(l)H2S2O7(l)+H2O(l)2H2SO4(l)SO_{3(g)} + H_2SO_{4(l)} \rightarrow H_2S_2O_{7(l)} \qquad H_2S_2O_{7(l)} + H_2O_{(l)} \rightarrow 2H_2SO_{4(l)}

SO3SO_3 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.

Haber process industrial flow schematic A schematic flow diagram of the Haber process. Nitrogen and hydrogen feed gas enters a compressor, then a heated reactor at 450 degrees Celsius and 200 atmospheres containing an iron catalyst, producing a gas mixture of ammonia, nitrogen and hydrogen. This mixture passes through a cooler/condenser where ammonia liquefies and is removed as product, while unreacted nitrogen and hydrogen are recycled back to the compressor inlet. N2 + H2 feed gas compressor to 200 atm reactor 450 °C Fe catalyst N2+3H2⇌2NH3 cooler / condenser recycle unreacted N2 / H2 NH3 liquid product removed Removing NH3 and recycling feed gas both lift OVERALL conversion above the ~15% single-pass figure

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 EaE_a, 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.

Illustrative trade-off: equilibrium yield and reaction rate against temperature for an exothermic industrial synthesis An owned illustrative dual-curve graph plotting, against increasing temperature, a falling equilibrium yield curve (consistent with Le Chatelier's principle for an exothermic reaction) and a rising rate curve (consistent with collision theory). The two curves cross near the marked industrial operating temperature, illustrating why this compromise temperature is chosen instead of the temperature that maximises yield alone. high low Temperature Yield / rate (relative) equilibrium yield reaction rate industrial compromise T Illustrative ExamExplained trade-off curves, not to thermodynamic scale.

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 V2O5V_2O_5 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 KeqK_{eq} 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 N2N_2/H2H_2 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 2SO2+O22SO32SO_2 + O_2 \rightleftharpoons 2SO_3 means the yield gain from extra pressure would not repay the capital cost of pressurised vessels, unlike the Haber process. V2O5V_2O_5 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 SO3SO_3 (exothermic). Collision theory: at 50 degrees C, far fewer collisions exceed EaE_a, so the rate would be uneconomically slow even with V2O5V_2O_5; 450 degrees C is the workable rate-yield compromise.

Q3. A Haber reactor is fed 4.00 mol of N2N_2 with excess H2H_2, achieving 15.0% single-pass conversion. Calculate the moles, then the mass, of NH3NH_3 produced. [3 marks]

  • Cue. n(N2 reacted)=4.00×0.150=0.600 moln(N_2\ \text{reacted}) = 4.00 \times 0.150 = 0.600\ \text{mol}; n(NH3)=0.600×2=1.20 moln(NH_3) = 0.600 \times 2 = 1.20\ \text{mol}; m(NH3)=1.20×17.03=20.4 gm(NH_3) = 1.20 \times 17.03 = 20.4\ \text{g}.

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, N2(g)+3H2(g)2NH3(g)N_{2(g)} + 3H_{2(g)} \rightleftharpoons 2NH_{3(g)}, ΔH=92 kJ mol1\Delta H = -92\ \text{kJ mol}^{-1}, 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 KeqK_{eq}) 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 N2N_2 and H2H_2 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 N2N_2 (with excess H2H_2) per batch. At the operating equilibrium, 14.0% of the N2N_2 is converted to NH3NH_3 in a single pass. Calculate the mass of NH3NH_3 produced per pass, to 3 significant figures. (M(N2)=28.02 g mol1M(N_2) = 28.02\ \text{g mol}^{-1}, M(NH3)=17.03 g mol1M(NH_3) = 17.03\ \text{g mol}^{-1}.)
Show worked solution →

Step 1: write the balanced equation and identify the mole ratio.

N2(g)+3H2(g)2NH3(g)N_{2(g)} + 3H_{2(g)} \rightleftharpoons 2NH_{3(g)}

1 mol N2N_2 reacted produces 2 mol NH3NH_3.

Step 2: moles of N2N_2 fed to the reactor.

n(N2)=mM=8400 g28.02 g mol1=299.79 moln(N_2) = \frac{m}{M} = \frac{8400\ \text{g}}{28.02\ \text{g mol}^{-1}} = 299.79\ \text{mol}

Step 3: moles of N2N_2 actually converted (14.0% single-pass conversion).

n(N2 reacted)=299.79 mol×0.140=41.97 moln(N_2\ \text{reacted}) = 299.79\ \text{mol} \times 0.140 = 41.97\ \text{mol}

Step 4: moles of NH3NH_3 produced (1:2 ratio from the equation).

n(NH3)=41.97 mol×2=83.94 moln(NH_3) = 41.97\ \text{mol} \times 2 = 83.94\ \text{mol}

Step 5: mass of NH3NH_3 produced.

m(NH3)=n×M=83.94 mol×17.03 g mol1=1429.5 gm(NH_3) = n \times M = 83.94\ \text{mol} \times 17.03\ \text{g mol}^{-1} = 1429.5\ \text{g}

Step 6: round to 3 significant figures (matching the 3 s.f. of 8.40 kg and 14.0%).

m(NH3)=1.43 kg (1430 g)m(NH_3) = 1.43\ \text{kg} \ (1430\ \text{g})

Marking criteria: 1 mark for correct moles of N2N_2 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 N2N_2 and H2H_2 are recycled industrially rather than discarded.

core5 marksThe graph below is an owned illustrative curve showing the percentage yield of SO3SO_3 at equilibrium in the contact process, 2SO2(g)+O2(g)2SO3(g)2SO_{2(g)} + O_{2(g)} \rightleftharpoons 2SO_{3(g)}, ΔH=198 kJ mol1\Delta H = -198\ \text{kJ mol}^{-1}, 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 SO3SO_3 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 (ΔH=198 kJ mol1\Delta H = -198\ \text{kJ mol}^{-1}), 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 SO3SO_3 back to SO2SO_2 and O2O_2 and lowering the equilibrium percentage yield of SO3SO_3 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 V2O5V_2O_5 catalyst. 450 degrees C is the industrial compromise: the V2O5V_2O_5 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: N2(g)+3H2(g)2NH3(g)N_{2(g)} + 3H_{2(g)} \rightleftharpoons 2NH_{3(g)}. 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): 2SO2(g)+O2(g)2SO3(g)2SO_{2(g)} + O_{2(g)} \rightleftharpoons 2SO_{3(g)}. Total gas moles fall from 3 mol (2 + 1) to 2 mol, a smaller decrease of 1 mol of gas per 2 mol of SO3SO_3 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 SO3SO_3 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 N2N_2/H2H_2, 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 V2O5V_2O_5 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. V2O5V_2O_5 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 KeqK_{eq} 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.

ExamExplained