An Insight into Chemical Engineering Through Instant Notes, Objective ‘Types and Problems (CENTRAL LIBRARY Asunai Engineering College ‘Tirwvaniamalai - 606 603 (Useful for GATE and othe? Aptitude Tests) [Re] Ratt Picton, Channa s‘ARUNAT ENGINEERING COU ‘Aa Insight toto TIRUVARWAMALAL - 606 4u0 Chemical Engineering CENTRAL LIBRARY , msubbu_ ‘Acc. No. First Etion 2008 To Almighty All rights reserved. No part of this book may be reproduced in any form without the written ‘permission of the author. ‘Typeset in BTEX ‘Total number of pages: 400 Price: Rs, 270.00 Published by: Rishal Publications 3/2, Dr.Nammalvar Strest ‘Vivekananda House ‘Chennai-600 005 Phone: 91-44.28443152 ‘Mobile: 98401 02078 ‘emul: rishalpublicetions@yahoo.coin Printed at: Novena Ofset Printing Co. Chennai-5 Copies can be had from: Publisher inten ne aFOREWORD Competitive examinations have become inevitable nowadays for admission to graduate ‘courses and placement in chemical and allied industries, or undergraduate students in chem- ical engineering. For such examinations, apart from wide knowledge of all aspects of unit operations of chemical enginoering a quick wit to solve the questions /problems is absoluteley essential. Exhaustic revision of all these operations studied in earlier somesters is a tedious procedure. A quick insight into the same along with solutions to short answer objective ‘questions or probleme is necossiated. With this objective in view, the author has made an ‘attempt to prepare this monograph after going through many question papers of this type from several universities along with an intensive study of the operations covered. had the oppurtunity of revising the text and providing academic advice wherever nec- essary. Tam confident this effort of the author will be well received by the budding chemical engineers taking their fist degree from engineering colleges. Dr. N. SUBRAMANIAN Former Professor & Head Department of Chemical Engineering Indian Institute of Technology Madras Chennai October 5, 2008PREFACE For competitive examinations to pursue higher studies or get jobs, depth of knowledge in problem solving and answering objective type questions should be the essential qualities of 1 successful Chemical Engineer. ‘A sot of instant notes are given for various important topics in the core subjects of ‘Chemical Engineering. Ihope this set of topies detailed in this book will be of extreme use to the undergracuate students and practicing engineers for enhancing and checking their ‘knowledge in the core concepts ofthe subject. In any competitive examination due weightage is being given te objective type questions. In this book I have also given objective type {questions which will be useful for the chemical engineers and students for their preparation. By lecturing for the past few years in eore subjects of Chemical engineering like Fluid “Mechanies, Thernodynamics and Process Control at Department of Chemical Engineering, ‘Sri Venkatesware College of Engineering (SVCE), Sriperumbudur I have found that the stu- ‘dents need additional input for applying theoretical knowledge for solving the problems. In this book comprehensive set of problems in each of the nine subjects of Chemical Engt- neering are given with the steps in solving the same from the frst principles which could be tunderstood easily by a novice in the field also. Most of the problems are questions that were ‘oskod in GATE (Graduate Aptitude Test in Engineering) and in Univesity examinations. extend my heartful thanks to Dr.N.Subramanian (Visiting Professor, SVCE — For- ‘mer Professor in Indian Institute of Technology Madras, Chennai) for sparing his valuable ‘time to review this book and provide technical guidance whenever necded, T sincerely acknowledge the management of SVC for their support. | am grateful to Dr.V Ravichandran (Assistant Professor, Dept. of Computer Applica~ tions, SVCB) for introducing and enthusing me to learn IATEX software, with which this ‘book is typeset. Also he helped me in solving the objective type questions of Mathematics. Mr.B.Nedumaran (Assistant Professor, Dept. of Chemical Bagineering, SVCE) was al ‘ways helpful in conducting GATE coaching to students of SVCE, that initiated me to prepare these materials, ‘Always my affection and thanks le with my students who extended their interest to the fullest. Also T thank the Chemical Engineering community allover the world for their encouragement through my website http://mwe.svee.o°.in/~msubbu for the study materials provided in the website My thanks are due to my wife MrsS.Panchi for her suggestions ia publishing this book and providing administrative assistance. I thank my dear parents and relatives for their emotional support during these years. {thank the publisher for bringing out this edition at the earliest. ‘Avaiting for your valuable ideas, to be posted at btp://srew.msubbu.com Chennai msubbu October 15, 2008 (4, SUBRAMANTAN)Contents 1 Process Calculations 1 Instant Notes 1.11 Units and Standards 1.1.2 Material Balance Calculations 1.1.3. Bnergy Balance Calculations LIA Saturation & Humidity. . 115 Combustion Caleulations =... « 1.2 Objective Type Questions... - 13 Problems with Solutions - : 1.3.1 Volume of Gas at SIP 132 Orsat Analysis of Flue Gas 133 Concentration of SO in Flue Gas. 1.3.4 Conversion of S02 . or re 1.35 Percentage Exoes Air 7 7 136 Caleination of Limestone. . 13.7 Percentage of Cis Burat 138 Percentage Conversion of Cal, 1.3.9 Propane Debydiogenation Plant... . 1.3.10 Methanol Production in Recycle Reactor. 13411 Recyele Ratio ic Reverse Osmosis Desalination 1.3.12. Reeyele to the Reactor . 1.3.13 Seturator Bypass : 1.3.14 Drying of CaCO Slurry 13.5 Crystallization 1.3.16 Heat Load on Heater 1.3.17 Heat of Resction . .. - ++ -3-5 1.318 Amount of Heat Required : 13.19 Flame Temperature and Excess Air. « 1.320 Heat Released from Reaction 113.21. Conversion in Exothermic Reaction... . 1.3.22 Maintaining Tscthermal Operation of Reactor 12. Fluid Mechanics QL 22 23 AN INSIGHT INTO CHEMICAL ENGINEERING — msubbu Instant Notes 24.1 Fluid Statics. 242 Fluid Flow 213. Flow Meters 2.14 ‘Transportation of Fluids - 21.5 Flow Past Immersed Bodies Objective Type Questions Problems with Solutions . 23:1 ‘Two Layer Buoyancy 2.3.2 Floating of Wood on Water . . 23.3 Force Required to Hold a Ball Immersed in Liquid 234 Average velocity of Mixture 235 Flow Direction 236 Pressure Drop for Flow threugh Circular Poe. 23:7 Velocity of Water in Cizeular Pipe 238 Flow Rate for a given Pressure Drop 23.9. Pressure Drop per Unit Length fora given Flow SSRIIeaRRserssses 2.8.10 Pressure Drop for a given Flow . 6 28.11 Pressure Drop due to Friction... - 8 28.12 Velocity of Water in a Drain Pipe... « 63 2.313 Time Required to Empty a Conical Vessel 64 23.14 Energy Required for Pumpiag 2 85 23.15 Power To Pump 6 23.16 Friction Lose Factor of Ben Redueer . | | or 23.17 Flow through Tank Bottom 68 23.18 Velocity Measurement by Orifice SILL 68 2.3.19 Orifice Size for a given Flow... 2.2... vie. 0 23.20 Flow Measurement by Venturi Meter 0 23.21 Flow Messurement by Pitat Tube oat sei seg TL 23.22 Minimum fluidization Velocty . .- sooe at 2 2.3.23 Water Tvieling by Gravity through « Packed Bed 2 2.3.24 Particle Sie of Powder m4 3 Mechanical Operations 5 31 Instant Notes ceeeec eee enee 3.1 Size Analysis titceneees eat puna vay 7 312 Size Reduction 21... 1 : : 6 8.13 Size Separation « cesses 6 814 Filtration... 2 80 BAS Agitation 00020222 + 82 32 Objective Type Questions «2. LL + 8 38 Problems with Solutions : 88 33.1 Surface-Volume Mean Diane of Particles «2212222221111 38. 332 Work Index 3.33. Energy Consumption in Greshing CONTENTS 3.344 Specific Rate of Grinding - 3.35 Spetd of Ball Mill 336 Diameter of Roll Crusher 337 Claseifestion based on Terrinal Settling Veloeity-1 33.8 Range of Velocities for Classification 3.3.9 Classification based on ‘Terminal Settling Velo um: 3.3.10 Screening and Classification nt 3.3.11 Filtration Equation... seis oat 3.3.12 Constant Pressure Filtration-1 thee ene 33.13 Constant Pressure Filtration d ©... 2s 3.3.14 Washing Time pecan aR 3.3.15 Washing Time is Fier Press vee ema saan 3.316 Optimal Time in Filter Press... we 3.3.17 Comprossibilty of Filter Cake PT 3.3.18 Speed of Agitator . oererrnre 3.3.19 Dimensional Analysis of Agitasion . .< « tiene awe 3.3.20 Scale-up Criteria of Agitation... - sieee 4. Thermodynamics 4a 42 43 Instant Notes - 41.1 Introduction «=. 4.1.2 Energy and its Transformations 4.13 Reversible and Irreversible Processes 41.4 First Law of Thermodynamics : Fr gs «7 418 PVT Realtionships. . . fe ooteronie Fae snes 41.6 Second Law of Thermodynamies 4.1.7 Refrigeration 4.1.8 Thermodynamic Relations 41.9 Flow Processes 4.10 Solution Thermodyoamics - 4.1.11 Phase Equilibrium 4.1.12 Reaction Bquilibrium Objective Type Questions Problems with Solutions 43.1 Rise in Temperature of Air. 432 Work Requited to Compress an Ideal Gas 4.3.3 ‘Triple Point Temperature and Pressure 434 Thermal EiGciency of Carnot Cycle 435 Evaluating a Claim 43.6 Batropy Change in Mixing of Two Gases 43.7 Lxeversbilty -.- + - 438 COP of Refrigeration Cycle « 43.9 Change in Entropy for Ice to Steam Transformation oe 43.10 Change in Internal Energy of Nowideal Gas... - « 43.11 Thermodynamic Relations fora van der Waals gas 4312 JouleThomson Expansion 238 108 a tt mm sty a2 us na U5 us 2136 ous ns 19 ug 120 129 129 130 ash as 132 132 2138 134 136 1 194 AN INSIGHT INTO CHEMICAL ENGINEERING — msubbu 43.13 Work of Compression 2... . 5 139 43.14 Fugacity of van der Waals Gas - 40 43.15 Rugecity and Fugacity Coefficient 43.16 Partial Molal Volume 43.17 Bubble Point Vapor . 43.18 VLE of Non-ideal Solution 43.19 Activity Coeficient and Excess Gibbs Free Boergy - 43.20 Activity Coefficient. 4271 Activity Coefficients x Punetion of Componitions | 4322 Activiy Cooficents and G#/2-« 43.23 Dewpoint Pressure... . . 4324 Composition of Vapor 4325 P—2—y Data 43.26 Variation of Equilibrium Constant with Temperature 43.27 Partial Pressures at Reaction Equilibrium . . 48.28 Dehydrogenation of Ethane . . . 43.29 Equilibrium Composition of Non ideal Gas phase Reaction 5 Heat Transfer 5.1 Instant Notes 5.11 Conduction = - Convection Boiling... Heat Exchanges Evaporation... - 517 Radiation . +. 52 Objective Type Questions | 53. Probloms with Solutions. 53.1 Conduction through Thermopane 532 Conduction through Two Layers 5.33 Critical Thickness of Insation . 2-2-2. 5.34 Reduction in Heat Loss by Insulation tae 53.5 Heat Conduction through Increasing Cross Section 5.3.6 Expression for Steady State Temperature Profle 53.7 Time Required fr Cooling of Stel Ball 53.8 Unsteady Heat Transfer 5.2.9 Expression for Unsteady Haat Tyansier 5.3.10 Time Required for Froceing the Tank Contents 5.3.11 Hoot Thanfr Area Constant Hest Flax 5.3.12 Convective Heat Transfer 5.3.13 Emissivity Measurement .. - 5.3.14 Momentum & Heat Transfer Analogy. pa 5.3.15 Expression for Optimum Length of Heat Exchanger. 5.8.16 Heat Transfer Area for Counterfiow & Parallel flow . .- 5.3.17 Heat Transfer Area of Jacketted Vessel CONTENTS 5 6 Mass Transfer 64 62 63 5.3.18 Heat Transfer Arcs fe Rate of Condensation of Steam . . 5.3.19 Condensation of Steam - 197 198 5.3.20 Tine Roe fr Hoting te Coins of ict Vol 199 5.3.21 Estimation of Fouling Fector . . . 200 5.3.22 Heat Transfer Area for 12 Exchanger 201 5.325 Condenser Losd in Evaporation 202 5.3.24 Steam Beonomy & Hest Transfer Area... 0. esse ese + 208 5.3.25 ‘Temperature of Radiation Shield Instant Notes... 6.1.1 Diffusion. - 6.1.2 Convective Mase Tranfor 6.1.3 Gas-Liquid Contactors . 614 Tray Bficiencies 5... 62.5 Absorption 6.16 Distillation 61.7 Drying . Objective Type Questions - Problems with Solutions . 63.1 Molecular Difasvity . 632 Diffusion of A through Now-dfusing B 6.33 Interfacial Gas Concentration : 6.34 Heat and Mass Transfer Analogy . . - ee 63.5 Sherwood Number for Baumol Contr Dison = <=. 234 636 Relative Humidity of Air : 6.3.7 Dry-bulb Temperature of Air 7 6.3.8 Minimum Liquid Rate for Absorption . . . 6.3.9 Height of Absorption Column... « 6.3.10 Flash Vaporization . .. .. - 63.11 Differential Distillation. . 6.3.12 Equation of qLine - 6.3.13 Refux Ratio... 6.3.14 Quality of Feed to Distillation Coluna 63.15 Reflux Ratio and Composition of Vapor 6.3.16 Reflux Ratio and Vapor Rate 63.17 Distillation with Partial Condenser 8:18 Adsorption of Moisture by Sie Gel.» ue 6.3.19 Leaching of Sulfur... perrers Sy asia = 255 6.8.20 Time Required for Drying... . 2... 256 262 321 Baul Maistre Cote . + 258 63.22 Drying of Solid . 259 6.3.23 Drying of Slabs . 260 63:24 Extraction of Acstone ©. sees cies + 2616 |AN INSIGHT INTO CHEMICAL ENGINEERING —msubba CONTENTS. 7 7 Reaction Engineering 263 835 Response of Thermometer to Step Input - 319 72. Instant Notes... 263 83.6 ‘Time Constant of Thermocouple weve ne 320 t 711 Reaction Kinetics «+ 2263 837 Dynamice of Temperature Alarm Unit. « « Lo 320 : 712 Design of Reactors 263 838 Analytical Expression for Unit Imps Respone CUED bess 71.3 Nowisothermal Reactors 264 8.3.9 Step Input to Setpoint 7 321 TXA Heterogeneous Reactions 205 83.10 Outpt from Control Valve 3 TAS, Catalytic Reactions 265 8311 Output of Proportionsl Controller 3 323 12. Objective Type Questions 205 8.312 Output from PID Controller. « 4 vee eSB 73. Problems with Solutions . 279 $315 lod Diagram Reduction and Ox: Caleulation » 325 731 Activation Bneray = + 210 S314 Servo and Regulator Transfer Functions : eee) 132 Bxpreasion for Rate forthe given Mechanism « 279 S.A18 Steady State Bror in a Closed Loop System 2... = s+ 0 += 27 733 Relation for Concentrations in Multiple Reactions + 280 $316 Proportional Band of Pueumatic Controller... =. 38 73a Material Balance Equations for Isothermal CSTR. 2 281 8317 Off in Feedback Control System ie Lo bas 735 Convenion in CSTR for Zeroth Order Reaction . 1 ome S318 Value of K, from Routh Test « eeneeeneeeee 1 738 Conversion in Equal Volume CSTR & PR a $19 Maximum Gain for Stable Operation. « 330 78:7 Convenion in Constant Pressure Bich Reactor 234 £320 Masimun Controller Gai for Stable Closed Loop System... - 331 7.38 Conversion in a Batch Resctor . « 2 £321 Maximum Controle: Gan fr Stabe Coss Loop System-II «=» « 331 +739 Order of Reaction from PFR Data « 235 £3.22 Limits on Controller Gain one 4 Tho Convesion of Second Order Reaction in CSTR. « : 231 Sas ‘Stability of Closed Loop System : eee 7341 Size of PFR for Gas-phase Reaction... - + 202+ + 287 $324 Steady State Brrr in the Closed Loop System te pees A S12 Si of PER for Garphase Reaction IE 22.2. 22 aa 8324 Sumy Stee sony te Ukimate Controer Gain -T es b 7.3.18 Reacters in Series» «« = . son 2 83.26 Crossover frequency & Ultimate Controller Gain - IL oo 888 y 7314 Reacters Arrangement ut TUL LD aa z 7318 Increase in Production Rave by PER LILI Ll 2a2 9 Process Beonomies & Design 337 & 7.16 Actual Conversion in the Reactor . « 203 $a nee ates ae ak ae 3 TAM Brpoced Comer in te Restor Sytem : 9.1.1 Cost Estimation - fees ve 387 7318 Reacts Arrangement for Higher Conversion TILL aoe S12 Demedation =... So 338 7319 Rate Constants of Parallel Reactions live Tiler a epee aut Ueda Cota BIS Ca 7.3.20 Catalyst Bffectiveness Factor 7 * = 208 OL Mechanical Design of Process Equipments «s+. gece cer 34 . 7421 Rate Controlling Sep bad 9.2 Objective Type Questions : cee HB 1:22 Bpreson fer Cua Renton LUNI 90035. Problems with Sotutions« CUE e 173.28 Bxpreson for Rate of Catalytic Reaction = 22.22 cet Pr Ee pues ras lg legs tae. 7 ©) Procens Ontlen 303 8132 Capital Cot of Fhid processing Pant 8 ai tastent Noles... i 9.33 Depreciation us S11 Laplace Transforms SIE 0.34 Present Worth of @ Peture Amount 349 812 Qualsative Response of Systems DTD 303 939 Capitalized Cost : PEs 380 13 Openloop Response of Dynamic Systems 50... e+ eee +++ + 308 936 Annuity & Periodic Payment ae wees 850 S14 Dynamics of Controllers» - ade 5 937 Net Profit & Payout Poriod . LIL 31 # S15. Stabity Analysis of Feedback Sra TUPLE or $28 Capitalized Cost - Useful Life for the Alterntive - LULT LT ssa & 8.2 Objective Type Questions . . - tee . 308 9.3.9 Capitalized Cost as a Criteria ¥ ee 383, | 83. Problems with Solutions... - LM aeeial a6 9.810 Disoounted-Cach Flow Rate of Return |=. ss ssc scores ces S54 4} 8.3.1 Linctization of Single Variable « DILL ae 9.31 Alternative Investments i 304 gl $32 Tempereture of Solution Leaving a tired Tank... 2.2.25. SIT 9.312 Rate of Return as 8 Proaity Criteria LIT 38s 833. Traner Function for First Order Reection - : 37 9319 BreakeEven Pot. 355 834 Dynamics of Thermometer =... vey sake aoe <0 3iB 98.14 Beonomic Pipe Diameter. ee : 23588 AN INSIGHT INTO CHEMICAL ENGINEERING — msubbu 10 Chemical Technology 101 Instant Notes... - 10.1.1 Water Conditioning’... 10.12 Fuel Gases - 10.13 Sulfuric Acid =<. - 10.1.4 Chlor-Allali Industries « 10.15 Nitrogen Industries... 10.1.8 Phosphorus Industries 10.1.7 Fertlizers = - 10.18 Cement Industries 10.1.9 Sugar Industries". . 10,110 Alcohol Industries 10,,.11 Leather Industries 10.1.120is and Fats « « « 10.1.13Pulp & Paper Industria -- 10,1.14Petroloum Processing \1011.15Polymer Industries 10.1. 16Rubbers or Elastomers 10.1.17 Common Names 10.1. 18Safety Tips. : 10.119 Materials of Construction forthe Proce Tadustries 10.2 Objective Type Questions . 11 Mathematics ILL Objecti ‘Type Questions Recommended Books for Detailed Study 386 Chapter 1 Process. Calculations 1.1 Instant Notes 1.1.1 Units and Standards ++ SII (International System of Units) ~ Mass in kg, Length in meter, Temperature in Kelvin, Number of gram-moles as ‘mole, Force in Newton ~ The unit of temperature is Kelvin, K (not degroe Kelvin, “K) ‘+ Composition of solids: expressed in woight % or in mole %. Whenever no specifica- ton is made about the composition ie, whether itis mole % or weight %, itis taken as weight %. * Very often, the impurities presant in solid or liquid compounds are expressed in ppm (parts per million parts). This is expressed on a weight basis. When the solution is watery, I mg/lit = 1 ppm. In water treatment and effluent treatment problems, the analyses are given in ppm or mg/lit, which are both taken as similer. ‘+ Molarity (I) is defined as the sumber of gol of solute dissolved in litre of solution. ‘+ Normality (WV) is defined as the number of gram equivalents dissolved in I litre of solution. + Concentration in g/lit = Normality (N) x equivalent weight ‘ Molality is defined as the number of gmol of solute dissolved in 1 ilogram of solvent. + ‘The volumetric composition of liquid solution will change with the temperature. The composition of a system expressed in mote perceat will nt vary with the temperature. 9AN INSIGHT INTO CHEMICAL ENGINEERING — msubbu « For ides! gases, the composition in mole percent is exactly same as the composition jn volumetric percent. It should be emphasized that this relation holds only for gases, tnd does not apply to liquid or solid systems. # S.TP; Pressure = 1.01325 x 10° N/m?; T = 273 K. At this conditions, for an ideal gas V = 224 m*/kmol 4.1.2. Material Balance Calculations + Withcut Chemical Reaction ~ Uader steady state conditions, Input = Under unsteady state conditions Input = output + accumulation + Atom balances Input (of some species of atom) = output (of the same species of atom) ‘The chemical reactions that take place ina process which are very complicated can be solved by stom balances without knowing the chemical reactions taking place in thot. «Inert substance: In most axidation process air is used as the source of oxrgen, and airs 79 mol percent nitrogen, an inert substance at the temperatures at which most substances are oxidized 1s Tie substances: Tie material is defined as a material, of necessarily inert or unre active, which passes through 8 system from a single input stream to a single output Stream and ofeourse remains completely unchanged during this proves. ‘s Incomplete reactions: Chemical reactions are generally not complete; that is, the limiting reactant isnot completely used up. This idea is expressed as percent complete ot percent completion, and it i important to note that this completion must be based fon the limiting reactant. Percent excess: Percent excess of excess reactant is based on the 100 percent com pletion of the limiting reactant Recycle ~ Recycle ta the operation or = procees stap whereby a part or fraction of the ‘products ftom the reactor is returned and mixed with the incoming fresh feed to the reactor. ~ Because of recycle, the overall conversion, which is based on the frst feed, will >be higher than the conversion per pass, whichis based on the mixed feed to the \ PROCESS CALCULATIONS n = The feed to the process itself is made up of two streams, the fresh feed and the recycled material: The gross produet leaving the process is separated into two streams, the net product and tho material to be recycled. + Conversion Overall fractional conversion = Met Men (1a) Tes where map = mas of reactant in fresh fod ti = mass of reactant in net product Sing-pss(neetbroug) atonal convenion = ™4=Te=—(1y where my = mase of reactant fed into the reactor ‘eq = mass of reactant existing the reactor ‘+ Bypass stream: one thet skips one or more stages of the process and goes directly to another downstream stage + Purge stream: a stream to bled off to remove an accumulation of inerts or unwanted material that might otherwise buildup in the reeycle stream, 1.1.3 Energy Balance Calculations ‘+ The distinction of constant volume and constant pressure processes is not so important in the ease of liquids nd solids, as the liquid and solid expands very litle with increase in temperature, ‘Phe specific heats of solids are lower than liquids. ‘The heat of formation is a Special type of heat of reaction from the elements. The reaction does not necessarily represent a real reaction but can be a fictitious process for the formation. ae + All exidation reactions are exothermic Similarly, the dissolution of sulfuric acid or ‘caustic soda is exothermic. + Industrially important stsam-hydrocarbon reforming reaction is endothermic. + The dissolution of common salt in water is also endothermic, ‘= The temperature of the products under adiabatic conditions of reaction is called the ‘adiabatie reaction temperature.2 AN INSIGHT INTO CHEMICAL ENGINEERING ‘mubbu 1.1.4 Saturation & Humidity ‘+ Bone-dry air: Alr that Is bone dry contains absolutely no water vapor. Bone-dry implies completely dry. ‘+ Molar humidity is also sometimes referred to as absolute humidity moles of water vapor Molar tunity = of water vp + Htuaty, or spac huty = HEL wae a ‘= Relative humidity: is defined as the ratio of the partial pressure of water vapor in air to the vapor pressure of water at dry-bulb temperature. Relative humility is ‘widely used in weather reporting but finds little application in engineering where it has been replaced by percentage humidity. «+ Percentage humidity or percentage saturation: is defined as the ratio of actual absolute homidity to the saturation humidity. Relative humidity is always greater than or equal to peroentage humidity. Reletive humidity fs equal to percentage humidity only at saturation. + Dew point ~ Partial pressure of water vapor in the mixture equals the vapor pressure of water at dew point = Dew point is always lower than or equal to dry bulb temperature. Dew point is always lower than or equal to wet-bulb temperature At 100% saturation: Dry bulb temperature ~ Wet bulb temperature = Dew poitt ‘The difference between the wet-bulb temperature and the dry-bulb temperature 18 proportional to the amount of water vapar in the atmospheric ar; it is zero ifthe air fs saturated and highest ifthe air is bone-dry. 1.1.5 Combustion Calculations + Calorifiec Value — The calorific value of a fuel is nothing but the heat of combustion of the fuel. It {s defined as the total heat produced when a unit mass of fuel Is completely burnt ‘with pure oxygen. It is also ssid to be the hesting value of the ful PROCESS CALCULATIONS 8 = When 2 fuel is burnt, hydrogen combines with eaygen and gets converted into water, When water vapor is present in the flue gases, the latent heat of vaporiza- tion is lost. Hence this quantity of host is not available for any useful purpose. ‘Therefore, when the calorific value ofa fuel is determined, considering that the water is present in the vapor form, itis said to be the net calorific value (NCV) (of net heating value or lower heating value. Ne} GOV — weight % of hydrogen x 9 x Usually, NCV and GOV (Gross Calorific Value) ofthe fuels are reported at 25°C. ~ It is customary to specify tho abbreviations NCV or GCV when the calorific values are reported, as the case may be. However, if no mention is made, the reported calorific value is taken as GOV. — In comparison to all the three types of fuels, gascous fuels offer higher heating values. ‘+ Nitrogen reduces the flame tompersture considerably and also accounts for high heat Joss to the stack # Air reqt ments ~ The theoretical or stoichiometric amount of air is the minimum amount of air roqured to burn the fuel completely so that carbon, hydrogen and sulfur are converted to COs, HyOand SO» respectively. Tn actual practice, theoretical air is not sufficient to get complete combustion. Excoss air supply is © must for complete combustion. Normally, gaseous fuels require very less excess alr. ‘The effect of exoess alr is to reduce the flame temperature and to increase the heat losses through the fue ‘gases. 1 The greater the moisture preseat in the fue gases, the higher is the dew point. ‘+ The major combustion reactions are all exothermic. 1.2 Objective Type Questions 1. Por a steady state system (8) The rate of input is ero (b) The rate of generation is 2er0 (c) The rate of consumption is zero (@) The rate of accumulation is zero Answer: (A) At steady state, Input = Output (for nonreactive systems)AN INSIGHT INTO CHEMICAL ENGINEERING — msubbu 2. tn paper mil, a wash liquor containing 9% (Ly weight) solids is concentrated in an evaporator to yield a lye containing 30% (by weight) solids. ‘The quantity of water evaporated per 100 kg of feed is (2) 30 ke (0) 70g (0) 00 ke (@) 90 ka, ‘Answer: (d) Basis: 100 kg of feed containing 3% (by weight) solid Solid in feed = 0.03 > 100 = 3 kg Solid in lye (product) = 3k 3 Tole = 4 = 10% | igo, Watet evaporated = 100-10 90 kg 3. The molar composition of a gas is 10% Hz, 10% Oz, 30% CO2 and balance 10. If 50% HaUcodenses, the tine! mole percent of Hz mn the dry gas will be (GATE-2000-1.07) () 10% (0) 5% (o) 18.18% @: 1% Answer: (A) For dry gas analysis HO amount should not be considered. ‘Therefore, Hin the dry gas = 100 x (0.1/(0.1 +0.1 +03)] = 20% 4. A solution of specific gravity 1.0 consists of 35% A by weight and the remaining B. If the specific gravity of A is 0.7, the specific gravity of B is, (GATE-1995-1.05) (125 1s (135 @12 Answer: (b) Basis: 1 Ite of solution Since sp.ge of pure A is 0.7 (ve, p =0.7 kg/lt), s 0.7 kg of A 0.35 kg of A ihe 0.35 x 1/07 ‘Therefore, 0.65 kg of B= po i.e, Specific gravity of B 5, Pure A in gas phase enters a reactor. 50% of this A Is converted to B through the reaction A $B. Mole fraction of A in the exit stream is (GATE-1990-106) eye (1/3 ou ous PROCESS CALCULATIONS 5 Answer: (¢) Basis: 1 mole of Ain fed. mole of A gives 3 moles of B for complete conversion. ‘Therefore for 80% eommersion of A, product contains: 1.5 mole B and 0.5 moe A. ‘Mole fraction of Ain product = 0.5/(1.5 +05) = 1/4 6. A liquid mixture contains 30% o-xylene, 60% p-xylene and 10% m-xylene (all per- ‘centages in w/st), Which of the following statements would be true in respect of this mixture? (GATE-1998-1.07) (0) The mixture exhibits an azeotrope at 101.3 kPa. (&) The composition of the mixture, in percent by volume is: o-xylene 30, p-xylene 60, and m-xylene 10 () The composition ofthe mixture in mole percent is: xylene 80, p-xylene 60, and smexylene 10. (4) ‘The mixture contains optical isomers. “Answer: (e) For isomers, molecular weights are equal; hence mol% & weight™% are ‘same. The composition in valurme% is equal to mole% for mixture of ideal gases 7. Pure ethanol vapor is fed to a reactor packed with Alumina catalysts at the rate of 100, lkenol/hr. ‘The reactor product comprise: Ethylene = 95 kmol/hr, Water vapor = 97.5 rmol/hr and diethyl ether = 2.5 kmol/hr. The reactions occuring ean be represented. by: CaHgOH + Coli, + HzO 20,HgOH + Calip-O-Calls + Ha ‘The percent conversion of ethanol in the reactor is: (GATE-1998-1.08) (8) 100 (0) 975, (0) 95 (25 Answer: (a) Basis: Lhe Ethanol used: for Grst reaction = 95 kmol (from ethylene rate) for second reaction = 2.5 x 2=5 kimol (from diethylether rate) Total = 9545 = 100 kmol Check for water vapor: Water from first reaction = 95 kmol Water from second reaction = 2.5 kmol ‘Total water produced = 95425 17.5 kamol (ince ethanol used = ethanot in feed; conversion is 100%)