Programme

4 Yr. B.Tech 6th Semester Examinations, 2021 in Chemical Engineering

Paper Name of Paper Theory/ Exam Time

Code Practical Date
PCRE Chemical Reaction Theoretical 09.08.2021 2.00 PM to 5.00
601 Engineering–II PM
PCCT Chemical Process Theoretical 10.08.2021 2.00 PM to 5.00
602 Technology–II PM
Professional Elective–II
PECE Petroleum Refinery Theoretical 11.08.2021 2.00 PM to 5.00
603 Environmental Pollution and Theoretical 11.08.2021 PM
PECE Control 2.00 PM to 5.00
613 PM
Open Elective–II
OECE Modeling Simulation and Theoretical 12.08.2021 2.00 PM to 5.00
604 Optimization Theoretical 12.08.2021 PM
OECE Solid Waste Management 2.00 PM to 5.00
614 PM
HMVE Value and Ethics Theoretical 13.08.2021 2.00 PM to 5.00
605 PM
PCMR Chemical Engineering Practical 17.08.2021 Group A: From
606 Laboratory–II 11.00 AM
Practical 18.08.2021 Group B: From
11.00 AM
PCED Process Equipment Design Practical 17.08.2021 Group B: From
607 and Drawing 11.00 AM
Practical 18.08.2021 Group A: From
11.00 AM
PIPT 608 Internship/ Plant Training Practical 20.08.2021 Group A: From
11.00 AM
Practical 21.08.2021 Group B: From
11.00 AM

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Formation of Groups will be notified in due course

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Common utilities

Electricity

The electricity demand of the process is mainly determined by the work required for
pumping, compression, air coolers, and solids-handling operations, but also includes the
power needed for instruments, lights, and other small users. The power required may be
generated on site, but will more usually be purchased from the local supply company. Some
plants generate their own electricity using a gas-turbine cogeneration plant with a heat
recovery steam generator (waste-heat boiler) to raise steam (Figure 3.1). The overall thermal
efficiency of such systems can be in the range 70% to 80%; compared with the 30% to 40%
obtained from a conventional power station, where the heat in the exhaust steam is wasted in
the condenser. The cogeneration plant can be sized to meet or exceed the plant electricity
requirement, depending on whether the export of electricity is an attractive use of capital.
This “make or buy” scenario gives chemical producers strong leverage when negotiating
electric power contracts and they are usually able to purchase electricity at or close to
wholesale prices

On any site it is always worth considering driving large compressors and pumps with steam
turbines instead of electric motors and using the exhaust steam for local process heating.
Electric power is rarely used for heating in large-scale chemical plants, although it is often
used in smaller batch processes that handle nonflammable materials, such as biological
processes.

The main disadvantages of electrical heating for large-scale processes are:

• Heat from electricity is typically two to three times more expensive than heat from fuels,
because of the thermodynamic inefficiency of power generation.

• Electric heating requires very high power draws that would substantially increase the
electrical infrastructure costs of the site.

• Electric heating apparatus is expensive, requires high maintenance, and must comply with
stringent safety requirements when used in areas where flammable materials may be present.

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• Electric heaters are intrinsically less safe than steam systems. The maximum temperature
that a steam heater can reach is the temperature of the steam. The maximum temperature of
an electric heater is determined by the temperature controller (which could fail) or by burn-
out of the heating element. Electric heaters therefore have a higher probability of
overheating.

Electric heating is more likely to be attractive in small-scale batch or cyclic processes,

particularly when the cost of heating is a small fraction of overall process costs and when the
process calls for rapid on-off heatin

Steam

Boiler feed water at high pressure is preheated and fed to boilers where high pressure steam
is raised and superheated above the dew point to allow for heat losses in the piping. Boiler
feed water preheat can be accomplished using process waste heat or convective section
heating in the boiler plant.

High pressure (HP) steam is typically at about 40 bar, corresponding to a condensing

temperature of 250 ºC, but every site is different. Some of the HP steam is used for process
heating at high temperatures. The remainder of the HP steam is expanded either through let-
down valves or steam turbines known as back-pressure turbines to form medium pressure
(MP) steam. The pressure of the MP steam mains varies widely from site to site, but is
typically about 20 bar, corresponding to a condensing temperature of 212 ºC. Medium
pressure steam is used for intermediate temperature heating or expanded to form low
pressure (LP) steam, typically at about 3 bar, condensing at 134 ºC. Some of the LP steam
may be used for process heating if there are low-temperature heat requirements. Low
pressure (or MP or HP) steam can also be expanded in condensing turbines to generate shaft
work for process drives or electricity production. A small amount of LP steam is used to strip
dissolved noncondensable gases such as air from the condensate and make-up water. Low
pressure steam is also often used as “live steam” in the process, for example, as stripping
vapor or for cleaning, purging, or sterilizing equipment. When steam is condensed without
coming into contact with process fluids, the hot condensate can be collected and returned to
the boiler feed water system. Condensate can also sometimes be used as a low-temperature
heat source if the process requires low-temperature heat.
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Hot Oil

Circulating systems of hot oil or specialized heat transfer fluids are often used as heat
sources in situations where fired heat or steam is not suitable. Heat transfer fluids and
mineral oils can be used over a temperature range from 50 ºC to 400 ºC.

The most common situation where a hot oil system is used is in plants that have many
relatively small high-temperature heating requirements. Instead of building several small
fired heaters, it can be more economical to supply heat to the process from circulating hot oil
streams and build a single fired heater that heats the hot oil. Use of hot oil also reduces the
risk of process streams being exposed to high tube-wall temperatures that might be
experienced in a fired heater.

Hot oil systems are also generally favored over high pressure steam in processes that involve
high pressure differentials between the process stream and high pressure steam. Hot oil
systems are favored in this scenario because of safety concerns. If the steam were to leak, the
pressure drop could cause serious safety issues.

The cost of the initial charge of heat transfer fluid usually makes a negligible contribution to
the overall cost of running a hot oil system. The main operating cost is the cost of providing
heat to the hot oil in the fired heater or vaporizer. If a pumped liquid system is used then the
pumping costs should also be evaluated. The costs of providing fired heat are discussed in
Section 3.2.2. Hot oil heaters or vaporizers usually use both the radiant and convective
sections of the heater and have heater efficiencies in the range 80% to 85%

Cooling water:

Cooling water is used to cool and/or condense streams. Cooling water is usually circulated
between process heat exchangers and a cooling tower.

When heat must be rejected at lower temperatures, below about 120 ºC (248 ºF) (more
strictly, below the pinch temperature), then a cold utility stream is needed. Cooling water is

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the most commonly used cold utility in the temperature range 120 ºC to 40 ºC, although air
cooling is preferred in regions where water is expensive or the ambient humidity is too high
for cooling water systems to operate effectively. If a process stream must be cooled to a
temperature below 40 ºC, cooling water would be used down to a temperature in the range
40 ºC to 50 ºC, followed by chilled water or refrigeration down to the target temperature.

Natural and forced-draft cooling towers are generally used to provide the cooling water
required on a site, unless water can be drawn from a convenient river or lake in sufficient
quantity. Sea water, or brackish water, can be used at coastal sites and for offshore
operations, but if used directly will require the use of more expensive materials of
construction for heat exchangers (see Chapter 6). The minimum temperature that can be
reached with cooling water depends on the local climate. Cooling towers work by
evaporating part of the circulating water to ambient air, causing the remaining water to be
chilled. If the ambient temperature and humidity are high, then a cooling water system will
be less effective and air coolers or refrigeration would be used instead

The cost of providing cooling water is mainly determined by the cost of electric power.
Cooling water systems use power for pumping the cooling water through the system and for
running fans (if installed) in the cooling towers. They also have costs for water make-up and
chemical treatment. The power used in a typical recirculating cooling water system is usually
between 1 and 2 kWh/ 1000 gal of circulating water. The costs of water make-up and
chemical treatment usually add about $0.02/1000 gal.

Refrigeration:

Refrigeration is needed for processes that require temperatures below those that can be
economically obtained with cooling water, i.e., below about 40 ºC. For temperatures down to
around 10 °C, chilled water can be used. For lower temperatures, down to −30 °C, salt brines
(NaCl and CaCl2) are sometimes used to distribute the “refrigeration” around the site from a
central refrigeration machine. Large refrigeration duties are usually supplied by a standalone
packaged refrigeration system

Vapor compression refrigeration machines are normally used, as illustrated in Figure 3.5.
The working fluid (refrigerant) is compressed as a vapor, and then cooled and condensed at

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high pressure, allowing heat rejection at high temperature in an exchanger known as a
condenser. Heat is usually rejected to a coolant such as cooling water or ambient air. The
liquid refrigerant is then expanded across a valve to a lower pressure, where it is vaporized in
an exchanger known as an evaporator, taking up heat at low temperature. The vapor is then
returned to the compressor, completing the cycle.

The working fluid for a refrigeration system must satisfy a broad range of requirements. It
should have a boiling point that is colder than the temperature that must be reached in the
process at a pressure that is above atmospheric pressure (to prevent leaks into the system). It
should have a high latent heat of evaporation, to reduce refrigerant flow rate. The system
should operate well below the critical temperature and pressure of the refrigerant, and the
condenser pressure should not be too high or the cost will be excessive. The freezing
temperature of the refrigerant must be well below the minimum operating temperature of the
system. The refrigerant should also be nontoxic, nonflammable, and have minimal
environmental impact.

A wide range of materials have been developed for use as refrigerants, most of which are
halogenated hydrocarbons. In some situations ammonia, nitrogen, and carbon dioxide are
used. Cryogenic gas separation processes usually use the process fluids as working fluid; for
example, ethylene and propylene refrigeration cycles are used in ethylene plants.
Refrigeration systems use power to compress the refrigerant.

The operating cost of a refrigeration system can be determined from the power consumption
and the price of power. Refrigeration systems are usually purchased as packaged modular
plants and the capital cost can be estimated using commercial cost estimating software.

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 CONSTITUENTS OF PAINTS:
1. Pigments: Pigments are various inorganic or organic insoluble substances which are
widely used in surface coatings. The most important properties of pigments are opacity,
good covering power, mixing ability with oil, chemical inertness, non-toxicity or low
toxicity, high hiding power, high tinting strength and reasonable cost. They protect the
film by reflecting the destructive ultra violet light, to strengthen the film.
2. Extenders or Fillers: They are used for decreasing the cost of paint and to supplement
the pigment in increasing the covering and weathering power of the film. Extenders
improve consistency, levelling and setting of the paint. E.g. Talc, china clay, gypsum,
silica, barite, glass flakes, asbestos and anhydrite etc.
3. Film forming materials: The vehicle or film forming materials plays dual role as carriers
for the pigments and as formers of protective films. Reactive oils containing olefinic
unsaturation are used as vehicles. These are usually called drying and semidrying oils,
depending on degree of unsaturation. E.g. Linseed oil, soyabean oil, tung oil, talc oil,
castor oil, varnishes, casein, fish oil etc. These oils form a protective film through
oxidation and polymerization of the unsaturated constituents of the drying oil.
4. Thinners or Diluents: In order to dissolve film forming material and to thin concentrated
paints for better handling as well as brushing thinner is added. It is also used to suspended
pigments. Diluents or thinners may include aliphatic or aromatic naphtha fractions or
many contain turpentine. Solvent such as turpentine in spite of its low volatility,
maintains the fluidity of the freshly applied film for reasonable period of time.
5. Resins: Resins are required for water base paints contain no oils and depend on vinyl
acetate, acrylic or butadiene styrene polymer resin as the film forming materials.
Varnishes are also, used in the form of natural or synthetic resins. Examples of natural
resins are copal or rosin, while that of synthetic resins are urea formaldehyde, acrylate,
vinyl or silicone resins. Laquers also contain nitrocellulose as the resin constituent.
6. Plasticizers: Plasticizers, low melting solids or liquids of low volatility which provide
elasticity to the film and thus prevent cracking of the paint. Chemically, plasticizers are
mostly esters. Triphenyl phosphate, dibutylphthalate and castor oil etc are used as
plasticizer.

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7. Binders: Binders act to fix the paint on the coated surface and provide tough, tenacious
and glossy film on the surface being painted.
 Paint Manufacturing Process:
Required amount of ingredient along with pigments and vehicles are mixed in mixer which
is usually high speed disperser. The basic operation in the manufacture of paint is the
dispersion of pigment particles (often mixed with extenders) in a paint vehicle or medium to
produce uniform, stable system. The process of pigment dispersion essentially consists of
wetting, dispersion and stabilization of pigments and extenders in vehicle. The dispersion
involves breaking down bigger aggregates and agglomerates to smaller units, wetting of
these units and particles by the paint medium and stabilization of the

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1. Discuss economy in soap manufacturing process ?
Ans:

 The vacuum still uses the steam from triple effect evaporator thus reducing the make
up steam in the still.
 Good amount of glycerin is produced as a byproduct which is sold in market.
 Fatty acid is also taken out as a marketable product. These fatty acids find use in
manufacturing cosmetics, beauty products etc.
2. What are the byproducts of sugar industries ?
Ans: Bagasse, filtercake and molasses.

3. Sizing effect:
In Paper making fibre have strong tendency to interact with water due to hydrophilic nature
of cellulosic fibre. The process which imparts resistance to water penetration is called sizing
process. Sizing makes the fibre surface water repellent by using chemical additive. In
unsized paper liquid tends to spread out on the surface of paper, and the process is called
“feathering”. Various sizing agents like rosin, paraffin waxes, wax derivatives, wax
emulsions and synthetic sizing agents like alkyl ketene dimer (AKD) and Alkenyl Succinic
anhydride (ASA) are being used to make paper reasonably hydrophobic.

Requirement of good internal size:

 The size must be readily available and chemically stable

 It must be possible to add in a form that ensures good and even distribution across the
papermaking fibres
 The size must be retained in the wet end
 The molecules must orientate themselves so that the hydrophobic end is away from the
fibre
 The size must be sufficiently hydrophobic so that sizing is achieved in cost effective
manner
 The size must not cause unacceptable problem in paper and board manufacture
4. Alkaline Sizing

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5. What are the two different type of meachine in paper manufacturing process?Write
the difference between the two

 Cylinder Mould Machine differs from Fourdrinier machine by replacing

Fourdrinier wire part by cylinder mould part
 In general, fourdrinier machines are good for producing a web of the
same type of fiber throughout, while cylinder machines are good for
producing a multilayer web.
 An important quality issue is the higher fiber orientation produced by
the cylinder machine compared to the fourdrinier.
 While the paper from fourdrinier paper machine has much better performence,
but the cost for setting up this machine is much higher. It can reaches two to three
times of cylinder paper machine, thus cylinder paper machine is mostly used for
making tissue paper and towel paper, because normally these paper don't need
very good physical performence. Fourdrinier paper machine is used for making
all kinds of paper and the paper will have much better physical performence
 In terms of tensile strength, the difference in vertical and horizontal tension of the cylinder
mould paper is much larger than that of the fourdrinier paper.
 In terms of the smoothness of the two sides, the cylinder mould paper is generally larger
than the fourdrinier paper.
 .In terms of uniformity, cylinder mould paper is generally worse than fourdrinier paper.
 Cylinder mould paper is generally more diseased than fourdrinier paper, which is prone to
dust, pulp, warping, and brittleness.
6. What is the different route for alcohol production?
Ans:

 Alcohol from Fermentation of molasses: Molasses is the residue left after extraction of
crystallized sugar and is one of the major byproducts of the sugar industry. Ethyl alcohol
is made from molasses by fermentation process utilizing yeast enzymes.
 Alcohol from Lignocelluloses biomass: All conversion schemes involves following basic
steps:
1. Feedstock harvest, transport and storage
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2. Pretreatment of lignocellulosic biomass
3. Enzyme hydrolysis of cellulose in the lignocellulosic materials to fermentable reducing
sugars
4. Fermentation of sugar into ethanol
5. Downstream processing of ethanol
 Alcohol from starchy feed stocks:
 Petrochemical route via Catalytic hydration of ethylene and Ethylene esterification and
hydrolysis
7. How ethanol is used as a gasoline?

8. What Are The Challenges For Using Ethanol Fuel In India?

1. Ethanol fuel is produced using biomass from agricultural produce thereby having a
high dependency on agriculture.
2. The ethanol fuel industry also faces challenges due to its impact on agriculture and
land use. As farmers will have to clear more lands which will affect the native
wildlife.
3. Ethanol also finds usage in pharma, beverage and chemical industries hence facing
stiff competition from these sectors.

8. What Are The Advantages of Using Ethanol Fuel?

Ans:

1. Ethanol has a higher octane rating than petrol which reduces engine knocking.
2. A high octane rating of 113, ethanol is a high-compression, high-performance fuel.
3. Ethanol contains more oxygen than petrol thereby burning cleaner and greener.
4. Ethanol as a fuel doesn’t break down and leaves fewer to no deposits.
5. Ethanol burns cleaner than petrol and has a cleansing effect on the fuel system.

9. How is degermination carried out?

Ans: To free germs the maize kernels are coarsely ground in mill with cane to avoid oil
leakage from germs otherwise oil will get soaked up with starch granules, which reduce
starch quality. Lighter germs are separated by hydrocyclones.

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          For complete degermination, grinding and degeneration steps are performed twice.
Then the germs are washed, dried and sold for corn oil production.

10.What are the challenges in paper industry?

Ans

 Poor infrastructure
 Too many administrative hurdles, tedious bureaucratic methods
 Poor to non-existent commitment to innovation
 High cost of normal method of financing, recent setback from raising capital through
equity for new companies/ developing projects
 Rising cost of inputs: fibrous raw materials, chemical, labor, energy
 Uneconomic size and obsolete technology in many mills
 High cost of production
 Poor productivity
 Poor instrumentation
 Low availability of forest raw materials and poor forest management
 Poor recycling of waste paper
 Recovery of chemicals from agro-based black liquor
 Decolourisation and detoxification

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11.Hydrogenation of oil:

 Raw material: Oils which is to be saturated and pure hydrogen.

 Functional role of main units:

a)  Hydrogenator:

• Oil is fed to the hydrogenator.

• Hydrogen, and steam is introduced in it.

• The catalyst oil slurry of concentration 5 to 15 kg per ton of oil is also put.

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• The reaction is slightly exothermic so steam is sometimes turned off.

(b)  Deodorizer:

• The hydrogenated oil is now fed to vacuum steam deodorizer.

• It operates in continuous basis.

(c) Finishing

• Oil colour is removed by treating with fuller's earth or carbon.

• It is then filtered, mixed with some vitamins.

• Now the finished oil is sent for packaging and storage.

12.What is the technical difference between Sulfate(Kraft) Process and Sulfite Process?

i) Sulfate process is an alkaline process whereas the Sulfite process is an acidic process.

ii) The pulp has to be bleached more in the Sulfate Process as compared to the Sulfite
process.

iii) For Sulfate process, digestion time is 2-5hrs at temperature 170-176°C and pressure
660- 925kPa whereas for Sulfite process, time required is 6-12hrs at temperature 125-160°C
and pressure 620-755kPa.

iv) Raw materials are less significant and fibers have better strength properties in
Sulfate  process.

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