3618) 2018-19 B.TECH. (AUTUMN SEMESTER) EXAMINATION BRANCH: PETROCHEMIEAL ENGG. COURSE TITLE: Process Dynamies and Control COURSE CODE: PK 411 Maximum Marks: 60 Credits: 04 Duration; Two Hours Answer all the questions. Assunte suitable date if missing, Notations used have theiv usual meaning. Q.No Question MM. eh Discuss the characteristics of first order system for step forcing funetion in the input [5] variable of the system. (col) Se Develop the transfer function for an evaporator, Draw its block diagram and state all [5] the assumptions made in the analysis, How the transfer Runetion will be modified for (CO) tnultiple effect evaporator? OR place ina CSTR. The reactor hold up is [5] 1 (bY) The reaction A —* B (k=0.02/min} take 2000 lites, while the feed rate is 100 lites‘min. The inlet concentration of A shows @ cyclic variation with 2 mean value of 0.01 molllitre and a fiequeney of I sad/min, Obtain um expression for the exit concentration, if the amplitude of the input is 0.001 molllitre. N(s)_ The Armhenius law gives the dependence of the seaetion rate constant k with the [3] reaction temperate T and the energy of activation of the reaction FE, Obiain (COL) Fincarised solution. Further use Taylor's series approximation ta. linearise a seeand order reaction as: rkVC,? Discuss the effect of interaction on step response of two tank multicapacity control [5] YQ system. How the transportation lag parameter can be minimized in the petrochemical (CO2) industry?Daa ease ‘A step change of magnitude 5 is introduced into the nity feedback control systern ‘The second order eomtrol system having the transfer function as- 1/(1.25 +2545) is being contgolled by means of proportional controller having the vulue of gain (Ke =10}. Obtain damping factor and rise time: OR ‘A mercury. filled manometer 3s to be used to meusure the pressure drop across an ofifies meter, The meter will monitor the flow rate of air through a pipe Specifications call for a decay ratio (not damping factor) of 0.3. ‘The maximum pressure differential is such that « liguid column length of 75 em. should suffice Derive the equations used, Find the diameter of suitable glass tubing for the manometer, The specifie gravity of mercury is 15.6 and the viscosity is 1.6 C.P ‘Avinit step change in the etvor is introduced into a PID controller. IF Ke= 10, Integral lime =I, and derivative time= 05, Plot the response of the eontsaller. OR 34a") What are the types of plugs used in pneumatic valves? Discuss the fhetors that affect the selection of the valve type (linear, square rool, equal percentage, and hyperbolic) 3(b) Determine the range of values of k Rot the systems with the following characteristic SY, ssuation to be stable, St+KS?+S*sS+k=0. vy Plot the root locus diagram for the following system andl also determine which values of K make the system stable. Gis)= K (s#2V# t5+3) A) Draw the schematic diagram of cascade control of temperature in 2 jacketed CSTR, where a highly exothermic reaction is taking place Bale to (Fl C02) (10) (C02) 15] (C03) (C03) 15] B) (C03) [5] (cosy contd oe‘Seg Aw Obiain Gy for the system as shown below: bl (con OR 4) Fuel cells are used in space craft for generating power and heal, ‘The cell produces electric power by the reaction between liquid oxygen and liquid hydrogen. [5] 2H24+02—® 2H20, (C04) ‘The flows of bydrogen and oxygen to produce 0.5 kg/hr of water. The eontrol scheme should manipulate the flow of oxygen to maintain the required wanio. The transmission signals are linear with respeet to the rates, Caleulate ‘the Tange for the transmitters, 4(6) Describe briefly any vo the following: 5] (Discrete Lime model ofa second order process (COMy Gi) Samplers and hold elements iii) Supervisory control2018-19 (AUTUMN SEMESTER) Code: 3619 B.YECH, (VI SEM.) END-TERM EXAMINATION PETROCHEMICAL ENGINEERING PLANT DESIGN AND ECONOMICS PK-d3i Maximum Marks: 60 ‘Credits: hd Duration: 2 Hours Attempt alt the four questions fimarks will be given for steps). Assume suitable dada if missing. Use of basic ealeutatars is allowed. Q.No. Question MM. Monochlorobenzent is prosiuced by the reaction of benzene with ehlorine. The reaction (13) Produces a mixture of monochlorobenzene and dichlorobenzene, with a sinall amount of \richlorebenzene. Hydrogen Chloride is produced as a by-product, Benzene is fed to the reactor (O41, inexeess to promote the production of manoghlorobenzene, The reactor products are fed to a condenser Where the chlorobenzenes and unreacted benzene are condcused, The condensate is separaed ftom the non-condensable gases tra Separator. The non-condensuble gases, hydrogen chloride and unneacted chlorine, pass an absorption column where the hydrogen chloride is absorbed in water, The ehlorine av ing tho absorber is recycled to the reactar, The Liquid phase from the separator, containing chlorobenzenes and unreacted benzene, is fed to a distillation column, where the chlorobenzenes are separated {rom the unreacted bearene, The benzene is reeyele ty the reactor Using the date given below, caloulets the stream flows and draw up.a preliatinary low- Sheet For the production of 1.0 tonne (metric ton) of monachlorobenzcne per day, Data: Reacior Reactions; Cellg + Cl SHsCl+ HCI Cols + 2Cha > Catla Cla + HCI Mole ratio Cl> : Celie, at inlet to reactor = 0.9 Overall conversion af benzene = 35.3% Yield of monochlorobenzene = 73.6% Yield of dichlorabenzene = 27.3% Production of other chlorinated! compounds can be neglected. Separator Assume 0.5% of the liquid stream is entrained with the vapor. Absorber Assume 99.99% absorption of Bydrogen cliloride, and that 98 per eemt of the chlorine ts fecycled, the remainder being dissolved in the water. The water supply to the absorber ie set to produce « 30% ww strength hycrochlosie acid Disitlation coftmn Take the recovery of benzene zo be 95 jer cent, and 99.99% recovery of the ghlorvbenzenes ‘Mote; Start the material balance at the resetor inlet (afier the recycle stzeums have been addled ) and assume 100 kmol/h of benzene at this point, contd2a) 2b) 2b") ue) 2d) 3a) -u- Code: 3619 Suy, the purchased cast of a glass-lined jacketed reactor with volume of 1.5 min August 2017 [3] / ‘was 20,00,000, Estimate the purchased cost af a similat reactor with volume of 0.5 min July 2018, Make use of tables given at the end jp obtain relevant data. Make a study estimate of the fixed capital investment for a process plant if the purchased — [4] equipment cost is Rs, 80 lakh. The plant requires high degree of automatic controls, (02 OR In few semtences describe the following: 4] 3, Breakeven point ii, Time value of money COL iii, Minimum acceptable rate of return iv. The basic conditions in a banking transaction that makes it ‘Islamic? Answer any one of the fallowing problems: (3) G) A company has direet production costs equal to 50 percent of total annual sales, and fixed (7 charges, overhead, and general expenses equal to #1,50,00,000. Lf management proposes to increase present annual sales of €6,00,00,000 by 25 percent with a [8 percent increase in fixed charges, overhead, and general expenses, what annual sales amount is required to provide the same gross carnings as the present plant operation? What would be the net profit if the expanded plant were operated ut full capacity with an income tax on gross eamings of 30 percent? What would be the net profit for the enlarged plant if total annual sales remained at '26,00,00,0007 What would be the net profit for the enlarged plant if the total annual seles actually decreased to %5,00,00,0007 (ii) Suppose 2 manufacturing company purchases a machinery for %80,00,000 snd the useful life of the machinery are 3 years and the restdual value of the machinery is $20,00,000. Calculate the depreciation charges {or each year using Double cclining Balance (DDB) methed. (iii) In the design of a chemical plant, the following expenditures und revenues are estimated afier the plant has achieved its desired production rate Total capital investment = 275,00,00,000 Working capital 28.00,00,000. ‘Anmual sales £60,00,00,000/yr ‘Annual expenditures 17,00,00,000/yr ‘Assuming straightline depreciation over a {0-year project analysis period, determine: the relurn an the investment aftcr taxes; and the payback peried Acash flow consisting of %8,00.000/- per year is received in one diserete amount at the end of [3] cach year for 10 yeass. Interest wil be at 8% per year compounded annually, Determine the 08 present worth at time zero and the dature worth at the end of LO years of this cash flow Answer any one of the following: (3) i. Draw and describe a typical characteristic curve of a centrifugal pump “03 Provide a basic guideline for preliminary sclection of pumps with help af'a Head vs. Capacity plot iii, Provide a busie guideline for preliminary selection of compressors with help ofa Head vs. Capacity plot iv. Discuss general guidelines in selection of separstion process for homogenous mixtures. combed +Code: 3619 G@) Enlist the design considerstions for selection of reactors. Also, write some general rules [6+4] of thumb of selecting appropriate reactor for a given reaction, C02 (ii) With help of a flowchart discuss the general methods for design of heat exchangers. OR A heat exchanger is required for cooling gasoline with a Now rate of $.0-Kg/s and a pressure [10] of 4 MPa, Gasotine, with a heat eapacity of 2.22 kiikg-K, enters the exchanger at 65°C and ty leaves at 35°C, Water, with a heat capacity of 4.2 kJ/ka-K, serves as the coolant and eatexs the exchanger at 25°C with a flow rate of 2.5 kgs, Evaluate the alternative heat exchangers listed ina Table attached herewith, and make a preliminary selection based an exchanger suitability and economies. What do you understand by the following in i) objective fimetion; ii) decision variables; ards to process optimization: B)coz ) dependent variables A vinegar-making company has received an order for 500 litres of vinegar with the consteaints thal the vinegar must contain > peicent acetic acid by volume, and it must be supplied immediately. The company wishes to fill the order, but does not have 3 percent vinegar in stock. {is decided to mix two vinegars now in stock to give the desired final product. One of the vinegars in stock (vinegar A) contains 3.5 percent acetic acid by volume and is valued at 24010 per litre. The other vinegar in stock (vinegar B) contains 2.7 percent acetic acid by volume and is valued at 2350 pertitre. Water can be added to the blend at no cost, What volume combination of the wg vinegars in stock with water, ineluding at least $0 lites of vinegar A, Will give the minimum ingredient cost for the 500 litres of 3 percent vinegar? OR A plant produces automotive diesel a the rate of, barrels per day. The variable costs per 15] Cag barre! have been established to be $27.73 + 0.1 P!?. The total daily fixed charges are $1850, and all other expenses are constant at $8325 per day, Ifthe sclling price of the diesel per barrel is $208, determine: a, The daily profit at a production schedule giving the minimum eost per barvel of diesel b. The daily profit at a production schedule giving the maximum daily prolit ©. The production schedule at the breakeven point (i Deseribe the following with respect to plantwide eomtal: outputieantrolled variables; B+? og, manipulated variables; and disturbance variables Ry (ii) Can all of the output variables af a process be controlled? Give reasons (ii) Discuss on “Degrees of Freedom” and number of manipulated variables permissible. OR The figure appearing below shows a process for the isothermal production of C fiom A and B17] ge (A+B — C). The owo reagents are fed to a CSTR, R-100, where complete conversion of B is assumed. The reactor effluent stream consisting of C and unreucted A is separated in a distillation column, T-100, where the more volatile A is withdrawn in the distillate and recycled, and produet C is withdrawn in the bottoms stream, Your task is to devise a conceptvel plantwide control system for the process Hint: It may be helpful \o reposition the feed stream of A, dootd -sy Code: 3619 sy a o 8 Useful Expressions, Tables and Figures: Alt)" = = ACEO. P=Fa+i- Total Product Cost = Manufacturing costs (Variable product costs + Fixed charges + Plant overhead costs) + General expenses (Administative expenses + Distribution & Marketing expenses + R&D) = Trout Tes Tein a =F ‘eaut — Tein 2=P[(R+1)—- (+ a) 2 4, Lisch tect 8 Oe a gee Ea Waa Yin (gp) Dm = PUR 41) + (R$ I, Oe crak bmae +e ‘eogi07 sealer se ero enced connate eto ails tae ater Sa) DK era ees reed a el trend rend ses ng cacnay Bben Cam ip JOe6 E72) font -og5 Code: 3619 encier,dauble cone ovary, carina sleet (€8.1 Blower, cennifupal slid bole, iver, vacuum bateh, 5. Carmperssor reciprcaling. ait-caoled, Weo-slage, 108F-KPa discharge Compressor: nary. single HNBS-RPi lischarge Dayer. drum, single vaewuns Dryer, dim, single atrmaspesie Van, centstngat Heat exchanger, shell-ana-tale, uatings head, Lent exchaiiger shell-si-tabe, fixed sheat, 6 Ket, castenon, packete wd. jacketed Motor, squintel eage. induetioa. 440-V, explosion ;woot Mor. squtercl cage, induction, 440-V, explasiaa proof Purp, rssisrocating, horizontal eas-inon (includes motor) Pump. censifugal, beriaostal ens steel fineledes moter) Reaciur. plansotined, jackets (wuvhowt drive) Reacans, staintess sil, 2070-4Pa Separstor, cemeifugal ©. Tank, flac head. ¢ Tower. 05. ‘Tray, bubble cap. es, i sighs, 17.1 mn (3H 280405) 85417 cvs 10108 sniny 25-75 OW (TE hyd dive 15-200 m3} (500-Ta00 te) 0.005-0.19 1x" (Lo-noD seeing 01.05-0.5 sn '¥.¢10" 108 Fa) 1m? (10-10) 10 m2 (WOLF HF) 1-160 n? (10716 £2) "Ys (1020 Sain) aoe (2a 17-2 OF Sy 140 m2 (160-100 803 10-40 m? (100-400 $5 128m} (250-K0 pot) 0.8-3 ww (200-800 exh 41S R(S-20 hp) 15-150 EW 120-200 hp) Tx 10 6.010°! mts 2-160.gpm 4-40 nfs kPa (10°—10° gpempsip 0.2-2.2 m¢st600 gar) OAK i? COPANF gay LS Ta (50-250 10) 0.410 m¢Lo—10" gay 04-40 1 (10%10? gal 310710" kg {20"-2 10°10) 1-3 m (3-104) diameter 19 mi -10 69 diame Table Typical percentages of fixed-capital investment values for direct and indirect cost segments for muttipurpose plants co largo additions ta existing taedtition, cl equepment Puccluused-equipinent insealtation Iagnumentation aid santzals (installed) Piping (installed Blecivieal syscems (stated) Buildings (including ser ‘yard impravements rie Legal eapenses Camiracten's fee Cort ee 15000 i zn elt 210 079 76 naa asd aad it 0.060 usd oat 031 0.69 099 034 033 os 036 nay ost i) 092 120 086Code: 3619 rg Dung ono 2pm SRAM 1D PEE CHS RO “Ld MOE RIO OO 29/182 era "EAE LAT RUE soaouecy pe weer meron 2310249 lg paral wtp ON FOYAN, ‘Wisap parnscpars| ‘onzanves ap aa ap oan “uouse(SF 29 26) 25 JOANN ose, uO DIRE peony sop Huor ‘adit Kop oscovdn Woe 2-0 _E ines ys rend sauuin 008 —0L0- wep "stuajoapeade 98007 PHEW — GOD qoove-or —VMMos—ore- GEE sou vopnnsuns (0 ayaa avo} ‘=iqutapy Pre O57 1 ost os qm minds “Pry bopoansun eae ‘025 JO] Pape ocean cocesdn z ares FES sano ring wesnieg dy wose- 1 oors e sree Pepa wsoo Fars years ‘vopnsuso poy nse SLL- t= stro amd yee suiasksuon sagas 04 to rayysistin som 0 Sues spe o-z cone ody toe iesepalens, sath eeur “2ygedepe an +09 = 00e— of acer puEIPAS ero =e aa, (uae) 0 adW-apnect Se Pod, sents sump 7edh soGueyae jeay meudardde sip Jo UaRDe/os Krmywyaad off 20) BBLS ae) pelieyTable Approximate design vakios of overall hnaLiranster eeotficients Puc fetoninr valuesef ove bccrtanafercenfiet tic are based primarily on raul wbsacT in andinoy fusinecring pracies, The values ane spprutuate Beraase variilon bn fhild ilotien sonun) pancondewinhte pate, vinvosiien elrantinenr cf Wateranierwafaten ype tp halen vgerodarer sear nel sill icons con love w sleuifcaae effect ox the averotf Reattrvsfercogffusonts The values one ‘sehfor pret aary desig essen ox for nnugh checks on hea-inoferaleubutann Pe agp range rf veal coagiciens given for cowders wy abi be used for condensers, while she epee anys af everatt eects piven for heater a2) lem be 4sed for crupwreane icin Taw Wace 3 Mathanol water 2 Ammonis Water 2 Acs weer 1250-2500, 2 Lighcorsiics Water 375-750 6 >ediomargancs? Water 250 900 6 dMeavy ones Water 2-475 5 Ges ‘water 10-256 5 Brine $00 1040, 6 ‘organics ane 200 a0 5 Heners Stes Water 1000 ~ 3800 zeiet Metbanat 10g —35n9 Beto ‘Acoma 1009 = 350, Be ‘Agaeous seta #26 10%Pes nu -3500 we2x Pos S00 3509 Steam Ligh organist 001000 Steen Medium osganisst 50 S00 Stes Heavy organs? 30-300 Steam Green 25-250 Usility tit fez. Dewitermy —Casea 20-200 ity uid Ce. Downer) Heavy engnicat 30-300 Exchangers (0 phoee cbange) wt oer teca— 2550 ‘Aqacous solutions Aqueoussolutions ——1400— 2850. Lightorganics! Light ogganica* Medium organics ‘Mecinm oganlest Hexvy oiganies! Heavy organic! ‘cary organics! Heavy erganiont [Tipdewratons thoueCa,gasclin, ght hols kecoocicsqa 283 ¥ 15> Poa [Absisber flat gn ol. tase, and Uphteradea:O8 ie 10" © Ae 28 x 10- "Rs est wi ol al ole gino, heany sf need eta: 28 0 pe 1D Pe Cartel a Cade: 3619ones we Chan ning eoriest mesa tenperause-aiereuse diving force for an / i i i ‘Ectanger wih one theless andlien er roe 1 bre imerchangeabsel Coswctron fact Fc based On th Tag ey oe COME Pow. FF fees tan 7 operation of heexchaager tay tt be pracical omen fa cores tsi F led aa Thwart? w Figure “Ternpereture driving fone covreetion facts for crussflow heat exchas- (one shell puss, one cr enore parallel sows of tubess opewu shell passes, nwo rows OF Lbs (for more Chan Gwe passes, uEe F = 1): (6) ame shell pass, book (uids umuixed. (Pan are inirchangeable) Cade: 3619 cantd veel—~4- sees? Pitire -Puschsed cost of ipl pips hea exchangers Figure Purchased cost af U-tubeheatexchungerswithO.0254-m (In) ODeabes 0284-41.) apr pc ae hey (6-40) hurls opcrting st [036 KPa (180 pls) Code; 3619020) 2018-19 B, TECH, (AUTUMN SEMESTER) EXAMINATION PETROCHEMICAL ENGINEERING ROCHEMICAL TECHNOLOGY IL PR-A32 Maximum Marks: 60) ‘Cremice: O4 Durution: Two Hours Auasiver al questions Assunte steteible deat if missing. Notations and spmbots used huve their sesiol miwevring. Question co MM, -muulsification is done in the eumene oxidation seaetor during phenol «CO1) [ony turing process? Nb) Phenol isa white __(erystalline/amorphaus) solid material at (C01) on) soon temperature Ve) What are the main applications of phthalic anhydride? won 02) Aa) Why is vacuum distillation required for maleic anhydride refining? Explain (C01) (06) with the help of a pracess Now sheet, how maleic anhyuride is manufactured? OR 1(a") Elaborate how styrene is produced from ethylbenzene? Also drawa neat — (Caml [05 and clean flow shee! far the process. Ife) What are the basie feedstocks of 2 petrochemical industry? Briefly explain (CO!) [03] atleast Iwo processes by which they can he produced 2a) Match the following: (C02) [e3) LTPA p. Esterification IL DMT 4g. Orthopedics HL MMA, 1, MOBIL process Ab) What are the various routes of manufacturing terephuhaiie acid? Briefly i851 explain each of them OR 240) With the help ofa neat and clean process Now sheet, explain AMOCO (COB) tos} process Condel ov-2240) 3a) stb) ey Sud) 3) 4a) ib) ae) Aud) Mention some important uses of: i) Dimethyt terephthalate ii) Methy! methsers Weite a short note om the catalysts used jn olefin polymerization. Differentiate between: i) Polyethylene and Polypropylene i PP-homopalymer and PP-copolymer Note down the applications of ANY TWO of une fallow iy pve i HDPE iii) LLDPE With the help of a neat agcbeteaa process flow sheet explain the Unipal process of manufacturing paly propylene OR Explain how the presence of pheny! group(-Cols) is key to the properties of polystyrene"! Draw a process flow sheet for the manufacturing prices of PVC. What ure elastomers? How ancl why vulcanization 4Fnatural rubber is done? Differentials between the following (ANY TWO}: i) ABS and styrene Epoay resins and unsaturated polyester resins iii) Natural Rubber and Synthetic Rubber Draw the chemical structure of the follewing: i) Aerytonitrite ify Nvton 6 Write Short noles on ANY TWO of the folknwing i) Natural Rubber iSDR Nylon @ «co2y (com COR} (cosy (cosy (cosy (coy, (coy (cosy 3620 jaa [02] {o4) fo] (os) [ost [03] (04) [02] 106]Hat) 2018-19 ECH, (AUTUMN SEMESTER) EXAMINATION PETROCHEMICAL ENGINEERING POLYMER SCIENCE AND TECHNOLOGY PK-433, Maximum Marks: 60 Credits: 04 Duration: Two Hours, Answer all questions. Asstine suitable data if missing, Notations and symbols tsed have their usval meaning. QNo. Question co MM. 1(a) Explain the mono functional atid trifinetional reactions af phenol. (con (0s) 1(b) Write the kinetic expressions for self-eatalysed and estemally catalysed (CON [05] polyesterification reaction and state which type of reaction is faster with Justificatian, 16) Show the ¢feet of temperature, pressure, plasticizer content and molecular vcight on (COL) — [05] viseomettic plot of polymer with the help of'a graph (1115. 7) 2a) Differentiate between the Free Radical Chain Polymerization and Paly- (CO2) [05] Addition reaction of styrene monomer with the help af reactions involve in both types of polymerize or 2a") What do you mean by average kinetig chain length? Drive the expression for (C02) [05] it 2¢b) Caleulate the feed mio (1) of Adipic acid (AAJ and Hexamethylene diamine (CO2) [05] (HMD) that should be used ta get polyamide 6,6 of molecular weight 15000 at p= 99.5 and 100% conversion, oR . eantel2b") Xe) 2e) Bay aa") 3b) 3th) 30) in a DSC experiment it was found that the area under the melting peak corespands to heat of fusion (Af4p) 125.0 Jig. W the pereentage erystallinity (96 Xe) of sample is 50.0%, calculate the heat of fusion oF [00% crystalline polymer 7). What do you mean by photo-depradation of polymer? Name and explain the role ofa photo-stabilizer with the help of photo-stabilization reaction OR Derive the following relationship for step polymerization reaetion: Ry = K.Ks1CGOH|-(HAL OH] Also explain the assumptions for above relation, Drive the Maxwell's equation for viscoelastic materials, Also explain the practical significance of relaxation time (2). OR Write down the cquation for “Shear Stress Profile” and “Velocity Profite” for flow of polymer melt in a circular capillary alang with the description of nomenelsnure. What do yout mean by the “Glass Transition Temperature (Tey" of polymer? Briefly mention various structure factors affecting glass wansition lemperature of polymers. OR Ina shealogical experiment the following data was obtained for a fuid; Strain rate (7 0 100 a0 10000 [Scar Stress (MPa) «| IS4ATS4 | 15488.166 | 1.02 x10 | 6.76% 105 | (. Caleulaie the power law index (i) aid viscosity (1) Gi), Deseribe the type of fluid, Name the viscoelastic model represented by the series combination of dasipgt teen) (coz (02) «cor, (C03) «o03) (c03) (03) (05) (5) f03]) [051 105) 95](reeyy as shown in figure below. Also calculate the rela; and spi i time (2) for lis mode. OR Me") What do you mean by crystallization of polymers? Does it change or rematn (CO3) [03] a5 itis during polymer processing? Atal What do you mean by process i OF polymer? Write the name of any six (COA) [M5] polymer processing technique with the examples of products that can be produced by those techniques, 4h) Drave & neat and clean diagram of plastisizing screw and briefly explain the (CO4) [05] ‘erms helis angle, fight, compression rate, channel depth and pitch. Me) Draw a neat and clean diagram of Blown Film Exarusion Line and explata the (CO4) fos} funstions of followings i, Breaker Plate and Sereen Pack ii, Corona discharge treatitent