(2907) 2019-20 B.TECH. (AUTUMN SEMESTER) EXAMINATION PETROCHEMICAL ENCANEBRING 7 Process Dynamics and Control COURSE CODE: PK 411 ‘Maximum Marks: 60 Credits: 04 Duration: Two Hours Answer all the questions. “Assume suitable data if missing. Notations used have their usual meaning. QNo. SE: 1(@) The liquid is heated in tank using saturated steam: flowing through 2 coll immersed in the iquid, Develop the transfer function ofthe system which has eapacity to store thermal energy. oR (a) / Develop the transfer function for aliquid-in-glass thermometer. What isthe time constant of thermometer? Draw the block diagram of the thermometer DI Explain the following with the help of examples: ’) Pure capacitive system and ii) Instantaneous processes aE approximation to estimate (2.001)% oh ‘A thermocouple witha time constant of 2 seconds is used to measure the temperature “ofan ar steam which is varying sinusoidally Ifthe indicated temperature is found to ‘oscillate between 50 °C and-30 °C with a oyele time’ of 36 seconds, calculate the agfal maximum and minimum temperatures of the air stream. Assume, steady state feain to be vnity. jscuss the response of a first order lag to a unit impulse input. Write the expression for the calculation of dynamic error and time lag. OR b) MM. (6 (col) (343) (con, 1) (col) (9) (02) (6) (C02) d contd 2ee (2907) es A process can be approximated by three first order lags in series with the time (6) ‘constants of 1, 2.and 5 seconds, and a gain of 1 unit. What is the transfer function of (CO?) the process? Obtain ¥(0) and Y(#). af With the help of an example (a thermometer with a metal bulb) explain the inverse BI response behaviour. Draw its block diagram. (co2) Disouss some ofthe factors you should take into account before deciding whether fo [6] a os close oF ait to open pneumatic control valve. Draw the flow expacity z (cos) characteristic curves for various valves. ago, _eletronic proportion conole has n innit ne of 4 mA to 20mA, and an 1g) Noe output range of 1V to SV. Fora change of 4A in the input determine the change in the output ifthe proportional band is 40%. (C03) OR UP) “Tune a Pl controller for the following open loop transfer function using Ziegler” 6 Nichols recommendations. (C03) G(S)= 11) (0.8541) (0.2841) 3o/ Determine the value of K for which the system with the characteristic equation BI (+1) (S42) Qstl) +5K= 0 remains stable (03) OR a4eyf_ Draw the Nyquist plot of a PID controller. BI (C03) . vk What are the different types of MIMO control systems? Discuss the cascade control [6] block diagram. What are the (C04) advantages of cascade control system over feedback control? oR 4g). What kind of processes stand to benefit the most from feed forward control? How do [6] the feedback controllers are designed for a stirred tank heater at steady state and (cO4) arrangement for a heat exchanger and draw ) dynamic?’ Draw the block diagram for Feed forward temperature control ofa stirred tank heater, : /* Explain in your own words why we need 10 convert continuous to discrete time (31 signals, and vice versa. (cos) (©) Describe any two ofthe following Bel (Supervisory eontrol for single loop and several loops (C04) iy Sampling the oscillating response of system (iy Reconstruction of continuous signal with zero-order hold(2908) 2019-20 B. TECH, (AUTUMN SEMESTER) EXAMINATION PETROCHEMICAL ENGINEERING PLANT DESIGN AND ECONOMICS PK-431 Maximum Marks: 60 Credits: 04 Duration: Two Hours Answer all questions. Assume suitable data if missing. Q.No. Question co 1(a) What do you understand by the following in relation to chemical process design (CO1) and economics? (Process Creation (ii) Development of base-case design (iii) Detailed Design 1(b) Match the following items on the left column to either one of the right column; (CO1) when the demand of a product is temporary better process control low rate of production Continuous Processes hazardous and toxic chemicals same processing equipment can process more than one product speciality chemicals, pharmaceuticals, electronic materials, etc commodity chemicals, petroleum products, plastics, etc. Batch/Semi-Batch high labour costs Processes uniform product quality when safety is a major concern 1()__ Write any 3 heuristic guidelines for each of the following: (col) 1. Pre-processing 2. Separation train sequencing eel erent MM. [06] [04] (05)(a) 2b) 2b’) 2) 2a) 3(a) 3(b) 3(b’) Draw a tree diagram showing cash flow for industrial operations based on a corporate treasury serving as a reservoir and source of capital. In the diagram, illustrate capital investment, working capital, operating costs, gross and net profits, ete. Suppose a manufacturing company purchases a machinery for %90,00,000 and the useful life of the machinery are 6 years and the residual value of the machinery is €20,00,000. Calculate the depreciation charges for each year using Double Declining Balance (DDB) method OR Describe the methods for calculating profitability that consider the time value of money. In the design of a chemical plant, the following expenditures and revenues are estimated after the plant has achieved its desired production rate: Total capital investment = $15,000,000 Working capital = $ 1,500,000 Annual Sales = $12,000,000 Annual expenditures = $3,000,000 Assuming straight-line depreciation over 10-year project analysis period, determine (a) the return on investment after taxes, (b) the payback period. How Islamic finance concepts are different that conventional banking/finance? Draw and describe a typical characteristic curve of a centrifugal pump. (include curves for various impeller diameters, efficiency, motor wattage, etc.) Answer both the questions: (i) Discuss general guidelines in selection of separation processes for homogeneous mixtures. (ii) Discuss the selection of catalyst in terms of chemical constituency, physical form, support for solid catalyst, surface area per unit mass, diffusion and reaction rates, stability to impurities and degradation, and physical strength. oR A heat exchanger is required for cooling kerosene with a flow rate of 1.0 kg/s and a pressure of 4 MPa, Kerosene, with a heat capacity of approximately 2 kivkg-K, enters the exchanger at 60°C and leaves at 30°C. Water, with a heat capacity of 4.2 kI/kg-K, serves as the coolant and enters the exchanger at 20°C with a flow rate of 2.86 kg/s. Evaluate the alternative heat exchangers listed in a Table at the end of this paper, and make a preliminary selection based on exchanger suitability and economics. (Approximate design value of overall heat transfer coefficient involving kerosene and water maybe considered to be ‘between 375-750 W/m?K) conld (2908) (co2) (co2) (C02) (C02) (C02) (C03) (C03) (C03) 4 ty [05] [05] [05] (01) [05] [10] [10]4(a) 4a’) 4(b) Answer both the questions: () Write few lines about the following related to optimization in your own words: Structural Optimization; and Parametric Optimization (ii) Describe the following with respect to plantwide control: output variables; input variables; controlled variables; manipulated variables; and disturbance variables. OR Willy Wonka has engaged your consultation services to assist in the recipe formulation of a new brand of chocolate bar, weighing 100 g, which he plans to name “Super-choc.” Each chocolate bar contains two types of chocolate, African and Belgian, with the balance consisting of sugar. Mr. Wonka has requested you to define the optimal composition of the new chocolate bar for minimum cost such that the following conditions are satisfied: (a) Each bar should contain at most 60 g of chocolate. (b) The amount of African chocolate in each bar should not be more than 10 g in excess of the amount of Belgian chocolate. (©) The sweetness of each bar, S, should not exceed 30 units. Each gram of African chocolate reduces S by 0.3 units (relative to sugar), and each gram of Belgian chocolate raises $ by one unit. (@) The “mouth feel” of each bar, M, should be at least 40 units. Each gram of African chocolate increases M by 2.2 units, and each gram of Belgian chocolate increases M by only one unit. (©) The “lustre” of each bar, L, should be at least 70 units. Each gram of African chocolate increases L by one unit, and each gram of Belgian chocolate increases L by 3.9 units. An example follows: A bar of Super-choc containing 35 g of African chocolate and 25 g of Belgian chocolate has these properties: S=-03 x35 +25=14.5 M=2.2x35 +25 = 102 L=39+3.9 x 25 = 132 Given that the cost of Belgian chocolate is three times that of African chocolate, and the cost of sugar can be neglected, set up a suitable LP and solve it to compute the optimal mass of each of the ingredients of a bar of Super-choe. The figure appearing below shows a process for the isothermal production of C from A and B (A + B — C). The two reagents are fed to a CSTR, R-100, where complete conversion of B is assumed. The reactor effluent stream consisting of C and unreacted A is separated in a distillation column, T-100, where the more volatile A is withdrawn in the distillate and recycled, and product C is withdrawn in the bottoms stream. Your task is to devise a conceptual plantwide control system for the process. Hint: It may be helpful to reposition the feed stream of A. contd ...-4. (2908) (C04) [02+03) (COS) (C04) (COS) [05} (10)-4- (2908) ‘Useful Expressions and Attachments: P=FA+0)% P=F(L+i/12)! P= (+ i/12) R=1—-(s/c)-!", ROI =Npavg/F, PBP = (V + Ax)/Aj — Ata ea AT o,t09 mean = Taeanjary? Tom = FATo, tog mean Trout = 1-P 2.— P[(R +1) - (R? +1)*?] P= (R24 1)*7In(Gas)/R - on ep) sera are. Purchased cow, $ Suen bPs 80 ps) 3.0) 2 (os ene a 33 Figure Purchased cost of double-pipe heat exchangers. a(2908) Poschased cont Figure Purchased cost of multiple-pipe beat exchangers Pech Figure Purchased cost of U-tube heatexchangers with 0.0254-m(I-in ) OD tubes x 0.0254-m(1-in) ‘square pitch and 4.88-m (16-ft) bundles operating at 1035 kPa (150 psia) Conese(2908) \ oO wo aigeuea nojs0}oot-9——ascondn wo~ sions spay aa4s0000 “1 news ijn aeuado of "uonoanTa09 ss us 008 0Lz- tae9 “aurayosyeane 8307 Jo sfou=neN coooe- or IV UMN 08 012— ort sate sou woran09 araqeus oy ‘31gbHPY Josfeeoneyy ost ose os qin eds se toons angsoni0> “sn025t4 JD Jose oz- ot cocerén z sued raids saw &> spiny uaenuaq dT ee Oor< t reid POPIA. ose | sui-st-- stro amd peer ot oozoren wo~ rea-pades, aqen-puetteas add-on, woRsAnsVo> SPO Jo steuoTE simpy ‘suomi pau(2909) j 2019-20 B. TECH, (AUTUMN SEMESTER) EXAMINATION PETROCHEMICAL ENGINEERING PETROCHEMICAL TECHNOLOGY-IT PK-432 Maximum Marks: 60 Credits: 04 Duration: Two Hours Answer allquestions. “Assume suitable data if missing. ‘Notationsand symbols used have their usual meaning. QNo Question co MM. 1(a) | What are the functions of emulsifiers and cleavage reactors In production of (col) (02) phenol from cumene? 1(b) Mention at least three major applications of phenol and styrene. Note down (CO!) [04] ‘the chemical reactions involved in the production of styrene from benzene. 1(@ Why is vacuum distillation required in maleic anhydride refining? With the (CO1) 09] help of a neat and clean process flow sheet describe how maleic anhydride is ‘manufactured. OR 1(¢°) What is a switch condenser? Explain with the help of a neat flow sheet how (CO1) [09] phthalic anhydride is manufactured. 24a) Explain the various routes for production of Dimethyl Terephthalate. Also (CO2) 05] mention the chemical reactions involved. : 2(b) What are the uses of methyl methacrylate? (coz) {02 2(¢) Mention the different routes for the production of terephthalic acid. Explain (co2) [08] with the chemical reactions involved. OR 2(¢?) Explain in detail the AMOCO Process of) manufacturing terephthalic acid. (C02) [08] 3a) How flexibility of PVC is attained even at low temperatures? (co3) {02} * contd3(b) 3(b) 30) 3c") (a) 40) 4©, 4’) a5 Name a few applications of: i) LDPE i) PVC iii) Polypropylene. Differentiate between: i) Polypropylene and Polyethylene ii) LDPE and HDPE Write a note on PVC. oR What are the major applications of polystyrene? Describe how the pendant group present in the polystyrene structure enhance its properties What are elastomers? Mention the properties that are most desired from a typical elastomer. Note down the properties and uses of natural rubber. Describe the production of SBR with the help of a neat and clean process flow sheet OR How Nylon-6,6 is manufactured? Explain with a neat process flow sheet. (2909) (C03) (C03) (C03) (C03) (Coa) (C04) (C04) [06] [04] (03) {03] (03] (04) [08]2b’) 20) 2") 3a) 3a’) 3(b) 300") ae The DSC thermogram (heating-cooling combined) of an unknown polymer is given in figure below. Name all the peaks in figure. 1474 | | 78.8 I | 4 ae | AP Perel Tomeeraters Explain the GEL effect in bulk polymerization, Suggest method to avoid this, situation. OR What would be the number average and weight average molecular weight of a sample of polyethylene oligomer that consists of 6 mol of hexamer and 10 mol of a decamer? Write the definition of Rheology. Classify non-Newtonian fluids based on their shear stress vs. shear rate relationship. Also state the name of the type to which most of thermoplastics belongs. OR Write down the equation for “Shear Stress Profile” and “Velocity Profile” for flow of polymer melt in a circular capillary along with the description of nomenclature. What do you mean by the “Glass Transition Temperature (Tg)” of polymer? State the factors affecting the Te. OR Name the viscoelastic mode! represented by the series combination of dashpot and spring, as shown in figure below. Also, calculate the relaxation time (?,) for this model. Nssscres & ss0Gre 2919) «€02) (C02) (C02) (c03) (C03) (C03) (C03) (05) (05) (05)30) 3c") (a) 4b) 4) oo (2910) What do you mean by processing of plastics? State the name of processing {05} methods tised for the production of; (i. Electrical cable (ji). Flexible hose pipe (ii). Disposable syringe (iv) ‘Overhead water storage tank OR Explain the relationship of polymer rheology with polymer melt processing. (CO3) [05] Give suitable examples to strengthen your explanation. Write down the name and brief function of parts of a Blown Film Line given (CO4) [05] below. BASIC BLOWN FILM LINE Draw a neat and clean diagram of extrusion screw and briefly explain the terms (CO4) [05] helix angle, flight, compression ratio, channel depth and pitch. Also explain the difference between extrusion and injection molding screw. What is Blow Molding? Explain the working of single stage stretch blow (CO4) — [05] molding ?Maximum Marks: 60 Credits: 04 2911) 2019-20 B.TECH. (AUTUMN SEMESTER) EXAMINATION PETROCHEMICAL ENGINEERING FERTILIZER TECHNOLOGY PK-442A rwo Hours Answer all the questions. “Assume suitable data if missing. “4All questions, and parts thercof, be started on a fresh page of the answer book(s). QNo. 1a) 1(b) 2@) 2@") 2b) 30a) MM. CO Question fos} COl Define fertilizer. Classify fertilizer on the basis of their nutrient content with example, Write down the nutrient content of following fertilizers. () Ammonium sulphate i) Urea i) Muriate of Potash (iv) Triple super phosphate Discuss the role of organic manure and chemical fertilizer. What are the (7) COI advantages and limitations of bio -fertilizers? Develop and describe an integrated process flow sheet for the manufacture [08] CO? of urea, Discuss the problems associated with the urea plant and also suggest some process modifications. oR What are the different routes available for the production of synthesis gas? [08] _ CO2 Draw and discuss a process flow sheet for the production of synthesis gas containing H2 with or without CO. Briefly explain the Contact process for the production of sulphuric acid. [7] CO2 with a neat flow diagram. What is the ammonia to phosphoric acid ratio in the pre-neutralizer and in [10] CO3 pel ae3(a’) 3(b) 4@) 4(b) SL the gramulator for the production of mono and d-ammonium phosphate? Draw and diseuss a neat process flow diagram for the production of ammonium phosphate. OR Desetibe the production of calcium ammonium nitrate using Ne, Hz and HINOs as feed stock Discuss the reason of ealcium carbonate addition. Differentiate superphosphate and triple super phosphate Agronomicaly What are the basic differences in their production process? Differentiate between Compounded fertilizer and Blended Fentilizers Define Antagonism and Synergism of Fertilizer. Wirite the names of four straight Potash Fertilizers, Draw the flow sheet of the production of either sulphate of potash or potassium Nitrate. 2911) {10} [05] {06} {09} cO3 co3 co4 co4(291y 2019-20 B. TECH. (AUTUMN SEMESTER) EXAMINATION PETROCHEMICAL ENGINEERING POLYMER SCIENCE AND TECHNOLOGY oh PK-433 Maximum Marks: 60 Credits: 04 Duration: Two Hours Answer all questions. Assume suitable data if missing. Notations and symbols used have their usual meaning. Q.No. Question cO MM, 1a) Explain the classification of polymers as per (i). Physical State, (ii), Thermal (COL) (05) Behavior, (iii). Polymerization reaction. 1(b), Explain the reasons for polydispersity of polymers. What do you meen by (CO1) [05] polydispersity index (PDI)? 1(6) Derive the following relationship for step polymerization reaction; (COl) [05] Rp= K.Ks [COOH]. [HA]. (OH) Also, explain the assumptions for above relation. 2(a) The fractionation data of a polyethylene sample is given below: (05) Group-> | 1 [ m [om [ ww |v | vi MolWt [280 [420 [532 [616 | 728 | 840 No.ofchain| 5 [9 a a 10 Calculate the number and weight average molecular weights M, and Wc of Polyethylene sample. OR 2a’) Ethylene gas can be polymerized to form polyethylene polymer. Can we (CO2) [05] polymerize the ethane to get Polyethane? Justify your answer. 2(b) Describe briefly evaluation of molecular weight of polymer sample us eryoscopy method. (02) {05} OR Cont. .-D-