MVJCE NEAR ITPB, BANGALORE –560 067

CHEMICAL ENGINEERING

COURSE DIARY (ACADEMIC YEAR 2011-12)

VI SEMESTER

Name : ______

USN : ______

Semester & Section : ______

The Mission “The mission of our institutions is to provide world class education in our chosen fields and prepare people of character, caliber and vision to build the future world”

DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

06CH61 – CHEMICAL PLANT UTILITIES & SAFETY

1 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY SYLLABUS Hours / Week: 5 I A Marks: 25 Exam Hours: 3 Exam Marks: 100 PART A Unit I Introduction: Different utilities, role of utilities in process plant operations and criteria for Selection and estimation of suitable utilities. Water: Water resources, process and cooling water, drinking water and boiler feed water Quality standards. Water treatment processes for drinking, process and boiler feed. Storage and Distribution of water, types and selection of pumps, Piping and accessories. Water pretreatment. Reuse and recycling. 09 hrs

Unit II Air: Compressed air, blower air, fan air. Types of Compressors, vacuum pumps and selection. Power requirements, performance and related calculations. Performance characteristics andselection, boosters and receivers, quality of compressed air for instruments and processes, compressed air distribution system, Piping and accessories. Air water vapour system: humidification/dehumidification and evaporative cooling-related calculations. 08 hrs Unit III Steam and power: Steam generation in chemical plants, types of boilers and waste heat boilers, Fuel types, emissions and global warming, green fuels. Calorific value. Proximate and ultimateAnalysis. HHV, LHV and related calculations. Cogeneration power plants. CHPs and boilerPerformance. Economy of steam generation with different fuels, calculation and estimation of steam storage piping and accessories. 09 hrs Unit IV Refrigeration: Different refrigeration systems, their characteristics, air conditioning systems. Coefficient of performance, power requirements and refrigeration effect- related calculations for each type of refrigeration system. Refrigerant properties and selection. Some commonly used refrigerants and secondary refrigerants. 08 hrs PART B Unit V Insulation: insulation materials & selection- economics of insulation. Insulating factors. Properties & classification. Cold insulation & cryogenic insulation 07 hrs

Unit VI Introduction to process safety: Intrinsic & extrinsic safety. The hazards- toxicity, flammability, fire, explosions. Sources of ignition, pressure. Hazard and risk assessment methods. MSDS. 08 hrs

Unit VII Safety devices: Pressure relief valves, Ruptured discs, Blow down drums, Flare systems, Flame arrestors, deflagration arrestors, personal safety devices, explosion suppression. 06 hrs

Unit VIII

2 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY Process Safety Analysis: HAZAN and HAZOP Comparison. Risk analysis and estimation. Safety checklist. Computer based quantitative risk analysis. 07 hrs

Reference Books : 1. Perrys Hand Book Of Chemical Engg, MC Graw Hill Publishers. 2. B.K.Sarkar, thermal engineering 1. P.K.Nag, power plant engineering 2. Mark J. hammer Jr., water and wastewater technology – 4 th edition. 1. R.K.sinnot, coulson and Richardson’s chemical engineering – vol 6, 3 rd edition 2. K.P.Roy, heat engines

3 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

LESSON PLAN Hours / Week: 05 I.A. Marks: 25 Total Hours: 62

Hou Topics to be covered

01 Different Utilities in Process Plant Operation 02 Role of Utilities in Process Plant Operation 03 Criteria for selection of Suitable Utilities 04 Estimation of Suitable Utilities Water Resources, Process, Cooling Unit 1 05 Above topic Contd. 06 Drinking Water Quality Standards. Storage & Handling of Water 07 Types & Selection of Pumps Piping & Accessories 08 Above topic Contd. 09 Water Pretreatment & Reuse&recyle 10 Compressed Air, Blower Air, Fan Air 11 Types of Compressor & Vacuum Pump Selection 12 Above topic Contd. 13 Power requirements, performance and related calculations. performance Unit 2 characteristics selection, 14 Boosters & Receivers, Quality of Compressed Air for Instruments & Processes 15 Compressed Air Distribution Systems Piping & Accessories 16 Air water vapour system: Humidification/dehumidification and evaporative cooling-related calculations 17 Above topic Contd. 18 Steam Generation in Chemical Plants 19 Boilers & Waste Heat Boilers 20 Fuel types, emissions and global warming, green fuels. Calorific value. Proximate and ultimateAnalysis Unit 3 21 Above topic Contd. 22 HHV, LHV and related calculations. Cogeneration power plants 23 Economy of Steam Generation with Different Fuels 24 Above topic Contd. 25 Calculation and estimation of steam storage piping and accessories 26 Above topic Contd. 27 Different refrigeration systems, their characteristics, air conditioning systems. 28 Coefficient of performance, power requirements 29 Above topic Contd. Unit 4 30 Refrigeration effect- related calculations for each type of refrigeration system. 31 Above topic Contd. 32 Refrigerant properties and selection. 33 Above topic Contd. 34 Some commonly used refrigerants and secondary refrigerants

4 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY 35 Insulation materials

36 Selection- economics of insulation. 37 Insulating factors. Unit 5 38 Properties of insulating materials. 39 Classification insulating materials 40 Cold insulation 41 Cryogenic insulation 42 Introduction to Process Safety –Intrinsic safety 43 Extrinsic Safety 44 The Hazards – Toxicity, Flammability, 45 Above topic Contd. 46 The Hazards – Fire, Explosions,. Unit 6 47 Above topic Contd. 48 The Hazards – Sources of Ignition, Pressure 49 Hazard and risk assessment methods. MSDS.

50 Safety Devices: Pressure Relief Valve, Ruptured Disc 51 Safety Devices: Blow Down Systems

Unit 7 52 Safety Devices: Deflagration, Arrestors 53 Safety Devices: Flare Systems 54 Personnel Safety Devices: Explosion Suppression 55 Personnel Safety Devices: Explosion Suppression 56 HAZAN & HAZOP Comparison 57 Sequence of Operability Study 58 Risk Analysis & Estimation Unit 8 59 Safety Check List 60 Safety Check List 61 Computer Based Quantitative Risk Analysis 62 Computer Based Quantitative Risk Analysis

5 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

QUESTION BANK

01 Explain the role of utilities in process plants 02 Discuss the various types of utilities employed in process industries 03 What are the criteria for selection of suitable utilities in a petrochemical plant? 04 Explain how estimation of water requirements is done in a typical process plant. 05 Discuss the sources of water for a chemical process plant and their storage 06 What are the various methods for pretreatment of water for boiler feed water? Describe any one type 07 Distinguish between fan, blowers and compressors and state the criteria for their selection 08 What is meant by quality of air for instruments and processes? How is it achieved? 09 Discuss in detail about different air compressors with their applications 10 Discuss various types of fuels employed in steam generation. 11 Explain how steam is produced, stored and distributed in process industries. 12 Problem on calculation of fuel requirement for steam raising 13 What are steam traps? How to minimize steam consumption? Explain. 14 Explain the different types of boilers used in chemical industry. How is waste heat recovered? 15 Explain the terms economy and capacity of boilers. What are the piping and accessories used in the transportation of steam? 16 Discuss various types of refrigerants used in chemical industries. 17 Explain the different refrigeration systems and their characteristics 18 Explain the different refrigerant properties. 19 Why insulation is done? Explain the selection of insulating materials with suitable examples. 20 Differentiate critical and optimum insulation thickness. What are the factors to be considered for selection of insulation for high and low temperatures? 21 Define the terms: Hazard, Toxicity, Flammability, Threshold Limit Value, and Accident with appropriate examples. 22 Explain the classification of Hazards and Hazard ratings 23 What is preventive maintenance? Explain. 24 What are the basic preventive and protective measures to prevent hazards? Safety devices 25 Discuss the two types of personnel and safety devices employed in process industries. 26 Explain the various safety devices for relieving pressure. 27 Explain the various safety devices for combating fire. 28 Compare HAZOP and HAZAN. What is the basic information required to carry out the same 29 Give a safety checklist for a fertilizer unit. 30 Write short notes on i. Wet Steam ii. Colour Coding of pipe lines iii. Hazards Symbols iv. HAZAN & HAZOP

6 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

06CH62 – CHEMICAL REACTION ENGINEERING – II

7 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY SYLLABUS Hours / Week: 4 I A Marks: 25 Exam Hours: 3 Exam Marks: 100 PART -A Unit -1 BASICS OF NON IDEAL FLOW: Importance and interpretation of RTD, C, E & F curves and statistical interpretation. Dispersion model. Tank s in series model. Conversion in non-ideal flow reactors for simple systems. 7hrs Unit-II NON-CATALYTIC SYSTEM: Fluid –Fluid reactions and Kinetics . 6hrs Unit-III FLUID PRACTILE REACTIONS: Mechanism and Kinetics . 6hrs Unit-IV CATALYSIS: Introduction to catalysis; properties of catalysts, Estimation methods for catalytic properties, Promoters, inhibitors etc, Mechanism of catalysis. Rate equations for different rate controlling steps. 7 hrs

PART -B Unit –5: DEACTIVATION: Deactivating catalyst . Mechanism, rate & performance equation 6hrs Unit-6 SOLID CATALYZED REACTIONS : Heterogeneous reactions-Introduction, kinetic regimes. Rate equation for surface kinetics. Pore diffusion resistance combined with surface kinetics. Thiele modulus and enhancement factor, Porous catalyst particles, Heat effects during reaction. 7 hrs Unit-7 SOLID CATALYZED REACTIONS (contd): Performance equations for reactors containing porous catalyst particles. Experimental methods for finding rates. Packed bed catalytic reactor, reactors with suspended solid catalyst. Fluidized reactors of various type. 7hrs Unit-8 GAS -LIQUID REACTORS: Trickle bed, slurry reactors. Three phase-fluidized beds. 6 hrs Text Books: Chemical Reaction Engineering - Octave, Levenspiel, 3 rd Edition, John Wiley & Sons-2001. Chemical Engg Kinetics- J. M. Smith, 3 rd Edition, Mc Graw Hill Elements of Chemical Reaction Engineering- H.Scott Foggler, 3 rd Edition,Prentice Hall-2001

Reference Books: Chemical and Catalytic Reaction Engineering- James J. Carberry, McGraw Hill, 1976.

8 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY LESSON PLAN Hours / Week: 04 I.A. Marks: 25 Total Hours: 52

Hour Topics to be covered 01 Importance and causes for no ideality

02 RTD curvesF C E curves 03 Relationship between F,C,E curves 04 Conversion in non ideal flow reactor for simple systems .expression for first order reaction 05 Study of simple parameter models dispersion model 06 Tanks in series model 07 Problem 08 Problem 09 Problems 10 Problems 11 Fluid particle reaction examples different models unreacted core model and progressive conversion model 12 Rate expression for diffusion through ash layer controls ,chemical reaction controls 13 Problems 14 Shrinking core model different steps rate expression for diffusion through gas film controls 15 Rate expression for chemical reaction controls 16 Problems 17 Fluid fluid reactions ,overall rate equation 18 Solubility contacting schemes kinetic regions for massstransfer and reaction cases A to H 19 Derivation of rate equation for case A and B 20 Derivation of rate equation for case C and D 21 Derivation for other cases 22 Definition of film conversion parameter ,kinetic regimes from solubility data 23 Introduction to catalysts 24 Properties of catalysis 25 Mechanisms of catalysts 26 Mechanisms of catalysts 27 Mechanisms of catalysts 28 Rate controlling step and their derivation for finding rates 29 Estimation method for catalyst properties 30 BET method for surface area determination Hour 31 Promoters 32 Poisons 33 Pore diffusion and its importance simple cylindrical pore and first order reaction 34 Effectiveness factor rate equation without and with resistance to pore diffusion 35 Heat effects during reaction within pellets 36 Experimental methods for finding ratyes and mixed reactor recycle reactor

9 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY 37 Determining controlling mechanisms 38 Examples for differential and integral reactors 39 Problems 40 Problems 41 Packed bed catalytic reactor 42 Deactivating catalyst mechanisms 43 Rate and performance equation 44 Gas liquid reactions 45 Gas liquid reactions 46 Trickle bed reactor 47 Problems 48 Problems 49 Problems 50 Slurry reactors 51 Three phase fluidized beds 52 Problems

10 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

QUESTION BANK

01 For the non catalytic reaction of particles with surrounding fluid, discuss various models considered with suitable examples 02 Define effectiveness factor. Derive an expression for the same for pore diffusion controlling first order reaction cylindrical pore 03 Discuss any two adsorption isotherms 04 Define enhancement factor and film conversion parameter. Discuss their significance 05 Write short notes on the following A) slurry reaction kinetics B) BET method for determining surface area of catalyst particles 06 Derive the rate equation for the non-catalytic solid fluid reaction when ash film is controlling and the particle of constant size write all the assumptions 07 What is catalyst poison discuss the different catalyst poison 08 Write a note on catalyst deactivation 09 What are the reasons for non ideal flow, describe E, F, C curves 10 Derive the relationship b/w E, C, F curves 11 Derive the expression for conversion directly from tracer information for a first order irreversible reaction taking place in a real reactor 12 What are the different steps involved in un-reacted core model for spherical particles of changing size also derive the expression for finding t / T when diffusion through ash layer controls 13 For the instantaneous reaction derive the rate equation in terms of gas and liquid film resistances 14 The reaction A+B C+D IS taking place over a solid catalyst. Derive the equation for overall rate when the surface reaction step is slow and rate controlling 15 Explain the concepts of fixed, fluidized and trickle bed reactors with sketches 16 Derive the equation for finding the rate in a slurry reactor 17 Derive an equation for the time required in terms of radius and conversion for un-reacted core model of unchanging size when diffusion through gas film controls 18 Explain the various kinetic regimes for gas liquid reactions as the relative rates for mass transfer and reaction vary from one extreme to the other 19 What is RTD and how it is used to measure the extent of non ideality 20 What are the different methods of preparation of catalyst explain any two of them in detail.

11 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

06CH63 – MASS TRANSFER – II

12 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY 06CH63 – MASS TRANSFER – II SYLLABUS Hours / Week: 4 I A Marks: 25 Exam Hours: 3 Exam Marks: 100 PART- A

Unit I Gas Liquid Contacting Systems : Types, construction and working of the plate and packed columns, Types and properties of industrial packings, Plate effieciencies, HETP and HTU concepts equipment 07hrs . Unit II Absorption : Solvent selection for absorption. Material balance and concept of driving force and minimum solvent rates. Multi stage absorption columns. Design of plate columns, Absorption and adsorption factors. 07hrs

Unit III Packed tower absorption: Liqiud phase hold up and pressure drop in absorption towers.Operating line and minimum solvent flow rates. Design of packed towers(process design –height and diameter).Multicomponent absorption .Absorption with chemical reactions. 06 hrs

Unit IV Distillation : Introduction.Vopour liquid equilibria(T-x-y,P-x-y,H-x-y and x-y diagrams for binary mixtures),relative volatility. Prediction of VLE from Vopour pressure data using raoluts law.VLE for multi component systems.Non ideal systems.Azeotrops.Immisible systems.Stteam distillation. 06 hrs

PART- B Unit V Distillation(Contd): Types of distillation. Flash and simple distillation.Multi stage rectification column.Design using Mccabe thiele Method for binary mixtures. 06 hrs

Unit VI Design of Distillation column: Using Ponchon Savarit method. Efficiencies-overall,local and Murphree plate efficiencies,Introduction to multi component distillation,Vaccum molecular,extractive and azeotrophic distillations. 07 hrs

Unit VII Liquid – Liquid extraction: Ternary equilibrium. Solvent selection.Multi stage cross current,counter current extraction,Equipment for liquid liquid extraction. 07 hrs

Unit VIII Leaching operation :Euipment for leaching .Preparation of solids for leaching.equilibrium diagrams . calculation of single stage and multistage leaching operations. 07hrs

Text Books: Robert. E. Treybal- “Mass Transfer Operation” – 3 rd Edition, Mc Graw Hill, 1981. McCabe & J.M.Smith – “Unit Operations in Chemical Engineering” - 6 th Edition, Mc Graw Hill, 2001.

13 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

Reference Books: Coulson and Richardson – “Chemical Engg Vol I and Vol II”, 4 th Edn Pergemen press, 1998 Badger & Banchero – “Introduction to Chemical Engg”. Tata McGraw Hill, 6 th reprint 2001. Foust et. al – “Principles of Unit Operations”, 2 nd edn., John Wiley, reprint 1994. Geankoplis, C.J.- “Transport Processes and Unit Operations”, Prentice Hall (I), 3 rd . Edn, 2000.

14 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY LESSON PLAN Periods / Week: 05 I.A. Marks: 25 Total Hours: 62

Period Topics to be covered 1 Gas Liquid Contacting Systems : Types, 2 construction and working of the plate and packed columns, 3 Types and properties of industrial packing’s, 4 Plate Efficiencies, 5 HETP and HTU concepts equipment – Distillation, 6 Absorption, Humidification & Drying ,Review of MT-I and 7 brief introduction of different MT-II operations 8 Absorption : Solvent selection for absorption. 9 Material balance and concept of driving force and minimum solvent rates. 10 Multi stage absorption columns. 11 Design of plate columns, 12 Packed tower absorption: Liquid phase hold up and pressure drop in absorption towers. 13 Operating line and minimum solvent flow rates. 14 Design of packed towers(process design –height and diameter). 15 Multicomponent absorption 16 . Absorption with chemical reactions 17 Distillation : Introduction .Vapor liquid equilibria(T-x-y, P-x-y, H-x-y and x-y diagrams for binary mixtures),.

18 Relative volatility. 19 Design of packed towers (process design –height and diameter). 20 Non ideal systems. Azeotrops 21 Immisible systems. 22 Steam distillation 23 Flash and simple distillation. 24 Multi stage rectification column. 25 Design using Mccabe thiele Method for binary mixtures 26 Above topic contd. 27 Problems 28 Problems 29 Design of Distillation column: Using Ponchon Savarit method. 30 Above topic contd. 31 Problems 32 Efficiencies-overall, 33 local and Murphree plate efficiencies, 34 Introduction to multi component distillation,

15 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

Hour Topics to be covered 35 Vacuum molecular, 36 Extractive distillations 37 Azeotrophic distillations 38 Liquid – Liquid extraction: 39 Ternary equilibrium. 40 Solvent selection. 41 Multi stage cross current, 42 Above topic contd. 43 Problems 44 Equipment for liquid liquid extraction 45 Problems 46 Leach ing operation : 47 Equipment for leaching. 48 Preparation of solids for leaching. 49 Equilibrium diagrams. 50 Above topic contd. 51 Problems 52 Calculations for multistage leaching operations

16 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

QUESTION BANK

01 Derive expressions ‘absorption factor’ and ‘stripping factor’ for c-c Operation 02 By means of a plate column, acetone is absorbed from a mixture of acetone-air in non- volatile absorption oil. The entering gas contains 20 mole & acetone and the entering oil contains 2-mole % acetone of the acetone in air, 95% is to be absorbed and the concentrated oil at the bottom of the tower is to contain 12% mole acetone. The equilibrium line relationship is y e = 1.9x e. Determine the number of ideal stages, graphically. 03 Describe the step by step procedure for design of c-c rotary dryer 04 Explain flooding, loading, weeping, coning in a packed tower 05 What are the factors to be considered in the selection of a solvent for an absorption operation 06 Distinguish between a tray absorber and a packed bed absorber. Highlight the advantages and disadvantages over each other 07 Derive an expression for number and overall transfer units for dilute solution in absorption tower 08 Derive an expression for overall height of a transfer unit with individual height of a transfer unit in an absorption considering equilibrium relation is linear 09 Establish the relation between (HTU) L, (HTU) G and (HTU) OG 10 Distinguish Between: i. Absorption and stripping factors, ii. Tray absorber and packed bed absorber 11 H2S concentration is to be reduced from 2.5% by volume to 0.25% by volume by absorption using H 2S free non-volatile wash oil in a multistage counter current absorber unit whose stage efficiency is 65%. If actual liquid flow rate is 1.5 times minimum liquid rate and Henry’s Law is applicable, Henry’s constant being 0.25 atm per mole fraction fluid the actual number of plates in the absorber 12 Oil containing 5 mole % of hydrocarbon is stripped by steam per 100 moles of oil 4 mole of steam is used. If the oil leaving the stripper should contain not more than 0.1 mol % hydrocarbon, find the number of theoretical plates required both graphically and analytically using Kermer’s equation. Equilibrium relationship is ye=33x where ye and x are the mole fractions. 13 In a plant for manufacturing dry ice, the flue gasses are contacted with activated K2CO 3solution to recover pure CO 2. The recycled absorbent solution contains one mole percent of dissolved CO 2 the flue gas has 19% by volume of CO 2. and it should be reduced to 1% by volume. The entire operation is isothermal at 1 atm absolute and is counter current in nature. Determine: Minimum flow rate of absorbent solution, For twice the minimum flow rate the number of actual stages when Murphree stage efficiently is 80% 14 Water is used for scrubbing SO 2 from a smelter gas containing 4% SO 2 in a counter 2 current absorption tower. Exit gas at top has partial pressure of SO 2 = 1.14 kN/m Water -6 is fed from top and exit water at bottom has 1145*10 mol SO 2/kg mol water. The tower operates at 293 K and vapor pressure of water is 2.3-kN/ m 2. Water rate is 0.43 kg mol per second. If tower area is 1.35 m 2 and overall coefficient of absorption is 0.19 kg mol 3 SO 2/s m (kg mol SO2 per kg mol H 2O) Calculate height of the column

17 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

15 Write short notes on: i. HTU and NTU concepts ii. Film theory iii. Packing materials and their characteristics iv. Ideal liquid solution v. Selection of an absorbent liquid 16 State and derive Fenske’s equation with assumptions 17 Derive Rayleigh’s equation 18 Compare and contrast Mc Cabe Thiele method with Ponchan Savirot method for solving binary distillation problems. Explain any one method with detailed steps and assumptions 19 Explain the Ponchan-Savirot method for the calculation of number of plates in a distillation column. Mention its advantages 20 Compare and contrast Azeotropic distillation with extractive distillation giving specific examples 21 State and explain equilibrium flash vaporization and show how you represent it on a x-y diagram 22 Explain the behavior of the following mixtures with the help of x v/s y, T-x-y and P-x-y diagrams i. A maximum boiling azeotrope ii. A minimum boiling azeotrope iii. A minimum boiling heterogeneous azeotrope 23 Derive the following equation fir the batch differential distillation of a binary mixtures (lnA1/A2)= α(lnB1/B2) where A1 = moles of A at start A2 = moles of A at end B1 = moles of B at start B2 = moles of B at end α = Relative volatility of system 24 A mixture of A and B Equimolar composition is fed to a distillation column with 10 plates having 805 efficiency as a 50:50 vapor: liquid mixture. The column is operated at 1.5 times minimum reflux ratio. If top distillate contains 95 mole% A find residue composition and also yields when 100 mole of feed is subjected to distillation. The relative volatility α=2.22 25 A binary of A and B components have the following temperature and vapor pressure characteristics (vapor pr in mm Hg)

Temp 38.5 42 46 50 54 58 62 Vap pr A 400 458 532 615 708 812 948 Vap pr B 160 185 217 254 295 342 400

Calculate the p x y and t x y diagrams for the above system at 50 0c and 400 mm Hg pressure respectively. Also calculate relative volatility

18 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

26 A continuous fractionating column operates with reflux ratio 3 to separate 15,000 kg/hr of minimum of 30% benzene and rest toluene to get a distillate containing 97% benzene and bottoms containing 95% toluene(all wt%). Calculate mole of distillate and residue if feed is at its boiling point and number of ideal stages required. The equilibrium data is as follows

Mol fraction of 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 benzene in liquid Mol fraction of 0.21 0.35 0.51 0.64 0.72 0.79 0.86 0.91 0.96 benzene in liquid

27 A benzene toluene mixture containing 0.50 mol fraction benzene is subjected to simple distillation unit 50% of the original mixture is distilled off. Estimate the composition of the composite distillate and residue in the still. Mean relative volatility can be taken as 2.5 28 A solution of carbon tetrachloride and carbon disulphide containing 50-wt% each is to be continuously fractionated at standard atmospheric pressure at the rate 4000 kg/hr. The distillate product is to contain 95-wt % carbon disulphide, the residue 0.5%, the feed will be 30 mol% vaporized before it enters the tower. A total condenser will be used and reflux will be returned at the bubble point, x, y = mol fraction of carbon disulphide is as follows: X 0 0.0296 0.1106 0.2585 0.5318 0.663 0.7574 1.0 Y 0 0.0823 0.2660 0.4950 0.7470 0.829 0.8784 1.0

29 A 20-mol % of benzene in toluene is to be distilled in a batch operation to obtain a product having an average composition of 60-mol % benzene. Calculate the amount of residue per 500 kg-mol of feed

X 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 Y 0.21 0.35 0.51 0.64 0.72 0.79 0.86 0.91 0.96

30 Explain T-x-y diagram and P-x-y diagram 31 1000 kg/hr of a mixture containing 42 mol% heptane and 58 mol% ethyl benzene is to be fractionated to a distillate containing 97 mol% heptane and a residue containing 99 mol% ethyl benzene using a total condenser and feed at its saturation. The enthaslpy concentration for the haptane-ethyl benzene at 1atm pr are as follows:

X(heptane)liq 0 0.08 0.18 0.25 0.49 0.65 0.79 0.91 1.0 Y(heptane)vap 0 0.28 0.43 0.51 0.73 0.83 0.90 0.96 1.0 -3 HL*10 kJ/kmol 24.3 24.1 23.2 22.8 22.05 21.75 21.7 21.6 21.4 -3 HV*10 kJ/kmol 61.2 59.6 58.6 58.1 56.5 55.2 54.4 53.8 53.3

Find the number of stages at a reflux ratio of 2.5

19 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

32 A benzene-toluene mixture in equilibrium proportions is subject to differential distillation at atmospheric pressure. The relative volatility for this system may be taken as 2.5. If the distillation is stopped when 70% of the moles charged has been condensed as distillate calculate: i. The distillate concentration ii. The residue concentration iii. Benzene recovery through distillate 33 Write a note on: i. Relative volatility ii. Q-line iii. Optimum reflux ratio iv. Steam distillation v. Simple distillation iv. Azeotropic distillation 34 Write a note on various types of equilibrium diagrams for a solid liquid system for leaching operation 35 For a multistage counter current leaching operation show how by graphical method the compositions of raffinate, extract can be obtained along with number of stages 36 Explain with a neat sketch the working of i. Boll man extractor ii. Pulsed column extractor iii. Rotary disc contactor iv. Y-S column 37 Discuss the principles of liquid-liquid extraction giving suitable Examples 38 Seeds containing 20% by wt of oil are extracted in a counter current leading operation. 90% of the oil is recovered in the solution, as 50% by wt of oil. If the seeds are extracted with fresh solvent and 1 kg of solution is removed in the underflow in association with every requirement for treating 1kg of feed 39 Solution A is to be extracted counter currently from a mixture of A and B containing 40% by wt% of A, using a solvent C. Raffinate should not contain more than 5% A. Evaluate minimum solvent per kg of feed and actual number of stages needed when actual solvent rate is twice the minimum and efficiency is 75%. The equilibrium test data available

C 95 85 75 65 55 Extract layer wt % B 2.5 2.9 3.5 5 10 C 2.5 3.0 5.5 8.5 15 Raffinate layer wt % B 92.5 87 65 50 40

40 If 500 kg/hr of nicotine-water solution containing 1.5 % nicotine is to be counter currently extracted with kerosene at 20 0c to reduce the nicotine content to 0.1% determine i. Minimum Kerosene rate, ii. The number of theoretical stages required if 650 kg of kerosene is used per hour the equilibrium data

Kg of nicotine per kg of water *10 3 1.0 2.46 5.02 7.5 9.98 20 Kg of nicotine per kg of water *10 3 0.8 1.96 4.56 6.86 9.13 18.9

41 Define the terms: i. Solutropic system ii. Plait point iii. Selectivity iv. Distribution coefficient 42 Write a note on: i. Preparation of solids for leaching ii. Shanks system of leaching iii. Principle of leaching and its application iv. Leaching equipment

20 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

43 Obtain an expression for the optimum concentration for minimum process time in the diafiltration of a solution of protein content S in the initial volume V o (a) if the gel polarization model applies (b) if the osmotic pressure model applies. 44 Write Notes on: i. Pervaporation ii . Electrodualysis iii . Membrane fouling iv . Liquid membranes 45 An ultra filtration plant is required to treat 50 m3/day of protein containing waste stream. The waste contains 0.5 kg/m 3 of protein, which has to be concentrated to 20 kg/m 3 so as to allow recycling to the main process stream. The tubular membranes to be used are available as 30 m 2 modules. Pilot plant studies show that the flux J through these membranes is given by: J = 0.02[ln (30/C f)] m/h where C f is the concentration of protein in kg/m 3 .Due to fouling, the flux never exceeds 0.4 m/h. Estimate the minimum number of membrane modules required for the of this process: i. As a single feed and bleed stage, ii. As two feed and bleed stages. Operation for 20 h/day may be assumed. 46 Explain: Reverse osmosis water treatment plant with a neat flow diagram 47 Write short notes on: (a) Ion repulsion and retardation (b) Higgins contactor 48 An acid solution containing 2. % by mass of NaNO 3 and an unknown concentration of HNO 3 is used to regenerate a strong acid resin. After sufficient acid had been passed over the resin for the equilibrium to be attained, analysis showed that 10% of resin sites were 3 occupied by the sodium ions. If the density of HNO 3 is 1030 kg/m , determine the concentration of the acid in the solution 49 A solution is passed over a single pellet of resin and the temperature is maintained constant. The take-up of the exchanged ion is automatically followed and the following results are obtained:

t, min 2 4 10 20 40 60 120 0.13 x (kg/kg) 0.091 0.097 0.105 0.113 0.125 0.128 r 2 On the assumption that the resistance to mass transfer in the external film is negligible, predict the values of x r, mass of sorbed phase per unit mass of resin, as a function of time, for a pellet of a resin twice the radius.

21 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

06CH64 -ENERGY TECHNOLOGY

22 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

Hours / Week: 4 I A Marks: 25 Exam Hours: 3 Exam Marks: 100

PART-A

Unit 1 Introduction to conventional & non-conventional energy sources: conventional energy sources; non- conventional energy sources; advantages; limitations. 04hrs Unit 11 Solar Energy : Solar radiation & its Measurement- Solar Constant, Solar Radiation at the Earth’s Surface, Solar Radiation Geometry, Solar Radiation Measurements. Applications - Solar Energy : Introduction, Solar Water Heating, Space-Heating (or Solar Heating of Buildings), Space Cooling (or solar Cooling of Building), Solar Thermal Electric Conversion, Agriculture and Industrial Process Heat, Solar Distillation, Solar pumping and solar cooking. 08 hrs

Unit 111 Energy From Biomass (Bio-Energy): Introduction, Biomass Conversion Technologies, Wet Processes, Dry Processes, Biogas Generation, Factors Affecting Biodigestion or generation of Gas , Classification of Biogas Plants, Advantages and Disadvantages of floating Drum Plant, Advantages, Advantages and Disadvantages of Fixed Dome Type Plant. Types of Biogas plants (KVIC Model & Janata Model),Selection of site for biogas plant. 08hrs Unit 1V Bio Energy (Thermal Conversion ) : Methods for Obtaining energy from Biomass, Thermal Gasification of Biomass, Classification of Biomass Gasifiers, Chemistry of the Gasification Process, Applications of the Gasifiers. 06hrs

Part –B Unit V Wind Energy : Introduction, Basic Components of WECS (Wind Energy Conversion system), Classification of WEC Systems,Types of Wind Machines (Wind Energy Collectors), Horizontal- Axial Machines,Vertical Axis Machines. Application of wind energy 08 hrs

UnitV1 Energy from the Oceans : Introduction, Ocean Thermal Electric Conversion (OTEC), Methods of Ocean Thermal electric Power Generation, Open cycle OTEC System, The closed or Anderson, OTEC Cycle, Hybrid Cycle. 06 hrs .

Unit V11 Energy From Tides: Basic Principles of Tidal Power, Components of Tidal power Plants, Operation Methods of Utilization of Tidal energy, Advantages and Limitation of tidal Power Generation. 06 hrs

UnitV111 Fuels : Introduction, Classifications of fuels, Calorific Value, Characteristics of good fuel, Comparison between solid, liquid and gases. 06 hrs .

23 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY Text Books: G.D. Rai, - “Non-Conventional Energy Sources” Khanna Publications, Fourth Edn., Second Reprint, 1997. P. C. Jain & M. Jain - “Engineering Chemistry”, Dhanapat Rai & Sons. Tenth edition 3 rd Reprint 1995.

REFERENCE BOOKS: 1. S.P.Sukhatme , solar Energy ,Second Edition, 3 rd Reprint, Tata Mc Graw Hill, New Delhi,1998 2. G.DRai, Solar Energy Utilization, 4 th Edition, Khanna Publications .

24 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

LESSON PLAN Hours / Week: 04 I.A. Marks: 25 Total Hours: 52

Hour Topics to be covered 01 Introduction to Conventional Energy sources, 02 Advantages and Limitations Conventional Energy sources 03 Introduction to Non-Conventional Energy sources 04 Advantages and Limitations Non-Conventional Energy sources 05 Solar radiation and its measurements Solar constant 06 Solar radiation at the earths surface 07 Solar radiation geometry 08 Solar radiation measurement 09 Introduction to solar energy, Applications-solar water, heating, space heating, space cooling 10 Thermal electrical conversion Agricultural and industrial process heating. 11 Solar distillation 12 Solar pumping, solar cooking 13 Introduction to bio mass 14 Biomass conversion technologies wet processes, Dry processes, biogas generation 15 Factors affecting bo digestion 16 Classification of biogas plants 17 Advantages and disadvantages of floating drum plants 18 Advantages and disadvantages of fixed drum type plant 19 Types of bio gas plants 20 Selection of site for biogas plant, Review of bio energy 21 Methods for obtaining energy from biomass 22 Thermal gasification of bio mass 23 Classification of biomass 24 Gasifier 25 Chemistry of the gasification process 26 Applications of the gasifier 27 Introduction to wind energy 28 Basic components of wind energy conversion system 29 Classification of wind energy conversion 30 Types of wind machines 31 Contamination of wind machines 32 Horizontal axial machines 33 Vertical axial machines 34 Review of wind energy 35 Introduction to energy from the oceans 36 Ocean thermal electric conversion (OTEC)

Hour 37 Methods of ocean thermal electric power generation 38 Open cycle ocean thermal electric conversion system 39 The closed or Anderson, Open cycle ocean thermal electric conversion cycle

25 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY 40 Hybrid cycle and Application of energy from oceans. 41 Introduction to energy from Tides 42 Basic principles of Tidal power 43 Components of tidal power plants 44 Operation methods of utilization of tidal energy 45 Advantages and limitation of tidal power generation 46 Applications of tidal energy 47 Introduction to fuels and 48 Classification of fuels 49 Calorific value 50 Characteristics of good fuel 51 Comparison between solid, liquid and of fuels 52 Comparison between Gases 53 Working of an instrument used to measure beam radiation 54 Various energy sources with suitable examples 55 Factors affecting the bio – gas generation 56 Classification of bio – gas plants 57 Types of bio gas plants 58 Selection of site for biogas plant, Review of bio energy 59 Methods for obtaining energy from biomass 60 Thermal gasification of bio mass 61 Classification of biomass 62 Applications of the gasifier

26 MVJCE DEPT. OF CHEMICAL ENGG. VI SEMESTER COURSE DIARY

QUESTION BANK

01 What is energy? Classify the different forms of energy. Briefly comment on the energy options available in India 02 With a neat sketch explain the working of an instrument used to measured global radiation of solar energy. 03 With relevant figures define (a) Declination (b) Hour angle (c) solar altitude (d) solar azimuth angle 04 Discuss the present energy crisis of world in general and India in particular and also give your solution. 05 Define (a) solar constant (b) insulation (c) scattering (d) beam radiation 06 With a neat sketch explain the working of an instrument used to measure beam radiation 07 Classify the various energy sources with suitable examples 08 Discussed the advantages of renewable energy technologies over conventional energy technologies 09 Discuss briefly the conventional energy scenario with reference to our nation 10 List the advantages and disadvantages of the following non – conventional energy sources: Solar (b) wind (c) OTEC (d) Tidal and wave (e) Geothermal 11 Explain the characteristics of sun’s energy available outside the earth’s surface 12 Explain the working of solar water heater with neat sketch. 13 Explain the working of solar cooling of Building with neat sketch. 14 Explain the working of solar thermal electric conversion with neat sketch. 15 Explain the working of solar agriculture and industrial process heat with neat sketch. 16 Explain the working of solar Distillation with neat sketch. 17 Explain the working of solar pumping with neat sketch. 18 Explain the working of solar cooking with neat sketch. 19 Discuss merits and demerits of concentrating collectors over flat plate collector 20 Sketch a liquid flat plate collector and label all its parts 21 List the different solar thermal devices and explain any three of them with relevant and neat sketches 22 Explain the factors affecting the bio – gas generation 23 Classification of bio – gas plants 24 Explain the floating drum plant with neat sketch 25 Advantages and disadvantages of floating drum plant 26 Explain the fixed dome type plant with neat sketch 27 Advantages and disadvantages of fixed dome type plant 28 Explain the biogas plant of janata model 29 Explain the features of selection of site for biogas plant 30 What are the different methods for obtaining energy from biomass 31 Explain the thermal gasification of biomass 32 Classify the biomass gasifiers 33 Explain chemistry of the gasification process 34 What are the applications of the gasifiers 35 What are the basic components of wind energy conversion System

27 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

36 Classify the wind energy conversion system 37 What are the different types of wind machines 38 Explain the horizontal-axial machines and vertical axis machines 39 Explain the ocean thermal electric conversion 40 What are different methods of ocean thermal electric power generation 41 Explain the open cycle ocean thermal electric conversion system and closed cycle ocean thermal electric conversion system or Anderson 42 Write a short note on hybrid cycle 43 Explain the principles of tidal power 44 What are the components of tidal power plants 45 What are the different operation methods of utilization of tidal energy 46 Advantages and limitation of tidal power generation 47 Write a short note on classification of fuels 48 Write a short note on calorific value 49 What are the characteristics of good fuel 50 Comparison between solid, liquid and gases

28 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

06CH65 – PROCESS EQUIPMENT DESIGN & DRAWING

29 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY SYLLABUS 06CH65 – PROCESS EQUIPMENT DESIGN & DRAWING

Hours / Week: 4 I A Marks: 25 Exam Hours: 3 Exam Marks: 100

Detailed Chemical Engineering Process Design of the following equipment. Necessary aspects studied in “Chemical Equipment Design” are to be applied for mechanical design. Use of standard code books to be taught. The detailed dimensional drawings shall include sectional front view, Full Top/Side view depending on equipment and Major component drawing with dimensioning and Part Template. 1. Double pipe heat exchanger 2. Shell and tube heat exchanger 3. Condensers – Horizontal & Vertical 4. Evaporator – Single Effect 5. Bubble Cap Distillation Column 6. Packed bed Absorption column 7. Rotary drier Note: The question paper to contain Two full design problems (100 Marks each) for the equipment from the above list and student to answer any One . 1. Perry’s Chemical Engineers Hand Book shall be allowed in the examination as reference. 2. I.S. Codes 4503 for Heat exchangers ( if required) shall be permitted.

The answer shall include detailed process design steps using the data given in the problem, mechanical design for component dimensions and drawing (Sectional Front View, Top/Side View and major component Drawings with Part Template).

Text Books : 3. Perry’s Chemical Engineers Hand Book, 7 th edition Mc. Graw Hill 1997. 4. I.S. Codes 4503

Reference Books:

1. R.H. Perry & D.W. Green : “Chemical Engineers Handbook”, 7 th edition, McGraw Hill 1998 2. Donald Q Kern, “Process Heat Transfer”, McGraw Hill 1997 3. Robert. E. Trybal – “Mass Transfer Operation” McGraw Hill 1981 4. J.M. Coulson & J.F. Richardson, “Chemical Engineering” Vol. 6, Pregman Press, 1993 5. IS Code – “Shell & Tube Heat Exchanger” – IS 4503, BIS New Delhi

30 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

LESSON PLAN Periods / Week: 04 I.A. Marks: 25 Total Periods: 52

period Topics to be covered 1-2 Introduction to design, importance of design, 3-5 Review of process equipment components 6-7 Heat exchanger: Introduction:- Different types of heat exchangers 1. double pipe heat exchanger : Mass flow rate of hot or cold fluid, heat load, determination of area required, diameter of inner and outer pipe, length of the pipe Number of hair pins, design of flange connection, pressure drop calculations. 8-10 Half sectional front view, side view and part list of DPHE 11-12 Shell and tube heat exchanger: Energy balance, area of heat exchanger, determination of number of tubes, tube arrangement

13-14 Shell & Tube Heat Exchanger Tube plate diameter, tube plate thickness, shell thickness, thickness of heads, bolts and gasket thickness, pressure drop calculation. 15-17. Shell and tube heat exchanger drawing: Half sectional front view, tube sheet layout and part list, tube plate tube plate. 17-18 Condenser design (Horizontal & Vertical): Energy balance, area of heat exchanger, determination of number of tubes, tube arrangement 18-20 Shell and tube heat exchanger drawing: Half sectional front view, tube sheet layout and part list, tube plate tube plate contd.. 20-21 Evaporator:- Introduction, mass balance, energy balance. To determine the area, diameter of the evaporator, number of tubes, calendria height, height of the vapour space drum. 22-24 Condenser vertical& Horizontal: Half sectional front view, tube sheet layout and part list. 25-26 Evaporator: Mechanical design :- Thickness of shell, tube arrangement. Thickness of top head and bottom head design, . Design of flange, inlet and discharge nozzle for feed and product.

27-28 Distillation column: Material balance, energy balance, determination of number of plates by McCabe Thiele method 29-31 Condenser (vertictal) : Half sectional front view, tube sheet layout and part list contd. 32-33 Distillation column height of the column, diameter of the column. Mechanical design: Thickness of the column, flange design, determination of number of bolts, head design, bubble cap design. 34-36 Evaporator drawing: Half sectional front view, top view, tube sheet layout and part list 37-38 Absorption column design: Material balance, determination of number of stages, determination of height of packing by graphical method.

Hour Topics to be covered 30-41 Distillation column drawing:- Half sectional front view, bubble cap drawing, part list. 42-43 Absorption column Mechanical design: Thickness of the column, flange design, determination of number of bolts, head design, bubble cap design. 44-46 Distillation column drawing:- Half sectional front view, bubble cap drawing, part list contd.. 47-48 Rotary drier design: Energy balance, determination of the diameter of the drier, determination of the length of the drier,. 49-51 Absorption column drawing: Full sectional front view and part list. 52-53 Rotary drier design: Design of flange and bolts, determination of the thickness of the drier and head, mechanical design Review of the whole syllabus.

31 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

QUESTION BANK

01 A batch jacketed distillation vessel is required for distilling a mixture. The vessel is to have an elliptical dished bottom and dished end cover. The main vessel is to be made of SS 316 and the jacket with MS. The volume of mixture to be 2.5. The temperature of the charge will be 150 0c. A minimum T g 25 0c is to be proved by condensing steam inside jacket. Design a suitable vessel for the purpose. The following dimensions are to be checked up by other methods a) Thickness of the shell 32 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY b) Thickness of elliptical and dished ends c) Thickness of jacket d) Flange design The vessel is to be provided with an anchor type with a shaft diameter of 50 mm. Draw to suitable scale the vessel showing all constructional details 02 A standard vertical tube evaporator is to be designed to concentrate a sugar solution from 10% solids to 60% solids at a rate of 35000 kg/hr. Stream is available at 2 kg/cm 2 and evaporation takes place at 660 mm kg vacuum. The feed enters at 25 0 c. The overall heat transfer co-efficient is 26500 w/m 2 0c. The specific heats of respective temperature. The calendria has vertical tubes of 2 cm OD with 3 mm thick plate and length of the tube is 1.5 m. The tubes are arranged on a triangular pitch. The area of down comer should be at least 40% total c/s area of all the tubes to ensure easy flow of liquid a) Calculate the required dimensions of evaporator b) Draw the sectional elevation of the evaporator c) Draw the plan of calendria 03 A standard evaporator is proposed to be used to concentrate an extract from 5% to 30% strength. The evaporator is operated under vacuum and the condenser pressure is maintained at 12.3 Kn/m 2. The solution has a boiling point elevation of 5 0c. All other properties may be assumed to be that of water. If the rate of solution is 5000 kg/hr, determine the important dimensions of the evaporator. Draw to scale the unit showing all the details. Additional information: Steam at a pressure of 200 Kn/m 2 is available as the heating medium. Tubes 50 mm OD and 45 mm ID and 1200 mm long are used. For effective promotion of natural circulation, it is proposed that a central downtake be provided having an arc of 25 percent of total cross section area of the tubes. A natural circulation evaporator operating under similar condition has an overall heat transfer coefficient of 1100 W/m 2 k In view of the foamy nature of the solution, the height of the vapor space must be at least 1.5 times diameter of the evaporator. A good entrainment separator is also considered essential. Sight must be provided in the vapor space

33 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

04 Design a single effect calendria type evaporator to concentrate a process stream 10,000 kg/hr of a 20% solution of caustic soda to 50% solids. The heat is supplied with steam at an absolute pressure of 2.4*10 5 N/m 3. The absolute pressure in the evaporator vapor space is 13330 N/m 2 . The feed temperature is 38 0c. Condensate may be assumed to leave at steam temperature and losses by radiation can be neglected Date: Boiling point of solution at 13330 N/m 2 : 91.7 0c Enthalpy of the feed = 128Kj/kg Enthalpy of the product(at 91.7 0c) = 514 Kj/kg Physical properties of the product at 91.7 0c, = 0 0 Sp heat C p 3.35 Kj/kg c, conductivity k = 0.68 w/m c Latent heat of vaporization λ = 2280 Kj/kg Surface tension σ = 7.2*10 -3 N/m 3 Vapor density ρv = 0.45 kg/m 3 Vapor density ρL= 1183 kg/m Select tubes 2 ” OD 12 BWG (Nickel alloy steel) 1.22m length Inside dia = 0.0506mm, outside dia = 2.5mm Tube thickness = 2.5 mm a) Determine heat transfer area, number of tubes and diameter of evaporator b) Determine the details of down corner, and evaporator sheet thickness c) Give the design drawing 05 A rotary drier is to be used for drying 30 to 40 mesh wet solid material in a counter operation at the rate of 9900 kg/hr. The wet material enters the drier at 8.8% moisture by weight (wet base) and 23 0c DBT and 20 0c WBT. It is heated to 140 0c by steam used as heating medium. Suitable heat can be assumed. a) Design the drier with all minor details b) Draw to scale the sectional elevation and end view c) Neatness and dimension 06 A direct heat counter current rotary hot-air drier is to be designed to dry an insoluble organic solid. The solid will enter at 20 0c, containing 20% water. It will be dried by air entering at 155 0c, 0.01 kg water/kg dry air. The solid is expected to leave at 120 0c with moisture content of 0.3%. Dried product delivered wills be450 kg/hr. The heat capacity of the dry solid is 837 J/kg K and its average particle size is 0.5 mm. The super field air velocity should not exceed 1.6 m/s in any part of the drier. The drier will be insulated and heat losses can be neglected for present purposes. Assume i) Air leaves at 40 0c 1. All moisture is evaporated in zone II at 35 0c and zone I as preheat zone for warming the solids to 35 0c 2. Peripheral speed as 6 rpm a) Determine the diameter and total length of the drier b) Draw the sectional elevation of the rotary drier c) Draw the cross section of the drier with the details of flight and roller supports d) Give the sketch of the hot air blower connection to the drier

34 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

07 16,400 kg/hr of ethyl acetate is cooled from 90 0c to 38 0c using water at 25 0c. The outlet water temperature is 35 0c available for this service is 600 mm ID, two pass shell side exchanger with 300 nos of 20 mm OD and 1.2 mm thick walls. The length of tubes is 3650 mm. The tubes are arranged on a triangular pitch of 25 mm. The tubes side passes are eight. Vertically cut baffles are spaced 200 mm apart. Check whether this equipment can be used for the required and design minor accessories. 1. Draw to scale the elevation of the heat exchanger 2. Draw the tube sheet layout 08 A shell and tube heat exchanger is required to sub cool the condensate from a methanol in the shell side is 100,000kg/hr. Brackish water will be used as a coolant with temperature rise from 25 0c to 40 0c. The overall co-efficient is expected to be in the range 500-1000 w/m 2 0c. a) Design a suitable exchanger b) Calculate the pressure drop for each fluid c) Draw to scale the full sectional front view of the exchanger, showing all details d) Draw to scale the details of the tube plant layout A natural gas with Sp. Gr. 1.2 at 143000 kPa and 45 0 C is being blown down to 102000 kPa. The flow rate could be from 95m3/day to 39 m3/day. The drop through the pressure- reducing regulator is 3100 kPa leaving 1000 kPa for the pipe. The pipe length is 140m upstream of the regulator and 8.7 m downstream. Determine the upstream and the downstream pipe sizes. Value of Ψ = 0.6, molecular weight of the gas = 20 09 500 t/day of hydrocarbon is to be cooled from 120 oC to 80 oC using water at 30 oC. The hydrocarbon flows in annulus and water inside the tube. The ID and thickness of inner tube and outer tubes are 50 mm and 2 mm and 75 mm and 3 mm respectively. The properties are given below

Properties Water Hydrocarbon Thermal conductivity kcal/mhr 0k 0.58 0.026 Density kg/m 3 996 790 Viscosity C p 0.66 0.046 Specific heats Kcal/kg 1 0.65

-4 2 0 The R d is 3.522*10 m / c w Design a DPHE required for the above process with the pressure drop Draw the sectional front view of the DPHE

35 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

10 A shell and tube heat exchanger is to be used to cool 20,000 kg/hr of kerosene leaving the bottom of a side-cut stripper; the kerosene is to be cooled from 200 0c to 90 0c by exchanging heat with 70,000 kg/hr of light crude oil coming from a storage tank at 40 0c.Design the exchanger and draw it to a suitable scale showing all the details. The following data is available for your calculations: Shell side (kerosene) heat transfer coefficients Film transfer coefficient = 1280 w/m 2 0k Dirt coefficients = 5000 w/m 2 0k Tube side (crude oil) heat transfer coefficients Film transfer coefficient = 395 w/m 2 0k Dirt coefficients = 3300 w/m2 0k Number of tube passes = 4 Number of tube passes = 1 Tube ID = 15.75 mm Tube OD = 19.05 mm Tube length = 4.83 mm Tube pitch = 25.4 mm Baffle spacing = 140 mm Number of baffles = 34 Baffle cut = 25% State your assumptions, if any 11 A solution of carbon tetrachloride and carbon disulphide containing 50 weight % each is to be continuously fractionated at atmospheric pressure at the rate 2000 kg/hr. the distillate product is to contain 95 weight % carbon disulphide, the residue 0.5%. The feed enters 30 mole % vaporized. A total condenser is used reflux will be returned at the bubble. a) Design the column b) Draw a section elevation of the column c) Draw the details of a tray 12 A coal gas is to be freed of its light oil by scrubbing with wash oil as an absorbent in a packed 3 0 tower. The gas enters the absorber at a rate of 0.250 m /s at 26 c and 803 mm Hg containing 2% by volume of light oil vapors. The light oil will be assumed to be entirely benzene and a 95% removal is required. The wash oil is to enters at 26 0c containing 0.005 mole fraction benzene, at a rate of 1.5 times the minimum wash oil-benzene solutions are ideal. The temperature will be constant at 26 0c and at this temperature, the vapor pressure of benzene is 100 mm Hg 38 mm Berl saddles are to be used as packing material and the column is to operate at 60% of the flooding velocity. i. Design a suitable tower ii. Draw to scale, a full sectional front view showing all the details Data: Properties of wash oil : Specific gravity = 0.84 Viscosity = 2 Cp Ave Molecular weight = 260 The film co-efficients of mass transfer are : 3 Kya = 0.0734 kmol/m s(mol fraction) 3 Kxa = 0.01541 kmol/m s(mol fraction)

36 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

13 An absorbent tower is to used to absorb vapors of methyl alcohol using fresh water as the solvent. The feed gas contains 100 gm of methyl alcohol per m 3 of air and is available at 27 0c and 101.3 kPa. The feed rate of inerts into the tower is 1200 m3 /hr. It is required to remove 98% of methanol present in the feed. The tower operations at 27 0cand 101.3 kpa. The equilibrium relation is given by the equation Y* = (1.15)(X), where Y* is moles of methanol per mole of dry air at equilibrium and X is the moles of methanol per mole of water , design the tower and draw it to the suitable scale showing all the details. The following data may be used in your calculations Packing material: 50mm ceramic berl Saddles Maximum wind speed = 105 kmph Seismic co-efficient = 0.08 state your assumptions if any Assume overall height of transfer units as 1.4 m if necessary

37 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

38 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

06CH661 – PETROLEUM REFINERY ENGINEERING

39 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY SYLLABUS Hours / Week: 4 I A Marks: 25 Exam Hours: 3 Exam Marks: 100 Part A UNIT-I Indian Petroleum Industry : Prospects and future, Major companies, World production, Market, Offshore and Onshore, Oil well technology. 06 hrs

UNIT-2 Composition of crude : classification of crude oil, evaluation of petroleum: UOP-K factor, TBP analysis, EFV analysis, average boiling point, ASTM curves, thermal properties of petroleum fractions. 06 hrs

UNIT-3 Product Properties and Test Methods : Gas, various types of gas and LPG, Reid vapour pressure analysis, gasoline and naptha: octane number, Oxidation stability, additives for gasoline: Kerosene: Characterization for flash point or fire point, volatility, burning qualities etc., diesel: octane testing, viscosity etc, grades of diesels eg., HSD, LDO, Diesel additives. Lubes Oils: Types, tests-Carbon residue and viscosity index. 07 hrs

UNIT-4 Crude Pretreatment : Pumping of crude oils; dehydration of crude by (1) Chemical, (2) Gravity, (3) Centrifugal and (4) Electrical De-Salter and comparison of each. Heating of crude: Heater (Furnaces). Different types of pipe still heaters including box type, cylindrical etc.,.crude distillation: Arrangement of towers for various types of reflux. Design aspects for- atmospheric and vacuum column. Atmospheric distillation unit: internals and operational. 07 hrs Part B UNIT-5 Treatment Techniques : Types of impurities present and various desulphurisation processes: Production and treatment of LPG: LNG Technology; sweetening operations for gases including merox, Ethanolamine, copper chloride, stretford etc., Catalytic de sulphonisation. Treatment of kerosene: De-aromatisation and merox. Treatment of diesel naphtha: desulphurisation by hydrogen and catalysts. Treatment of lubes: sulphuric acid, clay treatment, Solvent treatment– Phenol, Furfural. 06 hrs

UNIT-6 Thermal Processes : Thermal cracking reactions – theory of thermal cracking. Properties of cracked materials and factors influencing the properties of cracked materials. Visbreaking, dubbs two coil cracking process. 06 hrs

UNIT-7 Catalytic Cracking : Comparison of thermal and catalytic cracking carbonium ion chemistry, Feedback requirements. Cracking conditions; commercial cracking catalysts, various catalytic cracking possesses, fixed bed crackers, moving bed crackers, fluid catalytic cracking - flexi cracking – ortho-flow reactor. Theory of coking: various types of coking process. Delayed coking, fluid coking, contact coking, flexi coking. naphtha cracking: Naphtha cracking for ethylene as feed stock selection and gas yield. Hydro cracking: Theory of hydro cracking, catalysts for hydro cracking. 07 hrs

40 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY UNIT-* Catalytic Reforming : Theory of reforming, factors influencing, reforming, reforming catalysts, feedstock requirements. Plat - forming, isoplus hondri forming, refining forming, power forming and flexi forming etc. 07 hrs

Text Books: Nelson, Petroleum Refinery Engineering, 4 th edn., McGraw Hill. Bhaskara Rao, Modern Petroleum Refining.

Reference Books: Nagnal.J.M., Challenges in Crude oil evaluation, Gate McGraw Hill. Sland W.F. and Davidson.R.L., Petroleum Processing, McGraw HILl, 1967. Ram prasad, Petroleum Refining Technology, Khana Publishers, I st Edition, 2000.

41 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY LESSON PLAN Hours / Week: 04 I.A. Marks: 25 Total Hours: 52

Hrs Topics to be covered 01 Introduction. 02 Indian Petroleum industry- Prospects and future. 03 Major Companies, World Production. 04 Markets & Offshore –Onshore. 05 Oil well Technology. 06 Composition of Petroleum – Paraffins, oleifins, , , 07 alkynes, dioleifins, naphthalenes 08 aromatics, inorganic, oxygen, nitrogen 09 asphalts, resins, bitumens and inorganics. 10 Classification of crude oil – Paraffinic based crude oils, mixed base or intermediate crude oils and naphthalenic based crude oils. 11 Evaluation of petroleum – U O P characterization factor. 12 Correlation index and TBP analysis 13 Equilibrium flash vaporization analysis – Engler distillation (ASTM - 86), Humped distillation, average boiling point analysis 11 ASTM curves and relationship between boiling point and pressure. 14 Thermal properties of Petroleum fractions. 15 Gasses and its classification and LPG. 16 Reid vapor pressure tests. 17 Gasoline & Naptha :Octane number, Gum content and sulphur content 18 Additives of Gasoline. 19 Kerosene characterization – Flash point and fire point, volatility, sulphur content, aniline point. 20 Diesel characterization - Pour point, Aniline point, Diesel Index, 21 Flash point, Calorific value, Viscosity, 22 diesel additives, grades of diesel, diesel additives. 23 , grades of diesel, diesel additives 24 Lube Oils – Composition, types of lube oils, characterization tests for carbon residue and viscosity index. 25 Pumping of waxy crudes: Diluent addition and chemical additives, Chemical treatment, Gravity settling, Centrifugal separation, Dehydration and desalting 26 Heating of Crudes: Pipes still heaters and its categories 27 Calculation for heat determination and heat load of pipe still heaters 28 : Concentration for radiant section, heat duty, air fuel ratio 29 , tube spacing, over burned tubes, cross floating temperatures 30 Operation and maintenance of tube still heaters 31 Crude distillation, arrangement of towers for various types of reflux, top tray reflux, pump back reflux, pump around reflux 32 Design aspect: -design of columns operating at atmospheric pressure, design of columns operating under vacuum 33 Atmospheric distillation unit: internal and operational.

42 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY Hrs Topics to be covered 34 Treatment techniques: Types of impurities present and various desulfurisation processes. Oxidizing mercaptans to disulfides. 35 Production and treatment of LPG , LNG Technology. 36 Amine treatment for LPG, Stretford process, Gasoline treatment: Copper chloride process, unisol process. 37 Dualayer process, lead doctoring of gasoline 38 , sulfuring acid treatment, catalytic desulfurisation. 39 Treatment of kerosene: Dearomatisation and merox, Treatment of diesel, naphtha: Desulfurisation by hydrogen and catalysts. 40 Treatment of lubes: Sulphuric acid, clay treatment. 41 Solvent treatment – phenol, furtural, Duo sol process. 42 Thermal processes: Introduction to thermal cracking reactions. 43 Theory of thermal cracking properties of cracked materials. 44 Various factors influencing the properties of cracked materials. 45 Various factors influencing the properties of cracked materials continued. 46 Vis-breaking cracking process. 47 Dubs two coil cracking process. 48 Catalytic cracking: Comparison of thermal cracking and catalytic cracking, carbonium ion chemistry. 49 Cracking conditions, commercial cracking catalysts and feedstock requirements. 50 Various catalytic cracking processes: Fixed bed crackers, Moving bed crackers, fluid catalytic cracking. 51 Various catalytic cracking processes: Flexi cracking and ortho flow reactor. 52 Coking: Theory of coking.Various types of coking process: Delayed coking 53 , Fluid coking, contact coking, Flexi coking. 54 Naphtha cracking: Naphtha cracking for ethylene gas feed stock selection and gas yield. 55 Hydro cracking: Theory of hydro cracking, catalysts for hydro cracking. 56 Catalytic reforming: Theory of reforming, factors influencing reforming, 57 Reforming catalysts. 58 Feed stock requirements: Plat forming, isoplus 59 Feed stock requirements: hondri forming. 60 Feed stock requirements: Refining forming & power forming. 61 Feed stock requirements: flexi forming. 62 Revision of syllabus.

43 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

44 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

QUESTION BANK

01 What is UOP characterization factor 02 Explain the distillation characteristics 03 What is equilibrium flash vaporization 04 What is Engler distillation 05 What is average boiling point 06 What are the thermal properties of the petroleum 07 What are the main fractions in distillation of crude 08 Product properties and test methods 09 What is Octane number 10 Explain oxidation stability 11 What are the different additives for Gasoline 12 What are inhibitors? Explain 13 Explain antiknocking agents 14 What are the different tests prescribed for jet fuels 15 Explain Penskey’s Marten’s apparatus and test 16 What is fire point, smoke point, flash point, pour point, aniline point Treatment techniques 17 Give the classification of diesel oils 18 What are the different tests recommended for diesel fuels 19 What is softening point 20 What is penetration index 21 Estimate the gross calorific value of a kerosene fraction having an API gravity of 48 from equation heating value kJ/kg = 43,434+93.2(API-10). An natural gas having a calorific value 43.4 MJ/M 2 and density of 0.623 gm/lt is allowed to burn at 5milli bars a replacement with another gas of 25 wobbe number is sought find the pressure at which the gas should be combusted 22 What are the general methods for dehydration of crudes 23 What is electric desalting 24 What is the consideration for designing radiant section A petroleum stock at a rate of 1200 bbl/hr of specific gravity 0.8524 is passed through a train of heat exchangers and is allowed to enter directly the radiant section of box type heater at 220 0c. The heater is designed to burn 3500 kg/hr refinery off gases as fuel. The net heating value of fuel is 47.46 * 10 3kJ/kg The radiant section contains 150 sqm of projected area of one row of tubes (10.5 cm OD, 12m long and spaced at 2 OD) Find the outlet temperature of the petroleum stock. Data: ∝ = 0.88, Air fuel ratio = 25, Average specific heat of stock = 2.268 kJ/kg 0c 25 What are the different arrangements of towers 26 Explain atmospheric distillation unit and vacuum distillation unit In a fraction unit a light fraction, boiling range of 225 to 325 0 c is to separated from a high waxy distillate using steam distillation technique. If the distillation temperature should not exceed 200 0c find the number of moles of steam required for equimolal mixture of the stock. Pressure of the system remains at 760 mm data : i. Vapor pressure of light component at 200 0c = 650 mm, ii. Vapor pressure of heavy component at 200 0c = 35 mm, iii. Molecular weight of light fraction = 225,Cp = 0.47, iv. Molecular weight of heavy fraction = 435, Cp = 0.42

45 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

27 Explain blending of gasoline with a neat diagram A crude distillation is a column having a capacity of 10,000 bbls/day. Because of ineffective desalting the chloride ion concentration on top of the columns found to be 5 ppm If the crude contains volatile sulphide upto 0.7 gm/lt find the amount of ammonia required for nutralisation (1barrel ≅ 200lt) API gravity of crude is 20 28 Write in brief about the treatment techniques for petroleum (Types of impurities and various desulphurisation processes) 29 Explain the production of LPG using adsorption and desorption method with a neat flow sheet. 30 Explain LNG technology with a neat flow sheet. 31 Explain with a neat sketch the catalytic desulphurisation 32 Explain with a neat sketch the treatments used for gasoline 33 Explain with a neat sketch the treatments used for Kerosene? 34 Briefly explain with a neat diagram the Duo-sol process of lubricating oils 35 Explain with a neat sketch the process of Wax and purification 36 Briefly explain with a neat diagram vis-breaking process 37 Briefly explain with a neat diagram the propane dew axing process 38 With a neat sketch explain dubs two coil cracking process, thermal processes and catalytic cracking 39 Compare Thermal cracking and catalytic cracking 40 Explain with a neat sketch the catalytic cracking in fixed bed crackers 41 Explain with a neat sketch the catalytic cracking in moving bed crackers 42 Explain with a neat sketch the fluid catalytic cracking 43 Describe the catalytic cracking process in flexicracking and ortho flow reactors 44 With a neat flow sheet explain Delayed coking 45 With a neat flow sheet explain Fluid coking 46 With a neat flow sheet explain Contact coking and flexi coking 47 Write on the theory and the catalyst used for the process hydro cracking 48 With a neat sketch explain the process of Isomax cracking 49 With a neat sketch explain the process of UOP cracking 50 With a neat sketch explain the process of Two stage cracking process 51 Describe the process of Single and moving bed cracking with a neat flow sheet Reforming 52 Briefly explain with a neat diagram catalytic reforming process 53 Explain with a neat flow sheet the process of Plat forming and also give the feed stock requirements 54 Briefly explain with a neat diagram Isoplus hondri process 55 Explain with a neat flow sheet the process of Refining forming and also give the feed stock requirements

46 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

47 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

48 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

49 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

06CHL67 – CHEMICAL REACTION ENGINEERING LAB

50 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY SYLLABUS Hours / Week: 3 I A Marks: 25 Exam Hours: 3 Exam Marks: 50

1. Batch Reactor

2. Isothermal Plug Flow Reactor.

3. Mixed Flow Reactor

4. Semi Batch Reactor.

5. Heterogeneous Catalytic Reactor

6. Segregated Flow Reactor.

7. Adiabatic Reactor.

8. Packed Bed Reactor

9. RTD Studies In Tubular Reactor

10. Effect Of Temperature On Rate Of Reaction

11. Biochemical Reaction

12. RTD Studies In Mixed Reactor

13. Photochemical reactor

14. Sonochemical Reactor

15. Enzyme catalyzed reaction in batch

Note: Minimum of 10 experiments are to be conducted.

LESSON PLAN Hours / Week: 03 I.A. Marks: 25 Total Hours: 42

I Cycle of Experiments

1. Batch Reactor 2. Isothermal Plug Flow Reactor 3. Semi Batch Reactor 4. Adiabatic Reactor 51 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY 5. Mixed Flow Reactor

Hour. No Topics to be covered 1-3 Instruction for the 1 st cycle of experiments Experiment number 1 for group 1 Experiment number 2 for group 2 4-6 Experiment number 3 for group 3 Experiment number 4 for group 4 Experiment number 5 for group 5 Experiment number 2 for group 1 Experiment number 3 for group 2 7-9 Experiment number 4 for group 3 Experiment number 5 for group 4 Experiment number 1 for group 5 Experiment number 3 for group 1 Experiment number 4 for group 2 10-12 Experiment number 5 for group 3 Experiment number 1 for group 4 Experiment number 2 for group 5 Experiment number 4 for group 1 Experiment number 5 for group 2 13-15 Experiment number 1 for group 3 Experiment number 2 for group 4 Experiment number 3 for group 5 Experiment number 5 for group 1 Experiment number 1 for group 2 16-18 Experiment number 2 for group 3 Experiment number 3 for group 4 Experiment number 4 for group 5

II Cycle of Experiments

6. RTD Studies In Tubular Flow Reactor 7. Packed Bed Reactor 8. RTD Studies In Mixed Reactor 9. Bio Chemical Reaction 10. Hetero Geneous Catalytic Reactor

Hour. No Topics to be covered 19-21 Instruction for the II cycle of experiments Experiment number 6 for group 1 Experiment number 7 for group 2 22-24 Experiment number 8 for group 3 Experiment number 9 for group 4 Experiment number 10 for group5 Experiment number 7 for group 1 25-27 Experiment number 8 for group 2 Experiment number 9 for group 3

52 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY Experiment number 10for group 4 Experiment number 6 for group 5 Experiment number 8 for group 1 Experiment number 9 for group 2 28-30 Experiment number 10for group 3 Experiment number 6 for group 4 Experiment number 7 for group 5 Experiment number 9 for group 4 Experiment number 10 for group 5 31-33 Experiment number 6 for group 1 Experiment number 7 for group 2 Experiment number 8 for group 3 Experiment number 1 for group 5 Experiment number 2 for group 1 34-36 Experiment number 3 for group 2 Experiment number 4 for group 3 Experiment number 5 for group 4

53 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY VIVA QUESTIONS

01 What is RTD 02 What do you understand by ‘order’ of a reaction? 03 Distinguish between ‘order’ & ‘molecularly’ of a reaction 04 What is specific about ‘specific reaction rate constant? 05 What are ‘elementary & non-elementary’ reactions? 06 Give the balanced reaction of reactants you use in your experiments. What is its name? State whether it is an elementary & non-elementary’ reaction? 07 What are the usual methods of analyzing & determining the order and ‘k’ of a reaction? Explain briefly 08 If ‘k’ is k1 in a batch reactor, it will be (i) greater (ii) lesser (iii) equal to k1 if the reaction is carried in a mixed flow reactor 09 If ‘k’ is k1 in a batch reactor, it will be (i) greater (ii) lesser (iii) equal to k1 if the reaction is carried in a tubular flow reactor 10 If ‘k’ is k2 at temp=T1 ‘k’ will (a) remain the same (b) increases (c) decreases at a higher temp, T2 11 What are space-time & space velocity? 12 What is meant by residence time? 13 What are reasons for non-ideality of flow reactors? 14 What are C, E & F curves? 15 What is type of input you usually give to study the non-ideality of flow reactors? What are their names? 16 What are the characteristics of a tracer? 17 What are ‘mean, variance and standard deviation and how do you calculate them? 18 What is dispersion number? 19 What are batch, plug and mixed flow reactors? 20 If the dispersion number is very large, then the actual reactor approaches ideal plug flow! TRUE or FALSE 21 If the dispersion number is very small, then the actual reactor approaches ideal plug flow! TRUE or FALSE

54 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

06CHL68 MASS TRANSFER LAB

55 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY SYLLABUS Hours / Week: 3 I A Marks: 25 Exam Hours: 3 Exam Marks: 50

1. Diffusion of organic vapour in air

2. Distillation – Simple (Differential) distillation.

3. Packed column / Plate column distillation.

4. Steam distillation.

5. Solid – liquid leaching.

6. Surface evaporation.

7. Tray dryer.

8. Adsorption studies.

9. Liquid-Liquid/vapour - liquid equilibrium

10. Liquid extraction – (Cross Current: Single and 2 & 3 stage)

11. Holdup studies in packed columns.

12. Rotary/Vacuum dryer

13. Wetted wall column.

14. Cooling tower

15. Solid dissolution.

Note: Minimum of 10 experiments are to be conducted.

56 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

LESSON PLAN Hours / Week: 03 I.A. Marks: 25 Total Hours: 42

I Cycle of Experiments 1.Leaching 2.Diffusion coefficient 3.Tray drier 4.Simple distillation 5. Adsorption

Hour. No Topics to be covered 1-3 Instruction for I cycle of experiments. 4-6 Experiment number 1 for group 1 Experiment number 2 for group 2 Experiment number 3 for group 3 Experiment number 4 for group 4 Experiment number 5 for group 5 7-9 Experiment number 2 for group 1 Experiment number 3 for group 2 Experiment number 4 for group 3 Experiment number 5 for group 4 Experiment number 1 for group 5 10-12 Experiment number 3 for group 1 Experiment number 4 for group 2 Experiment number 5 for group 3 Experiment number 1 for group 4 Experiment number 2 for group 5 13-15 Experiment number 4 for group 1 Experiment number 5 for group 2 Experiment number 1 for group 3 Experiment number 2 for group 4 Experiment number 3 for group 5 16-18 Experiment number 5 for group 1 Experiment number 1 for group 2 Experiment number 2 for group 3 Experiment number 3 for group 4 Experiment number 4 for group 5

II Cycle of Experiments 1.Extraction 2.Solid dissolution 3.Packed bed 4.Vacuum drier 5.Ternary system

57 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY Hour. No Topics to be covered 19-21 Instruction for the II cycle of experiments 22-24 Experiment number 6 for group 1 Experiment number 7 for group 2 Experiment number 8 for group 3 Experiment number 9 for group 4 Experiment number 10 for group5 25-27 Experiment number 7 for group 1 Experiment number 8 for group 2 Experiment number 9 for group 3 Experiment number 10for group 4 Experiment number 6 for group 5 28-30 Experiment number 8 for group 1 Experiment number 9 for group 2 Experiment number 10for group 3 Experiment number 6 for group 4 Experiment number 7 for group 5 31-33 Experiment number 9 for group 4 Experiment number 10 for group 5 Experiment number 6 for group 1 Experiment number 7 for group 2 Experiment number 8 for group 3 34-36 Experiment number 1 for group 5 Experiment number 2 for group 1 Experiment number 3 for group 2 Experiment number 4 for group 3 Experiment number 5 for group 4 37-39 Repetition Class 39-42 Viva Question

58 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY VIVA QUESTIONS

01 Can you predict the loss of water per day from a pond from the result of experiment on surface evaporation? What is the underlying basic assumption? 02 When the partial pressure of the vapour in contact with the liquid equals the vapour pressure of the liquid, the rate of evaporation is zero. State whether the statement is true or false. Justify your answer. 03 What are saturation pressure and temperature? 04 What is normal boiling point? 05 What is the driving force for surface evaporation? 06 Does the rate of surface evaporation depend on the humidity of air? 07 What is wet bulb temperature? 08 Does the wet bulb temperature be greater than or lesser than dry bulb temperature? 09 What is adiabatic saturation temperature? 10 Theoretically when should the evaporation from the surface of a liquid stop? 11 What is percentage saturation and relative saturation? 12 Can you determine the diffusivity of water at different temperatures using your surface evaporation set up? If yes How? 13 What does Fick’s law state? 14 What are the different driving forces for diffusion? 15 What is the role of molecular diffusion in mass transfer? 16 What are steady state & unsteady state diffusion? 17 What is the effect of agitation on diffusion coefficient? 18 What is Knudsen diffusion? 19 What is the unit of diffusion Co-efficient and What are the analog terms in Heat and momentum transfer operations? 20 What are the different conditions under which diffusivity is determined? Give mass transfer operation for each. 21 Under what condition you are conducting diffusivity experiment? 22 Will the diffusion coefficient remain same for any given system or does it vary with systems? 23 What is an ideal mixture? 24 What does Raoults’ law state? 25 When is Raoults’ law used? 26 What does Henry’s law state? 27 For what type of system is Henry’s law used? 28 What is relative volatility? 29 Why is Simple distillation called as simple. What is the other name for it. 30 Under what important assumptions you are performing simple distillation experiment. 31 How do you proceed to determine relative volatility of the system using simple distillation setup. 32 What is Rayleigh’s equation. What is the use of this equation. 33 Why do you determine vapour quantity ‘D’ and and its composition ‘x D’ in simple distillation column Justify.

59 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

34 What is an azeotrope? 35 Can an azeotropic system be subjected to simple distillation. If yes what precaution do you take and What do you expect the product (Vapour) composition be. 36 For good separation by distillation the value of relative volatility should be equal to 1. Say true or false. 37 For a mixture of two components A & B with αAB <1, Which component is more volatile? 38 What is the primary requirement of a liquid subjected to steam distillation. 39 What are the characteristics of steam distillation. 40 What are different types of steam distillation based on the condition of steam. 41 What is the difference between differential distillation and flash distillation? 42 What is Vapour efficiency ( η) & what is thermal efficiency 43 Say true or false and justify: Vapour efficiency (η) is always greater than thermal efficiency. 44 What is Othmer plot and what is its uses. 45 Explain how you can construct Hanbrandt chart and use it. 46 Give two industrial applications of steam distillation one each for different types of distillation. 47 In steam distillation temperature is (a) less than the boiling point of water at the existing pressure (b) greater than the boiling point of water at the existing pressure (c) less than the boiling point of the organic liquid (d) greater than the boiling point of the organic liquid . 48 Steam distillation is useful for (a) liquids with high boiling point (b) with low boiling point (c) liquids with boiling point equal to that of water at the existing pressure (d) liquids with boiling point greater than that of water at the existing pressure. 49 The partial pressure of the organic liquid in steam distillation remain same as that of the liquid when it is pure. True or flase. 50 What is rectification? 51 What are the major components of a continuous rectification unit? 52 What are flooding and weeping conditions in a rectification column? 53 What are the different types of packing materials used in packed column? 54 For a column operating under total reflux, the number of stages required will be minimum. True or false? 55 How do you justify the fact that you determine the number of plates by conducting experiments on packed column distillation. 56 Why do you account re-boiler as the Equilibrium stage and not the total condenser stage. 57 What is reflux, reflux ratio, minimum reflux ratio. 58 Explain the fact that the feed line vanishes for experiment under total reflux condition. 59 What is Fenske equation and what are assumptions involved. 60 What is the reason for using geometric mean for α in using Fenske equation and How do you calculate average geometric mean of Relative volatility α. 61 Why are q lines necessary to find the number of stages required for rectification? 62 Does the slope of the q line vary with the feed condition or the column condition? 63 State the basic assumption for using Mccabe Thiele method to calculate the theoretical stages required for rectification?

60 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

64 What is HETP? Does it vary for different packing material? 65 What is drying. Classify different types based on solid gas contacting. 66 What are drying characteristics. 67 What are bound and unbound moisture. 68 Saturated air will be used for drying wet material. True or false. 69 The maximum temperature attained by air during drying will be (a) equal to dry bulb temperature (b) greater than dry bulb temperature (c) equal to wet bulb temperature (d) greater than wet bulb temperature. 70 What is critical and equilibrium moisture content. 71 Explain the drying mechanism for different rate periods. 72 For identical condition of (inlet air, initial moisture content, Weight of dry solid, Surface area).In which of the two i.e., atmospheric tray dryer and vacuum dryer you expect faster rate of drying. Justify. 73 The moisture content of the dried material be (a) less than the critical moisture content (b) equal to the critical moisture content (c) greater then the critical moisture content. 74 Draw a sketch of ternary diagram and explain salient features of the same. 75 Express different notations and appropriate diagram of liquid-liquid equilibrium. 76 What is selectivity? Can you separate by liquid extraction if β=1. 77 What are Tie lines & Plait points. Locate them in different diagrams. 78 The nature of the ternary diagram for completely miscible mixtures and partially miscible mixtures will be same. True or false. If false sketch the nature of the diagram for both the types. 79 Tie lines can be determined by (a) calculation (b) experimentally. 80 What is cross-current, co-current and counter-current operation in leaching, extraction and adsorption operation. 81 What is the equilibrium line for leaching operations. 82 What is meant by constant under flow condition and what is the analogus term in distillation. 83 What is Freundlich adsorption isotherm and why in adsorption alone the word isotherm is specially used. 84 Define differential and Integral heats of adsorption. 85 Name a few adsorbents and their applications. 86 What are molecular sieves. 87 What are the different types of adsorptions. Give industrial applications for each type. 88 What is enhancement factor? 89 What modifications in mass transfer theories is involved when mass transfer is accompanied by chemical reaction. 90 Different adsorbents are used for different systems. True or false. 91 What is deactivation of adsorbent. 92 What is regeneration of adsorbents? 93 What type of diffusion occur in adsorption? 94 Give different types of chemical reactions in mass transfer with chemical reactions. 95 What is solid dissolution?

61 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

96 Under what type of reaction your experiment in solid dissolution is based. What is the rate-determining step in such case. 97 Give practical examples of mass transfer with chemical reaction similar to your experiment ie., solid dissolution. 98 What is meant by ‘Heat of wetting’. 99 Explain adsorption wave with help of adsorption wave curve. 100 What is the use of Himus equation

62 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

CH664 – FERTILIZER TECHNOLOGY

63 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

SYLLABUS Hours / Week: 4 I A Marks: 25 Exam Hours: 3 Exam Marks: 100

1. Chemical Fertilizers and Organic Manures: – Types of Chemical Fertilizers. Nitrogenous Fertilizers – Methods of production of Ammonia and Urea. 07 hrs

2. Nitric acid, Ammonium sulphate, Ammonium Sulphate Nitrate, Ammonium Nitrate, Ammonium Chloride – Their methods of production, characteristics, storage and handling specifications. 13 hrs

3. Phosphatic Fertilizers: – raw materials, phosphate rock, sulfur pyrites – Process for the production of Sulfuric and Phosphoric acids. Ground phosphate rock, bone meal. single super phosphate, triple super phosphate – Methods of production, characteristics & specifications 17 hrs

4. Potassic Fertilizers: Potassium chloride, Potassium sulphate, Potassium schoenite – Methods of production, specification, characteristics. Complex fertilizers: NPK fertilizers, Mono- ammonium phosphate, Di-ammonium phosphate, Nitro phosphate – methods of production. 15 hrs

Text Books:

1. Collings.G.H. – Commercial Fertilizers, (5 th edn) McGraw Hill, New York, (1955) 2. Editorial board – Handbook of fertilizer technology, The Gertilizer Association of India, New Delhi, (1977) 3. Slack.A.V. – Chemistry and Technology of Fertilizers, Interscience, New York, (1966). 4. Sauchelli.V.(Editor) – The Chemistry and Technology of Fertilizers, ACS Monograph No. 148, Reinhold.

Reference Books:

3. Editorial Committee – FAI Seminar on Fertilizer in India in the Seventies (Proceedings), The Fertilizer Association of India, New Delhi, (1973). 4. Editorial Committee – Seminar on Recent Advances in Fertilizer Technology, The Fertilizer Association of India, New Delhi, (1972)

64 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

LESSON PLAN Hours / Week: 04 I.A. Marks: 25 Total Hours: 52

Hour. No Topics to be covered 01 Introduction to chemical fertilizer: origin 02 Introduction to chemical fertilizer: Importance and significance 03 Types of Chemical Fertilizers: Nitrogenous, Phosphatic and Potassic Fertilizers 04 Organic Manures: Availability and importance 05 Organic Manures: Significance 06 Methods of production of Ammonia: Production, Flow Charts, Significance and uses. 07 Methods of production of Urea: Production, Flow Charts, Significance and uses. 08 Methods of production of Nitric acid: Classification of processes-Ammonia oxidation process, Chemical reaction, Flow Charts and procedure. 09 Methods of production of Nitric acid continued: Significance, storage, uses and major engineering problems. 10 Methods of production of Nitric acid continued: Classification of processes- Sodium Hydroxide and Sulfuric acid process, Chemical reaction, Flow Charts and procedure. Significance, storage, uses and major engineering problems. 11 Methods of production of Ammonium Nitrate: Consumption pattern, methods of production, Chemical reaction, Flow Charts and procedure. 12 Methods of production of Ammonium Nitrate continued: Significance, storage, uses and major engineering problems. 13 Methods of production of Ammonium Chloride: Consumption pattern, methods of production, Chemical reaction, Flow Charts and procedure. 14 Methods of production of Ammonium Chloride continued: Significance, storage, uses and major engineering problems. 15 Methods of production of Ammonium Sulphate Nitrate: Consumption pattern, methods of production, 16 Methods of production of Ammonium Sulphate Nitrate continued: Flow Charts and procedure. 17 Methods of production of Ammonium Sulphate Nitrate continued: Significance, storage, uses and major engineering problems. 18 Methods of production of Ammonium Sulphate Nitrate: Consumption pattern, methods of production, 19 Methods of production of Ammonium Sulphate Nitrate continued: Flow Charts and procedure. 20 Methods of production of Ammonium Sulphate Nitrate continued: Significance, storage, uses and major engineering problems. 21 Introduction on Phosphatic Fertilizers: Importance to plant growth, Characteristics and uses. 22 Phosphate rock: Availability in India, demand and its cost. 23 Phosphate rock continued: Characteristic and its usage in fertilizer industry.

65 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

Hour. No Topics to be covered 24 Sulfur Pyrites: availability, characteristics and yield 25 Methods of production of sulfur pyrites : Flow Charts and procedure. 26 Methods of production of sulfur pyrites : Significance, storage, uses and major engineering problems. 27 Manufacture of sulfuric acid: By contact process- Chemical reactions, raw materials, raw materials availability and yield 28 Manufacture of sulfuric acid: By contact process- Flow chart and procedure 29 Manufacture of sulfuric acid: By contact process- Major Engg problems, storage and uses 30 Manufacture of sulfuric acid: By chamber process-Chemical reactions, raw materials, raw materials availability, yield and flow chart 31 Manufacture of sulfuric acid: By chamber process- Major Engg problems, storage and uses 32 Phosphate rock, bone meal: Availability characteristics and yield 33 Manufacture of phosphoric acid: By wet process- Chemical reactions, flow chart, major Engg problems storage and uses 34 Manufacture of phosphoric acid: By electric furnace process- oxidation and hydration Chemical reactions, flow chart, major Engg problems storage and uses 35 Manufacture of phosphoric acid: By electric furnace process- direct conversion at plant site method-Chemical reactions, flow chart, major Engg problems storage and uses 36 Manufacture of single super phosphate: Chemical reactions, raw materials, raw materials availability, yield, storage , uses and flow chart 37 Manufacture of triple super phosphate: Chemical reactions, raw materials, raw materials availability, yield, storage, uses and flow chart 38 Introduction to potassic fertilizer 39 Potassium chloride, Introduction raw material, method of production 40 Potassium chloride, Major Engg problems, physical properties, storage and handling 41 Potassium sulphate, Introduction raw material, method of production 42 Potassium sulphate, major Engg problems, physical properties, storage and handling 43 Potassium schoenit, Introduction raw material, method of production 44 Potassium schoenit, major Engg problems, physical properties, storage and handling 45 Introduction of complex fertilizers, Methods of production 46 NPK fertilizer, Introduction, raw material 47 NPK fertilizer, method of production and physical properties 48 Mono ammonium phosphate composition, introcduction and raw material 49 Mono ammonium phosphate composition, physical properties and production 50 Diammonium phosphate composition physical properties and production 51 Diammonium phosphate composition major engg problems storage and handling and uses 52 Nitrate phosphate introduction and raw material and production

66 MVJCE DEPT. OF CHEMICAL ENGG. V/VI SEMESTER COURSE DIARY

QUESTION BANK

01 Write specification, storage and handling of nitric acid 02 With a neat flow diagram describe the manufacture of Ammonia from fuel oil 03 With a neat flow diagram describe the manufacture of Ammonia by coal gasification process 04 With a neat flow diagram describe the manufacture of Ammonia by steam reforming process 05 With a neat flow diagram describe the manufacture of Nitric acid by ammonia oxidation process 06 With a neat flow diagram describe the manufacture of urea and also write specification, storage and handling. 07 With a neat flow diagram describe the manufacture of Ammonium chloride 08 Describe the manufacture of calcium ammonium nitrate with a neat diagram 09 Describe the manufacture of Ground rock phosphate 10 Describe the manufacture of single super phosphate with a neat flow diagram 11 What is the difference between super phosphate and triple super phosphate? 12 Describe the production of triple super phosphate 13 Describe the manufacture of phosphoric acid from phosphate rock 14 Describe the manufacture of Ammonium phosphate sulphate 15 Explain the manufacture of Mono Ammonium phosphate (MAP) 16 Explain the manufacture of potassium chloride 17 Explain the manufacture of Diammonium phosphate (DAP) 18 Explain the manufacture of NPK 19 Explain the manufacture of CAN with a neat flow sheet

67 MVJCE