Chemical Engineering Course Diary

DEPARTMENT OF CHEMICAL ENGINEERING COURSE DIARY
(ACADEMIC YEAR 2011-12)
VII SEMESTER
Name USN
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Semester & Section : _____________________________________________
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DEPT. OF CHEMICAL ENGG.
VII SEMESTER COURSE DIARY
06CH71- CHEMICAL PROCESS INTEGRATION
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V/VI SEMESTER COURSE DIARY
SYLLABUS Hours / Week: 4 Exam Hours: 3 I A Marks: 25 Exam Marks: 100
Part- A
UNIT 1
Introduction to process integration: graphics techniques. Overall mass targeting.

06Hrs UNIT 2
Systems of mass exchange network:: graphical approach . direct recycle strategies

7Hrs UNIT 3
Visualization strategies: for development of mass integrated system algebraic approach to targeting direct recycles 6hrs
UNIT 4
Algebraic approach: to targeting mass exchange. network recycles strategies using property integration 07 hrs
PART-B UNIT 5
Heat integration: combined heat power integration

UNIT 6
6 hrs
Overview of optimization: mathematical approach to direct recycles UNIT 7 Mathematical techniques: for synthesis of mass and heat exchange
7hrs
6 hrs
UNIT 8 Mathematical techniques: for mass integration initiatives and application case studies 7 hrs Text Book: 1. Chemical process Design and Integration Robin smith Wiley 29 chapter 772 pages 2005 2. Pinch analysis and process integration a user guide on process integration for efficient use of energy, kemp I.C 2nd edition butter worth Heinnerman 2006 3. Process integration Mahmoud. m el Hawalgi elseveier 44 pages 2006
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LESSON PLAN I.A. Marks: 25 Sl. No. 01 Chapter Introduction to Process Integration Hour No Topics to be covered Hours / Week: 04 Total Hours: 52
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What is Process Synthesis, process Analysis, Why integration, Categories of process Integration.
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Overall Mass Targeting
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Graphical Techniques for Direct Recycle strategies
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Synthesis of mass exchange network: A Graphical approach
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Visualization Techniques for the development of detailed massintegration strategies Algebraic approach to targeting Direct Recycle
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Targeting For minimum discharge of waste, Targeting For minimum purchase of material utilities Mass-integration strategies for attaining targets Problems Problem statement, source sink mapping diagram and lever arm rules Selection of Sources, Sinks, Recycle Routes Direct-Recycle targets through material recycle pinch diagram, Design rules for materials pinch diagram Multicomponent source sink mapping Diagram Design of individual mass exchangers, Cost optimization of mass exchangers Problem statement for synthesis of mass exchange Networks Mass exchange pinch Diagram Screening multiple external MSAs and constructing the pinch diagram without process MSAs, Example waste water treatment Visualization strategies: Low or no cost strategies Modest changes in process variables and operating conditions Medium cost strategies and main technology changes, Problems Algebraic targeting Approach Algebraic targeting procedure Case study: Targeting for acetic acid usage in a vinyl acetate plant, Problem
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Algebraic approach to
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The composition interval diagram, mass exchange cascade diagram
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targeting mass exchange networks
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Example of cleaning aqueous wastes, problems
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Combined Heat and Power Integration
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Overview of Optimization
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Mathematical techniques for synthesis of mass and Heat exchange networks Mathematical techniques for mass Integration
Property Based material Recycle pinch Diagram Process modification based on property based pinch diagram Example of solvent recycle in metal degreasing, clustering technique for multiple properties Cluster- Based Source sink mapping diagram for property based Recycle and interception Property based design rules for recycle and interception, Dealing with multiplicity of cluster to- property mapping Paper making and fiber Recycle Example, Relationship between Cluster and mass fractions Heat engines Heat pumps Heat Engines and thermal pinch diagram Heat pumps and thermal pinch diagram Cogeneration targeting Problems Optimization formulation Mathematical programming Classification of optimization programs Formulation of optimization models Use of 0-1 Binary-integer variable Enumerating multiple solution using integer cuts Modeling discontinuous functions and What if Scenarios using integer variables Problems Interaction between direct recycle and the process Synthesis of HENs Synthesis of MENs Problems Mathematical techniques for mass integration Initiatives and applications Case studies Source interception-Sink representation Incorporation of process model in mass integration Problems
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06CH72 INSTRUMENTATION & PROCESS CONTROL
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Part- A
UNIT 1
Instrumentation: Fundamentals, static and dynamic characteristics, Indictor and recorders.

Pressure Measurements: Gages: bourdon, diaphragm and bellow type gages, vacuum measurements. Temperature Measurements: Bi-metal Thermometers, Resistance thermometers, thermo couples, pyrometers: . 06Hrs UNIT 2 First Order Systems:: Thermometer, level, mixing tanks, stirred tank reactors. (STR) Linearization. I order system in Series Response for various input forcing functions. 06Hrs UNIT 3 Second Order Systems: Characteristics of manometer and damped vibrator. Transfer Functions. Response for various input forcing functions . Response for step input for under damped case-terms associated with it. Transportation Lag 07 hrs UNIT 4
Close Loop Systems: Basic Components .servo and regulator control. Controllers-P I D and
On OFF modes.Contrller Combinations. Final Control Element: Control valves, Actuators, valve positioners. 07 hrs PART-B UNIT 5 Close Loop response: Block diagram ,Closed loop transfer function, Transient response of servo and regulator control system with various controller modes and their characteristics 07 hrs UNIT 6 Stability: Stability of linear control system.: ROUTH Test..Frequency Response Bode plots 06 hrs
UNIT 7 Control System Design by Frequency Response:

Bode Criterion. Gain & Phase Margins.. Controller Tuning Ziegler Nichols, Cohen Coon Methods. 07 hrs
UNIT 8 Root Locus: Rules for plotting and problems
06 hrs
Text Book: 1. Coughanour & Koppel: Process System Analysis and control, McGraw Hill, New Delhi, II Edition 1991. Reference Books: 1. Luyben: Process modeling, simulation & control for Chemical Engineers, II Edition, McGraw Hill 1990 2. Coulson & Richardson Chemical Engineering Vol, III, III Edition, Pengeman Press 3. George Stephanopoules: Chemical Process Control, An Introduction to Theory & Practical, Prentice Hall, New Delhi, 1998 4. Ceagisokse : Automatic Process Control for Chemical Engineers
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LESSON PLAN I.A. Marks: 25 Hour. No 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Topics to be covered Introduction , Parts of instruments and their functions Static and dynamic characteristics, Indicators & Recorders Pressure gages Bourdon, Diaphragm bellow elements Vacuum measurement: Mcloyd, Pirrani and Ionization gages Temperatutre measurement- Bi metal and resistance thermometers, Laws of thermochemistry& Thermo couples Pyrometers: optical and radiation pyrometers Review of laplace transforms and its important theorems First order systems:- Definition, examples, Derivations of transfer functions for Thermometer Derivations of transfer functions for (i) level process, (ii) mixing without any chemical reaction.. Derivations of transfer functions for STR Linerization Derivations of transfer functions for 1st order systems in series Response for step input forcing functions Response for inpluse input forcing functions Response for sinusoidal input forcing functions Problems on 1st order systems Second order systems:-Definition, examples. Derivations of transfer functions for manometer Derivations of transfer functions for damped vibrator Response for various input forcing functions Response for various input forcing functions Response for step input for under damped case- terms associated with it. Transportation lag Solution t of numerical problems Solution t of numerical problems Closed loop system: basic components. Servo And regulator control Controllers:-defnition a and types Controllers-P I D and On OFF modes. Controller Combinations. Final Control Element: Control valves, Actuators, valve positioners. Problems Closed loop Response: block diagram Closed loop transfer function, Block diagram reduction Transient response of servo and regulator control system with various controller modes and their characteristics Transient response of servo and regulator control system with various controller modes and their characteristics Transient response of servo and regulator control system with various controller 8
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Hours / Week: 04 Total Hours: 52
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modes and their characteristics Problems on block diagram reduction Problems on transient response of controllers Stability of linear control systems Routh Test Problems on Routh Test Problems on Routh Test Problems on Routh Test Frequency Response Bode plots Problems for plotting Bode plots Problems for plotting Bode plots Bode criterion, gain & phase margin Problems on , gain & phase margin Problems on , gain & phase margin, bode criterion Controller Tuning Ziegler Nichols Controller Tuning Cohen Coon Methods. Problems on Tuning Problems on Tuning Root-Locus Method. Angle & Magnitude Criterion Steps and Rules for plotting R-L diagram/ plots of R.L diagram of a system with open-loop poles & open loop pole at the origin.. Numerical problem Steps and Rules for plotting R-L diagram/ plots of R.L diagram of a system with open-loop poles & open loop pole at the origin.. Numerical problem R.L diagram of a system with open-loop poles and open loop zeros with an open loop pole at the origin. Numerical problem R-L diagram with complex poles/zeros. Numerical problem R-L diagram with complex poles/zeros. Numerical problem Plots of R.L diagram of a system with open-loop poles & open loop pole at the origin.. Numerical problem Advantages and dis advantages of root locus metod.
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QUESTION BANK 01 02 03 04 05 06 07 08 Describe briefly the various types of instruments used in chemical process industries Differentiate between indicating, recording and control instruments What are the essential features of a good measuring instrument? Define and distinguish between (i) static and dynamic error (ii) span and range. What is measurement? How do you classify measuring instruments? Define: (a) Threshold (b) Hysterisis (c) dead zone Describe the different types of instruments, which utilize change of electrical properties for the measurement of temperature. A large number of thermo couples are connected in parallel, then the generated e m f will correspond to mean of the temperature of individual junctions. Is this statement true? if yes how? If no why? With a neat sketch, the construction and working of a radiation pyrometer With a neat sketch, the construction and working of a optical pyrometer Write short note on : Bimetal thermometer Describe with one example each, the principle of liquid, gas expansion and vapour actuated thermometers. Give the relative advantages and limitations of each type. Suggest most suitable measuring device for the following operations: Temperature range of 50 to 3000 C, 400 to 12000 C in an oxidizing atmosphere, Measuring and recording the temperature of the contents of a continuous stirred tank reactor Explain the working of thermo couple and describe the compensation methods for variation in the ambient temperature Write a note on: resistance thermometer If several thermocouples were to be installed in a furnace to provide average temperature, how would you recommend that they be connected? Discuss briefly the installation of a thermocouple in an equipment Classify the pressure measuring instruments used in the industries, based on the principle behind their working Describe the construction and working of McLeod gage stating the range in which it can be used With the help of neat sketches, describe the operation of an un bonded and bonded strain gauge transducers With the help of neat sketches, describe the principle & operation of following pressure measuring instruments (i) thermo couple gage (ii) Ionization gage Explain the use of bellows as pressure transmitter Write short notes on (a) pressure measurement in corrosive fluids (b) Pirrani vacuum gauge What are Bourdon gages? Explain its working with neat diagram indicating the errors involved in these. Discuss how they can be minimized? Describe the working of a well-type manometer. Derive an expression for the pressure indicated and compare the same with that of of an inclined tube manometer Write short notes on (i) ring type differential pressure manometer (ii) dead weight Gage.
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Suggest a typical flow measuring devices for each of the following cases: (i) measuring the flow rate and transmitting over 100m (ii) 300 m (iii) 10 km Classify the various types of flow meters and explain one from each category Give their relative advantages and limitations Suggest suitable flow meter for measuring flow rate of steam in apipe line What are Head meters? Explain the one that is used for measuring local, velocities What are area meters? Explain the typical one in detail Explain the working principle of flow measurement using ultra sonic waves Describe the working of Hot wire anemometer and magnetic flow meters When and what situations venturi meter is preferred over orifice meter? Write a note on rotary vane meter How is radioactive method used in level measurements? Explain the measurement of liquid level through electrical conductivity Measurements Explain Bubbler method of liquid level measurement How do you measure liquid level if (i) the liquid is corrosive? (ii) The liquid has suspended particles? Suggest the equipment that is to be used in these two cases Briefly describe their principle of functioning. Derive the Transfer Function between the liquid levels, H and inlet flow rate, Qi considering a non-linear valve at the exit of the tank. List all the assumptions clearly Derive the Transfer between the thermometer reading and the bath temperature, o(s)/i(s) List all the assumptions clearly Derive the Transfer between the exit concentration, C o (s) and the inlet concentration C i(s) List all the assumptions clearly Derive the Transfer between the exit concentration, C o (s) and the inlet concentration C i(s) in a tank where first order reaction takes place. List all the assumptions clearly Derive the Transfer between the exit concentration, C o (s) and the inlet concentration C i(s) in a tank where second order reaction takes place. List all the assumptions clearly Derive the Transfer Function between the liquid level, H and inlet flow rate, Qi considering a linear valve at the exit of the tank. List all the assumptions clearly Derive the response Y(t) to a first order process for (i)unit step changes(ii) unit ramp changes (iii)impulse changes(iv) sinusoidal changes in input variable, X(t) List all the assumptions clearly Explain, with suitable examples (i) Resistance (ii) Capacitance (iii) Time constant And (iv) Dead time Calculate the gas capacitance of a 20 m3 pressure vessel containing Air at 20 C A liquid flows in to a tank at a rate of Q m3 / min. The tank has three vertical walls and a fourth one sloping inwards at an angle to the vertical at the base. The base of tank is square with side, A. The average operating level is ho m. (a) Develop a formula for determining the Time Constant , (i) for a linear relationship between Q &H (ii) for a non linear relationship between Q/H, with Q = C H where C is a Constant (b) Calculate the time constant , for ho = 1.0 m , A = 0.8 m Q = 1.5 m3 / min
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A mercury thermometer having a time-constant of 12 sec. is placed in a constant temperature bath at 100 C. At time, t=0, the bath temp begins to vary sinusoidally about its mean temp of 100C with an amplitude of 5 C. If the frequency of oscillation is (5/) cycles /min., plot the response of the thermometer reading as a function of time. Also plot, on the same graph sheet the input function. Determine the phase lag in units of time. A thermometer having a time constant of 0.2 min is placed in a constant temp bath and after the thermometer comes to equilibrium with bath temp., the temp of the bath is increased linearly at a rate of 1.2 / min. What is the difference between the indicated temp and the bath temp at (a) 0.1 min after the change in bath temp begins (b) What is the maximum deviation between the indicated temp and the bath temp and when does it occur? (c) Plot the forcing function and response function on the same graph. After long enough time, by how many minutes does the response lag the input? Estimate the pneumatic capacitance of an instrument air storage tank with a volume of 1.0 m3 at 2 kgf /cm2 (gage) and 30C A gas tank is supplied air by compressor at a rate of 0.12 m3 (std) /min. The normal pressure in the tank is 3.0 kgf /cm2 (Ab) and the volume of the tank is 0.3 m3 . The gas is then throttled through a valve to a process down stream. The temp of the surrounding and in the tank may be assumed as constant at 30C. (i) If the pressure of a downstream process is 2.5 kgf /cm2, what is the time constant of the tank (ii) If the pressure of a downstream process is 1.25 kgf /cm2, what is the time constant of the tank? A temperature measuring instrument, which has been in a bath at 75C is suddenly placed in an oil bath maintained at 400C and the following readings were observed. What is the time- constant of the Instrument? Time (Sec) Int. Reading, C 0 75 1 107 2.5 140 5 205 8 244 10 282 15 328 30 395
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A thermometer is kept inside a constant temp bath at 70C. This is suddenly transferred to another bath at 60C and the following readings are obtained. Calculate the time constant of the thermometer. Time (Min) 0 1 2 4 6 8 10 12 70 68 66 64 63 62 61.5 61 Thermometer reading, C Gases A & B are continuously fed in to a tank having a volume of 30 m3 and at a temperature of 30 C. The normal flow rates of A & B in to the tank are FA = 40 m3/min and FB =10 m3/min, respectively. If the flow rate of B is suddenly increased to 12 m3/min, find the time required for the concentration of B to reach 90% of the new steady state value Water flows in to a tank of dia 1.5 m at a rate of 1.3 m3/min. The following Flow Head characteristics are observed. Flow rate m3/hr) Level of water, (m) 0 0 18.9 0.21 37.9 0.34 75.7 1.19 94.6 1.92 113.5 2.68
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Determine the time constant of a Refractory thermocouple sheath having a heat transfer area of 23.6 x 10-3 m2 and mass of 0.2 kg. The specific heat, Cp of the refractory is 0.8 kJ/ (kg)(C) The furnace is at a temp of 1400 C and the sheath is at 30 C. Heat transfer by radiation is only significant. Stefen Botlzman constant is 5 .667 x 10-8 W/ (m2) K4). The emissivity of the sheath is (i) 1.0 (ii) 0.8. A first order reaction is taking place in a continuous stirred tank reactor (CSTR) with holdup time of 1.5 hr and a specific reaction rate constant of 2 hr-1 . (i) Obtain an expression for the transfer Function between exit and feed concentration. (ii) If the feed concentration changes at a rate of 0.01 kmol/(m3)(hr), what is the dynamic error? (iii) Derive the equation used to solve the problem. Volumetric flow rate over a V notch/weir is given by q = cv 2gh5. Calculate the resistance Which of the following five gases causes greatest and least capacitance in the same vessel and at the same temp. (1) Air (2) Ammonia (3) Carbon dioxide (4) Nitrogen (5) steam A stirred tank has a hold up capacity of 0.1 m3 with a flow rate of 5 kg/sec. Heated water passes in to a well-insulated pipe of 0. 02 m2 (cross sectional area) .The temp. is measured at a point 5m down steam by a thermometer with negligible lag. An electric heater provides a constant heat input, 100 kcal/sec. If the inlet temp is 50 C and cycle continuously with amplitude of 2 C and the period is 1.0 min., determine the steady state behavior of the thermometer reading compared to inlet temp and that in the tank. Show this behavior with the help of neat sketches. List all the assumptions made in solving the problem. A tank having a time constant of 1.0 min and a valve resistance of 0.1 m /(m3)(min) is operated at steady state with an inlet flow rate of 10m3 /min. Then at t = 0 , the flow rate is increased to 100 m3 /min by adding 9 m3 of water to the tank uniformly over a period of 0.1 min. Find an expression for liquid level as function of time. Find out, what would be the liquid level from its steady state value at t = 1.0 min. Derive the transfer function H(s)/Q(s) for the liquid level system of figure (1) when 1. The tank level operates about the steady state value of hs = 1 m 2. The tank level operates about the steady state value of hs = 3 m The pump removes water at a constant rate of 10 m3/min; this rate is independent of head. The c/s area of the tank is 1.0 m2 and the resistance R = 0.5 min/ m2
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A tank having a cross sectional area of 2 m2 is operating at steady state with an inlet flow rate of 2.0 m3/min. The flow head characteristics are shown in Figure 2. 1. Find the transfer function H(s)/Q(s) 2. If the flow to the tank increases from 2.0 to 2.2 m3/min according to a step change, calculate the level h two minutes after the change occurs. 2.4 Q0 m3/min 1.0
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0.3 1.0 Develop a formula for finding the time constant of the liquid level system shown in figure 2 when the average operating level is h0. The resistance R is linear. The tank has three vertical walls and one, which slopes, at an angle from the vertical as shown. The distance separating the parallel walls is 1
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A mixing process may be described as follows: a stream with solute concentration Ci is fed to a perfectly stirred tank at a constant flow rate at of q. The perfectly mixed product is withdrawn from the tank, also at the flow rate q at the same concentration as the material in the tank, C0. The total volume of solution in the tank is constant at V. Density may be considered to be independent of concentration. A trace of the tank concentration versus time appears as shown in figure 4. 1. Plot on this same figure your best guess of the quantitative behavior of the inlet concentration versus time. Be sure to label the graph with quantitative information regarding times and magnitudes and any other data that will demonstrate your understanding of the situation. 2. Write an equation for Ci as a function of time
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What are inter acting and non inter acting processes? What are the different types of classifications of inter acting and non inter acting processes? Give examples Derive the transfer function for a two tank interacting process relating the level in the second tank and flow to the first tank, H2(s) /Q1(s) Derive the transfer function between reading of a thermometer in a thermal well and bath temp, 3 (s) / 1 (s) What are damping and damping coefficient? Classify processes based on damping coefficient. Give examples. Explain the effect of interaction Derive the transfer function for U tube manometer Obtain the response expressions for II order processes for a unit step change in input (for all the cases), Y (t) v/s X (t). Describe, with neat sketch, the various terms associated with an under damped process Derive the transfer function for dead time element Mercury filled manometer is to be used to measure the pressure drop across an orifice meter. The meter will monitor the flow rate of air through the pipe. Specifications call for a decay ratio of 0.3. The max. Pressure differential is such that a liquid column length of 75 cm should suffice. (a) Find the diameter of suitable glass tubing for the U tube. Specific gravity of mercury is 13.6.and viscosity is 1.6 cp (b) The calculations of part (a) having been made you find that only tubing available has a dia of 0.2cm. What should be done to meet the specifications A thermistor used as a thermometer in a gas duct begins to respond immediately when the gas temp is changed from 6.6 to 14.9 C , at a gas velocity of 6.5 m/sec, 90% net change in temp occurs in 7.1 sec. When the gas velocity is 1.3 m./sec the rise time is 3 sec.(a) What is the dependency of surface heat transfer co efficient between gas and themistor If the gas velocity expressed in the form of h = kUn (b) At the gas velocity of 6.5m/sec How long will it take for the thermistor to be of 99.9 % recovery of a step change in the gas temp.? A step change of magnitude 4.0 is given to a process whose transfer function is Y(s)/ X(s) = [10/ (s2+ 1.6s+4)] Determine (a) the percent overshoot (b) period of oscillation (c) rise time (d) natural frequency (e) ultimate value of Y(t). Two non interacting tanks are operating in series at steady state, when a step change is made in the flow rate to the first tank. The transient response is critically damped and it takes 1 min. for the change in the level of the second tank to reach 50% of the total change. The ratio of the cross sectional area of the tanks is A1/A2 = 2. Calculate I) the ratio R1/R2. ii) the time constant for each tank. iii) the time taken for the change in the level of the first tank to reach 90% of the total change. A proportional controller is used on a process. The proportional band is 10%. It is observed that the valve output undergoes a deviation of 20% of its scale due to disturbance. Determining the corresponding deviation that must have occurred in the controlled variable to cause this change.
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The signal to pneumatic PI controller is = 0.5 sin t. The controller gain KC = 3 and the reset time I = 2 minutes. Give the equation for the controller output in consistent units for = 10 radians/min. The normal controller is 6 x 104 N/m2. Sketch the output and the input on the same sheet (no need to use graph sheet) A proportional controller is used to control the liquid level within the range of 60 cm to 75 cm. It is found that after adjustments, the controller output pressure changes by 0.1 kg/cm2 for a 2 cm deviation in level with the desired value (set point) held constant. If the variation in the output pressure is 1 kg/cm2 causes the control valve to move from fully open to fully closed. Determine the proportional gain and proportional band. Obtain and sketch the responses of proportional, integral and derivative controllers to a sinusoidal input. An electronic temperature controller has an output range of 0-15 mA and a chart calibration of 50C to 2000C. If the output is 5 mA at 800C when the proportional gain is 0.5 mA/0C. Determine (a) the proportional band (b) the output at (i). 900C ii. At 100 0C A Proportional temperature controller has an output range of 0-20 mA and a chart calibration of 0-200 0C. If the output is 5 mA at 850C when the proportional gain is 1.0 mA/0C (a) Determine the proportional band (b) the output at 120 0C (c) the temperature for an output of 15mA. A Pneumatic PI controller has an output of 0.68 kg/cm2 when the set point and the indicator per point are together. The set point is suddenly moved 1 cm and the following data be obtained Time (sec) 00+ 20 60 90 Output Kg/cm2 0.68 0.54 0.45 0.34 0.24 Determine the proportional sensitivity in Kg/cm2 and the integral time in seconds The liquid level in a tank of 0.5 m2 cross sectional area is controlled by a two-position controller with a differential gap of 10 cm at a desired value of 1.5m. The tank has a constant outflow of 1.5 x 10-3 m3/sec. The inflow is 1.0 x 10-3 m3/sec.when the control valve is completely opened and a bypass flow of 1.0 x 10-3 m3/sec. Plot the response against time and determine the effect of (i) a dead time of 3 secs. And )ii). 20% decrease in bypass inflow. Plot on a single graph, the response of each mode to a sine wave function input l= 0.4 sin2t where l is % span. The floating controller has = 2% per minute per % error. The proportional band is 10% and the rate time constant is 4 minutes. The error signal to a controller is changing linearly so that = 0.1t, where t is minimum and t is % span. Given a floating controller with f = 2% per minute per % error, proportional band of 10% and rate T of 4 minute. Determine the output signal for each controller (separately) after an elapsed time of i. 30 seconds and ii. 2 minutes. A proportional + reset controller is used to control the temperature of a process. The following data are available 100% measurement input = 80 0 C deviation. 100% controller output = 1 cm value deviation Proportional band = 10% Reset rate = 2 repeats/min. For a step change of 2 0 C, what is the valve deviation after 2 min
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A proportional controller is used to control the temperature within the range of 50 0 C to 100 0 C. The controller is adjusted such that the output pressure varies from 0.2 kg/cm2 (valve fully opened) to 1.0 kg/cm2 (valve fully closed) as the temperature varies from 55 0 C to 59 0 C with the set point held constant. Determine the proportional sensitivity and proportional band A proportional band is used to control temperature within the range of 40 0 C to 80 0 C. The controller is adjusted such that the output pressure varies from 0.2 to 1.0 kg/cm2 (fully open fully closed) as the measured temperature varies from 580 C to 62 0 C. Determine the proportional sensitivity and proportional band A PID controller is used in a pressure control process with the following data. Full pressure change 10.0 kg/cm2 Full valve travel 2 cm Proportional band 10% Reset rate 1 repeat/min Rate time 1.5 min. If the pressure changes linearly at a rate of 0.2 kg/cm2 per minute, find the valve deviation at the end of 1 minute. Before the start of pressure change, the valve was at its midpoint and the pressure was 5 kg/cm2 Explain the different types of classification of controllers with example What is the different controller combination? What are the relative merits and limitations of controller combination? What is the different pneumatic controller path? Explain the construction of working of a pneumatic narrow band proportional controller. Explain the construction of working of a pneumatic wide band proportional controller. Explain the construction of working of a proportional reset controller. Explain the construction of working of a proportional + rate controller. Explain the construction of working of a three-mode controller. What are inherent and effective valve characteristics? What are rangability and turndown ratio of control valves? What are the different types of valve plug and valve seat geometry. Bring out the salient features of them. What are valve activator and valve positioner? Derive with a neat sketch, the construction and working of a pneumatic valve positioner. What are servomechanism and regulatory problems? Deduce an expression for C (S)/R (S) for a proportional controller as I order process. Deduce an expression for C (S)/U (S) for proportional controller of a I order process. Deduce an expression for C (S)/R (S) for proportional controller of a II order process. Deduce an expression for C (S)/U (S) for proportional controller of a II order process. Deduce an expression for C (S)/R (S) for proportional +Integral of a II order process Show that P+I controller eliminates offset automatically by considering servo problem as an example. Show that P+I controller eliminates offset automatically by considering regulator problem as an example.
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Show that an integral controller is a pure capacitance changes sinusoidal oscillatory behavior to a unit step change in set point and hence the controller action is not suitable, by taking appropriate example. Show that the performance and stability is same for both servo and regulator problem. Determine the transfer function C (S)/R (S) for the control system shown in the figure below
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A proportional controller is used on a process with time constant of 1 mon and a measuring lag of 10 secs. What value of proportional gain KC will result in a damping coefficient of G = 0.7 for the two cases of (i) D = 0 (ii) D = 3 secs Water at a rate of 0.4 Kg/sec flows through 2 tanks operating in series. The volume of the 2 tanks is 15 and 24 liters respectively. The temperature in the I tank is controlled using a P.D. controller which supplies 50 watt power to the I tank per unit change in the output pressure (KN/m2). There are no lags in the system. Find the offset for the unit step change in inlet water temperature when the controller gain is 40 KN/m2 0 C. The derivative time is 1mon. Also calculate the damping coefficient A process has two major time constants and is controlled with a proportional controller. The transfer functions are given by G1 = 1/(2s+1) and G2 = 1/(0.4s+1). Find the controller gain for the damping coefficient of 0.5 A simple feed back controller system consisting of a proportional controller with a gain KC coupled to a process characterized by 2 and 10 secs. The controlled element is sensed by an element with a time constant of 10 secs. and a time delay of 4 secs. And the reference signal is fed to the controller-summing junction through a first order pneumatic transmitter with a time constant of 1 sec. i. Sketch the block diagram for this system ii. Write the transfer function relating the controlled variable C to the reference R iii. Write the transfer function relating sensor output B/ to the reference R A simple feed back controller system consisting of a proportional + integral controller coupled to a proceass characterized by two time constants of 3 and 6 secs. The controlled element is sensed by an element with a time constant of 10 secs. and a time delay of 4 secs. and the reference signal is fed to the controller summing junction through a first order pneumatic transmitter with a time constant of 1 sec. i. Sketch the block diagram for this system ii. Write the transfer function relating the controlled variable C to the reference R iii. Write the transfer function relating sensor output B/ to the reference R
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A closed loop control system has time constant of 1 and 2 minute respectively. A proportional controller and unity feed back element and unity steady state gain. Obtain the response to a unit step change in the set point at a controller gain that gives a damping coefficient of 0.8. Would a higher or a lower gain be advantageous for the system. How & Why? A simple feed back control system consists of a proportional controller with a gain KC coupled to a proceass characterized by two time constants of 2 and 10 secs. And a steady state gain of 10 secs. The controlled variable is sensed by an element with a time constant of 5 secs. and a dead time of 1 sec. i. Sketch the block diagram for this system ii. Write the transfer function relating the controlled variable C to the reference R The major elements of a closed loop control system are having the following transfer function GP(s) = (1.5) / ((s+1)(2s+1)) GC(s) = KC Transfer functions for the rest of the components in the loop are unity. All time constants are in minutes. Determine the transient response for unit impulse input in set point at a controller gain that gives critically damped system A unit feed back control system has two processes each having a time constant of one minute under a proptional controller working in series. Obtain the response to a unit step change in set point at a controller gain that gives a damping coefficient of 0.8 for the case of a) Non interacting tank in series b) Interacting tanks in series Would a higher or a lower gain is advantages? How and Why Determine the overall transfer function C/R of a control system having the following transfer functions for its elements in a servo type negative feed back system Controller GC = KC Final control element Gv = Kv Process Gp = Kp/ (1s+1) (2s+1) Measuring element H = 1/(Ms+1) Controlled variable is C and set point is R A unity feedback system is characterized by an open loop transfer function Gp = Kp/ s(s+10) and proportional controller with proportional gain is Kc. Determine the proportional gain Kc so that the closed loop will have a damping coefficient of 0.5. Determine the settling peak overshoot and time to peak overshoot (rise time) for a unit step input (Kp = 1) The major elements of a closed loop control system are having the following transfer function GP(s) = (1.5) / ((s+1)(2s+1)) GC(s) = KC Transfer functions for the rest of the components in the loop are unity. All time constants are in minutes. Determine the transient response for unit impulse input in set point at a controller gain that gives critically damped system
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A unit feed back control system has two processes each having a time constant of one minute under a proportional controller working in series. Obtain the response to a unit step change in set point at a controller gain that gives a damping coefficient of 0.8 for the case of: i. Non interacting tank in series ii. Interacting tanks in series Would a higher or a lower gain be advantages? How and Why A unity feedback system is characterized by an open loop transfer function GC = KP/ s(s+10) and proportional controller with proportional gain is Kc. Determine the proportional gain Kc so that the closed loop will have a damping coefficient of 0.5. Determine the settling peak overshoot and time to peak overshoot (rise time) for a unit step input (KP = 1) A proportional Derivative controller is used in a system with a process and a first ordermeasuring lag. Find expression for the characteristics time C and damping factor for closed loop system. If the process time constant is 1 min and measuring time constant of 10 sec. Find the gain that gives G = 0.5 for the two cases of D = 0 sec, D = 3 sec A closed loop system has time constant of 1 min and 10 min and a proportional controller. Obtain response of a unit ramp change that gives a damping coefficient of 0.3 would a higher or lower gain the advantageous? How? And why? A block diagram of a control system is presented in the fig below
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i. What value of proportional gain KC will result in critically damped behavior ii. If the controller gain of part (a) is used what OFFSET will result for an unit step change inset point R iii. For unit step change in set point R what must be the controller gain if the offset is 10% A heat exchange is used to preheat a process fluid passing through tube side by means of shell side hot oil. The exit fluid temperature Tfe is controlled by means of automatic manipulation of the pressure on the diaphragm of a pneumatic valve in the oil line. The temperature of inlet oil Toi is a major distribution to the process. Experimental data indicate that the T F relating to Tfe and Toi is Tfe (s)/ Toi (s) = 1/(50s2+1s+0.5) and F, the flow rate of oil is Tfe(s) /F(s) = 20/(s+1)(50s2+12s+0.5) a) Sketch pictorial and a block diagram for control loop of the heat exchange including a proportional controller and a fast acting-measuring device. The controller uses air pressure for input and output signal. The gain of the control valve is 30 lt/min per psi and its dynamics is negligible. Label all the variables and transfer function b) Find the max valve of proportional gain of controller that can be used
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A unity feed back control system has a process and a controller whose transfer functions are GP = 1/(s2+2s+6); GC = KC (1+0.5s) it is desired that the offset in the controlled variable should not exceed 0.091 for a unit step change in set point What is the damping coefficient for this condition For each of the block diagram shown in the fig below determine the closed loop transfer function Cs/Rs and from the overall system differential equation
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Integral action is used in an already built speed control system as shown in the fig below the response of the system is considered to be too oscillatory, a suggestion was made to add derivative control action that is use of (I+D controller) Investigate this addition and then recommend whether or not derivative control should be used. If need be, assume KI , K and T all equal to 1
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Determine the characteristics equation for the control system should in fig below
Move A and B into the main loop by block diagram algebra does this affect the nature of characteristic equation
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134 135 136 137 138 139 140 141 142 143 144 145 146
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The major elements of a closed loop control system are given below. The time constants are min. Calculate (obtain) the transient response for unit step change in load at a controller gain that gives critical damp system GP (s) = 1.0/((2s+1)(10s+1)) Transfer function of load change = 1.0/(10s+1) GC(s) = Kc All other transfer functions are unity A liquid level system consists of two non-interacting tanks in series the first tank has a cross sectional area of 0.2m2 the flow head characteristics for the tank can be given by the equation q = 2h. The second tank has a cross sectional area of 0.1 m2 and outflow is by a constant displacement pump delivery 2m3 /sec. The (outflow of tank is 2m3 /sec and the level is 1m) level in the second tank is controlled by pneumatic PD controller and a valve with linear characteristics delivering 0.01 m3 /sec per KN/m2 controller output pressure, to the first tank. The first tank has an independent inflow varying fro 0.75 to 1.25 m3 /sec draw the block diagram for this control system with appropriate numerical transfer functions and various quantities of signal A process of two first order elements with time constant of 10 min each is connected to a measuring element with a 4min time constant and one min time delay. The process is controlled by a proportional controller .The Kc of which is 5 i. Draw the block diagram with appropriate numerical transfer functions ii. Obtain C(s)/R(s) for the system Define stability Explain Routh Hurwitz stability criteria Explain step by step procedure for plotting root locus diagram What is Bode plot. Explain the construction of the Bode plot Explain Bodes stability criteria What is gain margin and phase margin The characteristic equation s4+2s3+6s2+8s+1=0 find the roots of the equation and discuss the stability of the system The characteristic equation s3+4s2+5s+10=0 find the roots of the equation and discuss the stability of the system Find the root of the equation: G(s) = 10/s(s-1)(2s+3) The characteristic equation is s4 + s3+2s2+2s+3=0 find the roots of the equation and discuss the stability of the system Determine the range of K for stability of a unity feed back control system whose open loop transfer function is G(s) = K/s(s+1)(s+2) A four-stage process has time constant of 1,2,3 and 4 minutes with a gain of 5. Is this system stable if proportional controller with gain of KC = 2 is used The open loop transfer function a unity feed back control system is given by G(s) = K/(s+4)(s+2)( s2+6s+25) determine the value of K which gives sustained oscillation in the closed loop system. What are the corresponding oscillation frequencies (use RH method)? Draw the Root Locus Diagram for the control system whose open loop transfer Functions are: GH =
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K s ( s + 2) ( s + 4) K GH = s ( s + 6) ( s + 8)
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149 150 151 152 153 154
GH = GH =
K s ( s + 9)
2
K s ( s + 1) ( s + 3) ( s + 4) K ( s + 8) GH = ( s + 14) ( s + 10 + j10) ( s + 10 j10) K GH = ( s + 1) ( s + 2 j ) ( s + 2 + j ) K ( s + 2) GH = ( s + 1) ( s + 3 + j ) ( s + 3 j )
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Draw the Root Locus Diagram for the control system whose closed loop transfer functions are: a. 1 + GH = 0 = s(s+3)(s2+2s+2)+K = 0 b. 1 + GH = 0 = s(s+2) +K(s+4) = 0 c. 1 + GH = 0 = s(s2+2s+2)+K = 0 d. s2 (s+8) + K = 0 e. s3 + 8s3 + Ks + K = 0 f. (S+2)2 + K = 0 A unity feed back control system has an open loop transfer function as
GH =
K s (1 + 0.025) (1 + 0.0053)
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Sketch the root locus diagram for K > 0. Determine the value of K for stability. Determine the value of K when the system has two equal characteristic roots A unity feed back control system has an open loop transfer function as
GH =
K ( s + 2) s ( s 2 + 2 s + s ) ( s + 5) ( s + 6)
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Sketch the root locus diagram for K > 0. Determine the value of K for stability. Determine the value of K when the system has two equal characteristic roots A feed back control system has an open loop transfer function as
GH =
K s ( s + 3) ( s 2 + 2s + 2)
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Find the root locus diagram as K varies from 0 to . Determine the value of K for stability. Determine the value of K when the system has two equal characteristic roots K A unity feed back control system has an open loop transfer function as GH =
s ( s + 2) 3
Sketch the root locus diagram and determine the following (i). Value of K for which root locus crosses the imaginary axis (ii) Frequency for sustained oscillation
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159 160
The characteristics equation of a feed back control system is: s4 + 3s3 + 12s2 + (k-16) s + K = 0 Sketch the root locus diagram for 0 K and show that the system is conditionally stable (i.e. stable for only a range of k) Determine the range of gain k for which the system is stable
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G(s) =
K s ( s + 1) ( s + 2)
i. Sketch the root locus for 0 K ii. Determine the range of K for which the system is stable iii. Determine the value of K when the system is critically damped 162
GH =
K s ( s + 1) ( s + 5)
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Sketch the root locus diagram for the system. Indicate the crossing points of the loci on the imaginary axis and corresponding values of K and the frequency of oscillation. Sketch the root locus diagram for the system. Determine the stability of the system A unity feed back control system has an open loop transfer function as
GH =
K ( s + 1) s ( s 1)
GH =
K s ( s + 1) ( s + 5)
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Sketch the root locus diagram with K as variable parameter. Is the system stable for all values of K. If not determine the value of K for stable system operation and determine the following Sketch the Bode diagram for the following transfer functions: i. (1+s)2 ii. s/(2s+1) iii. (1-0.5s)/(1+0.5s) Sketch the gain vs frequency asymptotic Bode diagram for each of the following transfer function: i. 100/(10s+1)(s+1) ii. 10s/(s+1)(0.1s+1) 2 iii. (s+1)/(0.1s+1)(10s+1) iv. (s-1)/(0.1s+1)(10s+1) v. (10s+1) 2 vi. (10+s) 2 Sketch the Bode diagram of: A second order system with a natural frequency of 1c/s and a damping factor of 2, A PID controller with a interal time of 2 min a derivative time of 0.4 mins and a proptional gain of 4 units
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168 169 170 171 172
Sketch the Bode open loop frequency response diagram for the following transfer functions and calculate the gain and phase angle for = 10 rad/min in each case (is in min-1): i. 50/(10s+1)(2s+1) ii. 10s/(0.2s+1) 2 (s+1) iii. (s+1)/(10s+1)(3s+1) iv. (s-1)/(10s+1)(2s+1) v. (1+s)2 vi. (1-0.5s)/(1+0.5s) Draw the Bode diagram for a second order system whose dampling coefficient are 0,0.5,0.7,1.0 and 2.0 Explain the change in trends of these plots Draw the Bode diagram of the following transfer functions: G(s) = e-0.5s / 1+s Draw the Bode diagram for: G(s) = 10(s+3)/s(s+2)(s2+s+2) Plot Bode diagram for the transfer function: G(s) = 10(s+10)/s(s+2)(s+5) Plot Bode diagram for the open loop transfer function of the control system G(s) = 10(0.5s+1) e-s/10 /(s+1)2(0.1s+1)
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Plot the overall Bode diagram for a level control system of two non interacting vessels with a inlet control valve approximating to first order element. The valve has a time constant of 15s and one percent change valve position changes the inlet flow by 0.5% of the average value. The first tank has a time constant of 30s and10% increase in flow rises the level by one meter. The second tank has a time constant of 60s and the level increases by 0.8 mt for an increase in level of 1 mt in the first tank Plot the open loop Bode diagram for a system with a first order lag of 10sec and 30sec and time delay of 3sec Determine the value of KC to give 300 phase margin. What is the gain margin at this value of KC Kc
2 6s + 1
1 2s + 1
Kc
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Obtain the phase margin and gain margin of system whose open loop transfer function is
G (s) H (s) =
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K for the two cases K = 10 & K = 100 s ( s + 1) ( s + 5)
Sketch the Bode plot for a process and measuring element with an overall transfer
e 0.55 function and determine the maximum value of KC for a proportional controller (2s + 1) 2
(s in min-1)
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Plot the open loop Bode diagram for the control loop and determine the phase and gain margin
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A temperature control system has a process time constants of 20 mins. And 5 mins. The control valve and the thermometer bulb have time constants of 10 secs. A 1 psi change in controller output changes the controlled flow 25 gpm from the normal value of 200 gpm. The process temperature is 175 0 F for 200 gpm and 174 0 F for 210 gpm. A bulb with a range of 80 0 F is used. i. Calculate the overall gain ii. Calculate the maximum controller gain For the transfer function
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100 Sketch gain Vs. frequency asymptotic Bode (10s + 1) ( s + 1)
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diagram. Find also the actual gain and the phase angel at = 10 139.Consider the unity feed back control system whose open loop transfer function is
G (s) =
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(as + 1) , Determine the value of a so that the phase margin = 45 0 2 s
Plot the Bode diagram for an experimental test on a process which gives the following results. Frequency Rad/min A.R. Phase Lag 2.5 4 6.3 10 15.8 0.87 0.72 0.57 0.35 0.14 30 60 100 150 200
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SEVEN
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VII/VIII SEMESTER COURSE DIARY
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06CH73 COMPUTER APPLICATIONS & MODELING
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SYLLABUS Hours / Week: 4 I A Marks: 25 Exam Hours: 3 Exam Marks: 100 ALGORITHM AND PROGRAM FOR CASES OF UNIT I TO VI PART A UNIT 1 Numerical Techniques: 1. Simultaneous linear algebraic equation- Gauss Jordan (material balance for distillation and mixing), 2. Non-linear algebraic equation-Newton Raphson (Specific volume of binary mixture using real gas equations) 3. Ordinary Differential Equation- R-K Method (dCA/dt= K Ca2) 4. Numerical Integration-Simpsons 1/3 Rule (Batch Reactor to find time) 5. Curve Fitting- Least Square (Arrhenius) 07 Hrs UNIT 2 Applications: 6. P X,Y and T X, Y evaluation 7. Calculation of Bubble Point and Dew Point for Ideal multi-component system 07Hrs UNIT 3 Flash Vapourization 8.For multicomponent system 9.Design of Adiabatic Batch Reactor 06Hrs UNIT 4 10. Design of Adiabatic Plug flow Reactor 11. Design of Adiabatic CSTR and Combinations 06Hrs PART B UNIT 5 Design 12.Double pipe Heat Exchanger (Area, Length and Pressure drop) 13.Shell Tube Heat Exchanger (Area, Number of tubes, Pressure drop) 06Hrs UNIT6 Absorbtion &Distillation Columns 14.Calculations for plate and packed columns 06Hrs UNIT 7 Modeling: Models and model building, principles of model formulations, precautions in model building, Fundamental laws: Review of shell balance approach, continuity equation, energy equation, equation of motion, transport equation of state equilibrium and Kinetics, classification of mathematical models. 07 Hrs UNIT 8 Mathematical Modeling and Solutions to the Following: 1.Basic tank model -Level V/s time 1. Batch Distillation -Vapor composition with time 2. Three CSTR in series 07Hrs
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Text Books:
1. M. Shanthakumar Computer based Numerical Analysis, KPS publicher, First edn, 1987.
2. Introduction to Chemical Engineering and Computer Calculations Myers, A.L. and Seider. W.D. 3. William. L. Luyben Process Modeling simulation and control for chemical engineers 2nd Edn., Mc Graw Hill, 1990.
Reference Books: 1. H. Scott Fogler, Elements of Chemical Reaction Engineering, 2nd Ed., Prentice Hall, 2001. 2. Smith J.M. and H.C. Vanness Introduction to Chemical Engg. Thermodynamics 5th Edition, MGH, 1996.
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LESSON PLAN I.A. Marks: 25 Hours / Week: 04 Total Hours: 52
Chapter
N U M E R I C A L T E C H N I Q U E S
Hour No 1 2 3 4 5 6 7 8 9 10 11 12
Description Introduction to C program: Structure of C, types of data base, input & Output statements. Introduction to C program: Input & output statements, Arrays, general programs. Algorithm: To find a specific volume of binary mixture by using Newton Raphson method. C program: To find a specific volume of binary mixture by using Newton Raphson method. Algorithm & C program: To fit a curve by using least square method for Arrehenius equation. Algorithm & C program: To find the residence time for a batch reactor using simpson 1/3rd rule Algorithm & C program: To solve ordinary differential equation using Runge Kutta method. Algorithm: To solve material balance equation of mixing using Guass Jordan method. C Program: To solve material balance equation of mixing using Guass Jordan method. Algorithm & C program: To evaluate P X, Y data Algorithm & C program: To evaluate T X, Y data Algorithm: To evaluate bubble point temperature for ideal multi component system. C Program: To evaluate bubble point temperature for ideal multi component system. Algorithm: To evaluate dew point temperature for ideal multi component system. C Program: To evaluate dew point temperature for ideal multi component system. Algorithm: To evaluate flash vaporization for ideal multi component system. C Program: To evaluate flash vaporization for ideal multi component system. Algorithm: To evaluate adiabatic batch reactor. C Program: To evaluate adiabatic batch reactor. Algorithm: To evaluate adiabatic CSTR. C Program: To evaluate adiabatic CSTR.
A P P L I C A T I O N S
13 14 15 16 17 18 19 20 21
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D E S I G N
22 23 24 25 26
M O D E L I N G
M O D E L I N G&S O L U T I O N S
Algorithm & C program: To evaluate adiabatic PFR Algorithm & C program: To evaluate adiabatic flame temperature Algorithm: To calculate area, length & pressure drop for an DPHE C Program: To calculate area, length & pressure drop for an DPHE Algorithm: To calculate area, number of tubes, pressure drop for an STHE 27 C Program: To calculate area, number of tubes, pressure drop for an STHE 28 & 29 Algorithm: To calculate number of theoretical plates of distillation column 30 & 31 C Program: To calculate number of theoretical plates of distillation column 33 Use of mathematical models, principles of formulation & precautions in model building 34 Continuity equations: Total continuity equation (Mass Balance) 35 Component continuity equation 36, 37 & Energy, Motion and Transport equations 38 39 & 40 Equations of state, chemical Equillibrium and phase equillibrium 41 Chemical kinetics 42 Modeling of : Basic tank model, level V/S time 43 Modeling of : Series of isothermal, constant Hold up CSTRs 44 continued 45 Modeling of : Multi component flash drum rigorous model and practical model 46 Continued 47 Modeling of : Batch reactor 48 Modeling of : Batch distillation column with hold up 49 Continued 50 Modelling of CSTR in seris 51 Continued 52 Review of various models
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QUESTION BANK 1. Write a C program to pick negative, zero and positive numbers from a given set of N numbers using arithmetic IF. Using the format statement print the answer 2. Write a C program which will evaluate the function for x=0.5 to 3 varying in steps of 0.5 and tabulate the results: f = 1 + x2/2 + x4 / 4 0.5 sin2x + (4 x2) 1/2 3. Write C program to find the root of the equation: f(x) = x3 x 1 = 0, by bisection method 4. Write C program to find the root of the equation: f(x) = x3 + x2 1 = 0 by Newton Raphson method 7.52 5. Write C program to integrate Area = (x) dx from the given Values 7.47 X (x) 7.47 1.93 7.48 1.95 7.49 1.98 7.50 2.01 7.51 2.03 7.52 2.06
With h = 0.001 using trapezoidal rule 1 1. Evaluate I = 1/ 1 + x. The values of x and y are tabulated below: 0 X 0 0.5 1.0 Y 1.000 0.667 0.5 h = 0.05 and write a C program to solve the above problem using Simpsons 1/3rd rule. 2. Write a C program to solve the simultaneous equation using Gaussian Elimination method and Gauss Jordan method. 10x + 2y + z = 9 2x + 20y 2z = -44; -2x + 3y + 10z = 22 3. Write a C program to Solve the ordinary differential equation: dy/dx = x2/y2 + 1 using Eulers method 4. Write a C program to Solve the ordinary differential equation dy/dx = y x where y (0) = 2. Find y (0.1) and y(0.2) using Runge-Kutta method 5. Write a C program to Solve the ordinary differential equation: dy/dx = y2 x2 where y(0) = 2. Find y (0.1) and y(0.2) using Runge-Kutta method 6. Molar volume of benzene vapour at 563.15 0K is given as a function of pressure. Assume that the P-V data obeys the virial equation of state terminated after the third virial coefficient. Write a C program to find the second and third virial coefficients. Hint: Method of least squares can be used. 7. Assuming that Raoults law is applicable for the system acetone (1)/acetonitrile (2) /nitromethane (3), write a C program to calculate bubble pressure, dew pressure, bubble temperature and dew temperature.
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8. Calculate the molar volume of propane at 440 K and 150 atm. Using Pitzers theory. The vapour pressure of propane is given by Antonine Equation lnP = A B/T + C where A = 15.7260, B = 1872.46 & C = -25.16. TC = 370 K, PC = 42 atm. 9. Write a C program to find the molar volume of a gas using Vanderwalls/s equation 10. What is principle of corresponding states? Explain 11. What is UNIFAC method? Explain its significance 12. A gas furnace burns propane fuel, the chemical reaction for complete combustion is C3H8 + SO2 = 3CO2 + 4H2O, This is a fast and irreversible reaction. Solve for the composition and flow rate. 13. Assume that the fuel is pure propane and that air is 21% oxygen and 79% nitrogen. 13. Hot soap is chilled on a roller and scraped continuously from the roller onto a moving conveyor belt (stream 1), which carries the soap into a dryer. The entering soap contains 25% water by weight. It is desired to reduce the water content to 15% water by weight (stream 3) and to produce 1200 kg/hr of dried soap chips. The entering air contains 0.3-mol% water vapour. The air/wet chip ratio = 3 (1) Set the material balance equation and find the number of design variables. (2) Calculate the unknown flow rates and composition. 14. Give the algorithm and write a C program for an adiabatic, non-isothermal batch reactor, in which a first order liquid phase irreversible reaction is taking place. The residence time required for a specified conversion should be the output result of the program. 15. The feed to an ammonia reactor contains nitrogen, recycled ammonia and inert impurities (methane and argon). The reaction is N2 + 3H2 = 2 NH3. Nitrogen and hydrogen in the feed are in the stoichiometric proportion 1:3. Determine the flow rate and composition of the product stream in terms of the feed stream variables. Take suitable design variable. 16. The process shown in the flow diagram converts feed stream (1) of n-butane to isobutene in a catalytic reactor. The conversion to isobutene is incomplete and the products from the reactor stream (2) are separated by distillation into isobutene (stream 3) and unreacted n-butane (stream 4). The isobutene is more volatile than n-butane and is obtained from the distillation tower as the distillate. Use CSTR for butane isomerization. Determine all process flow rates and mole fractions. Take suitable design variables. 17. Write a program to design a double pipe heat exchanger. Write down the algorithm and explain the design procedure in detail. 18. Write a program to design a single effect evaporator. Write down the algorithm and explain the design procedure in detail. 19. Write a program to design a shell & tube heat exchanger. Write down the algorithm and explain the design procedure in detail. 20. Write a program to determine the number of ideal stages required in a binary distillation column by McCabe Thiele method. Write down the algorithm and explain the design procedure in detail.
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06CH74 BIO CHEMICAL ENGINEERING
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PART-A UNIT-1 INTRODUCTION: Bioprocess engineering and technology Role of a chemical engineer in bioprocess industry An introcduction to basic biological sciences. Microbiology structure of cells Prockaryotes and eukaryotes classification of microorganisms taxanomym environmental industrial microbiology 6hrs UNIT-1I Biochemistry: Chemicals of life lipids sugars, polysaccharides, amino acids, and protein Vitamines Biopolymers nucleic acids RNA, DNA and their derivatives.(structure biological function and importance for life only to be studied.) 7hrs UNIT-1II Enzyme and Proteinss: details structure of proteins and enzymes functions methods of production and purification of enzymes Nomenclature and classification of enzymes, kinetic of enzymes action Michaelis menten rate equation derivation 6hrs UNIT-1V Kinetics of enzymes action: Reversible enzymes two substrate multicomlex enzymes kinetics(derivation of rate equation)experimental of rate parameter batch & continuous flow experiment Lineweaver burk Eadie Hofstee and hanes woolf plots Batch kinetics (integral and differntial methods) 7hrs PART-B. UNIT-V Enzyme Inhibition: effect of inhibiton (competitive, non competitive substrateand product inhibition) Temperature and pH on the rates enzymes catalyzed reactions determination of kinetics parameters for various types of inhibition Dixon method enzyme immobilization uses methods of enzymes immobilization. 7hrs UNIT-VI Fermentation technology: Ideal bioreactors, A review of batch and continuous flow reactors for bio kinetics measurements microbiology reactors operation and maintenance of typical aseptic fermentation process.formulataion of medium ,sources of nutrients, alternate bioreactor configuration.introduction to sterilization of bioprocess equipments. 7hrs UNIT-VII Growth Kinetics of microganisms: Transient growth kinetics (different phase of batch cultivation) Quantification of growth kinetics substrate limited growth ,models with growth inhibitor, logistic equation ,filaments cell growth model, continuous culture optimum dilution rate in ideal chemostat introduction to fed-batch reactors. 6hrs 41
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UNIT-VIII Downstream processes: strategies and steps involved in product purificatiaon methods of cell disruption, - Filtration, centrifugation, sedimentation chromatography freeze drying/lyophilization menbrane separation technology reverse osmosis ultra filtration micro filtation dialyusis 6hrs Text Books: 1. Biochemical Engineering Fundamentals- Bailey & Ollis, II Edition, McGraw Hill, 1986 2. Microbiology Concepts & Application:- McGraw Hill, 1993 by Pelczar Reference Books: 1. Biochemical Engineering: Aiba, Academic Press, 1965 2. Industrial Microbiology- Casida 3. Biochemistry: - Lehninzer 4. Chemical Engineering III Edition, Coulson & Richardson
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LESSON PLAN I.A. Marks: 25 Hour. No 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Hour. No 27 28 29 30 31 32 33 34 35 Topics to be covered Bioprocess engineering and technology Role of a chemical engineer in bioprocess industry An introcduction to basic biological sciences. Microbiology structure of cells Prockaryotes and eukaryotes. classification of microorganisms taxanomym environmental industrial microbiology Chemicals of life lipids. sugars, polysaccharides Amino Acids to proteins, protein structure, primary structure, secondary and tertiary structure. Vitamines Biopolymers nucleic acids RNA, DNA and their derivatives.(structure biological function and importance for life only to be studied Enzyme and Proteinss: details structure of proteins and enzymes functions methods of production and purification of enzymes Nomenclature of enzymes classification of enzymes kinetic of enzymes action Michaelis menten rate equation derivation Kinetics of enzymes action: Reversible enzymes two substrate multicomlex enzymes kinetics(derivation of rate equation) experimental of rate parameter batch & continuous flow experiment Lineweaver burk Eadie Hofstee and hanes woolf plots Batch kinetics (integral and differntial methods Enzyme Inhibition: effect of inhibiton competitive, Topics to be covered non competitive substrateand product inhibition Temperature and pH on the rates enzymes catalyzed reactions determination of kinetics parameters for various types of inhibition Dixon method enzyme immobilization uses methods of enzymes immobilization Fermentation technology: Ideal bioreactors, A review of batch and continuous flow reactors for bio kinetics measurements microbiology reactors operation and maintenance of typical aseptic fermentation MVJCE 43 Hours / Week: 04 Total Hours: 52
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
process. formulataion of medium ,sources of nutrients, alternate bioreactor configuration. introduction to sterilization of bioprocess equipments Growth Kinetics of microganisms: Transient growth kinetics (different phase of batch cultivation) Quantification of growth kinetics substrate limited growth. ,models with growth inhibitor, logistic equation , filaments cell growth model, continuous culture optimum dilution rate in ideal chemostat introduction to fed-batch reactors Downstream processes: strategies and steps involved in product purificatiaon methods of cell disruption, - Filtration, centrifugation, sedimentation chromatography freeze drying/lyophilization menbrane separation technology reverse osmosis ultra filtration micro filtation dialyusis
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QUESTION BANK 1. List out some important applications of biotechnology. 2. Discuss the difference between Procaryotic and Eucaryotic cells 3. What is the basis of the five-kingdom classification scheme according to Whittaker? 4. Why is Whittaker five-kingdom classification so accepted in the biological community? 5. Define the various Organelles of a typical caell and give their characteristics 6. Compare the general characteristics of the following. (a) Spirilla (b) Cocci (c) Bacilli (d) Budding (e) Sexual fusion (f) Sporulation 7. Why is it essential to classify microorganisms 8. What must be done before classification of microorganisms 9. Give the classification of microorganisms belonging to the kingdom protista 10. What are bacteria? Discuss their activity in biochemical process. 11. What do you understand by gram positive and gram-negative species? 12. If two microorganisms have an identical mol% G+c value for their DNA, are they necessarily related? Explain 13. If two microorganisms have a different mol% G+c value for their DNA, are they necessarily unrelated? Explain 14. Explain cell fractionation in biochemical analysis. 15. Bring out the importance of microorganisms in the fixation of nitrogen in the atmosphere. 16. Explain briefly the method of biological wastewater treatment. 17. State the different basic monomeric chemicals. 18. Give the basic molecular structure that forms the important super macromolecules in a living cell. 19. Distinguish the following Amino acid and nucleic acid Lipids and proteins DNA & RNA Starch and glucose 20. Describe the death rate pattern of bacteria when exposed to a lethal agent. 21. Give the great range of protein structures and functions. 22. Discuss the diverse biological functions of proteins 23. What are lipids? 24. How are lipids classified? 25. What is rancidity? 26. How is rancidity prevented? 45
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27. Discuss the biological and physiological role of lipids. 28. Define the meaning of a high-energy compound. 29. Name the high energy compound that occur in the glycol tic compound. 30. Suggest a method for sterilization for : 01 02 03 04 Petri Dish Water Nutrient Agar Dry powder 05 06 07 08 A heat liable solution of vitamin A heat liable antibiotic solution Contaminated hospital linens Operation room in hospitals
31. Write briefly on nitrogeneous bases that are found in DNA and RNA. 32. Distinguish between DNA & RNA 33. Distinguish between starch and glucose. 34. Define enzyme and a super enzyme 35. Enzyme carbonic anhydrase catalyses the hydration of carbon dioxide reaction: H2CO3 H2O + CO2 The molecular weight of the enzyme is 30000. If 10g of pure enzyme catalyzes the hydration of 0.3 g of CO2 in 1 min at 370C under optimal condition calculate the turnover number of the enzyme. 36. Write the sequence of 3 to 5 end base for the following double helix 5 AA TGCG3 DNA nucleotide. Also write RNA strand for the same in 3 to 5 sequence. 37. Assuming the reaction sequence: S+E [ES1] [ES1] P+E
Develop a suitable expression using Quasi steady state approximation for the complexes. 38. Beef liver catalyst has been to used to accelerate the decomposition of H2O2 to yield water and oxygen. The concentration of water is given as a function of time for a reaction mixture with PH 6.76 maintained at 300 C. Concentration of Time (Secs) H2O2 (mol/lit) 0 0.2 10 0.1775 20 0.0158 50 0.0106 100 0.022 a. Determine the M-M parameter b. If the total enzyme concentration is tripled, what will be the substrate concentration after 20 minutes? 39. Derive Michaelis-Menten equation for an enzyme-catalysed reaction. 40. Show how the Michaelis-Menten equation constants are evaluated by Lineweaver-Burk plot. 41. Discuss the effect of substrate concentration on the rate for the enzyme-catalysed reaction. 46
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42. The following data were recorded for an enzyme reaction S = P. Estimate Vmax and Km S, mol/l V, mol/l. min 8.33x10-6 1.25x10-5 13.8 19.0 3.33x10-5 36.3 8x10-5 53.4 2x10-4 66.7
43. At room temperature Sucrose is hydrolysed by the catalytic action of the enzyme as Sucrose = Product, Initial sucrose concentration CA0 = 1.0 mM/L and an enzyme concentration CE0 = 0.01 mM/L, the following data are obtained in a fresh batch reactor Time (hr) 1 2 3 4 5 6 CA mM/L 0.84 0.68 0.53 0.38 0.27 0.16 Time (hr) 7 8 9 10 11 CA mM/L 0.09 0.04 0.018 0.006 0.0025
Check whether the reaction follows MM model and if it fits the model then evaluate K3 and M in the equation -rA = K3CACE0 CA + M 44. For the enzymatic conversion of the substrate, the dependence of the reaction rate on the substrate concentration is as given below: S [mM] 1 0.5 0.25 0.75 0.13 -1 V min 71.4 55.5 40.1 30.3 25.2 i. Plot V Vs. S and find Vm and Km from the plot ii. Construct the Eadie-Hofstee plot and find Vm and Km from the same 45. What are the factors that affect the rate of enzymatic reactions? 46. Explain all the factors that affect the rate of enzymatic reactions. 47. What is enzyme inhibition? 48. What is the meaning of inhibitor constant KI? 49. Explain briefly ant two methods of estimation of the value of KI. 50. Derive the M-M equation for the reaction and a method to evaluate km, km1 when Vm = Vm1. Write the equation and what is the type of inhibition 51. The decarboxylation of glyoxylate by mitochondria is inhibited by malonate. In a kinetic study the following results were obtained. Is the inhibition of the reaction by malonate competitive? If so find the kinetic parameter.
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DEPT. OF CHEMICAL ENGG. Glyoxylate concentration mM 1.00 0.75 0.6 0.5 0.33 0.25
VII/VIII SEMESTER COURSE DIARY Rate of evolution of CO2 (arbitrary units) Malonate Concentration, mM 1.26 1.95 2.17 1.82 1.82 1.39 2.41 1.28 1.30 1.00 1.09 --1.01 ---
52. At room temperature the initial rate of reaction of enzymatic cleavage of de oxygnanosine triphosphate was measured as a function of concentration as follows.
Substrate concentration (M/L) 6.7 3.5 1.7 Initial Reaction Rate (M/L min) Without inhibitor With inhibitor (1.46M/L) 0.3 0.11 0.25 0.08 0.16 0.06
a. Calculate M-M constants b. What type of inhibition occurs when inhibitor of concentration 146 M/L is added? 53. In the initial reaction rate of hydrolysis of acetyl choline (substrate) by dog serum (source of enzyme) in the acsence and presence of prostigmine (inhibitor), 1.5 x 10-7 M/L the following data were obtained.
Substrate concentration (M/L) 0.0032 0.0049 0.0062 0.0080 0.0095 Initial Reaction Rate (M/L min) Without inhibitor With inhibitor (1.46M/L) 0.111 0.59 0.148 0.071 0.143 0.091 0.166 0.111 0.200 0.125
Find the type of inhibition by prostigmine presence Find all the parameters that appear in the rate equation. 54. The enzyme, cathepsin, hydrolyses L-glutomyl L-tyrosine to carbobenzoxy L- glutamic acid and L tyrosine. It has been found that glutamic acid formed in the hydrolysis, inhibits (competitively), the progress of the reaction by forming a complex with cathepsin. The course of the reaction is followed by adding tyrosine decarboxylase, which evolves CO2
[S] Mml 4.7 4.7 4.7 10.8 10.8 10.8 30.30 30.30 30.30 [I] Mml 0 7.57 30.30 0 7.57 30.30 0 7.57 30.30 Rate of CO2 Mml-min 0.0434 0.0285 0.0133 0.0713 0.0512 0.0266 0.1111 0.0909 0.0581 generation
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Calculate
a. The value of M-M constants of the enzyme b. The dissociation constants of enzyme inhibitor complex KI
55. Give the partial classifications of reversible inhibitors. Describe them and give their effects on kinetic parameters with different rate plots. 56. Derive the expression for the reaction velocity V, in terms of total enzyme concentration C0 and free substrate and inhibitor concentrations, S for the following reactions E + S = ES KS: dissociation constant E = I = EI KI: dissociation constant ES = E + P slow step Where E & S are enzyme and substratr and I is the inhibitor. State how kinetic parameters are estimated? 57. Illustrate how reactions, the manner in which organically bound sulphur is released by microbial dissimilation. 58. Explain carbon dioxide cycle. 59. Describe how the physical composition of soil influences the magnitude and diversity of the microbial flora. 60. What are the components of bacterial nitrogen fixing system? 61. Explain nitrogen cycle. 62. What is oxidative phosphorylation? 63. Where does phosphorylation occur in the respiration chain? 64. What are the essential difference between photosynthesis by bacteria and algae? 65. Explain the following with the help of neat flow sheets: TCA cycle, Calvin cycle 66. What is meant by respiration? 67. Discuss respiration with the help of TCA cycle 68. Distinguish between catabolism and anabolism 69. Explain the following metabolic pathway briefly: EMP pathway, ATP cycle 70. What is carbon catabolism? 71. Write about electron transport and photophosphorylation.
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50
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51
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06CH753 ELECTROCHEMICAL TECHNOLOGY
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ELECTROCHEMICAL TECHNOLOGY : IA : 06CH753 Marks 25 No. of Lecture : 04 Exam : Hours/Week Hours 03 Total No. of : 52 Exam : Lecture Hours Marks 100 PART - A UNIT - 1 INTRODUCTION TO THEORETICAL ASPECTS: Faradays laws, mechanism of conduction in solids, liquids and gases and in ionic melts. Conduction in metals and semiconductors. 6 Hours UNIT - 2 Reversible electrodes and potentials, electrode processes and electrode kinetics. 6 Hours UNIT - 3 Various types of overpotentials. Polarisation. 6 Hours UNIT - 4 Butler-volmer for one electron and mute electron steps. Models of electrical Double layer. 8 Hours PART B UNIT - 5 Applied aspects: Potentiometry and ion-selective electrodes. Polaroraphy. 6 Hours UNIT - 6 Electrode deposition of metals and alloys. 6 Hours UNIT - 7 Primary, Secondary and Fuel Cells. 6 Hours UNIT - 8 CORROSION AND ITS PREVENTION:. Electro winning. Electro organic and inorganic synthesis (and some typical examples). Environmental electrochemistry. Bio-electro chemistry. 8 Hours Subject Code TEXT BOOKS: 1. Modern Electrochemistry - J.O.M., Bockris & A.K.N. Reddy, Vol.1 & 2, Plenum, New York 2002. 2. Industrial Electrochemical Processes - A. Kuhn,, Elsevier, Amsterdam 1971. REFERENCE BOOKS: 1. 2. Electro Analytical Chemistry - J.J. Lingane, Wiley, New York-1958. Electrochemistry, Principles and Applications - E.C. Potter, Cleaverhume Press, London 1956. Organic Electrochemistry - M.M. Baizer, Marcel Dekker, New York 1991. 53
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3.
06CH754 SUGAR TECHNOLOGY
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PART-A UNIT-I 1. Sugar Industry in India: Chemical and physical properties of sucrose and reducing sugars. Sources for sucrose, formation of sucrose plants, non-sugar compounds of sugar cane, inorganic constituents of sugar cane juices and sugars analytical methods used in sugar industry. 6 Hrs. UNIT-II 2. Purification: Chemical technology of purification process, fundamental reactions and physical chemistry aspects of clarification, liming, sulphitation and carbonation process, filtration of sugar juices. 8 Hrs. UNIT-III Evaporation: Evaporation of sugar juice, heat transfer in evaporators, evaporation equipments and auxiliaries. 6hrs UNIT-IV Evaporation Methods of obtaining steam, and quality of steam. Steam economy, chemistry of the evaporation process. 6Hrs. PART-B UNIT-V Chrystallography : Solubility of sucrose, nucleation in super saturated solutions kinetics and growth of crystallization, chemistry of crystallization, 7hrs UNIT-VI Chrystallography:control methods & equipment in sugar crystallization, technology of sugar crystallization, evaporation & circulation in vacuum pans. 7 Hrs. UNIT-VII Centrifugation : Theory of the centrifugal process, centrifugal operation, 4hrs UNIT-VII Centrifugation: engineering principles of sugar centrifugals and the centrifugal equipment and auxiliaries, production of final molasses and molassess utilization, grading of sugar. 8 Hrs. TEXT BOOKS: 1.Honing P. (Ed). Principles of Sugar technology, Vol. I to III, Elsivier Publishing Company, 1953. 2. Jerkins, G.H. Introduction of Cane Sugar Technolgy, Elsivier, 1966. REFERENCE BOOKS : 1. Mathur, R.B.L., Handbook of Cane Sugar Technology, 2nd edn. Oxford and I.B.H. Publishing Co., 1997. 2. Jink. R.W. and Pan Coast H.M., Hand book of Sugars, Avi Publishing Co., 1974. 55
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Sl. No.
Chapter
1 Sugar Industry in India
Purification
Evaporation
Crystallography
Hour Topics to be covered No. 1 History of sugar industries in India, global and Indian scenario of sugar products 2 Carbohydrates classification : Mono and disaccharides 3 Chemical properties of sucrose: action of heat on dry sucrose solutions 4 Chemical properties of sucrose contd.. 5 Physical properties of sucrose 6 Formation of sucrose: Plants 7 Composition of cane 8 Characteristics of cane 9 Coloring matters of cane 10 Chemical decomposition of cane 11 Unit operation 12 Fundamental Reactions 13 Physical Chemistry aspects 14 Liming 15 Density of lime, treatment with sulphur 16 Sulphur dioxide, phosphoric acid etc.. 17 Treatment with carbon dioxide 18 Filtration of sugar juice 19 Disposal of filter press juice 20 Rotary vacuum filters 21 Types of evaporators 22 Principles in multiple effect evaporators 23 Material and energy balance equations 24 Energy balance contd.. 25 Various features of multiple effect evaporator design 26 Design features contd.. 27 Working process of forced flow 28 Boiling point raise 29 Calculation of steam economy 30 Scale formation and cleaning 31 Solubility of sucrose 32 Specific gravity and refractive index 33 Energy and material balance 34 Saturated and super heated steam 56
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Centrifugation
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
Nucleation in crystallization Crystal growth Types of crystallization Control methods Chemistry and technology Evaporation and circulation in pans Theory of centrifugation Centrifugal operation; Double curing Factors affecting curing rates Factors affecting curing rates contd.. Engineering principles of centrifugation Continuous centrifuges Centrifugal equipments Conical Type centrifuges Coproducts of sugar cans Molasses utilisation Alcohol industry Grading and drying of sugar
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QUESTION BANK 1. Discuss the present scenario of Indian Sugar Industry in relation to world sugar Industry? 2. Mention the chemical and physical properties of sucrose and reducing sugars. 3. Explain the factors to be considered for establishment of sugar plants. 4. Explain the factors to be considered for proper layout of sugar factory. 5. What are the various milling processes employed in sugar industry? 6. Explain the working of any 2 milling equipments with neat sketches. 8. What is compound imbibition? Explain with neat sketch. 9. What is the purpose of sugar cane juice clarification? 10. What are the various chemicals used in the clarification of juice? 11. What are the colouring matters present in cane juice? Explain 12. Explain the methods of removing the coloring matter from the cane juice. 13. With neat sketches explain the production of sulphur and sulphur dioxide. 14. What are the various sulphitation processes employed in juice purification? Explain. 15. What are the various carbonatation processes employed in juice purification? Explain 16. What factors decide the type of clarification for the cane juice? 17. Explain with a neat sketch the working of a multiple effect evaporator. 18. What are the causes for the entrainment in the evaporators? 19. How are the entrainments removed in the evaporators? 20. Explain the methods of circulation of sugar syrup in the crystallizer pans. 21. Explain the working of any one sugar juice clarifier. Explain the methods of sugar seeding in the pans. 22. What are the various grades of sugar massecuites obtained in the crystallizers? 23. Explain the process of sugar drying in the rotary dryer. 24. What are the various grades of sugars? 25. Explain the working of centrifugals. 26. What are various types of evaporators used in the sugar industry? Explain their working with neat sketches.
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06CH763 PETROCHEMICALS
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06CH763 PETROCHEMICALS : 06CH763 No. of Lecture : 04 Hours/Week Total No. of : 52 Lecture Hours PART - A UNIT - 1 DEFINITION OF PETROCHEMICALS: Petrochemical. Industries in India. Principal raw materials. Introduction to chemicals from C1, C2, C3 and C4 compounds. 4 Hours UNIT - 2 CHEMICALS FROM C1 COMPOUNDS: Manufacture of methanol and chloromethanes. Manufacture of perchloro ethylene. 6 Hours UNIT - 3 CHEMICALS FROM C2 COMPOUNDS: Ethylene and acetylene, ethanol, polyethylene, ethylene dichloride, acetaldehyde, vinyl chloride, ethylene oxide, ethanol amines, vinyl acetate, acetic acid. 8 Hours UNIT - 4 CHEMICAL FROM C3 COMPOUNDS: Isopropanol, acetone, lumen (isopropyl benzene), acrylonitrile, isoprene, polypropylene, epichlorohydrin, propylene oxide. 8 Hours PART - B UNIT - 5 CHEMICAL FROM C4 COMPOUNDS: Butadiene dehydrogenation of butane (Houdry). Dehydrogenation of butylenes. Dehydrogenation-dehydration of ethanol. Steam cracking of hydrocarbons. 8 Hours Subject Code IA : Marks 25 Exam : Hours 03 Exam : Marks 100
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UNIT - 6 CHEMICALS FROM AROMATICS: Primary raw material. Hydroalkylation. 5 Hours
UNIT - 7 Manufacture of phenol 5 methods. Styrene 2 methods. Pthalic anhydride amleic anhydride, nitrobenzene, aniline. 8 Hours UNIT - 8 Manufacture of industrial dyes based on petroleum feed stocks. TEXT BOOKS: 1. Petrochemicals- By B.K.B. Rao CRC Press 1990. 2. Chem Tech II, III and IV Published by Chemical Engg. Education developments centre IIT, Madras 1979. REFERENCE BOOKS: 1. Outlines of Chemical Technology - Gopal Rao M and Marshall Sittig 3rd Edition, EastWest Press 1997. 2. Chemical process industries - 5th edition- Shreve McGrew Hill 1984. 3. Chemical Technology- G.N. Pandey 3rd Edition 1977. 4. Chemical Technology- Mukhlyonov-Mir Publications-1982. 5 Hours
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06CH764-OIL AND FATS
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SYLLABUS
Sub code: 06CH764 Hours / Week: 04 Total Hours: 52 I A Marks: 25 Exam Hours: 03 Exam Marks: 100
PART-A Unit-1 INTRODUCTION Classification of fats and oil, characteristics of oils. Utilization of fats and oils. Composition of oils. (General). 6hrs Unit-2 VEGETABLES OILS-Composition. Extraction. Refining processes and uses of coconut oil, cottonseed oil. 7hrs Unit-3 VEGETABLES OILS-Composition. Extraction. Refining processes and uses of palm oil, Soya been oil, sunflower oil. 7 hrs Unit-4 MARINE OILS- Composition. Extraction. Refining processes and uses of fish oils. 6 hrs PART-B Unit-5 OBTAINING OILS AND FATS FROM SOURCE MATERIALS-mechanical pretreatment, mechanical expression solvent extraction (two types of extractors). 10hrs
Unit-6 PROCESS TECHNIQUES- Refining and hydrogenation (H2 production and catalyst) 6hrs Unit-7
PROCESS TECHNIQUES-Degumming. Alkali Refining and bleaching. 6hrs Unit-8

DEODORIZATION- Theoretical consideration and operation of commercial deodorizer. 4hrs
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TEXT BOOKS 1. Basily industrial oil and fats products-Vol I to V-Y.H.Hery John Wiley Internataional,2nd Edition-1976 REFERENCES 1.Chemistry And Technology Of Oils And Fats-Devine j and Williams P.N 1961 2.Chemical Process Industrials Austin G.T , Shreves fifth edition, Mc graw-hill international Book Company, Singapore 1984 3.Outlines Of Chemical Technology- Dryden C.E., edited by Gopala Rao, M and M. Sitting, Second Edition, Affiliated East West Press 1993 4.Hand Book Of Industrial Chemistry- Kent J.A (Ed) Riegels Van Nostrand Reinhold,1974.
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Hour. No
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Topics to be covered
Introduction of fats and oil Classification of fats Classification of oil Characteristics of oils. Utilization of fats and oils. Composition of oils Composition of Vegetables Oils Extraction of Vegetables Oils Composition of Vegetables Oils Refining processes of coconut oil. Uses of coconut oil Refining processes of cottonseed oil. Uses of cottonseed oil. Composition of palm oil Soya been oil, Extraction of Soya been oil, Composition of sunflower oil. Refining processes of Soya been oil, Uses of Soya been oil, Refining processes of sunflower oil. Uses of sunflower oil Composition extraction of marine oils Extraction of marine oils Refining processes & use of marine oils, Extraction of fish oils Refining processes of fish oils, Uses of fish oil, Obtaining oils from source materials Obtaining oils from source materials like plants Obtaining oils from source materials like animals Mechanical Pretreatment for oils Mechanical Pretreatment for fats Obtaining fats from source materials 67
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33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
Mechanical expression for fats Mechanical expression for oils Solvent extraction (two types of extractors) Recent advance in solvent extraction Introduction to process techniques Refining Hydrogenation H2 production Catalyst Advantages and Disadvantages of the above procees Introduction to process techniques -. degumming Alkali refining. Bleaching. Advance processing techniques of the above procees Advantages and Disadvantages Deodorization Theoretical consideration Operation of commercial deodorizer Recent advance in the above process.
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QUESTION BANK Time-3hrs Max Marks-100 Note- 1. Answer any FIVE full questions. 2. Draw the process flow sheet wherever necessary. (17 Marks) (03 Marks)
1 a. Explain in detail the classification of oils and fats. b. Explain batch solvent extractor of oils.
2 a. Describe the process of extracting cotton seed oil with flow sheet. b. Explain the composition of cotton seed oil.
(14Marks) (06Marks)
a. Explain the conventional fish meal process for extracting fish oil with flow sheet, and unit operations. (14 Marks) b. Explain the major industrial uses of fish oil. (06Marks)
4 a. Name the various pretreatment of oil seeds, explain one treatment in detail. (10 Marks) b. With neat sketch explain vertical basket type of extractor. (10 Marks)
Explain in details methods of coconut oil extraction.
(20 Marks)
6 a. How the degumming of oil is done? Describe. b. Explain the bleaching technique of oil.
(10 Marks) (10 Marks)
Explain with flow sheets continuous and semi continuous process for deodorization of oil. (20 Marks) Write short notes on a. b. c. d. Utilization of oils Peanut oil extraction Characteristics of oils Immersion extractor (20 Marks)
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06CHL77 PROCESS CONTROL LAB
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List of Experiments: 1. Time constant determination and response to step change of thermometer, pressure I order 2. Single tank system step responde 3. Non Interacting step responde 4. Interacting step responde 5. Pressure system 6. U tube manometer 7. single tank impulse response 8. Non interacting tanks-impulse response 9. interacting tank impulses response 10. level /flow pressure/pH/temperature control- Pcontroller 11. level /flow pressure/pH/temperature control- PIcontroller 12. level /flow pressure/pH/temperature control- PDcontroller 13. level /flow pressure/pH/temperature control- PIDcontroller 14. valve characteristics 15. flapper nozzle system 16. valve positioner Note: Minimum of 10 experiments from above choosing are to be conducted.
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I CYCLE EXPERIMENTS 1.Time constant determination and response to step change of thermometer, pressure I order 2. Single tank system step responde 3. Non Interacting step responde 4.Interacting step responde 5.level /flow pressure/pH/temperature control- Pcontroller 6.Pressure system Hour. No 1-3 4-6 Topics to be covered Instruction for the I cycle of experiments. 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 Experiment number 6 for group 6 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 6 for group 5 Experiment number 1 for group 6 Experiment number 3 for group 1 Experiment number 4 for group 2 Experiment number 5 for group 3 Experiment number 6 for group 4 Experiment number 1 for group 5 Experiment number 2 for group 6 Experiment number 4 for group 1 Experiment number 5 for group 2 Experiment number 6 for group 3 Experiment number 1 for group 4 Experiment number 2 for group 5 Experiment number 3 for group 6 Experiment number 5 for group 1 Experiment number 6 for group 2 Experiment number 1 for group 3 Experiment number 2 for group 4 72
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7-9
10-12
13-15
16-18
Experiment number 3 for group 5 Experiment number 4 for group 6
II CYCLE EXPERIMENTS 7.level /flow pressure/pH/temperature control- PIcontroller 8.level /flow pressure/pH/temperature control- PDcontroller 9.level /flow pressure/pH/temperature control- PIDcontroller 10.valve characteristics 11.flapper nozzle system 12.valve positioner Hour. No 19-21 22-24 Topics to be covered Instruction for the II cycle of experiments Experiment number 7 for group 1 Experiment number 6 for group 2 Experiment number 9 for group 3 Experiment number 10 for group 4 Experiment number 11 for group 5 Experiment number 12 for group 6 Experiment number 8 for group 1 Experiment number 9 for group 2 Experiment number 10 for group 3 Experiment number 11 for group 4 Experiment number 12 for group 5 Experiment number 7 for group 6 Experiment number 9 for group 1 Experiment number 10 for group 2 Experiment number 11for group 3 Experiment number 12 for group 4 Experiment number 7 for group 5 Experiment number 8 for group 6 Experiment number 10 for group 1 Experiment number 11 for group 2 Experiment number 12 for group 3 Experiment number 7 for group 4 Experiment number 8 for group 5 Experiment number 9 for group 6 Experiment number 11 for group 1 Experiment number 12 for group 2 Experiment number 7 for group 3 Experiment number 8 for group 4 Experiment number 9 for group 5 73
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25-27
28-30
31-33
34-36
37-39
Experiment number 10 for group 6 Experiment number 12 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 group 5 Experiment number 11 for group 6
VIVA QUESTIONS 1. What is time-constant? 2. What are Resistance & Capacitance? 3. Distinguish between linear & Linearised Resistance. 4. Distinguish between time constant and time delay 5. Distinguish between transfer lag & transportation lag 6. What is a transfer function and why is it essential that the process be linear to obtain its transfer function? 7. Why do you take 63.8% of response to unit step change to calculate the time constant graphically? 8. Can you take 63.8%of response for all types of forcing functions and irrespective of the order of the process 9. You determine time constant of a thermometer as 60 sec if you want to decrease it to 30 sec. What modifications you suggest to achieve it? 10. Which of the following vessel has lesser time constant, when their volumes are equal
Vol = V
Vol =V
11. Give an expression to calculate Capacitance of a vessel of the shape as shown in fig. Below Diameter
12. Give an expression for calculation for capacitance of gases. List out the assumptions involved. 13. Which of the following gases causes largest & least capacitances? & Why? (i) Water vapor (ii) Helium (iii) Argon (iv) Oxygen (v) Ammonia 14. What are interacting & non-Interacting processes? 74
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15. Give different classifications of interacting & non-interacting processes 16. What are advantages and disadvantages (give at least one each) over non-interacting processes 17. How do you usually represent a 6th order process? 18. How do you overcome the difficulty of presence of dead-time element in a closed Loop control system 19. What is damping? & Damping co-efficient? Give examples of processes with different damping co-efficient 20. Say True or False: by manipulations & changes one can make a two tank non-interacting process to be made to be under damped process 21. Say True or False: A two-tank process with equal values of time-constants (identical Resistance & capacitance) will always be over damped 22. What is proportional gain? What is proportional bandwidth? 23. If proportional sensitivity is 60%, the level ranges from 0-250 mm, what is the corresponding proportional band? 24. What are the advantages & disadvantages of combining I action with proportional action? 25. What is the effect of adding D action with proportional action? 26. What is offset? Explain briefly with suitable example (s) 27. For a particular setting of a proportional controller of kc the offset is, say, 5%. If kc is increased the offset (i) will increase (ii) will remain constant (iii) decreases 28. For a particular setting of a PI controller the corresponding damping co-efficient is . If the integral time is decreased with kc held constant, the damping co-efficient, . , i) will increase (ii) will remain constant (iii) decreases 29. What do you understand by order of a reaction? 30. Distinguish between order & molecularly of a reaction 31. What is specific about specific reaction rate constant? 32. What are elementary & non-elementary reactions? 33. Give the balanced reaction of reactants you use in your experiments. What is its name? State whether it is an elementary & non-elementary reaction? 34. What are the usual methods of analyzing & determining the order and k of a reaction? Explain briefly 35. 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 36. 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 37. If k is k2 at temp=T1 k will (a) remain the same (b) increases (c) decreases at a higher temp, T2 38. What are space-time & space velocity? 39. What is meant by residence time? 40. What are reasons for non-ideality of flow reactors? 75
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41. What are C, E & F curves? 42. What is type of input you usually give to study the non-ideality of flow reactors? What are their names? 43. What are the characteristics of a tracer? 44. What are mean, variance and standard deviation and how do you calculate them? 45. What is dispersion number? 46. What are batch, plug and mixed flow reactors? 47. If the dispersion number is very large, then the actual reactor approaches ideal plug flow! TRUE or FALSE 48. If the dispersion number is very small, then the actual reactor approaches ideal plug flow! TRUE or FALSE
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06CHL78 COMPUTER APPLICATIONS & SIMULATION LAB
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SYLLABUS Hours / Week: 3 Exam Hours: 4 List of Experiments: PART A 1. Non linear algebric equation Newton Raphson (Specific volume of binary mixture) 2. Ordinary Differential equation RK Method (dCA/dt = KCa2). 3. Numerical Integration Simpsons 1/3 rule (Batch Reactor to find time) 4. Curve fitting Least square (Nre V/s f) 5. Calculation of bubble point and dew point for ideal multi component system 6. Flash Calculation for multi component mixtures 7. Design of adiabatic Batch reactor, PFR 8. Adiabatic flame temperature 9. Double pipe heat exchanger (Area, Length and pressure) 10. Distillation column (Bubble cap) I A Marks: 25 Exam Marks: 50
PART B 1. 2. 3. 4. Introduction to suggested software available (flow sheeting). Simulation studies of flash drum, distillation column, CSTR, PFR, Heat exchanger Simulation studies of pump, compressor, cyclone, heater Process simulation study involving mixing, reactor, Distillation, Heat exchanger, any of the following process a). Ethylene glycol form ethylene oxide b). Atmospheric distillation of crude oil c). Phthalic anhydride process d). Aromatic stripper with recycle stream (Benzene, Toulene, Xylene) e). Styrene from Ethyl Benzene Note: One question form PART A Excluding Numerical Techniques 20 Marks One question from PART B (Simulation of any above process) 30 Marks
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1. Bubble point temperature for ideal binary and multi component mixtures 2. Dew point temperature for ideal binary and multi component mixtures 3. Flash vaporization for multi component mixtures. 4. Design of adiabatic CSTR. . 5. Design of adiabatic PFR Hour. No 1-3 4-6 Topics to be covered Instruction for the I cycle of experiments. 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 Experiment number 6 for group 6 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 6 for group 5 Experiment number 1 for group 6 Experiment number 3 for group 1 Experiment number 4 for group 2 Experiment number 5 for group 3 Experiment number 6 for group 4 Experiment number 1 for group 5 Experiment number 2 for group 6 Experiment number 4 for group 1 Experiment number 5 for group 2 Experiment number 6 for group 3 Experiment number 1 for group 4 Experiment number 2 for group 5 Experiment number 3 for group 6 Experiment number 5 for group 1 Experiment number 6 for group 2 Experiment number 1 for group 3 Experiment number 2 for group 4 Experiment number 3 for group 5 Experiment number 4 for group 6
7-9
10-12
13-15
16-18
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II CYCLE EXPERIMENTS 5. Design of distillation column 6. Simulation studies of heat exchanger 7. Simulation studies of distillation column 8. Simulation studies of ethylene glycol from ethylene oxide 9. Aromatic stripper with recycle stream (Benzene, Toluene, Xylene) Hour. No 19-21 Topics to be covered Instruction for the II cycle of experiments Experiment number 7 for group 1 Experiment number 6 for group 2 Experiment number 9 for group 3 Experiment number 10 for group 4 Experiment number 11 for group 5 Experiment number 12 for group 6 Experiment number 8 for group 1 Experiment number 9 for group 2 Experiment number 10 for group 3 Experiment number 11 for group 4 Experiment number 12 for group 5 Experiment number 7 for group 6 Experiment number 9 for group 1 Experiment number 10 for group 2 Experiment number 11for group 3 Experiment number 12 for group 4 Experiment number 7 for group 5 Experiment number 8 for group 6 Experiment number 10 for group 1 Experiment number 11 for group 2 Experiment number 12 for group 3 Experiment number 7 for group 4 Experiment number 8 for group 5 Experiment number 9 for group 6 Experiment number 11 for group 1 Experiment number 12 for group 2 Experiment number 7 for group 3 Experiment number 8 for group 4 Experiment number 9 for group 5 Experiment number 10 for group 6 Experiment number 12 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 group 5 Experiment number 11 for group 6
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22-24
25-27
28-30
31-33
34-36
37-39
VIVA QUESTIONS 1. What is the difference between mainframe and mini frame? 2. What is Syntax error? 3. What is a platform? 4. What are the High level and Low-level language? 5. How does a machine language is converted to High level language 6. What are Analog computer and Digital computer? 7. Why programming is necessary in Chemical engineering 8. What is Main function and function 9. What are the inbuilt files in C language? 10. What are sub functions and subroutine functions? 11. What is Bubble and Dew point? 12. Batch reactor, Mixed flow reactor, Plug flow reactor: where all it is used 13. What is exothermic and endothermic reaction? 14. Distinguish between isothermal and non-isothermal reactions 15. Define reaction rate constant 16. Differentiate reaction rate and rate constant 17. What is space velocity and time? 18. Differentiate between integral analysis method and differential analysis method 19. What are equations of states? 20. Differential between Raoults law and Henrys law 21. Differentiate between ideal and non-ideal solutions 22. What are virial-coefficients? 23. Define Gibbs free energy and fugacity coefficient 24. What is Vapour liquid equilibrium? 25. Define Daltons law 26. Differentiate between steady state and unsteady state conduction 27. Define LMTD 28. Significance of LMTD 29. Which flow in Heat exchanger is more convenient? 30. What is LMTD correction factor and why is it necessary? 31. Will the Boiling point of a solution increases or decreases with pressure
81 MVJCE

Chemical Engineering Course Diary

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DEPARTMENT OF CHEMICAL ENGINEERING COURSE DIARY

(ACADEMIC YEAR 2011-12)

Semester & Section : _____________________________________________

DEPT. OF CHEMICAL ENGG.

VII SEMESTER COURSE DIARY

06CH71- CHEMICAL PROCESS INTEGRATION

DEPT. OF CHEMICAL ENGG.

V/VI SEMESTER COURSE DIARY

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

Introduction to process integration: graphics techniques. Overall mass targeting.

Systems of mass exchange network:: graphical approach . direct recycle strategies

Heat integration: combined heat power integration

DEPT. OF CHEMICAL ENGG.

V/VI SEMESTER COURSE DIARY

Overall Mass Targeting

Graphical Techniques for Direct Recycle strategies

Synthesis of mass exchange network: A Graphical approach

The composition interval diagram, mass exchange cascade diagram

DEPT. OF CHEMICAL ENGG.

V/VI SEMESTER COURSE DIARY

targeting mass exchange networks

Example of cleaning aqueous wastes, problems

23 24 25 08 Recycle Strategies using Property Integration 26 27

Combined Heat and Power Integration

DEPT. OF CHEMICAL ENGG.

V/VI SEMESTER COURSE DIARY

06CH72 INSTRUMENTATION & PROCESS CONTROL

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

DEPT. OF CHEMICAL ENGG.

V/VI SEMESTER COURSE DIARY

Instrumentation: Fundamentals, static and dynamic characteristics, Indictor and recorders.

UNIT 7 Control System Design by Frequency Response:

UNIT 8 Root Locus: Rules for plotting and problems

DEPT. OF CHEMICAL ENGG.

V/VI SEMESTER COURSE DIARY

Hours / Week: 04 Total Hours: 52

DEPT. OF CHEMICAL ENGG.

V/VI SEMESTER COURSE DIARY

DEPT. OF CHEMICAL ENGG.

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DEPT. OF CHEMICAL ENGG.

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85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105

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DEPT. OF CHEMICAL ENGG.

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