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UNIT I
TWO MARKS
1. Define ISA?
A standard atmosphere is defined in order to relate flight tests, wind tunnel
results, and general airplane design and performance to a common reference. The
standard atmosphere gives mean values of pressure, temperature, density and
other properties as functions of altitude: these values are obtained from
experimental balloon and sounding rocket measurements combined with a
mathematical model of the atmosphere.
2. Define Aerodynamic lift, drag and moments?
Consider the body sketched in figure oriented at any angle of attack to the
free-steam direction. The free steam velocity is denoted by V and is frequently
called the relative wind. The resultant aerodynamic force R, is inclined rearward
from the vertical, as shown in figure. (Note that, in general R is not perpendicular
to the chord line. By definition, the component of R perpendicular to the freestream velocity is the lift L, and the component of R parallel to the free steam
direction is the drag, D.

Figure: Lift , drag and resultant aerodynamic force

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Figure: (a) Moment about the quarter-chard point, (b) Moment about the
leading edge.
3. Define centre of pressure?
The centroid of the distributed load on the body is the point through which
the equivalent concentrated force acts. This point is called the center of pressure.
4. Define Aerodynamic co-efficients?
The lift, drag, and moment coefficients for a given body, denoted by CL, CD
and CM, respectively , as follows:
CL

L
q S

CD

D
q S

CM

...(1)
...(2)

M
q Sc

...(3)

Where q is the dynamic pressure, defined as

q

1
V2
2

....(4)

And c is a characteristics length of a body (for an airfoil, the usual choice for
c is the chord length). Let us define the following similarity parameters:

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Re ynolds number (based on chord length): =
Mach number , M

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VC

..(2.5)

V
a

5. Define Stalling ?

Figure: Sketch of generic lift curve.

At high angles of attack, the lift coefficient becomes non-linear, reaches a
maximum value denoted by (c1)max in figure, and then drops as is further
increased. The reason for this drop in c1 at high is that flow separation occurs
over the top surface of the airfoil and the lift decreases (sometimes precipitously).
In this condition, the airfoil is said to be stalled.
6. Define Aspect ratio and taper ratio?
An important geometric property of a finite wing is the aspect ratio AR,
defined as AR b2/S.

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b2

1
Figure: Aspect ration AR S ; Taper ratio = C
r

7. Define pressure drag and friction drag?

Pressure drag- due to a net imbalance of surface pressure acting in the drag
direction
Friction drag due to the net effect of shear stress acting in the drag
direction.
8. What is mean by drag polar?
For every aerodynamic , there is a relation between CD and CL that can be
expressed as an equation or plotted on a graph. Both the equation and the graph
are called drag polar.
PART =B
9. Derive the relationship between the pressure and density variation in the
isothermal regions and gradient regions of the standard atmosphere?
The keystone of the standard atmosphere is a defined variation of T with
altitude, based on experimental evidence. This variation is shown in figure.

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Note that it consist of a series of straight lines, some vertical (called the
constand temperature, or isothermal, regions) and other inclined (called the
gradient regions) given T = T(h) as defined by Figure, Then , = (h) and =
(h) follow from the laws of physics, as shown below.
consider
Pressure First,
altitude
= 6000
mm
=again
6= km
Temperature
altitude
= 5000
5 kmCHEMICAL ENGINEERING
CHEMICAL PROCESS INDUSTRIES II

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UNIT I

PART A
1. What is meant by Pulping?
Paper production requires a disintegration of the bulky fibroins material to individual (or)
small agglomerate fibers. This is called pulping.
2. What are the raw materials used in paper Industry?
(i)
(ii)
(iii)
(iv)
(v)

Softwoods
Grasses and
Straws
Cotton linters
Hardwoods

3. What is meant by Pulp?

Pulp is a commercial cellulose from bamboo, bagarre wood, etc by mechanical (or) chemical
methods.
4. What are the methods used in the manufacture of industrial pulp?
i)
ii)

Sulfate (kraft) process

Sulfite process

5. Write the reaction for the sulfate process?

R "CooNa
R R ' NaoH RoH

R R ' Na2 S meccap tan s

6. Briefly explain about soda process?
Small tonnage (25-50 tons/day) plants initially set up in India use a process which involves
hydrolysis with NaoH and Na2co3 in 4:1 ratio Advantage is lowest cost of chemicals are not
recovered and sulfur requirement. The soda process produces inferior grade pulp at high cost in
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batch operations and is not used for modern, large tonnage pulp plants.

7. What is called as Paper?

It is defined as the felted sheets of fibrons, usually cellulose and generally formed on a fine
wire screen from a water suspension
8. What are the steps involved for the manufacturing of paper?
i)
ii)
iii)
iv)

Preparation of filter suspensions.

Forming a wet web
Pressing the wet web
Drying the sheet

9. For what reason the filters are added for the paper manufacturing?
They are added to improve the brightness, bulk, flexibility, capacity, softness and weight of
the finished paper.
10. What is the reason for doing sizing?
Sizing is an important ingredient often added to the slurry to reduce water (or) other liquid
penetration into certain paper products
11. What are the coloring agents added in the paper manufacturing process?
Coloring agents are mixed in to the slurry before processing. These are generally synthetic
organic dyestuffs; but some colouring is done by water- insoluble pigments.
12. Describe the Digestion process involved in the pulp production?
Hogs with bark are debarked by tumbling and rubbing action, then conveyed to chipper
where large rotary disks with many have knives reduce the wood to 2-5 cm flat chips.
The chips are recharged thro a rotating tapered plug in to the lift line where circulation
digestion liquor at 12 atms.
13. What is termed as Bleaching of pulp?
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Removal of colour residue (or bleaching may be accomplished by use of one of various
oxiding agents which must be cheap and have a minimum degrading action (or) cellulose.
14. What is the use of lignim obtained in paper industry?
It is used as fuel used itself in pulp and paper production Industry.
15. Explain the term paper?
Paper is defined as matted (or) felted sheets of fibers, usually cellulosic and generated
formed on a fine wire screen from a water suspension.
16. Explain the procedure for the formation of fiber suspension?
Pulps are water slurried to - % fiber content by mechanical disintegrators of various
designs . Then we are adding filters, sizing, coloring agents to improve the strength.
17. Define Inversion of sugar?
In handling sucrose, particularly in the sugarcane before pressing, the inversion to
monosaccharide is possible.
C12 H 22O11 H 2 C6 H12O6 C16 H12O6
Sucrose

d glu cos e

d fructose

18. What are the by-products of sugar manufacture?

i) Molasses
ii) Bagasse
iii) Press mud
19. What is the use of Bagasse?
It is the by-product used in sugar industry used as fuel in boilers for generation of stream
raw material for the paper industry as well as cogeneration of power.
20. What is the use of molasser?
Molasses in an important by product having strong linkager with alcohol industry. 70% of
the molasses is used for the manufacturer of industrial alcohol and balance 30% for potable
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alcohol.

21. Define the term Black strap molasses

The mixture of crystal and syrup is separate via high speed basket centrifugal. The syrup is
concentrated and cooled successively to obtain one (or) two more crops of crystals. The final
mother liquir is known as black strep molasser.
22. Define the term starch.
Starch is a high polymer carbonhydrate occurring in grains and roots in the form of
granules of 3-100 size. These granules can be extracted from the grains by water hydration of he
cells.
23. What are the type of pulp?
i)
ii)

Sulphate pulp
Sulphite pulp

24. What are the applications of starch?

i)
ii)

Starch has considerable usage in industry

Hydrolysed products used in food industry

25. What are the recent improvements in the paper making process?
i)
ii)

Increase in the wet strength of paper products

Modification in paper machine to improve properties of paper

26. What are the type of starches?

i)
ii)
iii)

Dextrin
Dialdehyde starch
Starch phosphate

27. What is viscon rayon?

It is a thread like structure of varying lengths capable of being woven of spume into larger
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units.

28. What are the miscellaneous starch derivates?

i)
ii)
iii)

Rice starch
Amylose
Potato starch

29. What are the application of the starchus?

i)
ii)

Starch has considerable usage in industries

Hydrolyzed products used n food industries

30. What is amylase and amylopectin?

Amylose occurs to the extent of 27% in corn starch and 73% is amylopectin
Amylose is a linear chain of dextore
Amylopectin is almost amylore and is being grown in increasing amounts.
31. What do you know about cane sugar refining?

Quality of sugar will be poor

The impurities are coagulated by the addition of vegetable bare to produce good quality
sugar.

32. Which machine is used in sugar manufacturing?

Fourdrinler machine
33. What are the products of the glorifications of coal?

Producer gas
Water gas

34. Write the two phases in the reduction of raw wood?

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Cellulose
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Non cellulose

35. What is the other name for the coal gasification process?
Kopper tozex process
36. What are the sizing agents?

Rosin
Wax emulsions

37. What are the types of paper products?

Wrapping papers
Tissue paper
Book paper
Paper board

38. Give examples of fiber types cellulose?

Viscose Rayon
39. What are the uses of coal?

Coal gas, ammonia, benzene and phenol in destructive distillation, Aromatics by

hydrogenation.
Organic acids under controlled oxidation

40. Give examples of beaching agents?

Sodium bisulphate
Chlorine
Sodium dithionate

41. What are detergents?

Detergents covers scientifically both soap and synthetic detergents. But, it is widely used to
indicate synthetic cleaning compounds as distinguished from soap. Detergents may react with the
hard water ions, resulting products are either soluble (or) remains colloid ally dispersed in water.
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42. What is the use of foundriniers machine?

It is used in the manufacture of
i)
paper
ii)
sugar
iii)
dyes
43. List some name of regents used for the chemical treatment of wood chips.
The different reagents are.
i)
Sulphite
ii)
Sulphate
iii)
Causing soda and / or soda ash
44. What is the chemical formula for paper makers alum?
Al2So4

18H2O

45. What is meant by affination in sugar industry?

In sugar industry the same sugar crystal are treated with a heavy syrup in order to remove
the film of adhering molasses. This refining step is called affination.

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PART B
1. Explain the sulphate process for the production of pulp with neat flow sheet?
Logs with bark and debarked by tumbling and rubbing action, then conveyed to chippers
where large rotary disks with many heavy knives reduces the wood to 2-5 cm flat chips.
The chips are metered via star valve to a deareator pre heater. After several minutes, the
chips are discharged thro a rotating tapered plug into the lift line where recalculating digestion
liquor at 12 arms. Transfer chips to the upper soaking zone of the 25-30 m tall digestion to wet.
The digestion chips are cooled at the base of the towel by injection of cold back liquors.
This s to avoid mech. Weakening of fibers from stream explosion of the hot liquor when passed
thro the blow down valve. The pulp liquor slurry is passed thro the value to blow tank where
residual heat is removed in the form of stream which passes overhead with turpentine vapour to
the chip preheater. The pulp is filtered to separate black liquor and screened to remove wood
knots and other undigested residue. The blown pulp goes either to produce finishing operations
(or) the bleaching plant.

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Figure: Process Flow Sheet

Preparation of wood pulp from sulphate process
2. Explain the recovery of chemicals flam digestion tower in sulphate process

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Figure: Chemical Recovery From Sulphate Process

The equation is
a)

Smelting furnace
2NaR (highnium salt) + air Na2Co3 + Co2
Na2So4 + 2c (flam R) Na2 s + 2 Co2

b)

Caustcizing
Na2CO3 (ag) + ca(OH)2 (s) 2NaOH(ag) + CaCo3(s)
CaCo3 Cao + Co2
Cao + H2o Ca(OH)2

Process description
Black liquor from the blow tank containing 98.99% of the digestion chemicals which must
be recovered to avoid water and air pollution problems and to provide a balanced economy of
Opn.
Multiple effect evaporation using 5-6 stage of calendar followed by disk evaporates contact
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rates the liquor from 15-18%. Solids to the point where combustion can be strained in a smelting
waste heater boiler.
The molten smelt falls into the dissolved where it contacts cold H 2o to yield green liquor
solution. The insoluble imparities, such as in carbon are unsettled out and the clear liquor
causticized by adding lime.
3. Explain the main reaction involved in sulphate process and process reactants and Bypro
chemical Reaction:
Digestion Hydrolysis and volatilization of liquor
n

R COONa
R R ' NaoH ]Z RoH

R R ' Na2 S melcap tan s

Chemical recovery from black liquor: Wood digestion liquor)
a) Smelting Furnace:
2NaR (liquor salt) + air Na2 Co3 + Co2
Na2 SO4 + 2C (from R) Na2 S + 2Co2
b) Causticizing:
Na2Co3 (ag) + Ca(OH)2 (S) 2NaoH (ag) + Caco3 (s)
Cao + H2O Ca(OH)2
By product utilization:
The germ resin and oil friction from softwood furnishers the naval products of tall oil rosin
turpentine.
The use of liquor thus used in low rubber return a fuel within the pulp and paper plant.
4. What is paper? Explain the types of paper and various raw materials?
Paper is defined as matted (or) felted sheets of fibers, usually cellulosic and generally
formed on a fine wire screen from a water suspension.
Types of paper products
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Wrapping paper Bay paper, grease proof paper

Tissue paper cigarette, carbon, toilet-towel, napkin paper
Writing paper bond weight linear paper
Ground wood printing paper catalog, newsprint, tablet porter, wall papers.
Paper board heavier less flexible, laminated paper stock

Raw Materials:
Fibrous raw material:
Paper pulp
Ground wood, bleached and unbleached sulfite and sulfate, semi- chemical pulp
Reuse pulp:
Paper products such as news papers and paper board and re-pulped and mixed with new
pulp for paper mill feed stock.
Non-fibrous raw material
Inorganic raw materials

Clay, talc, titanium dioxide zinc sulfide, alum, organic raw material
Rosin, glue, casein, waxes, glycol, dyestuffs
5. Explain the manufacturing process for paper.
Steps involving in paper making process:
o
o
o
o

Formation of wet web

Pressing the wet sheet
Drying the sheet
Addition of ingredients like filter, sizing agents, colouring agents etc.

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Paper making Process:

Figure: Schematic drawing of a paper making process

6. Explain the steps involved in the paper production process.
Preparation of fibre suspensions:
Pulps are water slurried to - % fiber content by mechanical disintegrators of various
designs. These usually consists of rotating drums with knife attachments (or) rotating stationary
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disks to produce vircous shear. Such operations are called beating and refining.
Filters are added to the slurry to the increase brightness, bulk flexibility, opacity, softness
and weight of finished products.
Sizing is an important ingredient of the added to the slurry to reduce water (or) other
liquor penetration in to certain paper pots.
Colouring agents are also mixed in to the slurry before processing. These are generally
synthetic organic stuffs, but some colouring is done by H 2O insoluble pigments.
Formation of wet web:
A wet sheet is formed by running 99 of water fiber flurry evenly onto a moving endless
belt of wire cloth at speeds of 50m/min for fine paper to 500 m/min for newsprint. Water drains
by gravity, a part is next removed by a paper roll and then by suction roll. The screen also a side
wire shaking motion to give better interlocking of fiber on the mat.
Drying the sheet:
The sheet from the press section has sufficient strength to carry it own weight. It is passed
thro smoothly rolls, then a series of steam-heated metal cylinder where heat and moisture are
transferred to a felting (or) convering belt.
7. Explain the process with neat flow diagram for the extraction of sugar from sugar cane.
Canes are shredded in crushes and then squeezed thro a series of pressures mills
containing grooved walls.
The juice is treated with CaHPo4, followed by lime to precipitate the colloids So2 is next
bubbled thro until the PH is 7.0 to 7.1 . This is for the flocculation of impurities. So 2 acts as
bleaching agent.
Closed steam in a coil is used to heat and further flocculate the impurities in a continuous
setter.

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Figure: Extraction of Sugar from Sugarcane

The clarified liquor overflows to the evaporator. The underflow muds are processed on a
continuous rotary press to recover sugar solution.
The clarified juice is concentrated from 80-85% water 40% in 3 (or) 4 effect evaporator with
crystallization.
The mixture of syrup, called massecute is separated via high speed basket centrifugal. The
syrup is re-concentrated and cooled successively to obtain one (or) 2 crops of crystals. The final
mother liquor is termed as Black strap molasses.
8. Explain the starch production from maize.
Process description:
The major source of starch in maize and a wet milling process for the removal of starch will
be presented.
Maize kelnels containing 60-65% starch are screened and air cleans, then steeped in 50-55C
water containing 0.15 0.30% So 2 grinding mills to rapture the cells and loosen the oil germ which
is floated off in a large slurry tank.
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The starch portion of the kernel is wet ground on burrstone mills and passed over nylon
cloth where water washes the starch thro and leaves the fiber and hulls on the screen.
The starch suspension in the underflow from the screen contains glucton (water in soluble)
which is separated as the light fraction in a 2 stage centrifugal operation.
The starch is recovered as filter cake on continuous rotary filter. It can be dried powdered
and sold as peal starch.

Figure: Starch Production from maize

9. Explain the production of Dextrin by starch hydrolytes in a fluidized bed
n
x

C6 H10O5 x
C6 H10O5 heat
Hel
A batch operation charges 5-10 starch to an air suspended fluidize. Heat is added via
rectangular shaped.

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Figure: production of dextrin by starch hydrolysis in a fluidized bed

Plate coils, using 10-12 atms. Steams, in the upper section of the fluidizer. The charges reaches
65- 170 C, depending on the degree of hydrolysis desired, within 30min. the charge reaches 65170 C, depending on the degree of hydrolysis desired. Within in 30 min Hcl vapour is introduced
in to the re-circulating air steam and de-polymerization continued for 1- 8 hr.
10. Explain starch derivations.
Description:
An oxidation form of starch which is used in the paper industry as a wet strength additive and in adhesives.

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Chemical Reactions:
a) Oxidation of Starch

HIO3 + H2O
b) Regeneration
Anode of electrolysis cell:
HIo3 + 2oH HIo4 + H2o
Starch slurry contact periodic acid in a batch reaction with the oxidized starch separated from
iodic acid solution by centrifuging. The reduced solution is re-oxidized as the anolyte in a unique
electrolytic cell.
11. Describe Starch Phosphate
A starch which is water soluble, has excellent freeze thro stability good tricking power
excepted usage is as thickness in canned and brozen foods, addresively , emulsion, paints
formulatons, Pharmaceutial filters and binder.

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Process description:
Starch slurry is a heated with alkaline phosphate solutions at various conditions depending
upon degree of estirification. Control of PH (8.5-9.5), temperature (50-70C) used. The water
soluble solutions are filtered and the filtered spray dried.
12. Describe briefly about the starch structure and properties.
Starch is a high polymer carbohydrate occurring in grains and roots in the form of
granules of 3-100 size. These granules can be extracted from the grains by water hydration of
cells.
Chemical Formula : C6H10 O5
Chemical structure
Amylose (or) Linear polymer

Amylopectin (or) branched chain polymerization:

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Values from 200- 500C, comment industrial starches from maize contain 15-30% amylase and
87.70% amylopection
13. Explain the section of coal garifier

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Figure: Section of coal gasifer

Coke (or) non coking coal taldistillation relate mainly to competitive petrochemical routs
to such products as aromatics hydrocarbons and phenol.
Raw material:
Coke (or) non-coking coal
Reaction:
4C+O2 + 2H2O 4Co+2H2

14. Explain the process in detail for coking of coal.

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The high temp carbonization of coal is carried out at 900C to 1.150C in batteries of tall
vertical ceramic chambers separated by heating flores. Each chamber may be 13ft high, 38 to 40ft
long and tapering in width from 17-18 inches at one end to 15-16 inches at another end. One even
may hold 16-24 tons of coal and a battery may contain 10-100 ovens. Crashed coal is dropped in to
an over preheated to 1,100C.
After a heating tie of about 17 hrs doors on the ends of the over are opened and the entire
red hot coke mars is pushed out into a quenching car by a power driven ram. After draining off
the water the coke is crushed and screening prior to use as fuel. The gar issuing from the over
during the coking process is cooled to remove tars, scrubbed with water to remove NH 3
15. Define the hydro formation of coal:
The coal may be fed to hydro formation process is various ways. Each of them requiring
produced coal.

Figure: Process of powdered coal to give aromatic liquids

UNIT II
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PART A
1. What are edible oil?
These are the mixture of glyserides of fatty acids.
2. Give any two examples (or) Uses of non-edible fats?
Manufacture of soap
Neam oil is used as pesticide
3. What is necessarily for the hydrogenation of oil?
To remove double bonds raise the melting point of the fat and improve its resistance to
rancid oxidation.
4. What are oils and fats?
Mixtures of glycerides of fatty acids where R1 R2 and R3 are not necessity the same.
R1Coo CH2

R2 COO CH
R3CooCH2
Oils are liquids and fat are solids at normal temperature
5. Define WAX:
Mixed enters of polyhydric alcohols other than glycerin usually solids at room temperature.
6. What are surfactants?
Any compound that affects surface tension where dissolved in water (or) water solution (or)
which similarly affects interfacial tension between two liquids.
7. Write soponification reaction?
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R.CooH+ M.OH R.Coom +H2O

Glycerides Caustic
Soap of Higher Fatty acids
M alkali metal such as Na (or) K
8. Give the fat splitting reaction:
Acid hydrolysis of glycerides followed by alkali addition (Rc000),
c3H5 +H2O RcooH+C3H5 (OH)
9. What are the uses of fatty acids?
As magnesium striates in face powders
Lithium steerages as a component of greases
Rosin soap consumed as a sizing of paper
10. Types of Surfactants
Quatenary ammonium compounds dialky, dimethy, quaternary ammonium.
Diamido alkoxylated quaternary ammonium compounds Amido imidazdinium
compounds.
11. What are the advantages of the continuous hydrolysis and saponification process?
(i)
(ii)
(iii)
(iv)

Flexibility in control of product distribution

Higher glycerin yields
Less off colour production and
Requires less space and ma-power

12. What are the raw material for the manufacture of soap?
Vegetable oils
Caustic soda
13. What are the products of saponification of a fat?
The products are
Glycerol
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Salts of higher fatty acids

14. What is meant by massecuite?
The mixture of crystals and syrup is called massecuite.
15. What are the favorable condition to maintain higher melting point fats of maximum
stability for cooking purpose.
The favorable condition to maintain higher melting points fats of max. Stability for cooking
purposes are higher pressure (2 to 3.5 atm) and lower temperature (20-160c)
16. What is the structural formula for sucrose:

17. Define the term saponification value?

The number of milligrams of potassium hydroxide required to saponify one gram of the oil.
18. Write the uses of Citric acid:
As an acidulant in carbonated beverages, jams, jellies and other food stuffs.
19. Give any fields where soaps and detergents are used?

Textile manufactures
Sanitation
Food processing
Shaving soaps
Paints and emulsion formation etc.

20. Give the usage Enzyme named Zymase in Fermentation Industry?

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Zymase is used to convert glucose into ethyl alcohol and carbon-di-oxide.

21. Write the reaction for the production of Nickel catalyst?
2Ai.Ni+6NaoH Ni* + 2NaAlo3 +3H2
Alloy
(Raney Nickel)
22. Names the raw material in the production of a soaps?
(i) Refined Tallow
(ii) Refined grease
(iii) Coconut and palm oils
(iv) Metal oxide such as Zno used as catalyst.
23. What are the different chemical reactions involved in the fermentation industries?
(i) Oxidation
(ii) Reduction
(iii) Hydrolysis
(iv) Esterification
24. What are the products of Saponification of fat?
(i) Glycerol
(ii) Salty of higher fatty acids
25. Write the chemical formula for silicic acid?
The chemical formula is H2 Sio3
26. What is the use of enzyme glucose iromers?
It is used to produce high fructose syrup from Corn.
27. Write the composition alcohol?
It is alcohol contains 95% of alcohol and 5% water is known as industrial alcohol.
28. What are the major engineering problems involved in fermentation industries?
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(i) Kinetics of submerged, aerobic fermentation

(ii) Scale up of submerged fermentation
(iii) Air sterilization
(iv) Media sterilization
(v) Continuous virus batch operation.
29. Define Beer:
Separations of 8-10% alcohol in the fermentation liquor is called Beer.
30. Which type of alkali is added to removed free fatty acid in oil-extraction?
In oil extraction, alkali such as Naoh (or) Na2Co2 is added to remove free fatty acids.
31. What is the used of Hydrogeneration?
It is used to remove double bonds raise the melting points of the fat, and improve its
resistance to ran acid oxidation.
32. What is the use of sodium silicate?
It is used in detergents to avoid aluminum corrosion in washing machines.
33. Define the term fermentation?
It is defined by microbial process controlled by humans that produces useful products.
34. What are the Unicellular enzymes?
Yeasts
Bacterias
35. What is the main-chemical reaction involved in the manufacture of alcohol and by products
acetic acid and glycerin?
C6H12O6
C2 H5 OH+2CO2
Monosaccharide
alcohol

OH =-130 KJ

2C6H12 O6 +H2O
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Monosaccharide C4H5OH +CH3COOH +2CO2 +2C3 H8O3

Alcohol
acetic acid
36. What are the uses of detergents?
(i) A cleaning agent
(ii) A water softener
37. What must be the temperature kept for the manufacture of ethanol?
20-30 C
38. What is meant by fusel oil?
Mixture of any 1 alcohols with some butyl, and Lexy1 alcohols and esters.
39. Define Molasses?
Molasses is a dark coloured, viscous liquid left after the crystallization cane sugars from
cane juice.
40. What is the other name of power alcohol?
Ethyl alcohol
41. What is the composition of Molasses?
Molasses contains 35-40 of cane sugar (or) sucrose
42. What is the molecular formula sucrose?
C12H22O11
43. In what substances sucrose soluble?
(i) Water
(ii) Methyl alcohol
(iii) Ethyl alcohol
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44. Give the example for detergent

Sodium dodecyl benzene sulphate

PART B
1. Briefly explain the edible oil extraction methods?

Figure: Vegetable extraction methods

Seeds cleared, and hulled stream cooked at 220-250 F for 15-20 min, then pureed either by
Continuous screw extruder (or) expeller
Batch Hydraulic press
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Alkali such as NaoH (or) Na2Co3 (or) Na2CO3 is added to remove free fatty acids as foots by
centrifugation. Bleaching is done with adsorbent clay as fullers earth and with adsorption carbon
Filtration is done on pre-coat rotary vacuum filter.
An alternate route to solvent extract by use of prop are

2. Explain the hydrogenation of vegetable oils:

Hydrogenation is the unit process which is need in the fat and oil industry to remove
double bonds, raise the melting point of the fat and remove its resistance to rancid oxidation. The
major end products in India is vansapathi
(C17 H 31COOH )3 C3 H 5 3H 2
Nix

(C17 H 32COO )3 .C3

Nickel catalyst preparation

Ni HCOO 2 2 H 2O

190
bare

oil

Ni* 2CO
2

H2

2 H 2O

Nickel catalyst preparation (Raney or spongy Ni catalyst method)

2A1.Ni+6NaoH Ni* +2NAA1O3 + 3H2
Raney Nickel

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Figure: Hydrogenation of vegetable oils

3. Explain the basic principles and reaction involved in soap manufacturing?

The grease is pulled away from the surface to be cleaned by the Keymechanism shown
The success of any cleansing agent is to supply components with hydrophobic any
hydrophilic groups which will also appreciably decrease surface tension and increase wet ability.

Sulfonated Fatty alcohols:

ROH + HOSO3 CH
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ROSO3H +H2O
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Fat Splitting
(RCOO)3 C3 H5 + 3H2O
Triglyceride

2RCOOH+C3 H5 (OH)3
Fatty acid

(b) Soponification reaction:

RCOOH + MOH

R.COOM + H2O
Soap

4. Explain the process description for the production of soap-Raw materials:

Refined Tallow, recovered and defined grease, coconut and palm oils are the principal fatty
constituent metal oxides such as zno are frequently added as fat splitting catalysts. Alkali for
soponification and builder-type additives mainly rorm. Complete the raw materials
Caustic soda and vegetables oil are 2 raw materials for the production of toilet soaps as the
use of animal fallon is not allowed in India. Distilled fatty acids derived from vegetables oil such
as palm oil (or) other solvent extracted oil and miner oils are an important constitutents. Demand
supply gap for vegetable oils and its derivatives is met thro imparts.
Basis:
For 1 tan of anhydrous soap
Oil (or) fat
1.1 tons
50% NaoH
0.3 ton
Sodium silicate
0.8 ton
Steam
1.5 tons
5. Flow diagram for the continuous production of fatty acids and soaps.

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Figure: Continuous process for fatty acids, soap and glycerin

Glycerides plus catalyst are added at the bottom of the hydrolysis tower when high
pressure water at 230- 250C is passed.
Reaction occurs with a 15-20% glycerin solution being removed from the bottom of the
tower.
The fatty acids passed overhead to a flash tank to remove excess steam
The crude fatty acids are vacuum distilled and the condensate in the distillate reeiver either
available as a marketable product (or) a soap manufacture.
6. Write the methods for the production of detergent manufacturing:
Molten sodium is added slowly to coconut oil in an aliphatic solvent plus etherification
alcohol. Such as any 1 alcohol. The reaction occurring are

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C6 H11OH Na O 6 H11ONa H *
(* indicates active H 2 )
R1COOCH 2

R1CH 2OOH 2

R2COOCH + 6H* R 2CH 2OOCH

R3COOCH 2

H 2O

R 3CHl 2OOCH 2
R1CH 2OH
R 2CH 2OH
R 3CH 2OH

C3 H 5 (OH )3
After reaction is completed, the batch is pumped into a water tank where the mixture settles into
three layer; the top is the high molecular weight alcohol, the intermediate layer contains
regenerated reducing alcohol, and the bottoms have caustic soda and glycerin for recovery , the
economic of the process compared to pressure compared to hydrogenation equipment on one
hand and higher cost sodium reluctant and more complex product separation on the other.
6. Explain the manufacture of glycerin from propylene via Ally chloride. Give the reactions.

This process
the
H intermediate Epichlorohydrin, a basic ingredient of epoxy region
H
H produces
manufacture.
CH

CI

7. Explain the reaction and process for the production of glycerin thro Actolein from propylene
H
O
Epichlorohydrin
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8. Explain the process description for the production of glycerin thro fatty acids?
The dilute glycerin (sweet water 0- is put thro successive beds of onions and cation
exchange resings to remove some colour and dissolved salts. The liquid effluent is concentrated by
triple effect. Evaporation and vacuum distilled to produce industrial grade (99%) yellow glycerin.
A final purification step is performed using activated carbon to obtain water white U.S.P glycerin.
Methods of production:
Classification of process:
(i) Natural product triglyceride hydrolysis
(ii) Synthetic glycerin from propylene (petrol chemical processing)
Allyl chloride route
Acrolein route
The acrolein route produces acetone co-products
9. Explain the chemical composition and physical properties of edible oils.
(i) Fats and oils mixture of glycerides of fatty acids where R 1, R2 and R3 are not necessarily the
same
R1 COOCH2
R2 COOCH
R3 COOCH2
By terminology of the industry ,oil are all Liq. And fats are solids at normal temperature

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Waxes: Mixed esters of polyhydric alcohols usually solid at room temperature.

Effect of degree of saturation:
Number of double bonds in the fatty acid radical controls the melting point and chemical
reactivity as shown in the following task.
Name
Stearic
Oleic
Linoleit
Linolenic

Composition
C17 H35
C17H33
C17H31
C17H29

No. of double
bands
0
1
2
3

Melting Points
69
14
-5
-11

Reactivity to O2
Nil
Fair
Rapid
Extremely rapid

The ability is react with O2 enhanced the use of unsaturated fatty acids as film forming vehicles for
plants. It also is the cause of rancidity is edible fat products.
10. Give the brief introduction about edible oils and essential oils?
Edible oils are naturally occurring compounds based on long chain fatty acids and esters
(particularly glycerides esters) as well as derivations such as glycerin, long chain fatty alcohols,
sulfates and fulsonates, products form these compounds are used for food, sanitation, polymers
and in the paint industry.
In India where facts of animal origin such as fish oil lard are seldom used as cooking media,
that term vegetable oil is used as a synonym for edible oils. However it neds to be remembered
that there are on the one hand, vegetable oils such as castor oil and linseed oil which are nonedible and on the other hand, edible oils like groundnut and coconut oil which are finding
increasing industrial applications as in cosmetics, soap making etc. Edible oils are a major source
of nutrition for the people in the country. Oil cakes, which are by-products of the oil extraction
process are important sources of animal nutrition. They can also be processed into protein rich
edible flour.
India has a highly developed oil based industry employing more than 15 million persons.
However, it remains an essentially food oil industry, accounting for as much as 83 percent of the
total supply of vegetable oil in the country. The major non-food users of oil are the soap and
varnish industries . these are the essential oils
Solvent extraction is a continuous chemical process for processing oil seeds such as
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groundnut, soyabean and rapeseeds as opposed to physical crushing for oil extraction. Crude
vegetable oil, the main product from the solvent extraction process, is primarily used in the
manufacture of refined edible oils and vanaspathi, and to a lesser extent in glycerols and fatty
acids use din soaps and other toiletries. While there are number of other value-added products
for varied application, the domestic industry and consequently the market for these products is
nascent.
11. Give an account on the classification of the cleansing compounds.
Soaps- compounds of the type R.COO.M where R.COO. is fatty acid radical representing
oleic, stearic, plasmatic Laurie and myristic. These are usually present in soaps as mixtures
based on glycerides raw materials M is the an alkali element such as Na or K.
Detergents synthetic organic chemicals which promote better surface tension lowering
than soap Anionic (give R in water).
R,OH + HO.SO3 H RO.SO3H + H2O
The sulfated compounds are quite stable in alkaline acid and hard water.

The molecular structure of R is important in determining a compound is biologically soft, straight

chain-normal structure gives a soft ABS.
Cationic:These have no strong detergent characteristics, but do have germicidal properties.
Non- Ionic:
Alkyl-aryl ethlylene oxide derivatives
Alphatic polyhydric alcohol esters.
Detergent builders:
Fluorescent dyes as brighteners.
Zealotries as alternative phosphorus free builders.
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12. What are the major engineering problems faced in the hydrogenation of oils?
(1) Thermodynamics and Kinetics:
(a) Heat of reaction:
The heat of reaction for hydrogenation of oils is mildly exothermic the energy liberation
during hydrogenation requires a normal amount of water cooling via cooling coils.
(b) Temperature:
This variable is kept below 200C to avoid side reactions such as pyrolysis and to prevent
sintering of the porous catalyst.
(c) Kinetic rate factors:
For a gas-liquid reaction of the hydrogenation type
H2(g) + oil (I) fat (I)
Research has shown that a series of rate processes exist with 8 kinetic resistances.
The rate behaviour was characterized as,
Surface reaction and adsorption controls reaction rae in the vicnity of 100C.
2) H2 handling problems:
Hydrogen gas has a wide explosive limit range. All equipment should be leak-tested with
Freon or helium detectors before operating, carbon steel can be used throughout for oil
hydrogenation to prevent hydrogen embitterment.
13. Write short notes on castor seed and soybean?
a) Castor seed:
India is one of the major producers of castor seed accounting for about 28 percent of the
world production the annual production of castor seed is around 5 lakh tones while that of castor
oil around 1.8 lakh tones. By acting in concert with the Technology mission on oilseeds, the
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Gujarat and Andhra Pradesh Governments have helped growers increase production. Inedible
castor oil has two significant potentials.
With suitable processing castor can be used in the manufacture of soap to the extent of over
25 percent thus relieving to some extent the pressure on other edible oils, by being used in
conversion and in the lubricant industry castors oil has a good export potential especially in view
of the high price of the high price of petroleum products.
b) Soyabean:
Soyabean is not new for India. Black soyabean has been cultivated for ages in the low hills
of Kumaon and Garhwal region in India. (U.P) as well as on the foothills of the Himalayas and in
some scattered pockets of central India. However, strangely enough, the crop has never been
popular in the India sub-continent and other tropical countries. The importance of soyabean in
Indian agriculture as a crop to narrow the oil and proteins gap has now been generally
appreciated, studies have indicated that the Soya flour, a by product can be used for fortification
of wht or other cereal flour up to 20 percent without detectable difference from the view point of
taste or appearance, but can considerable increased nutritional quality.
Besides, soya flour is known for its value as cattle feed in order to narrow the gap between
the availability and increasing requirement of nutritious feed for livestock.
14. Discuss about the raw materials and process description of hydrogenation of oils?
Raw materials:
Major raw materials are oils to be hardened and purified hydrogen which can be obtained
from several sources such as :
H2O or chlor- alkali
Steam iron reaction of steam on Fe followed by regeneration with water gas
Synthesis gas process:
Process description
Batch operation is used because of large residence times (1-3 hrs) and variation in oil input
and product properties from day to day. Batch hydro generators can treat 5-30 tons of oil per
batch, are equipped with coils for heating and cooling, and turbine agitators to disperse the
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injected hydrogen.
A typical hydrogenation batch process operates as follows. Oil is charged to the reactor,
heated and evacuated to drive off air and water. A catalyst oil slurry is pumped in, the catalyst
concentration is 5 to 15 kg per ton of oil Hydrogen is introduced and the steam is turned off since
reaction is mildly exothermic. After the derived hydrogenation has ensured as checked by an
iodine number iteration, the batch is cooled and filtered to recover the catalyst for reuse.
The hydrogenated oil is next deodorized in a Dow herm heated, steam, sparking vacuum
tower which operates on a continuous basis. The oil is next decolorized with fuller s earth, carbon
or similar absorbent , then filtered, mixed with vitamins and sent to the packaging storage
operations. This involves refrigerated slow-cooling in packaged tins to reproduce the granular
structure of ghee.
15. Write short notes on Rice bran oil, Linseed and coconuts ?
Rice Bran Oil:
Rice bran is the most important source of edible oil among the unconventional sources. Rice
bran is the brown coating around the white starchy rice kernel which is obtained by dehisicing
paddy and polishing the rice. Despite the impressive grown of rice bran technology in the
country, only a third of the available potential has been exploited. India produces about 80 million
tons of paddy annually.
Linseed:
Linseed is most commonly used for non-edible purpose. It is dual purpose crop yielding
oil and fiber. The relative contribution of this crop to the countrys total oil seed acreage and
production are 11.7 percent and 5.2 percent respectively. The crop is grown mainly as a source of
oil which is commonly used for cooking in M.P. and U.P, but a major portion is used in Industries,
as in manufacture of plants and varnishes.
Innovative processes have been developed which can improve the quality and quantity of
yield from coconut. Not , India imports coconut oil in spite of being the third largest grower of
coconuts in the world. India has the potential to export 1.25 lakh tons of coconut powder, 1.2 lakh
tons of coconut oil and one lak tone of other products annually after metering domestic
requirements. This plant is to used wet processing techniques which use 93 percent of the
coconut.

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UNIT - III
PART A

1. Butadiene is formed by the reaction of the raw materials of what?

(or)
Explain the formation of Butadiene?
(i) It can be obtained by steam creating of hydrocarbon gaser:
(ii) dehydrogenation of bur tone
(iii) Dehydrognation (or) dehydration of ethanol.
2. What are the catalyst involved in fixed bed catalytic cracking proceed?
(i) Sin2 Al2 O2- 6 mesh pellet
(ii) Bauxite (A12O3 Sio2 Fe2 O3 H2 O)
3. Which catalyst is used in the manufacture of acetone by dehydrogenation of iropropanol?
Cu is used as catalyst
4. What are the other names of crude Petroleum?
1. Rock oil
2. Black oil
3. Mineral oil
5. What are the raw materials of the production of ethanol a miner?
Ammonia
Ethylene Oxide
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6. What is the chemical Composition of Bauxite:

(A12 O3 Sio2 Fe2 O3 H2 O)

7. Give and example of exothermic dehydrogenation?

Methyl cyclohexane

Toluene

8. Give the example for Cyclization reaction

Ethyl chloro Pentane

Methyl cyclohexane

9. Give the example for isomerization reach.

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Ethyl cyclo pentane

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methyl cyclo Hexane

10. What are the user of ethylene?

It is use in the manufacture of
(i) Polyethylene
(ii) Styrene
(iii) Vinyl chloride
(iv) Ethylene dioxide
11. What is the use of iropropanol?
(i)
(ii)
(iii)
(iv)

In the manufacture of acetone

As solvents
In chemicals
In drugs

12. List the method of production of Butadiene?

(i)
(ii)
(iii)
(iv)

dehydrogenation of Butane
dehydrogenation of Butylene
dehydrogenation dehydrogenation of ethanol
Steam cracking of hydrocarbons.

13. Write main reaction involved in the formation of butadiene by dehydrogenation of butane?
C4H10 CH2 = CH- CH = CH2 + 2H2 ; DH = 32.2 KC-eL
Side rxn : C4 H16 C4 H8 + H2
H butylenes
14. What is the Chemical formula of Butadiene
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CH2 +CH CH = CH2

15. What are the different methods for the production of ethylene?
(i)
(ii)
(iii)

Steam Pyroylin of petroleum from LPC and Naptha feed stocks.

Thermal Pyrolyin of ethane and /or propane
Dehydration of ethanol.

16. How we can remove carbon deposits during Cracking?

We can remove it by applying
Stem
Air oxidation

17. Example of fir the hydro cracking reaction is

CH3 (CH2) CH2 + H2 C3 H8 + C4 H10
H= 9.74
Kd
18. What is the use of quenching operation?
It is applied to avoid back (or) side reaction is required where low contact timer high term
condition exit.
19. What is the use of octane number?
It shows the degree of amti-knocking property of gasoline.
20. How we can product phenol?
Phenol can be4 produced by the Catalytic oxidation of toluere
21. How we can produce pthalic anlyaride?
It is produced by catalytic Oxidatory of naphthalene

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22. How Styrene is produced?

Styrene can be produced by Dehydrogenation of ethyl benzene.
23. What are the classification of Petroleum?
Paraffin base
Napthelene base
Intermediate base
24. What are the different methods of refining petroleum?
(i)
(ii)
(iii)

Fractional distillation
Cracking
Treating

25. Define the term Cracking.

By virtue of this process , the high boiling range components can be disintegrated into
lower boiling range components with lower molecular substance.
26. What are the classification of cracking?
(i)
(ii)

Thermal cracking
Catalytic Cracking

27. What are the different types of catalytic cracking?

Fixed bed catalytic cracking
Moving bed catalytic cracking
28. What are the Catalytic used in Fixed bed Catalytic Cracking?
(i)
(ii)

Sin2 AI2 02 6 mesh pellet

Bauxite (A12 03 Sio2 Fe2 O3 H2 O)

29. What is meant by knocking?

In internal combustion engine, where gasoline is used as fuel operated as high load and low
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speed, a Sort of rattling noise with constant pitch is developed from the combustion is known as
knocking.
30. Define Compression ration:
Compression ration:

The volume at the end of suction stroke

Volume at the end of the compression stroke

31. Explain Octane number.

It is ration of the percentage of is o-octane is the mixture of is o-octane and n-heptane which
matches the fuel under.
32. Name some innibitors added to the gasoline.
(i) Butyl amino phenols
(ii) Benzyl amino Phenols
(iii) Phenylene diamines
33. Define cetane number.
It is defined as the ration on the percentage of cetane (or) hexadecane (C 16 H34) in the
mixture of cetane and methyl-nupthalene which matches the fuel under knocking characteristics.
34. What are the additives added to dieser?
(i) acetylene
(ii) acetone
(iii) diethyl ether
(iv) ethyl nitrate
35. What are the residues obtained from Petroleum?
(i) Greases
(ii) Petroleum
(iii)Asphalt
(iv) Road oils
(v) Petroleum coke
36. What are the uses of ethylene?
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Ethylene can be used for the manufacture of

(i) Polyethylene
(ii)Styrene
(iii) Vinyl chloride
(iv) Ethylene dioxide
(v) Ethanol
(vi)Ethyl chloride
(vii) Ethylene dichloride
37. What are the different methods for the production of ethylene?
(i) Steam Pyrolysis of ethane/propane
(ii) Steam Pyrolysis of petroleum from LPG and Naptha feed stock.
(iii) Dehydration of ethanol

38. What are the user of isopropanol?

It can be used.
(i) In the manufacture of acetone
(ii) as solvents
(iii) in chemicals
(iv) in drugs
39. What are the different methods for the production of Butadiene?
(i) Dehydrogenation of butane
(ii) Dehydrogenation of butylenses
(iii) Dehydrogenation dehydration of ethanol and
(iv) Steam cracking of hydrocarbons.
40. What are the main Consistent of Rubber?
Surplur
Zine oxide
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Stearic acid
Accelerator
41. What are the main Compositions of crude Petroleum?
(i) Paraffin (CnH2n+2)
(ii) Napthalene (CnH2n)
(iii) Aromtic hydrocarbons (Cn h2n-4)
42. What is meant by Flash point?
It is the minimum temperature at which an oil gives Sufficient amount of Vapour so as to
form and explosive nature with air.
43. What are the different types of gasoline?
(i) Natural gasoline
(ii) Straight over gasoline
(iii) Reformed gasoline
(iv) Aviation gasoline
(v) Polymer gasoline
44. Define the term Viscosity breaking (or) Visbreaking
The viscous oils and residues obtained after thermal cracking are further subjected to
cracking in order to produce fuel oils is called Viscosity breakenin.
45. Define Smoke Point.
The maximum flame height in millimeter at which the fuel without smoking when
determine in a smoke point apparatus under the specified condition is called Smoke point
46. What is Sweetening?
The process of removal of Sulphur from petroleum is called Sweetening.

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PART - B

1. Explain the Visbreaking Operation in Petroleum refining process.

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It is the operation to recluce the Virlosity of the oil. In this figure , feed stock comprising
Variety of materials ranging from asphalts, short residerums to medium oils is blanded separately
and Parred thro heat exchanging system. (i) the temperature rise in such exchange is close to
250C. The Prcheated stock, is heated din the furnak (2) to attain a temp of 470C, a pressure of 1015 kg/cm2 essential to keep the coke forming reactions in dormant stack. Obligingly steam
admission in to feed stock cheeks coke formations, thereupon the life of tubes can be Value (3).
Only to be quenched in a quencher (4) effectively with processed heavy oils. The light fractions
and bottom fractions from this quencher go into the distillation column(5) . At the top of the
column, the condenser system separates water and supplies adequate light fraction as reflux.
Column these light fraction will gases are sent to an extractor is meant to dissolve gasoline like
fractions in circulating oils and the bottom section of the extractor acts as the stripper to free the
gases. The circulating oil with dissolved fraction is again sent back to the distillation column and
sent to the stripper (6) The circulating oil is tapered as a bottom products.
2. Explain the operation of Neptha cracking.
Naptha cracking is appropriated to product olefins. Mainly ethylene and propylene. In
fact any petroleum stock is suitable and in the position to replace naptha, which is preferentially
reserved for steam reforming process.
C2 H6 C2 H4 + H2
C3 H8 C2 H4 + CH4
C3 H6 + H2
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C4 H10 C2 H4 + C2 H6
C3 H8 + H2
C4 H6 + 2H2
When ethanol and propone are chosen as feed stocks, the following points must be pondered.
Naptha cracking for olefins is Schematically present in figure. The Hydrocarbon feed stock
is Preheated and cracked in presence of stem in a fubutal furnace.

(i) The furnace is maintained at high temperature of 800-850C as soon as the furnace
efficient record a tem of 800-850C emerge out of fulnace, they are cooled in a transfer line the
exchanger.
(ii)
Which is set apart for production of high pr. Steam (100 - 120Kg/cm2). Still
hot, the products are rapidly quenched by showering with feedback stock (or) with Circulating
oils. Direct quenching with H 2O is also practiced in some cases quenching with oil is done in
pyloylis fractionation.
(iii) Where fraction also Carried Out simultaneously. The bottom pdts shall be heavy oils (or) fuel
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oils; mostly polymer produce. The lighter fraction are cooled in a reflux, Condenser, at the top of
fractionators . In a reflux condenser, Separation of gaseous products from light distillates take
place. The gases are always infested with acid constitutents like Co 2 , CO , H2S, SO2. Oxides of
nitrogen etc and these are stripped off by suitable solvents. The acids free are new cooled and
them compressed to a pr of 30-40 other whereby Propane and high components are liquefied.
3. Explain the term Hydro cracking.
Charge stock recycle hydrogen and make up hydrogen and mixed and passed thros a
heater. The mix entus the reactor (1) frame the top while cold hydrogen is admitted to the reactor
(i) from the top while cold H2 is admitted into reactor at diff parts. The efficient flam the reactor
are immediately heat exchanged with the c/s chilled and fed into a high px separator (2), where
H2 is separated. This h2 is contaminated with h2s and nh3, have a proper treatment for the
removal of these contaminated with H2S is required and is Practised in the heater. (5) The
recovered hydrofn is compressed to the required pr. And recycled back. Treated stock from high
px relcaler goes to a low px separator (3) where fuel gas (up to C 3 fractions0 H2S are obtained his
fractions from the bottom of their separated. The heavy oil from the fractionator is recy cled back
to the reactor.

Figure: Hydrocracking

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4. Explain the team of Reforming process and draw the neat flow diagram.
Catalyze reforming is used to convert hydrocarbons to aromatizes which have octane
rabing.

Figure: High pressure platinum catalyst reforming process

Process description:
Naptha fed stock is protracted by mild hydrogenation high temp bauxite reaction, (or)
absorption to remove sulfur, nitrogen and metals which lower pt catalyst activity. The treated feed
is mixed with recycled H2 prcheated and charge to three (or)more cylindrical reactor in series.
Reheat interchanges are required since in the overall reaction is ender thermion.
Fixed bed catalyst units are used because handling of expensive pt catalyst in a fluidized
bed would create too high an operating loss via dusting. The catalyst can be regenerated every 2-3
months by burning off the Carbonaceous deposit with mixtures of steam air carbonaceous deposit
with mixtures of steam, all and flue gas. Non-lubricated compressors are used to recycle H 2, thus
avoiding coking of catalyst by lubricating oil

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4.

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Explain the isomerization Process.

Catalystic isomerization of n-paraffins to isomers for alkylation feed stock is necessary

refinery operation since n-paraffins are of little value as an end-products.
Feedback, mainly from virgin and coking distillate, is dried and preheated, fed to a reactor
is designed for efficient vapour- solid, vapour- liq liq-liq (or) liq- solid contact, depending on the
reactant and catalyst from respectively. HCl and make up Alcld3 are also added Alcid3 recovery
by distillation (or) condensation is necessary because it is volatile at reactor conditions and slightly
soluble in water. Removal of light ends by flashing followed by HCl stripping caustic wash, and
fractionation are standard operations.

Figure: Low temperature isomerization process

5. List the processing methods for the production of methanol an craw the flow diagram?
H2 and CO in a mole ratio of 2.25 is compressed to 3,000 5,000 PS mixed with recycled gar,
and fed to a high pr. Converter Internal preheat is usually employed. The reactor is copper-lined
steel and contains a mixed catalyst of 2n or Mg (or) a1 Oxide. The temp is maintained at 300VEL TECH

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375C by proper space velocity and ht exchanger design.

The exit gases are cooked by exchange with reactants then with water the method cenderses
under full open or pr to maximize yields CN 50%. Conversion pel passi. The liq methanol is
deprecrized, purified by permanganate to remove trace of ketoner, aldehydes, and other such
impurities.

Figure: Methanol via synthesis gas route

6. Explain the production of formaldehyde from methanol.
Non purified air, compressed to about 0.2 atm gauge IN preheated by exchange with reacting
gaser and then conveyed to a methanol evaporator. Conditional are set to keep the CH3 OH: O2
ratios in the 30-50% range. The mixed gasser is preheated, sent to a reactor where liver (or) copper
gauze (otr) their oxides are catalysts. Catalysts activity is controlled to maintain a balance between
the endothermic dehydrogenation and exothermic oxidation rxn a reaction conditions of 450600C. Some complete Combustion takes place.

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Figure: Formaldehyde from methanol

The product gases are absorbed in a water scrubber which is cooled by external circulation,
and the fractionated to recover approximately 15% unreacted methanol for recycle . Ultimate
yields of 85-90% wt % bated on methanol are typical.
Reactions:

1
CH 2 OH O2 HCHO H 2O, H = 37 kcel
2
Pyrolsin:
CH 2OH HCHO H 2 ;

H = 19.8 kcel

Side rxn:
3
CH 2OH O2 2 H 2O CO2
2

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H =162kcel

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8. Explain the reaction involved in the production of Perchloro ethylene and draw neat diagram
Chemical reaction:
Pyrolysis of CCl4:
2CCl4 Cl3 C.CCl3 + Cl2
Hexa calloro ethane
Propane chlorination to yield Cel4 co-products:
Cl3 C.CC3 Cl2 C = CCl2 + 2Cl2
Chrorination of trichloroethylene to peta chlorine ethylene
2CCl4 Cl2C = CCl2 + 2Cl2
Process description:
CCl4 is vapourized, passed into resistively heated carbon electrode furnace at 800-900 c and
pyrolyzed to pelchlozo ethylene, hexa chloro ethylene, and chlorine. The effluent goes to a partial
condenser , held at 80-85 C where CL2 Plus unreacted CCl 4 are separated from heavy ends. The
CCl4 is stripped of Cl2 in a condenser and recycled. The heavy ends are distilled to separate
pechloroethlene from hexa chlora ethana. The lather can be recycled from further Pyrolysis or
further purified via distillation.

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Figure: Perchloroethylene by pyrolysis of carbon tetrachloride

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9. Steam cracking of hydrocarbons for the production of ethylene and acetylene.

Figure: Ethylene and acetylene production by steam cracking of hydrocarbons0.

Chemical rxn:
C2 H2 n + 2H2O + O2 (optinal) C2 H4 ( 4 15% ) +
C2H6 + C2H2 + H2 + C0 + CO2 + CH4 + CH4 + C2 H 6
C3 H8 + C4 H10 + C4 H6 C
The process to be detailed here is high temp thermal reforming using ethane, propane,
butane, and (or) tig naptha superheated stem is mixed with the hydrocarbon is fed thro the heated
coil of a pyrolyris furnace the c2 c4 feed is pyrolysized is a separate furnace be cause diff residence
time-temp conditions are required. The pyrolysized gases are quenched in a wasted heat steam
boiler and ten scrubbed with as oil to remove solids and heavy hydrocarbons before sending to
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compressors to boost pr to 35 atm.

The compression station may also handle refinery off-gases which can be separated in the
same system flash vaparrized removes the c1 c2 tractions which are caustic scrubbed to remove
Cp2n dried with activate alumina, and then separated into acetylene and ethylene by a combustion
of absorption extraction and fractionation steps. Ethane is recycled for pyroylsis and the CH4 Co
and H2 can be further processed to obtain synthesis gas (or) used for fuel.
The liquid fraction from the flash chamber (c3 higher is split by fractionation into a numsel
of products as indicated on the flow sheet. Extractive distillation is required to separated butanebutylene and butadiene because of the cost boiling point large of 3 components under pr.
10. Explain the procedure for the formation of acetylene.

Figure: Acetylene from calcium carbide

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11. Explain the production of ethylene dichloride

Figure: Ethylene dichloride production

Chemical reaction
CH2 = CH2 CL2

CLCH2 CH2 CL

Ethylene (with or) without C2H6, CH4 and H2 diluent) is mixed with chlorine and bubbled
thro a liq phase reactor. Ethylene dichloride product serves as the reacting medium. Heat of
reaction is controlled by external heat exchange and recycle, (or) by coil (or) jacked heat transfer to
hold the reactor at 45-50C with a pr of 1.52 atms traces of ferric chloride or ethylene dibromide as
catalyst give 90-95% yield with little dimmer formation. Gaseous products are cooled in 2 stages
to strip the acid gas of ethylene dichloride. The liquid product is allcali washed and fractionated.

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12. Explain the formation of vinyl chloride thro ethylene dichloride pyrolysis.
Chemical reaction
500C
CH 2 CHCL HCL
4 atm
Ethylene dichloride (EDC) vapour at 4 atm is dried by silica gel and sent to a stainless steel the
baler cracking furnace. This is externally flue gases fired and controlled at 480 520c. The contact
surfact catalyst with in the tubes is pumice (or) charcoal. The conversion per part is around 50%
and the ultimate yield is 95% -96% spray quenching with cold EDC prevents back-reaction
uncondensed gases are sent to a surface heat exchanger to remove the balance of the EDC and
vinyl chloride.
CH2CL . CH2 CL

The non-condensibles containing HCL are either sent to the acetylene HCL process.
The condensate is fractionated with the EDC bottoms returned for recycled and vinyl chcoride
monomer taken from over head.

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Figure: Vinyl chloride via ethylene dichloride phyrolysis

13. Explain the manufacture of vinyl chloride thro acetylene HCL reaction
CHEMICAL REACTION
CH CH HCL

160 200
CH 2 CHCI
1 atm

Figure: Vinyl chloride via acetylene HCI reaction

Acetylene and dry HCL in 5-10 % molar excess are vapour blended by jet mixing in a pipe and
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passed thro a tubular catalytic reactor containing carbon pellets impregnated with Hgl 2 the tem is
maintained at 160 C and is gradually raised to 215 c as the catalyst deteriorater. The effluents
gaser contain vinyl chloride which is separated from unreacted acetylene plus hydrogen chcoride,
these unreacted materials being recycled.

14. Ethylene oxide thro air oxidation of ethylene

Chemical rxn:
1
Ago
CH 2 CH 2 O2
CH 2CH 2 (CO2 H 2O )
2 250 300C
4-5 atms
=29.2 kcal
Ethylene of 95-98% purity an air are compressed separately, mixed together giving 3-10 C2C4 and
volume concentration and passed over a catalyst of ago on a porous inert carriers such as
Alumina. A side rxn suppressing agent such as ethylene dichlorider is added to the feed to reduce
the competitive oxidation reaction to CO2 + H2O
The rxn is highly exothermic and is best carried out in a fixed bed tabular reactor in which
heat transfer salt (or) . Dow them is pumped around the tube within the shell to maintain a 250300c temp Heat is received is a Walter steam boiler.
The effluents gases from the reactor are water washed under pr the absorbed ethylene oxide
is sent to a packet bed absorber fractionator are taken overhead.

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Figure: Ethylene oxide by air oxidation of ethylene

15. Describe the preparation of Acetone by dehydrogenation of isopropanol
Catalytic dehydrogenation of isopropanol

CH 3 2 CHOH CH 3COCH 3 H 2
CH 3 2 CHOH

1
O2 air CH 3COCH 3 H 2O
2

Isopropanol vapour Compounded to 3 atms. Is permuted by reactor effluent heat exchange

and passed thro a tubular catalytic reaction maintained at 500IC with the catalyst containing of
Cu or Bros deposited on porous carrier. The hot rxn gases pall thro a water condenser and them
into a water scrubber where final traces of isopropanol and acetone are removed from H2 to gie
product grade acetone over head and dilute isoproponal bottoms. These are further recycled to
give 88% isopropanol.

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Figure: Acetone by dehydrogenation of isopropanol

UNIT IV
PART AI
1. Define Polymer?
Polymers are composed to molecules of molecular weight from about 10 3 to 107. Polymer is
made up of repeated basic units produced form monomers.
2. Give example for Thermoplastic and Thermosetting?
Cellulose derivations thermoplastic
Phenol formaldehyde Thermosetting
3. Give the structure of polyethylene?
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H C = C H

4. Distinguish thermoplastic and thermosetting?

Linear or slightly branched molecules
Solvent soluble
Cane be repeatedly melted
Thermosetting:
Heavily branched
Solvent insoluble
Cannot be melted after forming
5. Give example for monomer and corresponding polymer?
Monomer
Ethylene
Propylene
Butylenes

Polymer
Polyethylene
Polypropylene
Polybutylene

6. Differentiate addition and condensation polymerization?

Additional Polymerization:
These reactions are carried out under controlled heat and catalyst conditions. It is classified
as homogeneous and heterogeneous polymerization.
Condensation Polymerization:
It can be processed without or with solvent addition. It follows procedures used for low
molecular weight functional group reactants. It can be mixed in batch reaction vessel with catalyst
addition and heat control to avoid premature gestation.

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7. What is emulsion polymerization?

Monomer and water emulsified with suitable reagent to yield spherical monomer particles
in the 1-10 range called micelles. Over come the difficulties of heat control.
8. What are the uses of thermoplastics?
Useful for melt casting and spinning, injection molding and extrusion
9. What are the properties of plastics?
Most of the plastics have low scratch resistance Luster, clarity, reflectivity and permanent
allowing.
10. What is fibre?
Fibre are thread formed solids with high tensile strength.
11. Give example for polyester and epoxy resin?
Decrease fibre nylon film polyester
Ebichloroshychin epoxy resin
12. What is plasticizer?
Plasticizer one organic compounds addict to plastics to improve workability during
fabrication.
13. What is PVC?
Polyvinyl chloride
14. What are used of epoxy resin?
In film formation and adhesives.
15. What are polyester?
It is formed by condensation of poly functional acids or esters.

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16. What are the classifications of polymer?

Thermo plastic
Thermosetting
Elastomers
Fibers
17. What are the Elastomers?
Resistant solids with high flexural stronger
18. What are LDPE and HOPE?
Low density and high density polyethylene
19. What is meant by high polymer?
The high polymers are substances of vary high molecule weight, which may occur is nature
or chemically synthesized.
20. Define degree of polymerization?
The degree of polymerization is defined as the number of repeating unit is chain formed is
a polymer.
21. Name some natural and synthetic polymers?
Polyethlene
Phenol formaldehyde
Polystyrene
Polyamides
22. What is meant by linear high polymer?
It is the repetition of the repeating units in a high polymer molecule is similar to that of the
links in a chains, it is called linear high polymer.
23. What is meant by homo chain polymer?
When the chain is made up of same species of atoms the polymer is known as hormochain
polymer.

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24. What is meant by hetrochain polymer?

When the chain is made up different species of atoms the polymer is known as hetrochain
polymer.
25. Explain Regular copolymer?
When monomer units in a copolymer molecules are arranged in the chain in a regular
manner, the molecule is called regular copolymer.
26. What is meant by statistical copolymer?
When monomer units are arranged in an irregular manner the copolymer molecule is called
statistical or irregular copolymer.
27. What is meant by block co- polymer?
Linear copolymers in which the like monometric units in relatively long sequences are
called block co-polymer.
28. Name some examples for network polymer.
Urea formaldehyde and phenol formaldehyde resins are some examples for network
polymer.
29. For what reasons plastics are used in wide range?
Plastics are used in wide because of their,
i.
Toughness
ii.
Water resistance
iii.
Excellent resistance of corrosion.
iv.
Easier for fabrication
v.
Remarkable colour range.
30. Explain Thermosetting.
If heating takes blue in the final stages of the manufacture, the resin are said to be thermo
setting.
31. What is meant by thermoplastic polymer?
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Those polymer which often on heating and regain their original properties polymer.
32. Name some common reinforcing fibers.
i. Cellulose fibers
ii. Fiber glass
iii. Carbon fibers
iv. Aramid fibers
v. Metal filaments.
33. Define Cellulose?
Cellulose is a structural material of the plant world is itself a polymer composed of 50 t 100
units of disacchanide cellulose.
34. Define the term blastmer used for rubber like polymer?
The terms blastmer is used for rubber like polymer which gains original shape when the
deforming stem is released.
35. What are the uses of adding filters and reinforcements to plastics?
(ii)
(iii)
(iv)

increase thermal conductivity

Reset to heat distortion
Lower thermal expansion

36. What are the some general polymerization process?

Bulk polymerization
Solution polymerization
Suspension polymerization
Emulsion polymerization

37. Define Polyester resins.

Polyester resins are complex esters formed when a dysfunctional alcohol is reacted with a
dibasic acid or anhydride.
38. What are the different methods of moulding of plastics?
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I.
II.
III.
IV.

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Compression moulding
Injection moulding
Transfer moulding
Extension moulding

39. What are the uses of Bakelite

o Electrical insulating materials
o Cycle parts
o Automobile parts
o Radio and T.V. set bodies.
40. Define degree of polymerization:
The degree of polymerization may be defined as the number of repeating in a units chain
formed in a polymer, polymer are compared of molecules their mol wt very 103 to 107.
41. Name some common reinforcing fibres:

Cellulose fibres
Fiber glass
Aramid glass
Metal filaments

42. Explain the property of thermo setting plastics?

They are usually harden stronger and more brittle than thermoplastic resins and they cant
be reclaimed back.

43. What are the common resins used in efficiently?

Actual, Fluoroplastics,

nyklon,

polypheylene

oxidepolycarbonate etc.

44. What is other name of isopropyl benzene?

Cumene

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PART - B

1. Explain the polymerization of Vingl polymer.

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Figure: Polymerization process for vinyl polymer

Process:
In emulsion polymerization, a typical formulation is too path of H 2O, 100 paths of Vingl
monometers, 1 part of persulate reactor catalyit and 1.5 parts of a detugent emulsifier. This is fed
is not permissed reactor.

2. Explain the method of manufacture of polyster using:

The common polyester fibers are polymers of the ester formed from dimethyl terephthalate
and ethylene glocol.
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Intermediates:
Dimethys terephthalate is preponced by oxidation of p- xylene and subsequent
esterification with methyl alcohol. Polymerization and fiber production.
Polymerization is two-stage process in which the monomer is first rezoned wither by an
ester interchange glycol, or by direct esterification of terephthalic acid.
PH 3COOCC6 H 4CooH 2CH 2 oH.CH 2OH
pH 0CH 2CH 2 ooCO6 H 4CooCH 2 OH+ 2 CH 3OH
Ester monomer.
pHooCC2 CH4 CooH + 2CH2 OH . CH2 oH
pHoCH2 CH2 ooCC6 H4 CooCH2 OH + 2H2 O
Ester monomer
The second stage is the polymerization of the monomer
N ( monomer ester)
260C (n-1) HoCH2 CH2 oH =
H [oCH2 CH2 ooCC6H4 Co]n - oCH2 CH2 OH
Polyethylene Terephthelate
The polymer is extruded from the bottom of the polymerization through a slot or holes on
to the smtace of a water cooled drum. The ribbon is cut to chips and died before melt spinning in
a manner similar to that described for nylon. The polymer chain contains approximately so
benzene rings. The filaments are stretched, with the application of heat, to about three to six times
their original length.
3. Explain the manufacturing process of epoxy resin?
The most common epoxy resins are formed by the reaction of bisphenor A with
epichlorohyudrin Bisphenol A is made from phenol and acetone.

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Bisphenol A plus epichlorohydrin gives resins of the following general structure

If the value of n is low, the resin is liquid if n is 25 the resin is a hard, tough solid. However any
resin containing one or more liquid groups is an epoxy resin.
RCH
RCH

CHR
O

Epocide group
Most commercial resins one not 100% chieperides but may contain some other terminal
groups such as glycol, phenolic or chlonohydin.
The epoxy resins are really intermediate, and must be cured, or cross-linked, to yield a
useful resin. Cross-linking occurs by the opening of the epoxide ring caused by addition of a
curing agent which must have active hydrogen atoms. Amines acid anhydides and mercaptans
one the most useful compounds used as coming agents.
Depending upon molecular weights, epoxy resins have a great many uses ranging from
adhesives to can and drum coatings. They have excellent chemical resistance, particularly to
alkalies, vary low shrinkage on cure, excellent adhension and electrical insulating properties and
ability to cure over a wide range of temperature.

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4. Explain the manufacturing process of phenol formaldehyde.

Figure: Phenol formaldehyde products production

5. Describe the steps individual in the productions phenol formaldehyde resin:Reaction: Condewation and polymerization.

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One step resins:

In these, al the necessary reactants (phenol, formaldehyde, catalyst) required to produce a
thermosetting resin one changed into a resin kettle in the proper proportions and react together.
An alkaline catalyst is used. The resin, as discharged from the kettle is thermosetting or heat
reactive and required only further heating to complete the reaction to an infusiable, insoluble state.
Two step resins:Only part of the necessary formaldehyde is added in the kettle in making these resins, and
an acid catalyst is used. They are permanently fusible or thermoplastic when discharged from the
kettle but react with additional formaldehyde to produce a thermosetting resin. This additional
formaldehyde is furnished by hexamethylane tetra mine.
6. Explain the manufacturing process of LDPE.
Low density polyethylene produced by high pressure methods, is used mainly for plastic
films High pressure process using oxygen or provides catalyst.

Figure: Low density polyethylene by high pressure processing

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Polyethylene manufacture requires high, purity ethylene and the first step involve the
demethamizer, where a mixtune of methane ethylene is removed and recycled. The feed passes
to a deethanizer, where 99.8% ethylene is taken overhead , and the bottoms (ethane) recycled. A
free radical yielding catalyst, such as peronide is added to the high-punity ethylene compressed
to operating pressure (150 Mpa), and fed to the tabular reactor which is maintained at 190c. The
reaction takes place in solution Conversion per pass is about 30%. The effluent from the reactor
passes to a high- pressure separator in which the unconverted ethylene is removed and recycled.
The polyethylene is extruded, palletized and died.
7. Explain the manufacturing process of HDPE?

Figure: High density polyethylene by low pressure resins

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8. Explain the production of (SBR) Butadiene styrene rubber process.

Figure: Butadiene styrene (SBR) rubber process

Butadiene and styrene are co-polymerized by emulsion polymerization is about 3.1 weight ratio.
The original world was II government plants were designed.
The process involves 20% age caustic purification of the fresh plus recycle monomer
followed by consecutive passage thro 6-12 glass lined (or) stainless steel reactor . The total
residence time ranges from 5-15 has and reactors are equipped for steam heating, water cooling
and refrigeration. The reactors can thus produce cold SBF (5c, 1 am gauge) (or) hot (50; 3-4 atm
gauge).
Latex from the reactors is pumped to blend tanks for addition certain compounding
ingredient. The latex is conjugated to rubber Crumbs which float onto shakes sirens, where wish
water removes catalyst, emulsifiens and other solubber.
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9. Explain the production of Viscous Rayon.

Cellulose wood pulp sheets (or) cotton lintens are placed in a streping press and contacted
with 18% agu NaoH for 2-4 at loom temp. the excess alkali is expressed out with hydraulic ram,
the sheets are shredded to crambs and aged for 2-3 days, depending an temp (20-25).
CS2 is added in a rotating drum mixer over a 3hr period. The orange cellulose Xanthate is
transferred to the solubilize when it is mixed into dilute caustie to produce an orange coloured
vircous sol containing 7-8 cellulose 6.5 NaoH.
For spinning Viscose Rayon. The extraction spinneretle it contact the acid both the
precipitate the filaments with causing them to stick together (or) break.

Figure: Viscose rayon production

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10. Write the chemical reaction involved in nylon 6.6 and Nylon -6.
Nylon 6.6:(a) Adipic acid:C6 H12
air

C6 H11OH
C 6 HO

80' c

ag HNO3

HOOC. CH 2 4 .COOH NO + y N 2O

(b) Hexa ethylene diamine:WC CH 2 4 .CN

2CH 2 CHCN

H2
10Wpr

a Irylonitrile

dimerization

Higher

adiponitrile

H 2 N CH 2 NH 2 ]

(b) 6.6 Nylon:xHOOC. (CH)4 . COOH + x H2N (CH2)6 . NH2

O

(-C (CH2)4
Polyhexa methlene

C-NH (CH2)6 NH-) x

adipimide (or)

Nylon:(a) Caprolactum
C6 H12 nitration

synthesis:

C6 H

11 NO2

NOcl
Photochemical

borophosphoric acid
catalyst

C
5 NOH
6 H

Backmamn
rearrangement

Uxime
b. stage wise condensation of corprolactumn
noc-(CH2)5 NH + H2O n H2 O n H2 N (CH2)5
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-COOH H2O H[HN. (CH2)5 C]N OH

11. Explain the process of production of Nylon

Figure: Nylon resin and fiber production (6,6 nylon)

Process description
Nylon salt is first prepared by mixing the amine and acid is agu. Rol and adjusting the P H
to 7.8. The salt is concerted under vaccum and then changed to an autoclave. Hence the must of
the water is removed and temp gradually to 280.
The final product of the md cut range of 12,000 16,000 is extruded as a ribbon into chilling
roles, then to a chipped or producing small chips heritable for storage and remanding.

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12. What is the basic chemistry involved in the production of polyester production.

User:
Dimenthyl terepthaletic is the ester prepared from clued terePthalic acid which comes from
oxidizing P-xylene. The ester allows for easiler control of the polymerization with glycol as in
more soluble in ethylene glycol.
The ester in charge reaction prier to polymerization proceeds smoothly into prier to
polyermization proceeds smoothly into pressure of alkali methanol is removed continuously in the
fractionating column. The reaction star5 rapidly at 160 c and rises to 230C before all of the
methyl groups are removed.
13. Explain briefly about polyurethanes:.
Polyb are used as raw materials (along with methylene disphencyl diisocyrante) and / or
(toluene dissocynates) in the manufactures of polyurethane foams.
These foams have extensive application in industrial insolution, refrigeration, manufacture
of mattresses, furniture and automotive seats, footwear and wood components replacements.
Progylene glycol is used in pharana Centicals, cosmetics, food flavors, Tobacco processing
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and in the manufacture of unsaturated polyester resin for (FRP).

A present 4 units manufacturing polyob and / or propylene glycol in the organized sector
in the industry.

14. Explain Briefly about polystyrene.

Installed capacity of Os at present in only 26, or tones per annum from two manufactures.
Poluchem Bombay
Hind polymers Vizay

} 16,000 MTA
} 10,000 MTA

Polychem plant has been set up with the process known how from dew Dow. USA and that
a Hind polymers is from BX plastics, U.K.
To increase the indigenous production capacity, new projects and capacity enhancement of
existing units under consideration.
New Projects:1. BASF has prospered to ser up a plant with 15,000 MTA capacity
2. Reliance industries Ltd, is set up to
Styrene
0.81 lakh TPA
Polystrene
0.51 lakh TPA
15. What are the types of polymerization and explain it.
Homogenous polymerization
Bulk- monomer is only feed: can be gas, liq (or) solid
Solution monomer is completely destroyed in a solve it
Hydrogenous:

Emulsion monomer is emulsified in an agu, Media as micelles.

Suspension monomer is held in an agucous (or) other type media as large droplets in
suspensions.

Bulk Polymensaton:
Gas phase type ethylene (or) propylene with BF3 catalyst.
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Lig phare

Most common
Problems of effective heat dissipation of exothermic reactions as viscosity of polymers
increases with DP.
Products are optically clear
Most frequently a batch wise process.

UNIT V
PART A

1. What is Teflon?
Tetrafluoraethylene is know as Teflon
2. What is Dacron?
Dimethyl terabthalate and ethylene glycol reacts to from Dacron.
3. What is meant by vulcanisation?
Valcanisation is a process of mixing rubber with sulphur and then heating.
4. What is tackiness?
When two fresh surface of mixed rubber are pressed together they coalesce to form a single
piece. This is called tackiness.
5. What is latex?
Latex is an emulsion of poly hydrocarbon chapter in aqueous solution.

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6. What are the raw materials for manufacture of Nylon-66?

Adipic acid
Hexamethylene diamine

7. Name some coagulants used in latex

Some coagulants are potassium or aluminium alum.
8. What is crude rubber?
As a result of adding acetic acid, the rubber hydrocarbon which is the solid from. This is
known as crude rubber.

9. What is the main raw material for cabrolactum?

The main raw material for the manufacture of caprolactum is benzene.
10. What is the function of adding retarders to the rubber?
The function of adding retarders to the rubber is to prevent discoloration and softening the
rubber.
11. What is the average modular weight of plastic?
The average modular weight of plastic varies from 20,000 to 250000.
12. What is the average modular weight o rubber?
The average modular weight of rubber is 1,80,000 to 4,00,000.
13. What is the starting material for the production of parachloraethylene?
The starting material for the production of puchloro ethylene is carbon tertrachloride.
14. What are the reinforcing agents added to the rubber?
Some common reinforcing agents are inorganic substances such as zinc oxide, carbon block,
magnesium carbonate or clay.
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15. In Nylon-6 the number what is refer?

In nylon-6 the number refers to the total number carbon atoms in the ring.
16. What is the function of adding filters to the rubber?
Filler improve the hardness and serve as diluents.
17. In which way the antioxidants are useful while adding in rubber?
Antioxidants protect the rubber goods from attacks by air heat and even ozone in
atmosphere.

18. What are vulcanizing agents?

Some vulcanizing agents are
i. Sulphur monochloride
ii. Selemium
iii. Tellurium
iv. Thiruram suphides
v. Poly sulphite polymers etc.
19. What is purpose of adding accelerators to rubber?
Accelerators are added to the rubber to increase the rate of vulcanization of rubber from
several hours to few minutes.
20. Give some example for accelerators
i. 2- mercptonbenzothizole
ii. benzothiozolyl disulphide
iii. Zinc diethyldithio carbonate
iv. tetra methyl thiruram disulphide
21. What is activation?
Increase the effect of acceleration is called activation.
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22. Give example for activation

i. zinc oxide
ii. stearic oxide
iii. litharage
iv. magnesium oxide
23. Why are poptizers added to the rubber?
Reduce the viswsity of rubber to permit easy processing.
24. Define forming.
The process is called forming which is carried out by calendaring and extrusion.
25. What is meant by calendaring?
Calendaring is the process of rolling the rubber compound into fabric on multiroll calendar
machine.
26. What are the polyurethanes?
The reaction products of certain organic disocyanates and bolyglycols one rubber products
known as polyurethane.
27. What are the raw materials for Thiokol?
i. Sodium tetra sulphide
ii. Ethlene dischloride
28. What are the uses of Thiokol?
Thiokols are used for seals gaskets, cable covering oil tanks lining etc.
29. How is silicone rubber produced?
Silicone rubber is produced by the polymerization of demethyl silicone hydro oxide or
cyclic siloxane into polymer polysiloxane.

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30. What is silicone?

Silicone rubber are mixed organic and inorganic polymers.
31. What are the uses of silicone rubber?
i. Making lubricants
ii. Paints and protective coatings for fabric finishing
iii. Water proofing
32. Give main uses of urethane rubber
i. Making surface coating
ii. Manufacture of forms
iii. Spandex fiberes
33. How foam rubber can be prepared?
Foam rubber can be prepared by bubbling a gas into compounded liquid latex, following by
gelling with the help of gelling agents like sodium or potassium silico fluride (Na 2 Si F6) in a
mould and ouxing.
34. What are the uses of foam rubber?
i.
ii.
iii.
iv.
v.
vi.

Bed billows
Mattresses
Furniture cushions
Automative pads
Vibration clamping
Insulation etc.

35. What are smoke sheets?

Smoke sheets are the verify of crude natural rubber.
36. In Nylon -66 the number what it refer?
In nylon-66 the first number designate the number of carbon atoms in the diamine and in
the second is for the carbon atoms in the dibasic acid.
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37. How are the polymeric chains of the rubber braken?

The polymeric chains of the rubber and broken by the process known
a) Masticating and kneading
38.What is the catalyst used in Ziegler process?
Low presume ziegiex for the manufacture of high density polyethylene uses of a catalyst
consist of aluminium triethyl combined with titanium tetrachloride.
39. What is Perspex?
Perspex id polyethyle methaciylate

40. What are the factors affecting vulcanization?

i.
ii.
iii.

Amount of sulphur used

Temperature
Duration heating

41. What are the reinforcing agents added to the rubber?

Some common reinforcing agents are inorganic substances, such as zinc, oxide carbon
black, magnetic carbonate (or) clay.
42. What is the starting material for the production of parachloro ethylene?
Carbon tetea chloride
43. What is the steps are performed the manufacture of rubber production
i.
ii.

Breakdown
Compounding

44. What is the function of adding retarders to the rubbers?

The function of adding retarding the rubber id to prevent the disoperation and softing the
rubber.
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As a result of adding acetic acid, rubber hydrocarbon which is the main dispense phase gets
coagulated in the solid from. This is known as crude rubber.

PART B

1. Give an introduction on paints and varnishes?

The pain varnish industry is essentially a compounding industry. The manufacture of
paints, varnishes , lacquers and enamels involves a few unit operations and thereafter unit
processes.
Although the chemical engineers involvements in paint manufacturing processed is not as
extensive as in some other industries , the use of protective coating for equipment and structure is
of protective coating for equipment and structure is of obvious importance to the chemical
engineers.
The formation of protective coatings by paints varnishes, lacquers and enamels involves the
production of films of the order of one mil (1/1000 inch) thick on surface. In general, the
requirement for such surface coatings. In general, the requirement for such surface coating include
the following:
i. Hiding power or covering power
ii. color
iii. Weather resistance
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iv. Washability
v. Glass
vi. Anticorrosive properties
vii. Consistency suited application
viii. Non-toxicity
ix. Low- cost.
2. Write short notes on pigments and extenders?
Historically, white lead (2pbco3 pb (oh)2), zinc oxide and lithopone (Zns Baso 4) were the
principle whites used. Colored pigments consisted of Prussian blue Fe 4 (Fe (CN)6)) lead chromates,
various iron oxides and a few lake colors la lake beings an organic dye on an inorganic adsorbent
such as clay).
Now titanium dioxides is one of the most important the white pigments harmonium oxides
and hydrales gives green, yellow and orange colors. Carbon block is the principal black pigment
used, organic pigments (metal ph thalocyanisnes) are finding an increasingly important place as
disable blue for use in outdoor advertising display and safety signs.
After independence the production of pigments was undertaken in India. These pigments
included titanium dioxide, ph thalocyanine blue, ultramarine, blue chrome pigments and carbon
black.
Besides the above prime pigments, an important group of anticorrosive pigments such as
zinc chrome, and basic lead surface are now being made in India the manufacturer of metallic
pigments such as aluminium pas has also been started.
3. What are the ores of titanium? Explain the process involved in the production of titanium
dioxide?
Titanim dioxide features low-cost per unit of hiding power as widely used in exterior
paints, enamel and pigmented lacquers. A typical exterior paints, enamel and pigmented
lacquers. A typical exterior paints, may actually contain 15% tio 2, 25% zinc oxide, 50% white lead
and 10% of pigment extender. Such a paint has a self cleaning feature by a chalking process.
The available titanium ores are rutile (Tio2) and limonite (Feo-Tio2) Titanium dioxide
pigments have traditionally been made from these ores by a rather complex wet chemical process
involving.

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Digestion in sulfuric acid

Removal in sulfuric acid
Concentration in titanium hydrate
Calcinations grinding and bagging

More recently the flame process has been developed. The pigment product from the finance
process has superior qualities and the flame process is potentially a lower cost process than the we
process. In this type of process the ore is just chlorinate and volatile Fecl 3 separated from Ticl4 if
iron is present in the ore . then the Ticl 3 which is a liquid at temperature is fed a burner along with
oxygen where the following reactions occurs.
Ticl4 + O2 Tio2 + 2cl2
The chlorine is recovered for recycle to the orchlorinator step.
Refractory line furnace or design are us in the process. The reaction takes at 1500 and the
chemical engineering design problems are facility formidation many patents have issued on
various burner designs featuring gas mixing devices etc.

4. Write note on oils resins & derives

Oils:
Oils serve a dual purpose in a surface coating formulation as carried for the pigments and
importantly of formers of protective films.
Hence reachiveoils containing some degrees of olefin maturation are used and there are
called drying or semi-drying oils, depending on the degree of insaturation . There are in contrast
to the edible and the essential oil which are described oils which are described in preceding
section.
Drives:
Metallic salts, partionlary heavy metal salts of carboxylic acids such as co ball napthenate
for example are used in conjunction with drying oils. The unsaturated drying oils polymerize by a
peroxide intermediate. The metallic drier salt are oxidation polymerization process.
Resins:
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A variety of resins are used in various surface coating formulation oil bare paints use
essentially no resins. Water bare paints on the other contains no oils and depends on vingyl
acetate acrylic or butadiene styrene polymer resins as the film-forming materials.
5. Write short note on diluents and discuss about one economics of the paint and varnish
industries in India.
Diluents:
Diluents or thinner for paints and varnish compositions may include aliphatic or aromatic
naphtha fractions or may contain turpentine. Laccuers employ aliphatic chemicals such as ethers
keystones and alcohols to provide the desired controlled volatility. India has virtually only one
natural solvent, viz, turpentine. The production of dipentene from turpentine has also been
started. The production of synthetic solvents- butyl alcohol, butyl acetate and ethyl acetate has
commenced in the country.
Economics of the paint and varnish Industry in India:
The paint industry belongs to the category of light chemical industries, using simple
machinery and plants moreover its power and fuel consumption forms a minor cost factor. The
investment factor is negligible compared to the large chemical industries. The industry is a raw
material intensive industry and raw materials counter for 70-80% of the paint.
India is fortunate in that number of paint raw materials such as barities gypsum, china clay
natural yellow and red oxide, of iron, shellac , unused oil, castor oil glycerin, white spirit ,
regrettable turpentine, solvent naphtha and denatured spirit are available indigenously.
Manufacture [figments and colour such as titanium dioxide, zinc and lead pigments , chrome
oxide green synthetic red oxide of iron and coal tar solvents are also available in the country.
8. Explain the raw materials in soaps manufacuturing?
Castor seed:
India is one of the major producers of costar oil, accounting for about 28% of the world
production of costar oil, accounting for about 28% of the world production. The annual
production castor seed is around 5 lakh ton white that of castor oil is around 1.3 lakh tons. By
acting in convert with technology mission on oil seeds.
Soyabean:
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Soyabean designed as a miracle crop with over 40% protein and 50% oil has now been
recognized all over the world as a potential supplementary source oil edible oil and nutritions
feed. Currently the USA brazil and china are the three big Soyabean production countries.
Black soyabean has been cultrated for aged in the low hills of kumaon an Garhwal regions
of U.P. as well as on the foot hills of imalayes and in some scattered products of central India.
7. Give short notes on
i. Nitrile rubbers
ii. Neoprene
i. Nitrile Rubbers (NBR)
Copolymers of butadiene and acrylonitrice are made by emulsion polymerization. The
acynylonitrice content of the copolymer may be varied from 20 to 50% depending upon the
properties designed resistance to hydrocarbons, solvents, abrasion and gas permeation increase
with increasing citric content. Decreasing the amount of nitric present increase the low
temperature proberties and resistance. NBRs are resistance to oil, solvent, water, salts, aliphatic
compounds, soaps and most foods. They are serviceable for continuous use up to 120 c in air and
to 150c immersed in oil.
ii. Neoprene
Polychloroprene was developed by Dupont under the name duprene. It is prepared by
emulsion polymerization at purified chloroprene at about 38 c in the frequency of sulfur. It is
resistance to oxidation , oil and heat is flame resistant and find specially uses especially in
automotive punts, adhesives, sealants and coatings . It is more expansive than natural rubber and
this only used where its special properties are needed.
8. Explain the manufacture of Thiokol
Thiokol, a polysulfide type of rubber was first developed in this country and was the first
commercial synthetic rubber produced in the units states. Thiokols are prepared by the
condensation polymerization of an alkaline polysulfide with a suitable organic
nCH1CH2 OCH2 OCH2CH2 + nNA2S2
dishlide
(-CH2 CH2 OCH2 OCH2 CH2 SS-)N + 2 n Nacl
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Thiokol
Various sodium polysulfide may be reacted with organic dihalides to give specially rubber of
somewhat different properties and are particularly useful for linings for petroleum tank, for
building and caulking buildings and caulking putties cement and sealants and eately for rocketfuel binders, ablative coatings and other items requiring ease of application and good weathering
resistance.
9. Explain the manufacture is silicone rubber
Silicon rubber are mixed inorganic organic polymers produced by the polymerization of
various Salinas and siloxane. Although expensive, then outstanding resitance of heat makes them
uniquely useful of high temperature application. The chain is based on alternate atoms of silicon
and oxygen with no carbon silicones are made either by the gangland reaction, or more
economically, by alkylating with an organic halide, usually CH 3 Cl (or C6 H5 Cl or mixture thereof)
and a silicon-copper alloy according to the following reaction

10%cu ) nCH 3C

200c100 200kp0
CH 3 n siC;(4mm)
48h

The principal product are the chlororlanes (CH 3)2 SiCl2 SiCl, CH3 SiCl3 . The chain length of
the polymers is varied by the percentage of R 3SiCi, which proves the end groups. Lower polymers
one oils, higher polymers and solids. The silicon or copper may absorb any polymer may be
expressed
RSiCl3

R2SiCl2

R3SiCl

Ch
10. Explain the manufacture pf SBR
The copolymer of styrene and butadiene that contain over 50% butadiene are known as
SBR. The usual monomer ration is 70 to 75 punts of butadiene to 30 to 25 pants of styrene. As the
styrene content is increase above 50% the product becomes increasingly plastic and is used 1 latex
paint. The polymerization is carried out in a emulsion at above 5C and required 8 to 12h, a series
of reactors are often used. The heat of polymerization is approximately 1280k/kg of rubber
produced and is removed by internal ammonia coils. The molecules weight of the polymer is
regulated by the use of a modifier, such as testing C 12 merchantman, which regulates chain
growth. The reaction is terminated at 60 to 75% of completion because higher conversion gives
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polymers with inferior properties that one due to cross-linking and brunching sodium nitrate and
sodium dimethyidithiocarbonate are added to terminate the reaction. The unreacted butadiene is
flashed off and the styrene is recovered by steam distillation.
The emulation in effect a latex, is accumulated in holding taken and blended to the proper
specification for the grade of rubber required. It is coagulated and intensively washed and
dewatered prior to the drying operation. Much of the SBR sold is in the from the master batches,
in which the oil and carbon have already been added.
11. Give short notes on
i. Butyl rubber
ii. Hyplon
Buyle rubber:
The copolymer of isobutylene with about 2% isoprene is know as butyl rubber. The
isoprene imparts sufficient unsatmutation to the molecule to permit curing or vulcanization. The
polymerization is carried out in a in a slurry of the monomers in methyl chlode using an
aluminum chloride catalyst at -100 to 90c, the reaction is very fast and produces 2000+ monomers
leakages. The rubber is precipitated by adding water and separates as a crump. Butyl rubber has
extremely low permeability to gases and thus its major use in inner tubes and in lingngs for
tubless times. Butyl rubber has ever better resistance to ageing is move compactable with other
rubbers and is used in tubes time.
Hypalon:
A rubber called hypalon results from the free-radical catalyzed reaction of chlorine and So2
with polyethylene into a vuleanziable elastomer, hypalon is extremely resistant ozone attack,
weathering and heat and has excellent chemical resistance.
12. Explain the manutaltme pf urbane rubber
The reaction products of certain organic dissociates and polyolycols are rubbery products
known as polyurethanes. These compounds are specially rubber with outstanding properties as
they posses high abrasion resistance and are useful at high temperatures and with oxygen or
ozone.
A major use of this type of rubber is in the production of flexible foam and elastic fibers,
which result when a dissocyanat with a punster containing both free hychexyl, with the evolution
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of gas which service to expand the mass yielding foam either hard or soft depending on the react
and the condition employed. These materials have found increasing use in uphoistery, mattresses,
insulation, vibration, damping and other field of application formerly restricted to foam rubber.
The tensile strength and abrasion resistance of polyurethanes are extraordinary in
comparison with those of hydrogen lassoers. Both rigid and flexible foams have encountered
difficulties in some applications because of flammability.
13. Explain Rubber Fabrication
As a plastic material rubber may be spread commented, calendered, moled, extruded,
caulked, puttied or wrapped into virtually any shape wasted on cloth, plastic or metal and
sandwiched or forced into cracks.
Calendening or coating:
One of the earliest uses for rubber was for coating fabric to make it water proof. Solutions
or cements of rubber in solvents one easily spread on fabrics but, unless the ingradients necessary
for cure and properly control one included, the results may be quite unsatisfactory. Rubber
compounds are applied to fabric by calendening i.e. rolling the rubber compound into the fabric
on multiroll calendar machines. Tine cord is a special case in which cotton, rayon, nylon or
polyester cords are arranged in parallel and bound together by rubber on a calendar.

Molding:
Doughlike rubber compounds may be molded into virtually any shape, which is retained
by cuning the compounds in the mold. A very high grace and resilient rubber compound is
molded in muffin tins shaped as havles of the ball. These are cemented together and vulcanized
to form the core of a ball, to which the fabric cover and proper map fiber are cemented.
Extruding:
Weather srip , hose, inner tubes, tine treads gaskets, channels, and many other rubber
articles are fashioned by extrusion of the plastic compound, which may be cured during this
operations or later. The automobile tine serves as an example. The tine is built up as a cylinder on
a collapsible , round rotating chum. Layers of cords embedded in a proper compounds are
applied, one layer tying the beads together in one direction and another layers in another
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direction. The beads-wire cables embedded in a tough, hard rubber are stitched to the tine by
folding the end of the cord fabric over. Last the tread formed by extrusion is laid on, and the ends
lapped together. The tine building drum is collapsed and cylindrical tine removed and placed in a
press.
14. Write notes on a (i) Latex compounds (ii) Reclaimed rubber
Latex Compounds:
Concentrated lattices permit the use of rubber as a liquid which may be spread, painted,
dipped or whipped into a foam. Suspensions of compounding ingradients provide cure, but
reinforcement is not nearly as effective. The use of latex is increasing , although the foam matters,
pillow and polyether rubbers for their supply.
Reclaimed rubber:
Reclaim is a useful compounding ingradients produced from snap rubber good. Articles
are ground finely and rubber, fabric, metals etc., separated by combinations of chemical,
mechanical and solution methods. Reclaimed rubber is partially depolymerized and contains a
high percentage of carbon black (or other bigment) ask and solvent oils. It impants some desirable
processing characters to rubber compounds but is usually used as a cheap serap material for very
cheap products. World wide only about 10% of new rubbers are reclaimed.
The recent increased of energy has spurred interest in using tine waste as fuel. The burning
of 1 kg of rubber produces 7.17 MJ compared with 5.26 MJ for coal. Chunks of old tire s have also
been mixed with asphalt to produce as asphalt road aggregated which has many advantages over
ordinary asphalt . This Swedish process , called Plus-Ride in the US, produces roadways that las
more than four time longer, have increased traction and lower noise and glare than regular asphalt
roadways.
15. Explain rubber derivatives:
Rubber particularly natural rubber , has been used as a raw material for chemical reactions
to yield various derivatives of altered nature. Plastics technology is displacing these rubber based
chemicals, for rubber is obviously an expansive raw material.
Halides react with rubber, adding at the double bonds, to form chlorinated rubbers or
bromide and iodide may be used) which are useful as paint ingredients are resistant to chemical
attack. The action of hydrogen chloride on a benzene solution of rubber produces rubber
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hydrochloride, decidedly different from rubber in many ways. A tough, transparent plastic, it
forms films used for packaging. Rubber hydrochloride is resistant to chemical attack, form
excellent thin films, and is colorless, adorless, and tasteless.
PVC, polyethycene, polypropylene and newer plastics are limiting the case of expansive
rubber hydrochloride. Rubber and resin blends are widely used, the rubber adding its precaution
properties of impact resistance, extensibility and resilience.
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