UNIT I

IMPORTANT OF UTILITIES

PART A

1. What is hard water?

Hard water is water that has high mineral content. Hard water is formed when
water percolates through deposits of limestone, chalk or gypsum which are
largely made up of calcium and magnesium carbonates, bicarbonates and
sulfates. When using hard water, more soap or detergent is needed to get
things clean, be it your hands, hair, or your laundry.

2. What is soft water?

Soft water is surface water that contains low concentrations of ions and in
particular is low in ions of calcium and magnesium. Soft water naturally
occurs where rainfall and the drainage basin of rivers are formed of hard,
impervious and calcium-poor rocks. Soft water naturally occurs where rainfall
and the drainage basin of rivers are formed of hard, impervious and calcium-
poor rocks.

3. What are the pre-requisites of industrial water?

The pre-requisites of industrial water differ with its purposes and uses. It also
differs with the industry in which it has been used. The Total dissolved solids,
color, turbidity are some of the factors to be considered for the use of water in
industries.

4. List the uses of industrial water.

Cooling, heating, transferring the materials, dilution, etc. are some of the uses
of industrial water.

5. Write the purpose of water treatment.

Water treatment is any process that makes water more acceptable for a
specific end-use. The end use may be drinking, industrial water supply,
irrigation, river flow maintenance, water recreation or many other uses
including being safely returned to the environment. Water treatment removes
contaminants or reduces their concentration so that the water becomes fit for
its desired end-use.
6. What is sedimentation?
Sedimentation is the tendency for particles in suspension to settle out of the
fluid in which they are entrained and come to rest against a barrier. This is due
to their motion through the fluid in response to the forces acting on them: these
forces can be due to gravity, centrifugal acceleration, or electromagnetism.

7. What is filtration?
Filtration is the process of separating suspended solid matter from a liquid, by
causing the latter to pass through the pores of some substance, called a filter.
The liquid which has passed through the filter is called the filtrate. Usually,
canvas cloth can be used as filter medium. Examples of filtration include the
coffee filter to keep the coffee separate from the grounds. HEPA filters in air
conditioning to remove particles from air. Belt filters to extract precious metals
in mining. Horizontal plate filter, also known as Sparkler filter.

8. What is sedimentation?
Sedimentation is the tendency for particles in suspension to settle out of the
fluid in which they are entrained and come to rest against a barrier. This is due
to their motion through the fluid in response to the forces acting on them: these
forces can be due to gravity, centrifugal acceleration, or electromagnetism.

9. What is water softening?

Water softening is the removal of calcium, magnesium, and certain other metal
cations in hard water. The resulting soft water is more compatible with soap
and extends the lifetime of plumbing. Water softening is usually achieved using
lime softening or ion- exchange resins.

10. What is ion exchange technique?

Ion exchange can be defined as the reversible exchange of ions between a
liquid phase and a solid phase (ion-exchange resin) which is not accompanied
by any radical change in the solid structure. Ion-exchange reaction, any of a
class of chemical reactions between two substances (each consisting of
positively and negatively charged species called ions) that involves an
exchange of one or more ionic components. Ions are atoms, or groups of atoms,
that bear a positive or negative electric charge.

11. What is forward osmosis?

Forward osmosis (FO) is an osmotic process that, like reverse osmosis (RO),
uses a semi-permeable membrane to effect separation of water from dissolved
 solutes. In FO processes we may have solute diffusion in both directions
depending on the composition of the draw solution and the feed water.

12. What is reverse osmosis?

Reverse osmosis (RO) is a water purification process that uses a partially
permeable membrane to remove ions, unwanted molecules and larger particles
from drinking water. In reverse osmosis, an applied pressure is used to
overcome osmotic pressure, a colligative property that is driven by chemical
potential differences of the solvent, a thermodynamic parameter. Reverse
osmosis can remove many types of dissolved and suspended chemical species
as well as biological ones (principally bacteria) from water, and is used in both
industrial processes and the production of potable water. The result is that the
solute is retained on the pressurized side of the membrane and the pure solvent
is allowed to pass to the other side.

13. What is nano-filtration?

Nanofiltration is a relatively recent membrane filtration process used most
often with low total dissolved solids water such as surface water and fresh
groundwater, with the purpose of softening (polyvalentcation removal) and
removal of disinfection by-product precursors such as natural organic matter
and synthetic organic matter.

14. What is demineralization?

Demineralization is the process in which the minerals were removed from the
water and it is reverse of mineralization process. It can be used when the
industrial water has high TDS. Demineralization is mostly caused by strong,
stable acids, which can be found in foods such as tomatoes and oranges. Acids
can also be caused by bacteria in the mouth and sugars from foods. These acids
dissolve minerals.

15. List the pre-requisites for members used in reverse osmosis.

 Low salt passage, typically >99,7% rejection at standard conditions in
brackish water
 High flow productivity
 Improved barrier layer chemistry (lower charge and higher cross-
linkage) providing lower membrane fouling rates
 More stable salt rejection during operating lifetime (as the rejection
mechanism is based more on solution diffusion than ionic repulsion)
 Improved organic compound rejection
 More durable to allow less frequent, more aggressive cleaning.
16. How Hardness of water can be expressed?
Water hardness is expressed in degrees of general hardness (dGH), German
degrees (°dH), parts per million (ppm, mg/L, or American degrees), grains per
gallon (gpg).

17. How chemical precipitation used in softening waters?

Chemical precipitation is one of the more common methods used to soften
water. Chemicals normally used are lime (calcium hydroxide, Ca(OH) 2) and
soda ash (sodium carbonate, Na2CO3). Lime is used to remove chemicals that
cause carbonate hardness. Soda ash is used to remove chemicals that cause
non- carbonate hardness.

18. Write about Conventional Lime-Soda Ash Treatment.

When water has minimal magnesium hardness, only calcium needs to be
removed. Only enough lime and soda ash are added to water to raise pH to
between 10.3 and 10.6, and calcium hardness will be removed from the water
(but minimal magnesium hardness will be removed).

19. What is Excess Lime Treatment?

When magnesium hardness is more than about 40 mg/l as CaCO 3, magnesium
hydroxide scale deposits in household hot-water heaters operated at normal
temperatures of 140 to 150° F. To reduce magnesium hardness, more lime must
be added to the water. Extra lime will raise pH above 10.6 to help magnesium
hydroxide precipitate out of the water.

20. What is boiler water?

Boiler water is the liquid phase of steam within a boiler. The term may also be
applied to raw water intended for use in boilers, treated boiler feed water, steam
condensate being returned to a boiler, or boiler blow down being removed from
a boiler.

21. What is the role of Re-carbonation in Lime Treatment?

A process in which carbon dioxide is bubbled into the water being treated to
lower the pH. The pH may also be lowered by the addition of acid. Carbonation
is the final stage in the lime–soda ash softening process. This process converts
carbonate ions to bicarbonate ions and stabilizes the solution against the
precipitation of carbonate compounds.
22. What are Primary Utilities?
These are the utilities serving the basic purpose of heating, cooling washing
and cleaning. Example; hot water, steam, cold water and fuel gas.

23. What are the types of water used in process plants?

Boiler feed water, DM water, Soft water, Distilled water, Make up water,
Drinking water, contaminated water, Waste water, Water condensate, Domestic
water and Phenolic water.

24. Distinguish between hard and soft water.

Hard water is water that has high mineral content (in contrast with "soft
water"). Hard water is formed when water percolates through deposits of
limestone and chalk which are largely made up of calcium and magnesium
carbonates.
Soft water is surface water that contains low concentrations of ions and in
particular is low in ions of calcium and magnesium. Soft water naturally occurs
where rainfall and the drainage basin of rivers are formed of hard, impervious
and calcium poor rocks.

25. State the difference between cold lime and hot lime water softening process.

cold lime hot lime

It is carried out at room It is carried out at High temperature
temperature(25 – 300C) (95 – 1000C)
It is slow process It is a rapid process
Use of coagulant is a necessary No coagulant required
Filtration is not easy Filtration is easy as viscosity of
water is low
Residual hardness is 60ppm Residual hardness is 15-30ppm
Dissolved gases are not removed Dissolved gases are removed
It has low softening capacity It has high softening point

26. Write the purpose of treating boiler water.

The treatment and conditioning of boiler feed water must satisfy three main
objectives:
• Continuous heat exchange
• Corrosion protection & Production of high quality steam.
 27. How the alkaline nature of feed water affects the performance of a boiler?
Higher value of alkalinity leads to scale formation and overheating of the inside
of the boiler causing internal damage. It causes generation of scale formation.
The more the chloride ions, the more the scale formation.

PART B

1. Write about process plant utilities in detail.

2. Elaborate about hard water and soft water and mention their properties and
merits and demerits.
3. Write about the softening of hard water.
4. Write about pre-requisites of industrial water.
5. Explain the methods involved in water treatment.
6. Write about chemical softening process.
7. Explain the demineralization process of water treatment with neat sketch.
8. Explain about the resins used in water softening process.
9. Elaborate about the reverse osmosis.
10. Explain in detail the effects of impure boiler feed water and the procedure for
treating impure boiler feed water.
11. Discuss about reuse and conservation of water in chemical plants.
12. Explain the zeolite process of waste water treatment with chemical equations.
13. Enumerate the operation of anyone boiler used for steam production. Explain
different techniques of waste heat utilization.
14. Explain osmosis and how reverse osmosis (RO) can be achieved. Write the uses
of RO
15. Explain how ion exchange resin works.

UNIT II
STEAM AND STEAM
GENERATION PART A
1. What is the role of steam traps in process industry?
A steam trap is a device used to discharge condensate and non-condensable gases
with a negligible consumption or loss of live steam. Most steam traps are
nothing more than automatic valves. They open, close or modulate
automatically. Others are based on turbulent 2-phase flows to obstruct the
steam flow.

2. What is steam economy?

Steam economy is the ratio between total steam evaporated and steam consumed
Se=Steam evaporated/steam flow at start
It should be above 1 for multi effect systems.
 3. What is steam jet ejector and how does it work?
A steam jet ejector is a simple device that uses pressurized steam to create a
partial vacuum inside an enclosed system by pumping gases and vapors out of
the system. The working principle of the ejector is based on the expansion of a
high-pressure steam jet in the converging/diverging nozzle section. The internal
energy of the motive steam is converted to kinetic energy. The high-speed
steam jet (primary fluid) entrains the low-pressure secondary steam jet
(secondary fluid).

4. What are the important functions of steam traps?

The three important functions of steam traps are:
 Discharge condensate as soon as it is formed.
 Have negligible steam consumption.
 Have the capability of discharging air and other non-condensable gas.

5. What is induced draft?

Induced draft: This is obtained one of three ways, the first being the "stack
effect" of a heated chimney, in which the flue gas is less dense than the ambient
air surrounding the boiler. The denser column of ambient air forces combustion
air into and through the boiler. The second method is through use of a steam
jet. The steam jet oriented in the direction of flue gas flow induces flue gasses
into the stack and allows for a greater flue gas velocity increasing the overall
draft in the furnace. This method was common on steam driven locomotives which
could not have tall chimneys.

6. What are the types of steam turbines?

The two most basic and fundamental types of steam turbines are the impulse
turbine and the impulse reaction turbine.

7. What is forced draft?

Forced draft: Draft is obtained by forcing air into the furnace by means of a fan
and ductwork. Air is often passed through an air heater; which, as the name
suggests, heats the air going into the furnace in order to increase the overall
efficiency of the boiler. Dampers are used to control the quantity of air
admitted to the furnace. Forced draft furnaces usually have a positive pressure.

8. What are super-heated steam boilers?

Most boilers produce steam to be used at saturation temperature; that is, saturated
steam. Superheated steam boilers vaporize the water and then further heat the
steam in a super heater. This provides steam at much higher temperature, but
can
 decrease the overall thermal efficiency of the steam generating plant because
the higher steam temperature requires a higher flue gas exhaust temperature.

9. What is saturated steam?

Saturated steam occurs when steam and water are in equilibrium. If you have a
closed container of water and heat it, above 100 Celsius the steam pressure will
start to rise, and as the temperature continues to rise, the pressure will go on
rising. The steam conditions are said to be saturated because if the pressure is
raised by external means, some of the steam will start to condense back to
water. Saturated steam is preferable, because it has a better energy exchange
capacity.

10. What are steam generators?

A closed tank in which water is converted into steam under pressure. A steam
generator is a device used to boil water to create steam. It may refer to: Boiler
(steam generator), a closed vessel in which water is heated under pressure.

11. What is a Condensate?

Condensate may refer to the liquid phase produced by the condensation of
steam or any other gas the product of a chemical condensation reaction, other
than water Natural gas condensate, in the natural gas industries.

12. What is super-heated steam?

Superheated steam is steam at a temperature higher than water's boiling point.
If saturated steam is heated at constant pressure, its temperature will rise, producing
superheated steam. This will occur if saturated steam contacts a surface with a
higher temperature. The steam is then described as superheated by the number
of degrees it has been heated above saturation temperature.

13. What type of steam traps should be used for efficient heating system?
Continuous flow traps will, to one degree or another, continuously discharge
condensate. These are float, thermostatic and fixed orifice traps. The
thermostatic trap is a hybrid. It can be considered either a continuous flow or an
intermittent flow, depending on the condensate load. Under heavy condensate
load or at start-up, it will tend to have a continuous discharge.
Intermittent traps will cycle open and closed. They have a pattern of hold-
discharge-hold. These traps are the thermodynamic, inverted bucket and
bimetallic in nature.
14. What is a steam turbine?
A steam turbine is a mechanical device that extracts thermal energy from
pressurized steam and converts it into a rotary motion. It almost completely
replaced the reciprocating piston steam engine primarily, because of its greater
thermal efficiency and power to weight ratio.

15. Differentiate between Scale and Sludge.

In boiler when water is heated, if the water is hard then would contain salts. So
on heating the water the water particles are evaporated by the time and the
saturated salts are left behind. Now it’s the part of the boiler, if the inner walls
are made up of nonstick material or such then the salts which is left as a
precipitate will not stick on the same and hence make the water thicker and
thicker as more and more water will evaporate which would result in a very
thick liquid substance having a lot of salt rather than water, this is known as
Sludge. On the other hand, if the inner walls of the boiler are not made up of
such non sticking material then the salts would stick on them resulting a
formation of a thick layer of salts on the walls, this is known as Scale.

16. What are the requirements of good boiler?

 The boiler should have maximum steam generation rate with minimum
fuel consumption.
 It can be started or stopped quickly.
 Its initial cost, running and maintenance cost should not be high.
 Its erection time should be less, and its parts should be easily dismantable.
 The boiler should have positive controls and safety apparatus.
 It should have a high rate of heat transfer and better combustion
efficiency.
 It should be able to accommodate the load variation.
 It should occupy less floor space.

17. Define British Thermal Unit (BTU).

The British thermal unit (Btu or BTU) is a traditional unit of heat; it is defined
as the amount of heat required to raise the temperature of one pound of water
by one degree Fahrenheit.

18. What are the different types of steam traps?

• Mechanical traps
• Temperature traps
• Thermodynamic traps
19. How Steam Economy can be improved?
The steam economy can also be improved by feed pre-heating systems using
the waste heat from process plants.

20. What is steam and mention its property?

Steam is water in the gas phase, which is formed when water boils or
evaporates. Steam is invisible; however, "steam" often refers to wet steam, the
visible mist or aerosol of water droplets formed as this water vapor condenses.
If heated further it becomes superheated steam.
 Produced from water.
 Clean, odorless, and tasteless.
 Easily distributed and controlled.
 Heat can be used over and over.
 High usable heat content.
 Gives up its heat at constant temperature.
 Well-known characteristics. Pressure, temperature, volume.

PART B
1. Explain in detail about the different types of steam traps, Mountings and
Accessories in the steam Boilers.
2. Describe in Detail about the steam generation methods and discuss the uses
of steam in process industry elaborately.
3. Describe the issues related with the Steam distribution
4. Enumerate the operation of any one boiler used for steam production.
5. Explain different equipment used for Waste heat recovery
6. Discus about the reuse and conservation of water in chemical plants.
7. Explain the steam generation process in in the water gas fired boiler with
neat sketch
8. Steam at a temperature of 623 K is flowing through a pipe with an outer
diameter of 100mm. the pipe is insulated with 20 mm thick mineral wool, the
average thermal conductivity of which is 0.055 W/mK. Determine the outside
surface temperature of the mineral wool if the ambient air temperature is 300
K. Assume the hot surface temperature of the mineral wool is same as that of
the flowing steam and the value of surface coefficient of the insulating material
is 30 W/ m.sq. K.
9. Distinguish between steam engines and steam turbines.
10. Write a detailed note on steam distribution.
11. Distinguish between steam engines and steam turbines. Explain any one
equipment in detail.
 12. Sketch the basic flow diagram of a steam power plant cycle showing by
product generation of electric power and process steam?
13. Explain the Rankine cycle and obtain an expression for the Rankine cycle
efficiency. Comment on the reasons for considering Rankine cycle as an ideal
cycle for steam power plant.
14. Describe the fluidized bed combustion process and how it compares with
pulverized coal and stoker firing. Name the major advantages of fluidized bed
combustion.
15. Discuss about steam Handling and its effective distribution in detail.
Explain the construction and working of Cochran Boiler in detail.

UNIT 3
REFRIGERATION
PART A
1. What is refrigeration system?
Refrigeration system is a system which involves the removal of heat from a space
at a temperature lower than the surrounding temperature.The refrigeration cycle
starts and ends with the compressor. The refrigerant flows into the Compressor
where it is compressed and pressurised. At this point, the refrigerant is a hot
gas. The refrigerant is then pushed to the Condenser which turns the vapour
into liquid and absorbs some of the heat.

2. Name the refrigerants used in air-conditioning. List the various

refrigerants.
The various refrigerants are ammonia, sulphur dioxide, isobutene,
methylchloride, Freon. The various refrigerants are ammonia, carbon dioxide,
sulphur dioxide, isobutane, methyl chloride.

3. What is Joule Thomson effect?

In thermodynamics, the Joule–Thomson effect or Joule–Kelvin effect or Kelvin–
Joule effect describes the temperature change of a gas or liquid when it is
forced through a valve or porous plug while kept insulated so that no heat is
exchanged with the environment. This procedure is called a throttling process
or Joule– Thomson process.

4. What is vapor compression system?

The vapor-compression refrigeration system uses a circulating liquid
refrigerant as the medium which absorbs and removes heat from the space to be
cooled and subsequently rejects that heat elsewhere.
5. Explain the selection criteria for good refrigerant?
 Boiling point of refrigerant should be lower than desired temperature
levels in the refrigerator.
 Very low freezing temperature as compared to minimum operating
temperature required
 Critical temperature and pressure should be well above the operating
pressure
 High Latent heat of vaporization and low specific heat is preferred.

6. What is steam jet refrigeration cycle?
In this system, water is boiled in an evaporator and converted into vapour at a
very low pressure. The vapour is then entrained by the jet pump, compressed to
a higher pressure and condensed in the condenser.

7. Explain the uses of Psychrometricchart?

Psychrometric Chart is one of the very important tools for the engineers to
carry out heat load or cooling load calculations and find solutions to various air
conditioning related problems. All the properties of air indicated in the
psychrometric chart are calculated at the standard atmospheric pressure and for
other pressures relevant corrections have to be applied.
USES: It can be very helpful in troubleshooting greenhouse or livestock
building environmental problems and in determining solutions. Understanding
psychrometric charts helps visualization of environmental control concepts
such as why heated air can hold more moisture, and conversely, how allowing
moist air to cool will result in condensation.

8. What is throttling of gases?

A throttle is the mechanism by which the flow of a fluid is managed by
constriction or obstruction. An engine's power can be increased or decreased by
the restriction of inlet gases (i.e., by the use of a throttle), but usually
decreased. The term throttle has come to refer, informally and incorrectly, to
any mechanism by which the power or speed of an engine is regulated.

9. What is a cooling tower?

Cooling towers are heat removal devices used to transfer process waste heat to
the atmosphere. Cooling towers may either use the evaporation of water to
remove process heat and cool the working fluid to near the wet-bulb air
temperature or rely solely on air to cool the working fluid to near the dry-bulb
air temperature. Common applications include cooling the circulating water used
in oil refineries, chemical plants, power stations and building cooling.
10. What is drying tower?
Absorption and drying towers for treating sulphur trioxide process gases and
air, respectively, with concentrated sulphuric acid in the manufacture of
sulphuric acid. Each tower has a suitably shaped downwardly angled gas
delivery duct protruding into a lower chamber of the tower to prevent acid from
entering inside the duct. Each tower also has its lower chamber defined by the
base of the tower and a suitably formed packing support. Additional packing is
interposed between the lower walls of the tower and the packing support.
Improved corrosion resistance of the metal components is obtained.

11. What is a cooling tower?

Cooling towers are heat removal devices used to transfer process waste heat to
the atmosphere. Cooling towers may either use the evaporation of water to
remove process heat and cool the working fluid to near the wet-bulb air
temperature or rely solely on air to cool the working fluid to near the dry-bulb
air temperature. Common applications include cooling the circulating water used
in oil refineries, chemical plants, power stations and building cooling.

12. What is dehumidification?

The process in which the moisture or water vapor or the humidity is removed
from the air keeping its dry bulb (DB) temperature constant is called as the
dehumidification process.

13. How liquid oxygen is produced?

To produce liquid oxygen, air is compressed and cooled to -196 degrees
Celsius. The gases in the air are liquid at this point before the room is heated
-183, reverting the nitrogen in the air to gas and leaving only liquid oxygen
behind.

14. Write the uses of liquid nitrogen?

The main use of liquid nitrogen is as a refrigerant. Among other things, it is
used in the cryopreservation of blood, reproductive cells (sperm and egg), and
other biological samples and materials. It is used medically in cryotherapy to
remove cysts and warts on the skin. It is used in cold traps for certain
laboratory equipment and to cool X-ray detectors. It has also been used to cool
central processing units and other devices in computers which are overclocked,
and which produce more heat than during normal operation.
15. What is air exhaust?
An air-exhaust unit used to carry away odors and fumes from a stove, griddle,
etc.; may contain a grease-extracting device or an air filter; sometimes includes
a fire-extinguishing device. An air-exhaust unit used to carry away dirt
particles, odors, or fumes (as in an industrial plant); the ventilator may be
mechanically actuated or of the gravity type.

16. What is wet bulb temperature?

The Wet Bulb temperature is the temperature of adiabatic saturation. This is the
temperature indicated by a moistened thermometer bulb exposed to the air
flow. Wet Bulb temperature can be measured by using a thermometer with the
bulb wrapped in wet muslin. The adiabatic evaporation of water from the
thermometer and the cooling effect is indicated by a "wet bulb temperature"
lower than the "dry bulb temperature" in the air.

17. What is dry bulb temperature?

The Dry Bulb temperature, usually referred to as air temperature, is the air
property that is most common used. When people refer to the temperature of
the air, they are normally referring to its dry bulb temperature. The Dry Bulb
Temperature refers basically to the ambient air temperature. It is called "Dry
Bulb" because the air temperature is indicated by a thermometer not affected by
the moisture of the air.

18. Differentiate Heat pump from a Refrigerator.

All the components of the heat pumps are same as the refrigerator and even
they perform the similar functions. The only point of difference between the
two is of the operating temperatures. The heat pump is the reverse refrigerator.
 Transfer of heat
 Location of the evaporator
 Location of the condenser & Working of evaporator and condenser

19. What is refrigeration capacity and mention its unit?

The refrigerator capacity determines the rate of circulation of the refrigerant,
which in turn, decides the design and size of the various units such a s
condenser, compressor, evaporator and the expansion devices. The capacity is
sometimes measured in ton of refrigeration. One ton is defined as the heat of
absorption at the rate of 12000 BTU per hour. These rates correspond to the
rate of heat removal that is required to freeze 1 ton of water in a day originally
at 273 K. One ton of refrigeration rate of 12600 KJ/h in SI units.
20. List four advantages of exhaust ventilation.
 Captures contaminant at source and removes it from the workplace.
 Can handle many types of contaminants including dusts and metal fumes.
 The only choice for highly toxic airborne chemicals.
 Requires smaller amount of makeup air since smaller amounts of air are
being exhausted.
 Less energy costs since there is less makeup air to heat or cool.

21. What are the properties of chloro fluro carbons?

These compounds are non-flammable, tasteless and odourless, and chemically
stable. Their other important property is their volatility, having boiling points
close to zero degrees Centigrade. These physical properties make them ideal
for use as refrigerant gases in air conditioners, freezers and refrigerators.

22. List four advantages of exhaust ventilation.

 Captures contaminant at source and removes it from the workplace.
 Can handle many types of contaminants including dusts and metal fumes.
 The only choice for highly toxic airborne chemicals.
 Requires smaller amount of makeup air since smaller amounts of air are
being exhausted.
 Less energy costs since there is less makeup air to heat or cool.

PART B
1. Explain the absorption refrigeration system with a neat sketch?
2. Explain the different type of condensers used in refrigeration system?
3. What are the various methods of refrigeration? Discuss the application of
refrigeration and air conditioning in chemical process industries?
4. Explain in detail about different types of dehumidifiers.
5. Explain in detail about different types of humidifiers.
6. Discuss in detail about air refrigeration systems
7. Mention the objectives of maintaining low temperatures using refrigeration in a
chemical plant with at least two examples. With a neat sketch explain the
function of any two cooling towers.
8. Explain various methods for the cryogenic temperature production.
9. Bring out the importance of providing ventilation in air conditioned systems
and explain how it is achieved?
10. Explain in detail about various parameters to be considered for the selection of
good refrigerant.
11. Explain the Vapor-Compression Refrigeration with a neat diagram.
12. Explain Reversed Brayton cycle in detail.
13. Enumerate different refrigeration system and their advantages and
disadvantages.
14. Discuss in detail on two humidification and dehumidification equipment’s used
in chemical industries.
15. Discuss Carnot refrigeration cycle in detail with a neat sketch.
16. Discuss the liquefaction process and draw a neat sketch of Linde liquefaction
process.
17. Explain the refrigerant and brines with their desirable properties.
18. Explain Linde and Claude Liquefaction processes with neat diagrams in detail.

UNIT 4
COMPRESSED AIR
PART A
1. What are compressors?
A compressor is a mechanical device that increases the pressure of a gas by
reducing its volume. An air compressor is a specific type of gas compressor.
Compressors are similar to pumps: both increase the pressure on a fluid and
both can transport the fluid through a pipe. As gases are compressible, the
compressor also reduces the volume of a gas. Liquids are relatively
incompressible; while some can be compressed, the main action of a pump is to
pressurize and transport liquids.

2. What are pumps?

A pump is a device that moves fluids (liquids or gases), or sometimes slurries,
by mechanical action, typically converted from electrical energy into Hydraulic
energy. Pumps can be classified into three major groups according to the
method they use to move the fluid: direct lift, displacement, and gravity pumps.
Pumps operate by some mechanism (typically reciprocating or rotary), and
consume energy to perform mechanical work moving the fluid. Pumps operate
via many energy sources, including manual operation, electricity, engines, or
wind power, and come in many sizes, from microscopic for use in medical
applications, to large industrial pumps.

3. What is lubrication?

Lubrication is the process, or technique employed to reduce wear of one or

both surfaces in close proximity, and moving relative to each another, by
interposing a substance called lubricant between the surfaces to carry or to
help carry the load (pressure generated) between the opposing surfaces.
4. What are lubricants?
A lubricant (sometimes referred to as "lube") is a substance (often a liquid)
introduced between two moving surfaces to reduce the friction between them,
improving efficiency and reducing wear. It may also have the function of
dissolving or transporting foreign particles and of distributing heat. A
lubricant's ability to lubricate moving parts and reduce friction is the property
known as lubricity. One of the single largest applications for lubricants, in the
form of motor oil, is protecting the internal combustion engines in motor
vehicles and powered equipment.

5. How oil is removed in compressors?

All reciprocating compressor cylinders require oil lubrication and suitable

separators must be provided at the discharge of the compressors to remove
unwanted oil from the gas streams.

6. What are reciprocating compressors?

A reciprocating compressor or piston compressor is a positive-displacement
compressor that uses pistons driven by a crankshaft to deliver gases at high
pressure. The intake gas enters the suction manifold, then flows into the
compression cylinder where it gets compressed by a piston driven in a
reciprocating motion via a crankshaft, and is then discharged.

7. What is the lubricating system seen in reciprocating compressors?

An angle type compressor may have three lubricating systems. A force feed
type lubricator supplies special cylinder oil under controlled feed rates to the
compressor cylinders and piston rod packing. It’s function is to create an
effective piston seal and to protect the compressor valve parts.

8. What are piping stresses?

Essentially all piping system stresses or certainly which require involved
stress analysis are the result of temperature changes there are ordinarily three
conditions which cause stress in piping. First caused by internal or external
pressure, second which remains in the pipe wall, third is the temperature
causing by fluid flowing.
9. What are the conditions involved for various type of compressors for a
job?
High differential pressures and low to high moderately high volumes –
reciprocating compressor
High volumes and moderate differentials –centrifugal machines
For low pressures operation and volumes – rotary compressor

10. Differentiate between reciprocating compressors and vacuum pumps.

A reciprocating compressor or piston compressor is a positive-displacement
compressor that uses pistons driven by a crankshaft to deliver gases at high
pressure. The intake gas enters the suction manifold, then flows into the
compression cylinder where it gets compressed by a piston driven in a
reciprocating motion via a crankshaft, and is then discharged.
A vacuum pump is a device that removes gas molecules from a sealed volume
in order to leave behind a partial vacuum.

11. What is mean by waste heat utilization?

This is the process of the recovery of the process heat which rejected and
utilizing to input some other heat duty in one of the operation. For instance,
the preheating of the boiler feed water using the heat from the flue gas.

12. Define slip factor.

In turbomachinery, the slip factor is a measure of the fluid slip in the impeller
of a compressor or a turbine, mostly a centrifugal machine.

13. Why intercooling is necessary in multistage compression?

 Reduced air temperature, volume and increased air density for next stage
so increased volumetric efficiency and compressor efficiency.
 Due to reduced temperature give better lubrication for cylinder and
piston rings.
 Drain are fitted from which water and excessive oil can be drained out,
to prevent air bottle corrosion and starting air explosion and fouling of
inter coolers and pipe.
 Save the work done.

14. What is the purpose of lubrication?

The purpose of lubrication is to reduce the friction between the moving parts
and removes heat. In addition to this it dissolves and removes the foreign
bodies.
15. Draw the velocity diagram at the outlet of the impeller of
centrifugal compressor.

16. Define Evaporative Cooling.

Evaporative cooling is a process that uses the effect of evaporation as a
natural heat sink. Sensible heat from the air is absorbed to be used as latent
heat necessary to evaporate water. The amount of sensible heat absorbed
depends on the amount of water that can be evaporated. Evaporative cooling
is based on the thermodynamics of evaporation of water, i.e. the change of the
liquid phase of water into water vapor. This phase change requires energy,
which is called latent heat of evaporation.

17. Define Absolute humidity and relative humidity.

Absolute humidity is the measure of the actual water vapor in the air. It is
measured in grams per cubic meter (g/m3). Relative humidity is the ratio of
the absolute humidity to the theoretical maximum for a given temperature and
pressure. It is expressed as a %. So, if the air holds half of what it could hold,
the relative humidity is 50%.

18. What is a rotary screw compressor?

A rotary-screw compressor is a type of gas compressor, such as an air
compressor, that uses a rotary-type positive-displacement mechanism. They
are commonly used to replace piston compressors where large volumes of
high- pressure air are needed, either for large industrial applications or to
operate high-power air tools such as jackhammers and impact wrenches. For
smaller rotor sizes the inherent leakage in the rotors becomes much more
significant, leading to this type of mechanism being unsuitable for small air
compressors.
19. What is humid heat?
Humid heat is the heat required to raise the temperature of unit mass of gas
and its accompanying vapor one degree at constant pressure.

20. What is reversible isentropic compression?

In thermodynamics, an isentropic process is an idealized thermodynamic process
that is both adiabatic and reversible. The work transfers of the system are
frictionless, and there is no transfer of heat or matter. Such an idealized process
is useful in engineering as a model of and basis of comparison for real
processes.

PART B
1. Discuss the merits and demerits of various compressors available?
2. Explain the working principle of a reciprocating type compressor with a neat
sketch.
3. Discuss in detail the Vapor Compression Refrigeration Cycle.
4. Explain in detail on vacuum production methods.
5. Discuss methods of oil removal and lubrication in compressors.
6. Draw the schematic sketches of rotary compressor and reciprocating compressor
and compare its performance characteristics.
7. What are the role and uses of boosters in the process industry?
8. Explain the working theory and performance of two stage Reciprocating
Polytrophic Compressor.
9. Describe with neat sketch, the working principle of any one vacuum pump.
10. Describe the methods available for estimating humidity of a sample of air.
11. What are the different types of cooling towers used in industries? Briefly
explain them.
12. Discuss briefly about spray chamber with a neat sketch.
13. Write a note on two industrial cooling towers with a neat sketch.
14. Write briefly about adiabatic saturator.

15. Discuss Air conditioning process.

16. Discuss the cooling tower principle and its operation with a neat sketch. List
the factors governing the operation of cooling tower.
17. Explain the working principle of a centrifugal compressor with suitable
diagrams.
18. Write short notes on absolute humidity, relative humidity and dew point.
19. Discuss Interphase mass transfer.
20. Write a note on induced and forced draft cooling tower.
21. Explain the working of cooling towers in detail with neat sketch.
22. Explain By Pass Factor (BPF) and contact factor(ᵦ).Show the relationship
between BPF and ᵦ.
23. Explain the concepts of adiabatic saturation and thermodynamic wet bulb
temperature.

UNIT 5
FUEL AND WASTE DISPOSAL
PART A
1. Define fuel.
A fuel is any material that can be made to react with other substances so that it
releases energy as heat energy or to be used for work. The concept was originally
applied solely to those materials capable of releasing chemical energy but has
since also been applied to other sources of heat energy such as nuclear energy
via nuclear fission and nuclear fusion. The heat energy released by reactions of
fuels is converted into mechanical energy via a heat engine. Other times the
heat itself is valued for warmth, cooking, or industrial processes, as well as the
illumination that comes with combustion.

2. What is natural gas and how is it formed?

Natural gas (also called fossil gas; sometimes just gas), is a naturally occurring
hydrocarbon gas mixture consisting primarily of methane, but commonly
including varying amounts of other higher alkanes, and sometimes a small
percentage of carbon dioxide, nitrogen, hydrogen sulfide, or helium. It is
formed when layers of decomposing plant and animal matter are exposed to
intense heat and pressure under the surface of the earth over millions of years.
Natural gas is a non-renewable hydrocarbon used as a source of energy for
heating, cooking, and electricity generation.

3. Define calorific value

The calorific value is the total energy released as heat when a substance
undergoes complete combustion with oxygen under standard conditions. The
chemical reaction is typically a hydrocarbon or other organic molecule reacting
with oxygen to form carbon dioxide and water and release heat. It may be
expressed with the quantities:
energy/mole of fuel
energy/mass of fuel
energy/volume of the fuel
4. What is the basic difference between coal and coke?
The basic difference between coal and coke is that coal is the natural source
and coke is the derivative product produced by destructive distillation. Both
are used as fuel, but coke contains a higher carbon content and few impurities.
Coke is also used during iron ore smelting as a reducing agent.

5. What is crank shaft?

A crankshaft is a rotating shaft which converts reciprocating motion of the
pistons into rotational motion. Crankshafts are commonly used in internal
combustion engines and consist of a series of cranks and crankpins to which the
connecting rods are attached. The crankshaft rotates within the engine block
through use of main bearings, and the crankpins rotate within the connecting rods
using rod bearings. Crankshafts are usually made from metal, with most
modern crankshafts being constructed using forged steel.

6. What is meant by petrol engine?

A petrol engine (known as a gasoline engine in American English) is an
internal combustion engine with spark-ignition, designed to run on petrol
(gasoline) and similar volatile fuels. It was invented in 1876 in Germany by
German inventor Nikolaus August Otto.

7. Difference between supercharger and turbocharger

The key difference between a turbocharger and a supercharger is its power
supply. Something has to supply the power to run the air compressor. In a
supercharger, there is a belt that connects directly to the engine. It gets its
power the same way that the water pump or alternator does. A turbocharger, on
the other hand, gets its power from the exhaust stream. The exhaust runs
through a turbine, which in turn spins the compressor.

8. What is the difference between gasoline and diesel fuel?

Both diesel engines and gasoline engines covert fuel into energy through a
series of small explosions or combustions. The major difference between diesel
and gasoline is the way these explosions happen. In a gasoline engine, fuel is
mixed with air, compressed by pistons and ignited by sparks from spark plugs.

9. What is four stroke engine?

A four-stroke cycle engine is an internal combustion engine that utilizes four
distinct piston strokes (intake, compression, power, and exhaust) to complete
one operating cycle. The piston makes two complete passes in the cylinder to
complete one operating cycle.
10. What is two stroke engine?
A two-stroke, or two-cycle, engine is a type of internal combustion engine
which completes a power cycle with two strokes (up and down movements) of
the piston during only one crankshaft revolution. This is in contrast to a "four-
stroke engine", which requires four strokes of the piston to complete a power
cycle.

11. How do two stroke engine work?

At the top of the stroke, the spark plug ignites the fuel mixture. (At the same
time, another crankcase compression stroke is happening beneath the piston.)
Since the two stroke engine fires on every revolution of the crankshaft, a two
stroke engine is usually more powerful than a four stroke engine of equivalent
size.

12. What is waste management?

Waste management is the process of treating solid wastes and offers variety of
solutions for recycling items that don’t belong to trash. It is about how garbage
can be used as a valuable resource. Waste management is something that each
and every household and business owner in the world needs. Waste
management disposes of the products and substances that you have use in a
safe and efficient manner.

13. What is plasma gasification?

Plasma gasification is another form of waste management. Plasma is a
primarily an electrically charged or a highly ionized gas. Lighting is one type
of plasma which produces temperatures that exceed 12,600 °F. With this
method of waste disposal, a vessel uses characteristic plasma torches operating
at +10,000 °F which is creating a gasification zone till 3,000 °F for the
conversion of solid or liquid wastes into a syngas.

14. What is composting?

Composting is an easy and natural bio-degradation process that takes organic
wastes i.e. remains of plants and garden and kitchen waste and turns into
nutrient rich food for your plants. Composting, normally used for organic
farming, occurs by allowing organic materials to sit in one place for months
until microbes decompose it. Composting is one of the best method of waste
disposal as it can turn unsafe organic products into safe compost. On the other
side, it is slow process and takes lot of space.
15. What is the role of Spark Plug in an IC Engines?
A spark plug is an electrical device that fits into the cylinder head of some
internal combustion engines and ignites compressed aerosol gasoline by means
of an electric spark. Spark plugs have an insulated center electrode which is
connected by a heavily insulated wire to an ignition coil or magneto circuit on
the outside, forming, with a grounded terminal on the base of the plug, a spark
gap inside the cylinder.A petrol engine (known as a gasoline engine in
American English) is an internal combustion engine with spark-ignition,
designed to run on petrol (gasoline) and similar volatile fuels. It was invented
in 1876 in Germany by German inventor Nikolaus August Otto.

16. What are the types of waste disposal?

The types of waste disposal include source reduction and reuse, animal feeding,
recycling, composting, fermentation, landfills, incineration and land
application.

17. Write the classification of coal by rank.

 Anthracite: The highest rank of coal. It is a hard, brittle, and black lustrous
coal, often referred to as hard coal, containing a high percentage of fixed
carbon and a low percentage of volatile matter.
 Bituminous: Bituminous coal is a middle rank coal between
subbituminous and anthracite. Bituminous usually has a high heating
(Btu) value and is the most common type of coal used in electricity
generation in the United States. Bituminous coal appears shiny and
smooth when you first see it, but look closer and you may see it has layers.
 Subbituminous: Subbituminous coal is black in color and dull (not
shiny), and has a higher heating value than lignite.
 Lignite: Lignite coal, aka brown coal, is the lowest grade coal with the
least concentration of carbon.

18. Brief Coke as fuel.

Coke is a hard gray fuel with few impurities and a high carbon content and it is
used when purity and high carbon content is desired. Coke is used worldwide
in blast furnaces. Coke is used most often in making metals. Coke is made in
brick furnaces with bituminous coal as the sources.

19. Define Recycling

Recycling is the process of converting waste products into new products to
prevent energy usage and consumption of fresh raw materials. Recycling is the
third component of Reduce, Reuse and Recycle waste hierarchy.
20. What are the different types of fossil fuels?
Fossil fuels consist of deposits of once living organisms. The organic matter
takes centuries to form. Fossil fuels principally consist of carbon and hydrogen
bonds. There are three types of fossil fuels which can all be used for energy
provision; coal, oil and natural gas

PART B
1. Explain in detail about two stroke engine.
2. Explain in detail about four stroke engine.
3. Explain in detail the classification of fuel based on power generation.
4. Comparison between petrol engine and diesel engine.
5. Briefly explain about the liquid petroleum fuels.
6. Explain the working principle of internal combustion with neat diagram.
7. Describe various measures in Waste land reclamation.
8. Explain in detail about any two waste disposal methods used in chemical
process industries.
9. What are the techniques used in incineration and explain the process of disposal?
10. Briefly explain about fuel surcharge and how it affects the waste management
and economy.
11. Discuss in detail about various components, construction and working of an
internal combustion engine.
12. Discuss the integrated gasification based power systems with neat sketch.
13. Draw the fluidized gasifier bed and its temperature profile.
14. Explain in details about various Fuels used in chemical process industries along
with their Applications and Limitations.
15. Explain the Otto engine cycle with neat sketch and derives an expression for
efficiency.
16. Explain the different waste disposal options and selection criteria for the same.