SEMESTER– VII
CH6702 Transport Phenomena
PM6701 Equipment Design and Drawing-II
PM6702 Petroleum Secondary Processing Technology
PM6703 Petrochemical Unit Processes
PM6704 Refinery Process Design
PRACTICALS
EL6713 Process Dynamics and Control Laboratory
PM6711 Petrochemical Analysis Laboratory
PC6711 Petroleum Product Testing Laboratory
CH6702 TRANSPORT PHENOMENA
OBJECTIVE: Different types of Fluids, their flow characteristics and different mathematical models are analysed and applied to actual situations. This subject helps the students to understand the mechanism of fluids in motion under different conditions.
UNIT I TRANSPORT PHENOMENA BY MOLECULAR MOTION
Importance of transport phenomena; analogous nature of transfer process; basic concepts, conservation laws; continuous concept, field, reference frames, substantial derivative and boundary conditions; methods of analysis; differential, integral and experimental methods. Phenomenological laws of transport properties Newtonian and non Newtonian fluids; rheological models; theories of transport properties of gases and liquids; effect of pressure and temperature.
UNIT II ONE DIMENSIONAL TRANSPORT IN LAMINAR FLOW (SHELL BALANCE)
General method of shell balance approach to transfer problems; Choosing the shape of the shell; most common boundary conditions; momentum flux and velocity distribution for flow of Newtonian and non-Newtonian fluids in pipes for flow of Newtonian fluids in planes, slits and annulus heat flux and temperature distribution for heat sources such as electrical, nuclear viscous and chemical; forced and free convection; mass flux and concentration profile for diffusion in stagnant gas, systems involving reaction and forced convection.
UNIT III EQUATIONS OF CHANGE AND THEIR APPLICATIONS
Conservation laws and equations of change; Development of equations of continuity motion and energy in single multicomponents systems in rectangular co-ordinates and the forms in curvilinear co-ordinates; simplified forms of equations for special cases, solutions of momentum mass and heat transfer problems discussed under shell balance by applications of equation of change, scale factors; applications in scale-up
UNIT IV TRANSPORT IN TURBULENT AND BOUNDARY LAYER FLOW
Turbulents phenomena; phenomenological relations for transfer fluxes; time smoothed equations of change and their applications for turbulent flow in pipes; boundary layer theory; laminar and turbulent hydrodynamics thermal and concentration boundary layer and their thicknesses; analysis of flow overflat surface.
UNIT V ANALOGIES BETWEEN TRANSPORT PROCESSES
mportance of analogy; development and applications of analogies between momentum and mass transfer; Reynolds, Prandtl, Von Karman and Colbum analogies.
OUTCOME: Students gain the knowledge of fundamental connections between the conservation laws in heat, mass, and momentum in terms of vector and tensor fluxes.
TEXT BOOKS:
1. R.B. Bird, W.E. Stewart and E.W. Lightfoot, “Transport Phenomena”, John Wiley, II Edition 2006.
2. Robert, S Brodkey, Harry C. Hershey, “Transport Phenomena A Unified Approach ”, Brodkey Publishing 2003.
REFERENCES:
1. L.S.Sissom, and D.R.Pitts, “Elements of Transport Phenomena”, McGraw-Hill, New York, 1972.
2. R.W.Fahien, “Elementary Transport Phenomena”, McGraw-Hill, New York, 1983.
3. J.R. Welty, R.W. Wilson, and C.W.Wicks, Rorer G.E, Wilson R.W. “Fundamentals of Momentum Heat and Mass Transfer”, V Edn. John Wiley, New York, 2007.
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PM6701 EQUIPMENT DESIGN AND DRAWING II
(All Tables/Chemical Engineers’ Handbook/Data Books/Graph Sheets are permitted during the Examination.)
AIM
To gain practical knowledge on the shape and drawing of the process equipments
OBJECTIVE: To become a design engineers on process equipments design and drawing consideration of the following:-
UNIT I THERMODYNAMIC PROPERTIES EVALUATION FOR DESIGN
Physical properties evaluation, Thermodynamic properties of gases and binary mixtures– Methods of calculations –Vapor-liquid equilibrium data for ideal and non-ideal mixtures. Bubble points and dew points, flash distillation calculation.
UNIT II HEAT EXCHANGER DESIGN
Design of double pipe heat exchangers, Heat exchanger types and its selection – shell and tube heat exchangers and Condensers – Effectiveness – NTU method of heat exchanger analysis.
UNIT III EVAPORATOR DESIGN
Steam – Uses of steam – Outstanding qualities of steam – BPE – Duhring’s rule –Principle of multiple effect evaporation – Temperature driving force – Evaporators types and its selection – Design of single and multiple effect evaporators.
UNIT IV COLUMN DESIGN
Design of distillation columns and Absorption columns.
UNIT V PUMPS, FANS AND COMPRESSORS
Pumps, fans and compressors – Types and its applications – Characteristics – Piping and pressure drop calculations – Performance analysis of pumps, fans and compressors.
OUTCOME: Students gain the knowledge to develop key concepts and techniques to design, process equipment in a process plant. These key concepts can be utilized to make design and operating decisions.
TEXT BOOKS:
1. Ernest E. Ludwig., “Applied Process Design for Chemical and Petrochemical Plants”, Vol.I, II and III, Gulf Professional Publishing, 2002.
2. D. Q. Kern, “Process Heat Transfer", Tata McGraw Hill Publishing Co., New Delhi, 1990.
REFERENCES:
1. Coulson, M. and Richardson, J.F., “Chemical Engineering”, Vol.6, 3rd Edition, Pergamon Press, 1987.
2. Robert H. Perry and Don W. Green, “Perry’s Chemical Engineer’s Hand Book”, 7th Edition, Mc Graw Hill – International, 1997.
3. Van Winkle, “Distillation Operations”, McGraw Hill Publications, 1987.
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PM6702 PETROLEUM SECONDARY PROCESSING TECHNOLOGY
OBJECTIVE: Students learn the refining operations like cracking, reforming, alklylation, isomerization and coking
UNIT I CRACKING
Need and significance, types and functions of Secondary Processing. Cracking, Thermal Cracking and Visbreaking. Different Feed Stocks, Products Yields, Qualities and Recent Development. Catalytic Cracking, Commercial Catalyst, Feedstock and Catalytic Cracking Conditions, Types and Processes- Fixed Bed Cracker, Fluid Catalytic Cracking (FCC), Flexi Cracking.
UNIT II CATALYTIC REFORMING
Theory, Reaction Conditions and Catalyst for Catalytic Reforming, Platforming, Houdri Forming, Rhein Forming, Power Forming, Selecto Forming. Ultra Forming and Rex Forming. Naphtha Cracking, Feedstock Selection and Effect of Steam.
UNIT III ALKYLATION AND ISOMERIZATION
Feed Stocks and Reactions for Alkylation Process- Cascade Sulphuric Acid Alkylation,Hydrofluoric Acid Alkylation. Isomerization Process- Isomerization with Platinum Catalyst and Aluminium Chloride Process.
UNIT IV COKING
Methods of Petroleum Coke Production – Koppers, Thermal Cracking, Delayed Coking, Fluid Coking and Contact Coking. Hydro Cracking- principles, reactions in Hydro Cracking, Catalyst, Hydro Cracking Reaction Conditions, Iso Max Processes and Hydro Desulphurization Processes.
UNIT V ASPHALT TECHNOLOGY
Source of Asphalt (Bitumen), Chemical Structure of Asphalt, Action of Heat on Asphalt, Types of Asphalts. Air Blowing of Bitumen and Upgradarion of Heavy Crudes. Specialty Products:Industrial Grease- Manufacture of Calcium Grease, Liquid Paraffin and Petroleum Jellys.
OUTCOME: Student attain the detailed knowledge on petroleum refining operations.
TEXT BOOKS:
1. Jones, D.S.J. and Pujadó, P.R., Handbook of petroleum processing, Springer, The Netherlands, 2006
2. Nelson, W. L “Petroleum Refinery Engineering”, McGraw Hill Publishing Company Limited,1985.
3. Watkins, R. N “Petroleum Refinery Distillations”, 2nd Edition, Gulf Publishing Company,Texas, 1981.
REFERENCES:
1. Parkash, S., Refining processes handbook, Gulf Professional Publishing, 2003
2. Hobson, G. D “Modern Petroleum Refining Technology”, 4th Edition, Institute of Petroleum,U. K. 1973.
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PM6703 PETROCHEMICAL UNIT PROCESSES
OBJECTIVE: To design and conduct experiments and analyze and interpret data related to petrochemical Unit processes
UNIT I FEED STOCK AND SOURCE OF PETROCHEMICALS
Overview of Petrochemical Industry – The key growth area of India, Economics – Feed stock selections for Petrochemicals – Steam cracking of Gas and Naphtha to produce Olefins,Diolefins and Production of Acetylene – Cracker product separation and BTX separation.
UNIT II SYNTHESIS GAS PRODUCTION
Steam reforming of Natural gas – Naphtha and Heavy distillate to produce Hydrogen and Synthesis gas – Production of Methanol – Oxo process.
UNIT III UNIT PROCESSES I
Fundamental and Technological principled involved in Alkylation – Oxidation – Nitration and Hydrolysis.
UNIT IV UNIT PROCESSES II
Fundamental and Technological principled involved in Sulphonation, Sulfation and Isomerisation.
UNIT V UNIT PROCESSES III
Fundamental and Technological principles involved in Halogenation and Esterification
OUTCOME: Students able to understand the principles of various unit processes in the petrochemical industry.
TEXT BOOKS:
1. Bhaskara Rao, B.K., “A Text on Petrochemicals”, Khanna Publishers, 2000.
2. Sukumar Maiti, “Introduction to Petrochemicals”, 2nd Edition, Oxford and IBH Publishers, 2002.
REFERENCES:
1. Margaret Wells, “Handbook of Petrochemicals and Processes”, 2nd Edition, Ash Gate Publishing Limited, 2002.
2. Sami Matar, and Lewis F. Hatch., “Chemistry of Petrochemical Processes”, 2nd Edition, Gulf Publishing Company, 2000.
3. Dryden, C.E., “Outlines of Chemical Technology”, 2nd Edition, Affiliated East-West Press, 1993.
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PM6704 REFINERY PROCESS DESIGN
OBJECTIVE: To get acquainted with process design of distillation columns involving multicomponent and complex mixtures. To learn methodologies practiced in rating and designing heat transfer equipment used in refining and process industry.
UNIT I MULTICOMPONENT DISTILLATION
Dew point and bubble point for multi component mixtures. Design of multi component distillation column, Number of variables, Selection of key components, Selection of column pressure, Feed condition, Plate-to-plate calculations, Empirical short cut methods, Introduction to rigorous solution procedures.
UNIT II PETROLEUM REFINERY DISTILLATION
TBP, EFV, ASTM distillation curves and their relevance, Material balance and flash zone calculations for petroleum refinery distillation columns, Pump around and pump back calculations, Overall energy requirements, Estimation of number of equilibrium stages, Design using Packie charts and Watkins method, Introduction to rigorous solution procedure based on pseudo components.
UNIT III COLUMN DESIGN
Process design of distillation towers. Flooding charts. Trays and packings. Vacuum devices.Pressure drops. Height,diameter,supports.Piping requirements. Aspects of mechanical design. A typical P&ID for a distillation column. .
UNIT IV FIRED HEATERS
Heat load calculations for furnace heaters used in crude refining, Basic constructional features, Different furnace types, Review of factors to be considered in the design of fired heaters, Introduction to manual calculations methods.
UNIT V PUMPS AND COMPRESSORS
Types of pumps and compressors. Selection criteria. Power rating calculations based on process duty.Use of operating curves of centrifugal pump. NPSHR and NPSHA. Pump Cavitation. Surge problem in compressors.
OUTCOME: Students learn process design aspects related to distillation column, Fired Heaters, pumps and compressors
TEXT BOOKS:
1. Van Winkle M., “Distillation”, McGraw Hill, 1967.
2. Watkins, “Petroleum Refinery Distillation”, McGraw Hill, 1993
3. Sinnott R. K., “Coulson and Richardson’s Chemical engineering”, Vol. 6, Third Edition, Butter Worth-Heinemann, 1999.
4. Kern D. Q., “Process Heat Transfer”, McGraw Hill, 1965. 5. Cao Eduardo,”Heat Transfer in Process Engineering”, McGraw Hill,2010
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EL6713 PROCESS DYNAMICS AND CONTROL LABORATORY
OBJECTIVE: To train the students to determine experimentally the methods of controlling the processes including measurements using process simulation techniques.
LIST OF EXPERIMENTS
1. Response of first order system
2. Response of second order system
3. Response of Non-Interacting level System
4. Response of Interacting level System
5. Open loop study on a thermal system
6. Closed loop study on a level system
7. Closed loop study on a flow system
8. Closed loop study on a thermal system
9. Tuning of a level system
10. Tuning of a pressure system
11. Tuning of a thermal system
12. Flow co-efficient of control valves
13. Characteristics of different types of control valves
14. Closed loop study on a pressure system
15. Tuning of pressure system
16. Closed loop response of cascade control system
*Minimum 10 experiments shall be Offered.
OUTCOME: Upon completion of this practical course, the students would know development and use of right type of control dynamics for process control under different operative conditions.
LIST OF EQUIPMENT FOR BATCH OF 30 STUDENTS
1. U tube manometer with controller
2. Interacting Tank
3. Non Interacting Tank
4. Open loop control system
5. Closed loop control system
6. ON/OFF controller
7. Control valve characteristics
8. Pressure Tuner
9. Temperature Tuner
10. Proportional Controller
11. Flow Transmitter
12. Level Transmitter
13. Cascade control system
PM6711 OBJECTIVE: PETROCHEMICAL ANALYSIS LABORATORY
To learn basic principles involved in analysis of petrochemical products.
LIST OF EXPERIMENTS
1. Sulphur content determination
2. Flue gas Analysis – Orsat Apparatus
3. Aromatic Content determination
4. Hydrogen sulphide content determination
5. Mercaptan as sulphur estimation apparatus
6. Determination of Lead, Acid and Salt content
7. separation from lubricating Grease (Oil Separation Apparatus)
8. Analysis of petrochemicals using UV spectrophotometer
9. Analysis of petrochemicals using NMR with MS
10. Analysis of petrochemicals using Gas chromatography
11. Biodegradation of petrochemicals
12. Bioremediation of petrochemicals
13. Refractive index of petrochemicals
14. Determination of moisture content – KF titrator
15. Total acidity determination
OUTCOME: Students would have knowledge about characterization of oil and lubricants and apply their knowledge in industries.
LIST OF EQUIPMENT FOR BATCH OF 30 STUDENTS
1. Bomb calorimeter
2. Orsat apparatus
3. Aniline point apparatus
4. UV- Visible spectrophotometer.
5. Gas Chromatography.
PC6711 PETROLEUM PRODUCT TESTING LABORATORY
OBJECTIVE: To learn basic principles involved in determination of flash point, cloud point, aniline point, viscosity etc.
LIST OF EXPERIMENTS
1. Determination of aniline point and diesel index
2. Softening point of bitumen by ring and ball method
3. Ductility and penetration number of bitumen
4. Rust preventing characteristics of lube oil
5. Drop point of greases
6. Cloud and pour point determination
7. Smoke point determination
8. Copper corrosion testing of petroleum products
9. Sediment content of crude oil and fuel oils
10. Coking tendency of oil
11. Saybolt color of petroleum products / loviband tintometer
12. Water separability of petroleum products
13. Refractive index of petroleum products
14. Hydrocarbon types in petroleum products
15. Carbon residue determination
16. Oxidation stability of gasoline and ATF
17. Bearing and grease noise characteristics
OUTCOME: Students would have knowledge about the lubricants and use of right type of lubricant in different machines.
LIST OF EQUIPMENT FOR BATCH OF 30 STUDENTS
1. Abel’s Flash point apparatus
2. Penky morten Flash point apparatus
3. Red wood viscometer
4. Sayboh viscometer
5. Cloud and pour point apparatus.
