Syllabus of Lecturer in Chemical Engineering
Detailed syllabus for the Post of Lecturer in Chemical Engineering (govt. Polytechnics)
Module I – 20 Marks
Fluid Mechanics
Properties of Fluids: Density, Specific gravity, Viscosity, Newton’s law of viscosity, Newtonian and Non-Newtonian fluid, Viscosity Index, Red wood viscometer
Types of Flows: Viscous, Turbulent Flow, Critical Velocity, Reynolds Number, Transition range & Velocity distribution in pipes
Basic equations of fluid flow-Continuity, Bernoulli s and Momentum equation-Toricelli equation. ‟ Kinetic energy and Momentum correction factors-Correction for fluid friction and pump work for Bernoulli s equation. Laminar flow of incompressible fluids in pipes and conduits. Shear stress and ‟ Velocity distribution-Maximum and average velocity-Hagen Poiseuille and Darcy Wiesbach equation-Definition of Friction factor on Reynolds number in laminar flow. Churchill, Darcy and Fanning friction factor. Turbulent flow of incompressible fluids in pipes and conduits- Universal velocity distribution equation-Friction factor and Reynolds number relationship- Prandtl one seventh power law- Friction factor chart-Friction from changes in velocity or direction-Sudden expansion and contraction-Fittings and valves. Flow through Non circular cross section-Equivalent length
Transportation of fluids: Flow rate equation for Venturi, Orifice, Mouth piece, Pitot tube, Rectangular, Triangular& Trapezoidal weir, Rotameter. Transportation of liquid through pipesEconomic pipe diameter- Pipes and tubes. Different types of fittings and Valves- pressure drop and equivalent length.
General description, classification, selection and application of Centrifugal, Reciprocating, Gear and Lobe pumps. Various losses-Characteristic curves- NPSH-Cavitation- Specific speed- Priming of Centrifugal pumps. Fans, Blower, Compressor-Different types-Compressor efficiency, EjectorPrinciple and different types.
Fluidization: Flow past immersed bodies-Drag, Drag coefficient for typical shapes. Stream lining, Stagnation point-Friction in flow through bed of solids-Ergun, Kozney Carman and Blake Plummer equation.
Motion of particle through fluids in gravity and centrifugal field. Terminal settling velocity in Stokes law. Intermediate law, and Newton s law range-Free and Hindered settling. Fluidization- Minimum ‟ fluidization velocity, Minimum porosity, Pressure drop calculation, Different type of fluidization. Slugging. Industrial application.
Particle Technology
Particle diameter and shape factor – particle size analysis – sieve analysis – particle size distribution – cumulative and differential methods of analysis – mean diameters – specific surface area and number of particles – sub-sieve analysis – pipette analysis – beaker decantation – Screening – effectiveness and capacity of screens and factors affecting them – types of industrial screens
Particle separation
Principles of free and hindered settling – equal settling particles – classifiers – types of classifiers – mechanical and non-mechanical, pneumatic classifiers – principles of mineral beneficiation methods – jigging – Wilfley table – heavy media separation – magnetic and high-tension separation – Froth flotation, principles, additives, and flotation cell arrangements batch and continuous thickening – Kynch theory Filtration – theory of constant pressure and constant rate filtration – cake porosity and compressibility – filter aids – optimum filtration cycle – types of batch and continuous filters – washing of filter cakes – centrifugal methods of separation including centrifugal filtration – continuous centrifuge – gas cleaning methods – gravity settling – cyclone separation – electrostatic precipitation – scrubbing Size reduction
Laws of comminution – mechanism and efficiency of size reduction – principles of important size reduction equipment – types and selection of equipment for all ranges – closed circuit and open circuit grinding – free crushing and choke feeding – wet and dry grinding –
Mixing, Storage and conveying
Purpose of agitation – agitation equipment – propellers, paddles and turbines – Flow pattern in agitated vessels – prevention of swirling – draft tubes and baffles – their power consumption in agitated vessels – simple problems in determination of power.
Mixing of granular solids and pastes – degree of mixing – type and selection of equipment – storage and conveying of solids – silos, bins and hoppers – different types of conveyors – selection of conveyors
Storage of fluids:
Storage of liquid – storage tanks
Storage of volatile liquids – floating roof
Storage of gases: Horton sphere – pressure cylinders – gas holders – wet and dry specifications.
Module II – 20 Marks
Stoichiometry
Units and dimensions, conversion of units, dimensional analysis, conversion of empirical equations, mole concept and mole fraction, weight fraction and volume fraction, concentration of liquid solutions – molarity, molality, normality, ppm, density and specific gravity, specific gravity scales, use of mole concept in chemical reaction stoichiometry, ideal gases and gas mixtures, various gas laws, average molecular weight and density of gases, critical properties and compressibility of gases.
Material balances with and without chemical reactions, material balance in unit operations such as evaporation, crystallization, drying, absorption, distillation etc.
Energy balances: Heat capacity, specific heat and enthalpy, heat capacities of gases and gaseous mixtures, estimation of heat capacity – relevant rules and laws, calculation of enthalpy changes, Estimation of latent heat of vaporization, heat balance calculations in processes without chemical reaction, heat of reaction, standard heats of formation, combustion and reaction, heat of solution and heat of mixing, adiabatic and non-adiabatic reactions, theoretical and actual flame temperatures.
Vapour Pressure: vapour pressure of pure liquids and immiscible liquids, ideal solutions and Raoult’s law, non-volatile solutes, humidity: Humidity and saturation: various term associated with humidity and saturation. Material and energy balance problems involving vaporization and condensation, fuels and combustion, heating value of fuels, proximate and ultimate analysis, Orsat analysis of flue gases.
Chemical Engineering Thermodynamics and Energy Engineering: Fundamental concepts and definitions of thermodynamics – various systems – intensive and extensive properties – Zeroth law of thermodynamics – First law of thermodynamics – applications – limitations. Second law of thermodynamics – general statements of 4 second law – concept of entropy – calculation of entropy changes – Carnot’s principle – Clausius inequality –– Third law of thermodynamics. Thermodynamic properties of pure fluids – Gibbs free energy, work function – Joule Thomson coefficient
Properties of solutions – partial molar properties and methods of determination – Lewis-Randall rule – Raoult’s law – Henry’s law – activity and activity coefficients in solutions – effect of temperature and pressure on activity coefficients – Gibbs-Duhem equations, property changes on mixing – heat effects of mixing processes.
Chemical reaction equilibria – reaction stoichiometry – equilibrium constant – standard free energy change – standard state – feasibility of reaction – effect of temperature on equilibrium constant – presentation of free energy data – evaluation of K – equilibrium conversion in gas-phase reactions – effect of pressure and other parameters on conversion
Energy engineering: Non-conventional energy resources-solar-biogas and biomass-ocean and tidal energy, geothermal-wind Solar radiation-solar collector-solar trough systems-solar power towerssolar dish/engine system-solar thermal power plant-solar pond-solar water heater- solar cooker. Biogas and biomass-availability -biomass conversion processes- biogas generation-biogas production plants (batch ,continuous, movable drum type, fixed dome type)
Geothermal energy-resources of geothermal energy- vapor dominated power plant-liquid dominated system-total flow geothermal plant-merits and demerits of geothermal power generation- applications of geothermal energy.
Wind energy-wind turbine- wind power- power and velocity duration characteristics of wind-airfoil construction and types-types of wind power plants-types of wind genitor units with its constructionsite selection-merits and demerits of wind power generation.
Ocean thermal energy conversion (OTEC)- working principle- types of OTEC systems advantages and limitation. Ocean wave energy and tidal energy- tidal power plants. Hydraulic energy-hydel power- principle of operation- hydro electric power systems
Module III – 20 Marks
Process Heat Transfer
Heat Transfer by Conduction and Convection:
Fourier’s law, thermal conductivity of solids, liquids and gases. Steady state heat conduction in systems without generation of heat having constant and varying thermal conductivity, steady-state conduction through single resistance and composite resistances in series.
Newton’s law of cooling, Thermal insulation: analysis of critical thickness of insulation for cylindrical and spherical system, concept of optimum thickness of insulation, heat transfer in extended surfaces.
Boundary layer concepts – thermal and velocity boundary layers, boundary layer thickness, relationship between hydrodynamic and thermal boundary layer thickness, dimensional analysis – Rayleigh and Buckingham’s pi theorem, its limitations, principle of similarity, application of dimensional analysis.
Forced Convection: General methods for estimation of convection heat transfer coefficient, flow in a circular tube (both developing and developed flows with constant wall temperature – its analysis and constant heat flux conditions) and noncircular tubes, flow over flat plates, flow over cylinder, spheres and tube banks. Analogy between momentum and heat transfer, Reynold’s and Prandtl analogy,
comparison of different analogy expressions.
Natural Convection: Natural convection from vertical and horizontal surfaces under laminar and turbulent conditions for plates, cylinders under constant heat flux and wall temperature conditions, physical significance of Grashoff and Rayleigh numbers.
Heat transfer by Radiation: Theories of radiation, electromagnetic spectrum, thermal radiation, spectral emissive power, surface emission – total emissive power, emissivity, radiative properties, concept of black and grey body, radiation intensity, laws of black body radiation, non-black surfaces, Lambert’s cosine law, radiation between black surfaces and gray surfaces, radiation shape factor.
Heat Transfer with Phase Change: Boiling and condensation – dimensionless parameters in boiling and condensation, pool boiling – modes of pool boiling, nucleate pool boiling – correlations – parametric effects on pool boiling, forced convection boiling (flow boiling) – brief overview of external forced convection boiling and internal forced convection boiling – regimes
Mass Transfer
Molecular diffusion – Fick’s law – diffusivity and estimation – Mass transfer coefficients – film theory – F-type and k-type coefficients – dimensionless groups and dimensional analysis – elementary treatment of theories of mass transfer: penetration and surface renewal theories – interphase mass transfer – equilibrium – diffusion between phases – two-film theory – local and overall k-type coefficients.
Gas absorption, absorption equipment, multistage absorption, tray towers, continuous contact equipment, venturi scrubbers, packed columns, packing materials and characteristics, general constructional details of packed columns, solubility of gases in liquid, choice of solvent, material balance in counter current and concurrent absorption and stripping, multistage operation, tray efficiency, design of packed columns, dilute solutions and simplified design methods.
Humidification and dehumidification, wet-bulb temperature and adiabatic saturation temperature, types of cooling towers, enthalpy transfer unit, general design procedure,
Drying, equilibrium moisture content, batch drying, rate of drying, cross-circulation drying, mechanism of moisture movement, continuous drying, parallel and counter current, material and enthalpy balances, industrial dryers for batch and continuous drying.
Distillation – types of distillation – fractionation – plate columns for distillation – condensers – reboilers – principles of rectification – material and energy balance – reflux ration and its importance – enthalpy-composition diagrams – difference points and L/G ratio – number of plates – feed plate location – minimum reflux conditions.
Extraction – applications – mixer rule – distribution curve – choice of solvent – single-stage and multistage operations – extraction with reflux – construction and working of mixer – settler cascades, sieve-tray columns and baffle towers for extraction – continuous contact extraction – design for insoluble liquids – construction and working of agitated towers, pulse columns and centrifugal extractors.
Leaching – factors affecting rate of leaching – stage efficiency – working principles of leaching equipment – thickeners, classifiers and moving bed leaching equipment,
Description of adsorption processes and their application – agitated vessels for solid liquid adsorption – multistage fluidised bed adsorber for recovery of vapour – continuous contact adsorption: steady state moving bed adsorber – counter current adsorption of one component
Module IV – 20 Marks
Chemical Industrial Processes:Inorganic chemical industries (sulfuric acid, phosphoric acid, chlor-alkali industry), fertilizers
(Ammonia, Urea, SSP and TSP); natural products industries (Pulp and Paper, Sugar, Oil, and Fats); petroleum refining and petrochemicals; polymerization industries (polyethylene, polypropylene, PVC and polyester synthetic fibers).
Chlor-alkali : Diaphragm cell – mercury cell – membrane cells – manufacture of solid caustic soda. Chlorine
Hydrochloric Acid: – Properties and uses and commercial grades – manufacture of Hydrochloric acid
Sulphuric Acid: Importance of Sulphuric acid – properties and uses – raw materials – sulphur pyrites – production of sulphur dioxide, sulphur burners – cleaning
Nitric Acid: – Properties and uses – reaction – catalyst – manufacturing process – concentration
Phosphoric Acid:- Properties, uses and grades, raw materials manufacturing process.
Fertilizers: ammonia – nitric acid – urea – fertilizer industries – ammonium sulphate – ammonium nitrate – nitrolime – MAP, DAP and nitrophosphates – mixed and complex fertilizers Glass – manufacturing method; different grades – uses. Alumna brick, carbon ceramics – raw material – main unit operation and process
Oils And Fats: Of rancidity – acid value, saponification value and iodine value. Extraction of oils – oil expellers – Refining of vegetable oils, neutralization, bleaching and deodorization Catalysts – Materials, manufacturing process for toilet & laundry soaps. Batch and continuous process, comparison with soap. Biodegradability of detergents, detergent additives and formulation
Pulp & Paper : Paper – Paper industry in India and its future – Soda mechanical pulping – details of process and plant – Paper manufacture – Details of paper machine
Sugar: Manufacture from sugarcane and sugar beet, refining of crude sugar, byproducts of sugar industry. Starch: Raw materials, manufacture from corn, maize, tapioca. Manufacture of Dextrin and Dextrose. Fermentation Products: Manufacture of alcohol, alcoholic beverages and High Fructose Corn Syrup (HFCS).
Petroleum: Classification of crude, characteristics of crude, chemical composition of crude, processing of crude – sweetening, atmospheric and vacuum distillation of crude, cracking and coking, refining, reforming, hydro-cracking and isomerisation. Production of lubricating oils, lube additives, Motor gasoline, kerosene, aviation turbine fuel and aviation gasoline.
Petrochemicals: Primary processes for olefins, acetylenes, higher homologues, aromatics and their derivatives, propylene, acetylene, methanol and its derivatives.
Module V – 10 Marks
Instrumentation & Process Control: Functional elements and functions of an instrument – classification of instruments, performance characteristics of an instrument like static and dynamic type
Temperature measuring instruments – Principle and working of – Thermometers, filled system and vapor pressure thermometers –Thermocouples, types, materials – Resistance thermometers, thermistor – Pyrometer, radiation and optical.
Pressure measuring instruments – Principle and working of – Bourdon tube, bellows, diaphragm gauge, resistance transducer and piezo electric pressure sensors.
Flow measuring devices: Area flow meters, Coriolis mass flow meter, Ultra sonic flow meter, and positive displacement flow meters – Differential pressure transducer used in venturi and orifice meters.
Level measuring devices: Float level indicator, Magnetic level indicator, radar tank gauging system, guided wave radar tank gauging, differential pressure cell.
pH measurement, pH scale, reference and measuring electrode – Conductivity measurement, electrical conductivity meter – Density measurement, online density meter, hydrometer. Humidity measurement, dew point method, wet bulb method, hygrometer.
Chromatographic analysis – Working and applications of – Liquid solid chromatography – Gas solid chromatography – Liquid liquid chromatography – High performance liquid chromatography. Spectroscopy –classification of spectrometers –working of UV-visible absorption spectrometer – Atomic emission spectrometer – Mass spectrometer. Structure analysis – Working principles of SEM (scanning electron microscope), TEM (Transmission electron microscope), XRD (X-ray diffraction).
Process Control: Dynamics of first order and second order systems (Temperature, liquid level and mixing), open loop and closed loop systems, feedback control systems –servo and regulatory control – Proportional (P), integral (I), derivative (D) and PID control – Behavior of different modes of control.
Computerized Control in process plants: (Descriptive treatment of the following) Programmable logic controllers – Supervisory control and data acquisition (SCADA) – Distributed control system (DCS). Final control elements – Mechanism and working principle of pneumatic control valve, positioner, solenoid valve, motor operated valves, I to P converter – Variable frequency drive [VFD], Safety
Instrumentation System – Emergency shutdown system – Safety interlocks.
Module VI – 10 Marks
Environmental Engineering
Water Pollution: Sources and classification of water pollutants and their effects. Sampling and analysis. Water and Waste water treatment: Softening methods, Lime soda process, Preliminary, primary, secondary and tertiary treatment of waste water, recovery of materials from process effluents – anaerobic and aerobic sludge treatment and disposal – methods of physiochemical and biological
treatment of industrial effluents from fertilizer, petrochemical, pulp and paper, caustic soda, tanning and sugar industries
Air Pollution and Control: Nature of air pollution classification, properties and sources of pollutants, acid rain – Green house effect – Ozone depletion – Effects of man, animal, vegetation and material dangers, Air quality criteria and standards, methods of pollutant sampling and measurement.
Control methods for particulate emulsions and pollutants –Cyclone separator, Electrostatic precipitator – Bag house filter – Scrubbers – Indoor Air pollution control.
Noise Pollution – Solid Waste – Radioactive Pollution: Noise – pollution control programme – TLV, SIL, NEI – Noise barriers – Composition of earth – methods of disposal. Sources of radioactive waste – effects of radioactive pollution – monitoring
Safety, Fire Engineering: Definitions of the terms – factory, accident, hazard, risk, frequency rate, accident proneness – – 4 E’s of accident prevention technique – Precautions to be observed while working in hazardous environment – explosive limit – Flammable limit – Inflammable limit – characteristics of hazardous material – TLV, STEL, TLV – C, LD 50, LC 50 (definitions)– flammable liquids – Fire and
Explosion. Fire hazards. Fire pyramid. Types of fires. Types of fire extinguishers and its handling. Types of built in extinguishing systems. Fixed fire protection systems. Fire fighting techniques. UVCE and BLEVE. NFPA standards. Emergency procedures. Types of alarm systems. Emergency communication procedures. Containment of chemical spills or leaks.
Purpose of first – aid, contents of a typical first aid kit. First aid procedures for Artificial resuscitation, bleeding, electrical shock, poisoning, fractures and burns.
NOTE: – It may be noted that apart from the topics detailed above, questions from other topics prescribed for the educational qualification of the post may also appear in the question paper. There is no undertaking that all the topics above may be covered in the question paper.
