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DIPLOMA CHEMICAL ENG. 5TH SEM

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SCHEME OF DIPLOMA CHEMICAL SEM- V

SUBJECT CODE SUBJECTDCH-501 Industrial ManagementDCH-502 Mass Transfer - IIDCH-503 Petroleum Refining & Petro Chemical TechnologyDCH-504 Utilities and Instrumentation in Chemical PlantDCH-505 Fundamental of Chemical Engineering Reactions

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DIPLOMA IN CHEMICAL ENGINEERING SEMESTER: V

Subject Name: Industrial Management

Sr. No. Course Content

1. System Concept and Management: 1.1 Definition of system 1.2 Types of systems 1.3 System parameters 1.4 System variable 1.5 System behaviour 1.6 Definition of management 1.7 Functions of management

2. Organisation Structure and Organisational Dynamics: 2.1 Definition, Goals, Factors considered in formulating structure. 2.2 Division of labour, Scalar and functional processes, Span of control, Delegation

of authority, Centralisation and Decentralisation. 2.3 Types, advantages, disadvantages and applications of organization structure,

flexibility. 2.4 Organisational culture and factors affecting organisation culture. 2.5 Moral: factors affecting moral. 2.6 Relationship between moral and productivity. 2.7 Effect of high and low moral. 2.8 Job satisfaction, Factors influencing job satisfaction.

3. Materials Management: 3.1 Definitions, Functions, Importance of material management, Relationship with

other departments. 3.2 Objectives of purchase, Purchasing systems, Purchase procedure, Terms and

forms used in purchase department. 3.3 Functions of storekeeping, classification of stores as centralised and

decentralized with their advantages, Disadvantages and application in actual practice, Functions of store keeper, Types of records maintainedby store, Various types of storage equipment, Codification of stores.

3.4 Definition of inventory control, Objectives of inventory control, Derivation for expression for EOQ, ABC analysis, other modern methods of analysis various types of inventory models such as Willson’s inventory model, Replenishment model, Two bin model.

4. Production, Planning and Control:

4.1 Meaning, phases and objectives 4.2 Explain in detail the functions of PPC along with necessary forms used in it. 4.3 Types of productions, Calculation of Economic Batch Quantity (EBQ), critical

ratio scheduling and gantt charts.

5. CPM/PERT:

5.1 Meaning, Features, Difference, Application. 5.2 Understand different terms used in network diagram. 5.3 Draw network diagram for a real life project containing 10-15 activities,

Computation of LPO, EPO. 5.4 Determination of critical path on network. 5.5 Floats, its types and determination of floats. 5.6 Crashing of network, updating and its application.

6.

Value Analysis (VA):

6.1 Definitions, terms used, VA process, importance, methods, VA flow diagram Analysis.

7. Factory Act and Laws:

7.1 Factory act and its important provisions. 7.2 Workman compensation act its important provisions. 7.3 Industrial dispute act and its important provisions.

Reference Books:

1. Learning Package on Industrial Management: TTTI, Bhopal.

2. What every supervisor should know: Lester R.

3. CPM & PERT principles and Applications, L.S.Srinath.

4. Modern Production Management, Buffa.

5. Materials Management, N. Nair.

6. Value Analysis, Mikes.

7. Industrial Engineering & Management, O. P. Khanna.

8. System Analysis: System Analysis.

DIPLOMA IN CHEMICAL ENGINEERING SEMESTER: V

Subject Name: Mass Transfer-II

Sr. No. Course Content

1. Equipment for Gas Liquid Operations:

1.1 Need of equipment 1.2 Gas dispersed

1.2.1 Sparged vessels 1.2.2 Mechanically Agitated Vessels 1.2.3 Tray towers – Perforated tray towers, Bubble cap tray tower, Valve tray

tower 1.2.3.1 Various types of trays 1.2.3.2 Operating problems in tray tower 1.2.3.3 Efficiency in tray tower

1.3 Liquid dispersed 1.3.1 Venturi scrubbers 1.3.2 Wetted wall column 1.3.3 Spray tower 1.3.4 Packed tower & its operating problems 1.3.5 Various types of pickings & packing arrangement

2. Distillation:

2.1 Distillation and a separation method and versatility of its applications 2.2 Vapor Liquid Equilibria 2.2.1Constant pressure and constant temperature equilibria 2.3 Relative volatility 2.4 Raoult’s law and its use, Henry’s law and its use 2.5 Maximum and minimum boiling azeotrops 2.6 Flash vaporization with material balance and numerical based on direct use

of formula 2.7 Differential distillation with derivation of Rayleigh’s equation and calculation of

product 2.8 Continuous rectification- Binary systems 2.8.1 The fractionation operation 2.8.2 Overall Enthalpy Balances 2.9 Multistage Tray Towers-McCabe & theile method for enriching and stripping section 2.9.1 Introduction of Feed & Location of the feed tray 2.9.2 Total reflux ratio, minimum reflux ratio, Optimum reflux ratio 2.9.3 Calculations of product rates, minimum reflux ratio and number of

trays 2.10 Use of open stream 2.11 Types of Distillation

• Steam distillation

• Vacuum and molecular distillation

• Azeotropic and extractive distillation 2.12 Various types of reboilers and their use

3. Humidification:

3.1 Vapor-liquid Equilibrium and Enthalpy for a pure substance 3.1.1 Vapor-pressure curve 3.1.2 Enthalpy

3.2 Vapor-gas mixtures 3.2.1 Absolute Humidity 3.2.2 Saturated vapor-gas mixtures 3.2.3 Unsaturated vapor-gas mixtures 3.2.4 Concept of Dry bulb temperature, Dew point, Wet bulb temperature (laboratory concept) Humid volume, humid heat, adiabatic saturation temperature 3.2.5 Calculations of absolute humidity, relative saturation, percentage saturation 3.3 The system Air-Water, Psychometric charts 3.4 Gas-Liquid contact operations 3.4.1 Classification of Adiabatic operations 3.4.2 Classification of non-adiabatic operations 3.5 Dehumidification of Air-water Vapor 3.6 Equipments 3.6.1 Principles and types of cooling towers 3.6.2 Spray chambers 3.6.3 Spray ponds

4. Drying: 4.1 Equilibrium

4.1.1 Insoluble solids 4.1.2 Hysterisis 4.1.3 Soluble solids 4.1.4 Definitions and calculation of Moisture content, Equilibrium and free

moisture, Bound and un bound moisture 4.2 Classification of drying operation 4.3 Classification of drying equipment 4.4 Construction and working of following equipment

• Tray drier

• Tunnel drier

• Vacuum drier

• Rotary vacuum drier

• Spray drier

• Fluidized bed drier

• Pneumatic drier 4.5 Freeze drying 4.6 Drying test and derivation of equation for drying time for constant rate period

and falling rate period 4.7 Numerical for drying time

5. Adsorption & Ion-Exchange:

5.1 Adsorption 5.1.1 Definition and industrial application 5.1.2 Types of adsorption 5.1.3 Characteristics of adsorbents, nature of commonly used adsorbents 5.2 Adsorption Equilibria

5.2.1 Single gases and vapors 5.2.2 Adsorption hysterises 5.3 Effect of temperature on adsorption 5.4 Heat of adsorption 5.5 Liquids

5.5.1 Adsorption of solute from dilute solution 5.5.2 The Freundlich’s equation 5.5.3 Adsorption from concentrated solutions

5.6 Material balance and Freundlich’s equation for single stage operation and multistage cross-current operation 5.7 Ion-Exchange

5.7.1 Principles 5.7.2 Application 5.7.3 Equilibria 5.7.4 Rate of ion exchange

5.8 Higgins contactor

6.

Crystallization: 6.1 Crystal geometry 6.2 Equilibria and yields 6.3 Super saturation and methods to get it 6.4 Nucleation 6.5 Crystal growth 6.6 Crystallization Equipment

6.6.1 Vacuum crystallizer 6.6.2 Swenson walker crystallizer 6.6.3 Krystal Crystallizer 6.6.4 Draft tube-baffle crystallizer

6.7 Meir’s theory 6.8 Crystallization with and without seeding 6.9 Simple Calculations of crystal yield 6.10 Caking of crystals & prevention methods

Laboratories:

1. Study of Distillation Model

2. Vacuum Distillation

3. Differential Distillation

4. Steam Distillation

5. Measurement of moisture content (Dry and wet basis)

6. Measurement of wet and dry bulb temperature

7. Drying in vacuum drier

8. Measurement of drying time for sand in constant rate and falling rate region

9. Drying with and without air circulation

10. Adsorption of moisture by silica gel

11. Vacuum crystallization

12. Crystallization with and without seeding

13. Study of Cooling tower model

Reference Books:

1. Mass transfer operations, Robert E Treybal.

2. Unit operations in chemical engineering, Mc Cabe and smith.

3. Introduction to chemical engineering, Walter L Badger & Julius T Banchero.

DIPLOMA IN CHEMICAL ENGINEERING SEMESTER: V

Subject Name: Petroleum Refining and Petrochemical Technology

Sr. No. Course Content

1. Introduction: 1.1 Occurance & history of Petroleum. 1.2 Crude Petroleum oil reserves in India. 1.3 Refineries development in India. 1.4 Various refineries located in India. 1.5 Composition of Petroleum. 1.6 Classification of Petroleum

2. Fractionation of Petroleum: 2.1 Refinery products. 2.2 Dehydration & Desalting of crude oil. 2.3 Brief idea & sketches of pipe still heater. 2.4 Straight run distillation of crude oil. 2.5 Physical properties of petroleum products and its measurements :

2.5.1 Petrol 2.5.2 Diesel 2.5.3 Kerosene 2.5.4 Lubricant oil 2.5.5 Grease

2.6 Types of Refineries 2.7 Refineries processes.

2.7.1 Physical changes. 2.7.2 Chemical changes.

3. Chemical Processes in Refinery: 3.1 Cracking.

3.1.1 Purpose of cracking. 3.1.2 Effect of temp. & Process on cracking. 3.1.3 Difference between thermal cracking & catalytic cracking. 3.1.4 Catalytic cracking by fluidised bed.

3.2 Reforming. 3.2.1 Purpose of Reforming. 3.2.2 Difference between thermal reforming. & catalytic

reforming. 3.2.3 Reforming by platinum catalyst method.

4. Treatment Techniques: 4.1 Purpose of sulphur removal. 4.2 List various of suphfur removal. 4.3 Sulfur removal by doctor's sweetening method & catalytic desulfurization mehtod. 4.4 Treatment of kerosene by liquid SO2 extraction process. 4.5 Solvent extraction processes.

4.5.1 Furtural extraction method 4.5.2 Phenol extraction method 4.5.3 Difference between both the method

4.6 Duo sol (Selecto) extraction process.

5. Dewaxing: 5.1 Purpose of dewaxing. 5.2 Dewaxing without solvent. 5.3 Dewaxing with solvent.

5.3.1 Ketone dewaxing & propane dewaxing process

6.

Petrochemicals: 6.1 Development of petrochemical industry in Gujarat & in India. 6.2 Manufacturing of C1 compounds.

6.2.1 Methanol 6.2.2 Formaldehyde

6.3 Manufacturing of C2 compounds. 6.3.1 Ethylene dichloride. 6.3.2 Vinyl chloride. 6.3.3 Ethylene Oxide.

6.4 Manufacturing of C3 compounds. 6.4.1 Polypropylene. 6.4.2 Propylene oxide.

6.5 Chemicals from aromatics. 6.6 Phenol by benzene sulfonate process

Laboratories Experiences:

1. Determination of flash point by Penskey Martin method.

2. Determination of fire point by Penskey Martin method.

3. Aniline point measurement of petroleum product.

4. Etermination of penetration number of petroleum product.

5. Carbon residue by Ram's botton method.

6. Carbon residue by conradson method.

7. Carbon residue by conradson method.

8. Measurement of smoke point.

9. Measurement of cloud point.

10. Measurement of pour point.

11. Measurement of initial & final boiling point of any petroleum product.

12. Measurement of Viscosity by Red wood viscometer.

Reference Books:

1. Modern Petroleum Refining Processes, By B.K.Bhaskar Rao.

2. Outlines of chemical Technology, By Dryden.

3. A Text on Petrochemicals, By B.K.Bhaskar Rao.

4. Industrial Chemicals, By Faith, Keyes and Clark.

DIPLOMA IN CHEMICAL ENGINEERING SEMESTER: V

Subject Name: Utilities and Instrumentation in Chemical Plant

Sr. No. Course Content

1. Introduction of Utilities and Water as Basic Utility: 1.1 Brief Idea of various utilities: their role in chemical plant. 1.2 Sources of water. 1.3 Hard & Soft water. 1.4 Methods of softening of water: (a) Lime soda process (Hot & Cold) (b) Zeolite process (c) Ion exchange process (d) Phosphate process 1.5 Purification of water (a) Screening (b) Sedimentation (c) Coagulation (d) Filtration (e) Sterilization 1.6 Compare Boiler Feed water and demineralized water.

2. Steam: 2.1 Introduction 2.2 Definition of (a) Enthalpy

(b) Wet steam (c) Superheated steam (d) Specific volume (e) Saturated Steam

2.3 Steam Generator (with various components). 2.4 Classification & comparison of steam generators. 2.5 Factors affecting selection of Boiler. 2.6 Construction of various type of Boilers. (a) Locomotive Fire tube boiler (b) Lancashire boiler

3. Air/inert Gas: 3.1 Introduction 3.2 Compressed Air 3.3 Blower Air 3.4 Fan Air 3.5 Application of Air 3.6 Types of Air compressors (a) Reciprocating Air compressors (b) Multistage compressors

(c) Rotary compressors 3.7 Instrumental air 3.8 Inert gas like Nitrogen, Argon etc.

4. Refrigeration: 4.1 Introduction 4.2 Various method of Refrigeration (a) Ice Refrigeration (b) Evaporative Refrigeration (c) Vapor Refrigeration System 4.3 Unit of Refrigeration & Definition of TOR 4.4 Different types of Primary Refrigerants with Physical properties of following (a) Ammonia (b) Halo Carbons (Freon of Different type) (c) HFC (Hydro Fluorocarbon) 4.5 Different types of secondary Refrigerants

(a) Water (b) Brine

4.6 Selection of Refrigerants

5. Introduction to Instrumentation: 5.1 Concept and importance of instrumentation 5.2 Classification of instruments 5.3 Basic elements of instruments 5.4 Characteristics of instruments in detail (Dynamic and Static) 5.5 First order system and second order system(Upto understanding level only)

6.

Temperature Measuring Devices: 6.1 Definition of thermometer 6.2 Temperature scale 6.3 Mercury in glass thermometer: Principle, Construction & Working 6.4 Bi-metallic and pressure spring thermometers: Principle, Construction &

Working 6.5 Principles of thermoelectricity 6.6 See-back effect, Peltier effect and Thomson effect 6.7 Industrial thermocouple: their principle, construction, working range, lead wires. 6.8 Thermowells, in details 6.9 Construction and working of resistance thermometer 6.10 Simple Wheastone bridge circuit and Null bridge resistance thermometer. 6.11 Radiation and optical Pyrometers

7. Pressure Measurement & Flow Measurement: 7.1 Explain:

Pressure gauges like diaphragm, Bourdon tube gauge, Dead weight pressure, Gauge, Strain gauge.

7.2 Explain: Magnetic-Ultrasonic meter, Coriolis meter, Target meter, Vortex Shredding meter, Turbine meter.

8. Viscosity Measurement: 8.1 Capillary tube method 8.2 Rotating cylinder method 8.3 Falling sphere method 8.4 Torsion viscometer

9. Level Measurement: 9.1 Classify: Liquid level measuring devices

9.1.1 Direct level measuring devices (a) Probe and tape (b) Sight glass (c) Floats 9.1.2 Indirect level measuring devices. (a) Air trap box method (b) Diaphragm box method (c) Bellow system (d) Differential pressure manometer

10. Control Valves, Simple Control Loops & Control System: 10.1 Function of relays and interlocks 10.2 Temperature control 10.3 Pressure control 10.4 Important control modes with simple diagram 10.5 Brief Idea of PLC and DCS system

11. Miscellaneous: 11.1 Working and construction of Hair hygrometer 11.2 Working and construction of Hydrometer. 11.3 Working and construction of pH measurement

Laboratory Experiences:

1. Study of water treatment plant (Industrial visit) 8 hrs.

2. Study of Boilers (Industrial visit of a plant consisting boiler) 8 hrs.

3. Study of primary and secondary refrigeration in chemical plant 8 hrs.

4. Temperature measurement: bi-metallic thermometer 2 hrs.

5. Demonstration of thermo-couple 2 hrs.

6. Study of mechanical pressure gauges 2 hrs.

7. Demonstration of Bourdon tube 2 hrs.

8. Measurement of gas flow 2 hrs.

9. Viscosity measurement by capillary tube method 2 hrs.

10. Direct level measurement 2 hrs.

11. Study of control valves & actuators 2 hrs.

12. Study of DCS system (Industrial visit in a plant consisting DCS system) 8 hrs.

13. Measurement of humidity by Hair hygrometer 2 hrs.

14. Measurement of density by Hydrometer 2 hrs.

15. PH measurement by pH meter 2 hrs.

16. Measurement of concentration by conductivity 2 hrs.

Reference Books:

1. Industrial instrumentation, Donald P. Eckman.

2. Instrumentation, Kirk and Rimboi.

3. Instrumentation, Nirali Prakashan.

4. Unit operation of chemical Engineering Mccabe & Smith.

5. Plant utilities, Nirali Prakashan.

6. Process control Koppel,Coughnour.

7. Process Instrumentation and Control, A. P. Kulkarni, Nirali Prakashan.

DIPLOMA IN CHEMICAL ENGINEERING SEMESTER: V

Subject Name: Fundamental of Chemical Reaction Engineering &

Thermodynamics

Sr. No. Course Content:

1. CHEMICAL REACTION ENGINEERING 1. Introduction to Chemical Reaction Engineering

1.1 Overview 1.2 Classification of Reactions 1.3 Rate of Chemical Reaction – Definitions & Equations 1.4 Variables affecting the rate of chemical reaction 1.5 Simple examples(numericals)

2. Reactor types and characteristics Construction Working and Applications of

2.1 Batch Reactor 2.2 Semi Batch Reactor 2.3 Continuous flow stirred tank reactor 2.4 Tubular Reactors 2.5 Multiphase Reactors - Fixed bed Reactors with configuration like Tubular, Staged, Trickle bed; - Bubble Column, Spray Column, Slurry Reactor, Fluidized bed Reactor 2.6 Important points for Reactor selection 2.7 Simple examples(numericals)

3. Kinetics of Homogeneous Reactions

3.1 Ideal Reactors 3.2 Single and Multiple reactions 3.3 Elementary and Non elementary reactions & their kinetics 3.4 Molecularity and order of reaction 3.5 Temperature Dependence of Reaction rate -Arrhenius’ Law & Activation Energy 3.6 Simple examples(numericals)

4. Ideal Reactors 4.1 Introduction to Ideal Reactors- Batch, Plug flow and Mixed flow reactor 4.2 Ideal Batch Reactor- Performance Equation 4.3 Space time and Space velocity 4.4 Steady state mixed flow reactor- Performance Equation 4.5 Steady state plug flow reactor- Performance Equation 4.6 Holding Time and Space Time for Flow Reactors 4.6 Simple examples(numericals)

2. THERMODYNAMICS 1. Introduction and Basic Concept

1.1 Scope and limitations of thermodynamics 1.2 Definition and concept of (i) System, Process and surrounding (ii) Homogeneous and heterogeneous system (iii) Closed and open system (iv) State of System (v) Extensive and intensive properties (vi) State and Path function (vii) Force, Pressure, Work and Energy (ix) Reversible and irreversible processes 1.3 Steady state, Equilibrium state and Phase rule 1.4 Temperature and zeroth law of thermodynamics 1.5 Ideal gas temperature scale 1.6 Simple examples(numericals)

2. First Law of Thermodynamics

2.1 Statement & Explanation of first law of thermodynamics 2.2 Internal Energy, Enthalpy and Heat capacity 2.3 First law for non-flow processes 2.4 First law for flow processes 2.5 Simple examples(numericals)

3. PVT behavior 3.1 PVT behavior of pure fluids 3.2 Ideal gas and equation of state 3.3 Process involving Ideal gas: (i) Constant Volume process (ii) Constant pressure process (iii) Constant temperature process (iv) Adiabatic process (v) Polytropic process 3.4 Equation of state for real gases 3.5 Simple examples(numericals)

4. Second Law of Thermodynamics 4.1 Limitations of first law and direction of change 4.2 Difference between heat and work 4.3 Statements of Second law 4.4 Entropy, Entropy and heat, Entropy and temperature, Entropy and nature of

process 4.5 Carnot cycle and thermodynamic temperature scale 4.6 Calculation of Entropy change during

(i)Phase change (ii)Ideal gas processes (iii)Adiabatic mixing (iv)Isothermal mixing (v)Chemical reaction

4.7 Entropy & Irreversibly

4.8 Heat reservoir, Heat engine and Heat pump 4.8 Third law of thermodynamics 4.9 Simple examples(numericals)

Reference Books:

1. Chemical Reaction Engineering, Octave Levenspiel, Third Edition, John Wiley & Sons.

2. Chemical Engineering thermodynamics, K.V.Narayanan, PHI publishers.