Vishwakarma Institute of Technology (An Autonomous Institute affiliated to Savitribai Phule Pune University)

Transcription

1 Bansilal Ramnath Agarwal Charitable Trust s Vishwakarma Institute of Technology (An Autonomous Institute affiliated to Savitribai Phule Pune University) Structure and Syllabus of B.Tech. (Chemical Engineering) Pattern B14 Effective from Academic Year Prepared by: - Board of Studies in Chemical Engineering Approved by: - Academic Board, Vishwakarma Institute of Technology, Pune Signed by, Chairman BOS Chairman Academic Board Page 1 of 16

2 Contents MODULE VI T.Y. B.TECH. CHEMICAL ENGINEERING... 3 CH361THP :: PROCESS EQUIPMENT DESIGN... 4 CH362THP :: PROCESS CONTROL... 6 CH363THL:: CHEMICAL REACTION KINETICS... 8 CH364THL :: SEPARATION TECHNIQUES CH365TH:: CHEMICAL TECHNOLOGY CH366TH :: PROJECT MANAGEMENT CH360PRJ :: PROJECT Page 2 of 16

3 MODULE VI T.Y. B.TECH. CHEMICAL ENGINEERING Course No Course Code Course Name Contact Hours / Week Credits Th. Proj. Based Lab Regular Lab S 1 CH361THP Process Equipment Design S 2 CH362THP Process Control S 3 CH363THL Chemical Reaction Kinetics S 4 CH364THL Separation Techniques S 5 CH365TH Chemical Technology 3 3 HSS CH366TH Project Management 2 2 Following course to be offered in Semester I only CH355SD SD/PD CH358SD Basics of Computer Aided Chemical Engineering Heat Exchanger design using HTRI Fire Protection Industry Training CH356SD 2 CH359PS 2 Following course to be offered in Semester II only PROJ CH360PRJ Project Page 3 of 16

4 CH361THP :: PROCESS EQUIPMENT DESIGN Credits: 04 Teaching Scheme: 05 Hours/Week Unit 1: Heat Exchangers Introduction, process heat transfer, types of heat exchangers, codes and standards for heat exchangers, materials of construction, API scale, forced convection equation, mean metal temperature, LMTD, caloric temperatures, countercurrent & concurrent exchangers, temperature approach & cross,, counterflow: double pipe exchangers, baffles and tie rods, tube joining methods, design of shell and tube heat exchangers as per IS: 4503 and TEMA standards i.e. shell, tube sheets, channel, channel cover, flanged joints. Condensers &reboilers. Awareness on commercial software for thermal design. Unit 2: Evaporators & Crystallizers Classification of vaporizing equipment, evaporators (including different types such as kettle, thermosiphon, vertical, horizontal etc.) Chemical evaporators, natural circulation & forced circulation evaporators, the calculation of chemical evaporators, crystallizers, types of crystallizers, design considerations. Unit 3: Tray Column Design Design of plate column- distillation columns, design variables in distillation, design methods for binary systems, plate efficiency, approximate column sizing, plate contactors, plate hydraulic design. Unit 4: Packed Column Design Choices of packing, types of packing, packed bed height (distillation and absorption), HETP, HTU, NTU, Cornell s method, Onda s method, column diameter, column internals, column auxiliaries. Unit 5: Filters & Dryers (06 Hours) Study of various types of filters like vacuum filters, pressure filters, centrifuges and rotary drum filters, design of rotary drum filters including design of drum, shaft, bearing and drive system. Types of dryers, batch type dryers, continuous dryers. Unit 6: Auxiliary Process Vessels (06 Hours) Study of auxiliary process vessels such as reflux drum, knockout drum, liquid-liquid and gas-liquid separators, entrainment separators, oil water separator, Decanter, gravity separator. Safety devices used in process industries, Introduction to design and engineering software. List of Project areas: 1. Design of heat exchanger considering particular heating or cooling objective 2. Design of evaporator to obtain thick liquor with particular concentration considering various industrial needs 3. Design of tray/packed column for separation by using distillation, absorption, etc operations with an industrial example. Text Books: 1. D. Q. Kern;Process Heat Transfer; Tata McGraw Hill Publications, R. K. Sinnott; Coulson & Richardson s Chemical Engineering, Volume-6; Elsevier Page 4 of 16

5 Butterworth Heinemann, MA, V.V. Mahajani, S. B. Umarji; Joshi's Process Equipment Design; 5 th Edition; Trinity Press Reference Books: 1. Walas, S. M; Chemical process equipment: selection and design; Butterworth-Heinemann, Ludwig, E.E.; Applied Process Design for Chemical and Petrochemical Plants, Vol. 1 and 2; 3rd Ed.; Gulf Publishing Co., Course Outcomes: The student will be able to 1. Carry out the detailed thermal design of double pipe and shell and tube heat exchanger for given requirement 2. Design a multiple effect evaporation system for specific requirement of concentration 3. Do hydraulic plate design and tray column design for desired separation needs 4. Select type and size of packing and packed column design with internals for required separation 5. Do preliminary design and selection of drying and filtration equipment 6. Choose and design auxiliary process equipment required for various simple separation & storage requirements Page 5 of 16

6 CH362THP :: PROCESS CONTROL Credits: 03 Teaching Scheme: - Theory 3 Hrs/Week Unit I Laplace and Integral transforms, Signals and systems (8 Hours) Elementary theory of Laplace transforms; Inverse Laplace transforms; Simultaneous differential equations (two equations leading to 2 2 controller); Initial value problems having a scalar or two differential equations; Block diagram; basic theorems; Mason's rule and signal flow diagram; Steady state error and sensitivity. Input forcing functions; Introduction to systems, signals and transforms. Unit II Introduction to frequency domain synthesis. (8 Hours) Hurwitz stability criteria for closed loop systems; Theory of complex variables and derivation of Nyquist array for various types of controllers for closed loop control systems. Basics of PID controller design and tuning for SISO control loops. Design of pole placement controller, bang-bang controller. Unit III Linear state space theory and time domain synthesis (8 Hours) Basics of state space theory in ; Phase plane analysis and motion upon manifolds. Controllability and its dual observability; Design of Linear quadratic regulator; Synthesis of exogenous system and tracking regulatory control. Unit IV Lebesgue measures and Radon transforms (8 Hours) Lebesgue measure theory. Radon transforms. Basic methods of control and optimization. Commensurate delays and under-/ over- actuated controllers. Introduction to model-based cost optimal control. Unit V Interaction measures and Introduction to 2 2 controllers (4 Hours) Relative gain array; µ-synthesis; PID controllers tuning using autotune with relay feedback. Elimination of input and output multiplicity for closed loop system in frequency domain. Introduction to IMC controller and optimal control in frequency domain,, control; Introduction to adaptive control. Unit VI Set-valued & Linear switched controllers (4 Hours) Multiple steady states in chemical reactor and distillation dynamics; notion of set-valued arguments to design switched controllers; Introduction to elementary applications of bot-assisted automation system. Project Areas: 1. To derive Nyquist array theorem from fundamentals and derive stability criteria for a closed loop system, and perform MATLAB (SIMULINK) simulation. 2. To derive an appropriate approximation for a transfer function for a nonlinear process that may contain non-smooth components. 3. To derive switching curves for a bang-bang controller and tune the same for a SISO control loop. 4. To derive a linear quadratic regulator (LQR) for a physical process that is an example from chemical processes. 5. To derive a exogenous system for a given chemical process, and derive a tracking regulatory control and determine its stability. 6. To derive analytical results for multiple chemical reactions as a lumped system represented as a square matrix, and based on its singularity derive controllability and observability criteria. Page 6 of 16

7 7. To derive equation of motion upon manifolds in time domain for a chemical process and apply bang-bang controller. 8. To derive Lebesgue measures for a reduced order model of measured output and semicontinuous function of a control valve forming a SISO controller pair. Textbooks: 1. Coughanowr, L, 'Process Systems Analysis and Control', McGraw Hill Education; 3 rd edition (June 2013). 2. Postlaithewaite and Skojestad, 'Multivariable Feedback Control: Analysis and Design', 2nd Edition, September J. Warga, 'Optimal control of differential and functional equations', Academic Press, New York and London, J.-P. Aubin, A. Cellina, 'Differential inclusions: set-valued maps and viability theory', Springer, Reference Books: 1. Morari and Zafiriou, 'Robust control', McGraw-Hill International Edition, Distefano J. J., Stubberud, A.J., Williams, I. J., 'Schaum's Outline of Feedback and Control Systems', 2 nd Edition, Oct Course Outcomes: At the end of the course the students will be able to 1. Derive Laplace transform of systems described by scalar differential equations and form block diagrams. 2. Derive plant stability applying Hurwitz criteria and Nyquist array for design and tuning of PID controller for SISO control loops. 3. Design linear quadratic regulator and tracking regulatory control for exogenous inputs. 4. Derive Lebesgue measures in time domain and Radon transforms in frequency domain for control and optimization of systems. 5. Derive interaction measures for 2 2 controller and tune using autotune relay with feedback. 6. Compute set-valued arguments for design of switched controllers using differential inclusions for SISO and 2 2 controllers. Page 7 of 16

8 CH363THL:: CHEMICAL REACTION KINETICS Credits: 04 Teaching Scheme: - Theory Hrs/Week Unit 1: Kinetics of homogeneous reactions (7 Hours) Irreversible and reversible reactions, Equilibrium Order and molecularity of reaction. Elementary and non elementary reactions; Stoichiometry, Fractional conversion. Rate of reaction based on all components of the reaction and their interrelation. Law of mass action, Rate Constant-Based on thermodynamic activity, partial pressure, mole fraction and concentration of the reaction components and their interrelation, Temperature dependency of rate Constant - Arrhenious law, Transition state theory and collision theory. Unit 2: Interpretation of batch reactor data (7 Hours) Batch reactor concept, Constant volume Batch reactor system; Design equation for zero, first, Second irreversible and reversible reactions, graphical interpretation of these equations and their limitations, Variable volume Batch reactors. Design equation for first and second order irreversible and reversible reactions, Graphical interpretation of their limitations, Multiple reactions-stoichiometry and Rate equations for series and parallel reactions; Chain reactions development of rate expressions Unit III: Ideal flow reactors (6 Hours) Concept of ideality, Types of flow reactors and their differences, Space-time and Space velocity, Mean holding time. Design equation for plug flow reactor and CSTR; Design equations for first and second order reversible and irreversible constant volume and variable volume reactor. Graphical interpretation of these equations; Unit IV: Single and multiple reactor system (6 Hours) Size comparison of single reactors; Optimum size determination; Staging of reactors, Reactors in series and parallel; Performance of infinite number of back mix reactors in series, Back mix and plug flow reactors of different sizes in series and their optimum way of staging; Unit V: Product distribution in multiple reaction (7 Hours) Recycle reactors, Optimum recycle ratio for (auto-catalytic reactions) recycle reactors. Yield and selectivity, Parallel reactions Requirements for high yield, best operating condition for mixed and plug flow reactors, Series reactions.multiple reactions in CSTR and PFR reactors. Maximization of desired product rate in a plug flow reactor and back mixed reactor, product distribution in multiple reactions. Unit VI: Temperature and Pressure Effects (7 Hours) Equilibrium Conversion, Optimum temperature progression, Adiabatic and non adiabatic operations, Temperature and conversion profiles for exothermic and endothermic reactions. Temperature and conversion profiles for exothermic and endothermic reactions, Stable operating condition in reactors. List of Practicals 1. To calculate value of rate constant k for Pseudo first and second order reaction in batch reactor 2. To calculate value of rate constant k for Pseudo first and second order reaction in semi batch reactor Page 8 of 16

9 3. Varification of Arrhenius law 4. Determine conversion for second order reaction in single CSTR 5. Determine conversion for second order reaction in CSTR in series 6. Determine conversion for second order reaction in PFR 7. Study dissolution kinetics in batch reactors 8. Finding τ optimum using polymaths for parallel Reactions 9. Semi batch Reactor Addition of NaOH in Ethyl acetate, Utilization of POLYMATHS for finding product behavior. Text Books 1. Levenspeil, O., Chemical Reaction Engineering, 3rd. edition, John Wiley& Sons, Fogler, H. S., Elementsof Chemical Reaction Engineering, 3rd Ed., PHI, Reference Books 1. Walas, S. M., Reaction Kinetics for Chemical Engineers, McGraw Hill, Smith, J.M., Chemical Engineering Kinetics, 3rd ed., McGraw Hill, Course outcomes Student will be able to- 1. Develop rate expressions from elementary and non elemenary step mechanisms using steadystate and quasi-equilibrium approximations. 2. Determine rate expressions by analyzing reactor data including integral and differential analysis on constant- and variable-volume systems 3. Design ideal reactors i.e. plug flow and CSTR for first and second order reversible and irreversible constant volume and variable volume reactor. 4. Select and size isothermal reactors for series and/or parallel systems of reactions. 5. Determine the product distribution for multiple reactions 6. Determine temperature and pressure effects and their influence on product distribution, yield and selectivity and quantitatively predict the performance of common chemical reactors in various combinations. Page 9 of 16

10 CH364THL :: SEPARATION TECHNIQUES Credits:04 Teaching Scheme: Theory: Hours / Week Unit I: Distillation -I Vapour liquid equilibria for ideal and non-ideal systems, relative volatility, methods of distillation - differential, flash, low pressure, batch rectification. Continuous rectification for binary system, multistage (tray) towers, Lewis Sorrel method, McCabe Thiele method, concept of reflux, Fenske s equation, Fenske-Underwood equation, use of open steam. Partial and total Condensers, reboilers Unit II: Distillation-II Ponchon Savarit method for multistage operations, tray efficiencies, packed column design, complex distillation columns, concept of multi component distillation, extractive and azeoptropic distillation, Fenske- Underwood-Gilliland shortcut method for multi-component distillation. Unit III: Liquid-LiquidExtraction Ternary liquid-liquid equilibrium, triangular coordinates, single-stage extraction, Multi-stage crosscurrent extraction, continuous countercurrent multistage extraction. Types of extractors. Unit IV: Solid-Liquid Extraction (Leaching) Single stage leaching, continuous counter current leaching, ideal stage equilibrium, operating time, constant and variable underflow, number of ideal stages, stage efficiencies, Leaching equipments. Unit V: Adsorption and Ion-Exchange Physical and chemical adsorption, adsorbents, adsorption equilibrium and isotherms, Single-stage, multi-stage cross-current and multi-stage counter current operations, equilibrium and operating lines, Liquid-solid agitated vessel adsorber, packed continuous contactor, breakthrough curves, Rate equations for adsorbents, nonisothermal operation, pressure-swing adsorption, Ion Exchange- Principles of Ion Exchange Equilibria and rate of ion exchange. Unit VI: Introduction to Membrane Separation (05 Hours) Introduction to membranes, material and types of membranes, physical and chemical properties of membranes, membrane modules and techniques for membrane preparation. List of Practical: Experiments based on above units (In a group of maximum five students) 1) To generate VLE data for binary systems 2) To study differential distillation and verify Rayleigh equation 3) To carry out steam distillation of high boiling substance and determine steam requirement 4) To conduct binary distillation in a packed column at total reflux and to estimate HETP and HTU for column 5) To prepare the ternary diagram for a system of three liquid one pair partially soluble for example acetic acid, benzene and water system 6) To obtain data for equilibrium distribution of solute in two insoluble solvents for example acetic acid in water and toluene phases and determine percentage extraction Page 10 of 16

11 7) To study the (cross current) liquid- liquid extraction for extracting acetic acid from benzene using water as solvent. 8) To study the liquid- liquid extraction in a packed column and to calculate HTU and HETP for the tower 9) To carry out leaching operation using groundnuts and n-hexane and find out quantity of oil and to determine the efficiency of single stage leaching operation 10) To verify Freundlich/ Langmuir isotherm equation for batch Adsorption 11) To obtain the breakthrough curve for continuous process in fixed bed adsorption column 12) Design of multi-component distillation system using ASPEN software Text Books: 1. R. E. Treybal; Mass Transfer Operations; Third edition, McGraw Hill, J. M. Coulson, J. F. Richardson; Chemical Engineering Vol. I & II, Sixth edition, Butterworth- Heinemann, C.J. King; Separation Processes; Tata McGraw - Hill Publishing Co. Ltd., B. K. Dutta, Principles of Mass Transfer and Separation Processes; Prentice-Hall of India Private Ltd., 2007 Reference Books: 1. W. L. McCabe, J. C. Smith, P. Harriett; Unit Operations of Chemical Engineering; Fourth edition, McGraw-Hill, P.C. Wankat; Separations in Chemical Engineering: Equilibrium Staged Separations; Prentice Hall, NJ, US, R. H. Perry, D. W. Green; Perry's Chemical Engineer's Handbook; Sixth Edition, McGraw-Hill, 1984 Course Outcomes: The Student will be able to 1. generate VLE data and carry out process design of distillation column 2. analyze implications of factors affecting distillation column operation and design like the effect of reflux ratio, feed conditions etc. and also the implications of non-ideal phase behaviour (e.g., azeotropes) and apply to multicomponent distillation 3. select suitable solvent for liquid-liquid extraction based on properties like selectivity, distribution coefficient etc. and design liquid-liquid extraction column and select equipment required for given separation 4. calculate the number of stages required for a leaching operation 5. draw analogy between adsorption and ion exchange, carry out process design of adsorption operation 6. review importanceof membrane separation Page 11 of 16

12 Credits: 03 CH365TH:: CHEMICAL TECHNOLOGY Teaching Scheme: 3 Hours / Week Unit 1: Basic Concepts (5 Hours) Theory of Unit operations and industrial equipment and systems used in large scale plants; Unit processes, Development of flow diagram, schematic representation and application for unit operations and unit processes. Study the selection and process specific applications knowing available industrial equipment and plant accessories Unit 2: Chlor-Alkali Industry (7 Hours) Chlor-alkali chart and importance of chlor-alkali industry, manufacturing processes process economics, and plants in India and a few examples of latest technology used in other nations; Manufacturing of soda ash, caustic soda, chlorine and engineering problems. Membrane cell, mercury cell diaphragm cell processes and electrolytic cell processes and flowsheets Unit 3: Nitrogen industry (7Hours) Role of nitrogen in fertilizers, manufacturing of ammonia, nitric acid, urea, the above study must involves different routes adopted, limitations, advantages and disadvantages of the process; steamreforming process technology. Coal gasification technologies (Fixed bed (Lurgi Process), Fluidised bed (Winkler Process) Unit 4: Sulfur and Sugar Industry (7Hours) Importance, manufacturing of sulfur by Frasch process, technology for the manufacturing of sulfuric acid. Sugar Industry: Manufacture of sugar and engineering problems associated, Dextrin and starch derivatives. detailed study and comparison between chamber and DCDA processes; process economics. Unit 5: Phosphorus and Paper Pulp Industry (7 Hours) Importance, manufacturing of super phosphate, triple super phosphate, phosphoric acid, electro thermal processes and NPK fertilizers, production of pulp, engineering problems involved, paper manufacturing from pulp, and comparison of methods of manufacturing. Unit 6: Petroleum industry Overview of refinery process, Crude distillation, Cracking, Reforming, supporting processes. (7 hours) hydroprocessing, Refinery Textbooks: 1. Dryden Outline of Chemical. Technology, Rao, M. Gopala,, 3rd Edition, East West Publishers, Shreve's Chemical Process Industries, Austin, George T., 5 th Edition, McGraw-Hill, Reference Books: 1. Chemical Process Design and Integration, Smith, R., 3 rd Edition, Wiley, Unit Processes in Organic Synthesis, Groggins, P.H., 3 rd Edition, McGraw-Hill Book Co., Page 12 of 16

13 Course Outcomes: The student will be able to 1. Understand process fundamentals of chemical technology in process industries. 2. Apply knowledge of chemical technology in unit operations and unit processes happening in chemical industry. 3. Draw process flow sheets for production of specific chemical product. 4. Comprehend reaction temperature, pressure condition and heat network in process flowsheet. 5. Analyze different process for same product based on economics, effluent treatment, social aspects.. 6. Appreciate Petroleum refinery operation and supplementary processes. Page 13 of 16

14 Credits: 2 CH366TH :: PROJECT MANAGEMENT Teaching Scheme: 2Hours / Week Unit 1: Overview of Project Management, Concepts and Techniques (4 Hours) Introduction to types of management, management suitable for projects, Introduction to Project management, Project management Process and role of Project Manager, Characteristics of projects, Definition and objectives of Project Management, Stages of Project Management. Unit 2: Types of Projects, selection and cost estimation (4 Hours) Types of projects, financial evaluation of projects using various methods such as payback period method, average rate of return method, net present value method, profitability index method, internal rate of return method, etc. Project cost estimation methods and application. Unit 3: Project Planning and scheduling (4 Hours) Introduction to project planning, Dynamic Project Planning and Scheduling, Building the work breakdown schedule, Estimation of task and project duration, Project Scheduling with Resource Constraints, Project scheduling and Planning Tools: Work Breakdown structure, CPM/PERT Network, Gantt charts. Project monitoring and evaluation plan, Project evaluation approaches, Project Cost Control and Time Cost Tradeoff Unit 4: Project Evaluation and Time Cost Tradeoff (4 Hours) Project monitoring and evaluation plan, Project evaluation approaches, Project Cost Control and Time Cost Tradeoff Unit 5: Project Contracts (4 Hours) Types of contract, sub-contracts, tenders, types of payments to contractors. Unit 6: Post ProjectEvaluation (4 Hours) Introduction and objectives of project audit, phases of project audit, types of project audit, agencies of project audit (Indian scenario). Text Books: 1. Nagarajan K.; Project Management; 1 st Edition., New Age International. 2. Mahajani V. V., Nokashi S. M.; Chemical Project Economics; 1 st Edition; Macmillan India Ltd. Reference Books: 1. Choudhury S.; Project Scheduling and Monitoring in Practice, 1 st Edition; SAP. 2. Joy P. K.; Total Project Management: The Indian Context; 1 st Edition; Macmillan India Ltd. Course Outcomes: The student will be able to 1. Obtain an understanding of management, project management and its principles in a contemporary project environment. 2. Understand functions of project manager, project life cycle and project portfolio management. 3. Select project from options, estimate cost, time and do the planning and scheduling activity. Page 14 of 16

15 4. Monitor and evaluate the project progress and cost time relationship and estimates. 5. Understand contracts and tenders and billing system and use in the project. 6. Understand types, necessity and importance of audit and learn from audit. Page 15 of 16

16 CH360PRJ :: PROJECT Credits: 02 Teaching Scheme: 2 Hours / Week Contents This stage will include a report consisting of synopsis, the plan for experimental/theoretical work and the summary of the literature survey carried out till this stage.students may undertake studies in application chemical engineering knowledge for manufacturing project, synthesis, design and development, experimental work, testing on the product or system, generation of new ideas and concept, modification in the existing process/system, development of computer programs, solutions, modeling and simulation related to the subject. Topics of interdisciplinary nature may also be taken up. A detailed literature survey is expected to be carried out as a part of this work. The group of students is required to choose the topic in consultation with the Guide. A technical report of 15 pages is required to be submitted at the end of the term and a presentation made based on the same. Modern audio-visual techniques may be used at the time of presentation. Text Books 1. Project Writing Manual Chemical Engineering Department, VIT, Pune Reference Books: NIL Course Outcomes: The student will be able to 1. Apply Chemical Engineering knowledge. 2. Learn How to Work in Team. 3. Define a task (problem) and execute it. 4. Carry out literature search related to topic. 5. Write synopsis and complete literature search related to topic. 6. Technically communicate about literature search.. Page 16 of 16