Acrylamide Production Process Quiz
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Questions and Answers

What inhibitors are used in acrylamide?

  • Urea and salt (correct)
  • Acrylic acid and caustic (correct)
  • Boric acid and ammonia
  • Copper and oxygen

What is free monomer?

  • A type of catalyst used in reactions
  • Unreacted or un-polymerized monomers used to make polyacrylamide gel (correct)
  • The temperature at which polymerization starts
  • The percentage of liquid that drains during the U. test

What piece of equipment measures the amount of product transferred to the reactor?

  • Weight cells
  • Pressure indicator
  • Flow meter (correct)
  • Thermal conductivity meter

When should thermal catalyst be added to the reactor?

<p>During the propagation process (A)</p> Signup and view all the answers

If a reactor foams, what could happen?

<p>Could result in a dead reaction (A)</p> Signup and view all the answers

What does BVE create more of in the dissolution tank?

<p>Foam (B)</p> Signup and view all the answers

What type of charge do anionic products have?

<p>Negative (D)</p> Signup and view all the answers

When are dissolution tank samples discarded?

<p>Once a corresponding reactor sample to QC silo blend is confirmed (A)</p> Signup and view all the answers

In which form is acrylamide considered most dangerous?

<p>Crystalline form (D)</p> Signup and view all the answers

When should you take a gel sample?

<p>When we fail any kind of QC result and the product becomes non-conformed (D)</p> Signup and view all the answers

Is it acceptable to use homemade tools for unclogging equipment?

<p>No, that practice is unsafe (B)</p> Signup and view all the answers

What do we add to the dissolution tank when we use BVE?

<p>Antifoam (C)</p> Signup and view all the answers

Which chemical in polymerization is considered a known carcinogen?

<p>MEHQ (C)</p> Signup and view all the answers

What is the approved amount of catalyst that can be in the plant at any given time?

<p>48 hours' worth (B)</p> Signup and view all the answers

What is a significant hazard associated with using nitrogen?

<p>It can lead to asphyxiation (C)</p> Signup and view all the answers

What can occur when smaller granulator screens are used?

<p>High amps (D)</p> Signup and view all the answers

Which type of pump is used to transport aqueous phase solutions to the reactors?

<p>Centrifugal pump (D)</p> Signup and view all the answers

What requires the additive BVE in its formulation?

<p>Product 934 SH (B)</p> Signup and view all the answers

What effect does caustic have when charged into a dissolution tank?

<p>Increases temperature (B)</p> Signup and view all the answers

Why should aqueous solutions be kept within the dike?

<p>For proper disposal and containment (C)</p> Signup and view all the answers

What is the primary function of dryer cyclones?

<p>They vent dryer air through ducts and stack while returning the product. (B)</p> Signup and view all the answers

What happens when the redox catalyst is increased?

<p>It leads to a quicker kinetic response. (C)</p> Signup and view all the answers

If products are emitting from the stack, what could be the cause?

<p>A cyclone being plugged. (B)</p> Signup and view all the answers

Why is monitoring dryer moistures critical?

<p>It ensures compatibility of all rotors. (D)</p> Signup and view all the answers

What causes the kason to vibrate?

<p>Air flow from cyclones and the center spiral gasket. (C)</p> Signup and view all the answers

What is the primary purpose of a reactor pressure test?

<p>To test for leaks (A)</p> Signup and view all the answers

Which are the correct steps in the reaction curve polymerization process?

<p>Initiation, propagation, and termination (D)</p> Signup and view all the answers

What may result from adding too little hypo to a reaction?

<p>Slower reaction curve (A)</p> Signup and view all the answers

Why is acetic acid chosen for adjusting pH in post hydro products?

<p>It prevents adverse effects on anionicity (A)</p> Signup and view all the answers

What is the reason for setting dissolution tanks to -2 degrees C during polymerization at 0 degrees C?

<p>To prevent auto-polymerization and ensure consistency (B)</p> Signup and view all the answers

Which of the following statements is true regarding the chemical breakdown of a compound?

<p>Hydrolysis is the chemical breakdown due to reaction with water. (C)</p> Signup and view all the answers

What effect can over drying products have on the filtration process?

<p>It can cause the filter ratio to fail. (B)</p> Signup and view all the answers

What role does caustic play in the production process?

<p>It gives the product its charge. (C)</p> Signup and view all the answers

What is the main purpose of oiling reactors during production?

<p>To enhance the process of draining out the gel. (D)</p> Signup and view all the answers

What information is determined by the production sheet?

<p>How much catalyst each batch receives. (D)</p> Signup and view all the answers

What type of reactors are used at SNT Flopa?

<p>Tube reactors (B)</p> Signup and view all the answers

What could be a cause of high moisture levels coming out of dryer 1?

<p>Operator could be using the wrong drying conditions (C)</p> Signup and view all the answers

What does a brownish gel color signify?

<p>Glycol could be leaking through the exchanger (B)</p> Signup and view all the answers

Why should catalyst not be mixed for too long?

<p>Mixing too long can cause chemicals to lose potency (D)</p> Signup and view all the answers

What must be present inside the granulator for a lower flow rate of oil?

<p>Atomizer (A)</p> Signup and view all the answers

Should empty catalyst bags be discarded?

<p>Yes, they should be discarded. (D)</p> Signup and view all the answers

What is the primary reason for taking dissolution tank samples?

<p>Due to issues and drying upsets. (C)</p> Signup and view all the answers

Why is it important to close manual valves on reactors and dissolution tanks?

<p>To ensure proper draw-down temperature. (C)</p> Signup and view all the answers

What could cause the finished product to test high?

<p>Acrylamide leaking by an actuator valve. (B)</p> Signup and view all the answers

What should be checked first if oversize particles are produced from the dryer?

<p>The granulator screen. (A)</p> Signup and view all the answers

What problem could arise if the pressure is too low in the dryer?

<p>High moistures (A)</p> Signup and view all the answers

What could cause a low reading on the pressure transmitter in the dryer?

<p>Pressure transmitter could be clog (B), Granulator fan is clog (C), Plant is running at slower rates (D)</p> Signup and view all the answers

What does the term VHM represent?

<p>Very high molecular weight (B)</p> Signup and view all the answers

Why is TBHP stored in the process lab flammable cabinet?

<p>It can cause a fire if it comes in contact with a reducer (D)</p> Signup and view all the answers

If a batch will not start, what could be a potential issue?

<p>Operator could have skipped adding thermo-catalyst (A), Too much foam in dissolution tank (B), pH is incorrect (D)</p> Signup and view all the answers

Flashcards

Do smaller granulator screens cause high amps?

Smaller screens lead to more frequent collisions, increasing energy consumption and raising the current draw.

Are centrifugal pumps used for transporting aqueous solutions?

Centrifugal pumps are designed for moving liquids, which is why they're used for transporting aqueous solutions.

Does adding caustic raise temperature?

Caustic (usually referring to sodium hydroxide) reacts exothermically with water, generating heat during the charging process.

Does the granulator hopper use a flow meter for weight measurement?

The flow meter measures the volume of liquid passing through a point, not weight.

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Does hypo act as a reducer?

Hypo, a common name for sodium thiosulfate, is used as a chain transfer agent in polymerization reactions, not as a reducer.

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Free monomer

Unreacted or un-polymerized monomers: molecules used to make polyacrylamide gel.

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Free monomer - U test

The percentage of liquid that drains during the U. test.

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Drawdown

The process where the reaction is cooled to stop the polymerization.

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Ammonia

A by-product of the post hydro process.

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Flow meter

A device to measure the amount of product transferred to the reactor.

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Acrylamide's most dangerous form?

Acrylamide is most dangerous in its solid, crystallized form.

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Using homemade tools for equipment maintenance?

It's unsafe and potentially dangerous to use homemade tools for equipment maintenance. Use approved tools to prevent accidents.

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What's MEHQ and its risk?

MEHQ, a chemical used in polymerization, is classified as a known carcinogen.

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Maximum allowable catalyst storage?

The plant's maximum allowable catalyst storage at any given time is 48 hours' worth.

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What's a hazard associated with nitrogen?

Nitrogen, while not flammable, is considered a hazard due to its inert nature, which can displace oxygen, leading to asphyxiation.

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Why does BVE cause more foam in the dissolution tank?

BVE, a type of polymer, increases foam formation within the dissolution tank, making it crucial to manage and minimize foam buildup.

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What kind of charge do anionic products have?

Anionic products carry a negative charge. This property plays a role in their interactions with other chemicals and materials.

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When are dissolution tank samples discarded?

Dissolution tank samples are discarded when the corresponding reactor sample for the QC silo blend has been confirmed. This ensures the accuracy and reliability of the QC process.

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When should you take a gel sample?

Gel samples are taken when a QC test fails, resulting in a non-conforming product. This allows for a closer examination of the problem.

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Where is the dryer pressure transmitter located?

The dryer pressure transmitter is located in the top side of the dryer shell, monitoring the pressure within the dryer during the drying process.

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What is the function of dryer cyclones?

The dryer cyclones are responsible for separating the product from the air stream, allowing the air to exit through the ducts and stack while returning the product back into the dryer.

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How does redox catalyst impact polymerization?

Increasing the amount of redox catalyst speeds up the chemical reaction rate, which in turn accelerates the polymerization process.

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What does product emitting from the stack suggest?

Product emitting from the stack indicates problems with air flow and product separation within the dryer system.

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Why are dryer moisture levels important?

Dryer moisture levels are crucial for maintaining consistent product quality and ensuring all rotors are compatible.

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What causes the vibration in a Kason screen?

The vibration in a Kason vibrating screen is generated by the combined force of air flow from the dryer cyclones and the center spiral gasket.

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Hydrolysis

The chemical breakdown of a compound due to reaction with water.

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Caustic and charge

The product's negative charge is determined by the addition of a caustic agent.

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Drying process

The process of removing excess moisture from the product by applying heat.

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High filter ratio

A high ratio of water to solids in the product, resulting in a less-than-ideal filter flow.

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What safety gear is needed for caustic soda?

Caustic soda, also known as sodium hydroxide, is a highly corrosive substance that requires specific safety protocols. Handling it necessitates personal protective equipment like goggles, gloves, and lab coats to prevent skin and eye irritation.

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What does a reactor pressure test prevent?

A reactor pressure test is designed to detect and prevent leaks in the pressure vessels used in chemical processes. It ensures that the vessel can withstand the intended pressure without failure.

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What happens if you over sparge?

Over-sparging refers to exceeding the optimal amount of gas introduced into a polymerization reaction. This can lead to poor mixing of catalysts, resulting in an inconsistent reaction and an undesirable product.

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What are the stages of a polymerization reaction?

Polymerization reactions proceed through three distinct stages: initiation, propagation, and termination. Initiation starts the chain reaction, propagation builds the polymer chain, and termination stops the reaction.

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What happens if too little hypo is added?

Adding too little hypo, a chain transfer agent, to a reaction slows down the polymerization process. This is because hypo controls the growth of the polymer chains.

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Discard empty catalyst bags?

Empty catalyst bags should be disposed of properly to prevent contamination and safety hazards.

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Why take dissolution tank samples?

Dissolution tank samples are taken to analyze the product and troubleshoot potential issues in the drying process.

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Why close manual valves?

Closing manual valves on reactors and dissolution tanks helps maintain the desired temperature during the draw-down process.

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What could acrylamide leakage cause?

Acrylamide leaking through a valve can contaminate the finished product, leading to high test results.

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Oversize particles in the dryer, what to check first?

If large particles are coming out of the dryer, the screen on the granulator is the first place to check for potential issues.

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What type of reactors are used at snt flopa?

A tube reactor is a type of chemical reactor where the reaction mixture flows through a tube or series of tubes. This design helps to increase the efficiency of heat transfer and improve product consistency.

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What could cause high moisture coming out of dryer 1?

If the moisture content of the product coming out of the dryer is high, it could indicate a problem with the drying conditions, such as incorrect temperature or airflow settings. The operator may need to adjust the drying parameters.

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What does a brownish gel color signify?

A brownish gel color may indicate a problem like too much Mohr's salt being added to the product. This salt is used in the polymerization process, and an excess can lead to color changes in the final product.

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What could cause a burner flame to not light?

The photo eye is a sensor used to detect the flame in the burner. If the photo eye is malfunctioning, it may not be detecting the flame, preventing the burner from igniting properly.

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Why shouldn't we mix catalyst too long?

Overmixing can lead to a decrease in the catalyst's chemical activity, affecting the polymerization process. It's essential to follow the proper mixing time to ensure that the catalyst retains its potency.

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Low dryer pressure: What's the problem?

Low pressure in the dryer can lead to issues with the product exiting the dryer, potentially causing it to become over-moisturized. This can impact the quality and consistency of your final product.

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Low dryer pressure reading: What's the cause?

A clogged pressure transmitter can give a false reading of low pressure within the dryer, leading to incorrect adjustments or even stopping the process.

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What does VHM signify?

VHM stands for 'Very High Molecular Weight' and it implies a polymer with a large chain structure. This is often a desirable characteristic in certain applications, contributing to desired properties like viscosity or strength.

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What inhibitors are used in acrylic acid?

Acrylic acid is a common ingredient in polymers. To prevent its premature polymerization, inhibitors like MEHQ (monomethyl ether hydroquinone) and oxygen are used to slow down the reaction.

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Why won't a batch start?

If a batch won't start, there could be multiple factors: Missing thermo-catalyst (a key ingredient needed for chemical reaction to start), excessive foam in the tank (preventing proper mixing), or an incorrect pH (affecting the reaction conditions).

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Study Notes

Safety and Procedures

  • Smaller granulator screens can cause high amps to occur. (True/False)
  • Centrifugal is the type of pump used to transport aqueous phase solution to the reactors. (True/False)
  • Product 934 SH requires the additive BVE. (True/False)
  • Caustic causes temperature to increase when charging a dissolution tank. (True/False)
  • Aqueous solution should never be allowed outside of the dike so it can be contained and disposed of properly. (True/False)
  • The granulator hopper measure weight by the use of a flow meter. (True/False)
  • Hypo is used as a chain-transfer agent but has a reducer properties. (True/False)
  • The purpose of the Kason is to help transport powder through piping. (True/False)
  • Diffusion is the type of drying done in dryer 1. (True/False)
  • Evaporative is the type of drying done in dryer 2. (True/False)
  • Only powders shift supervisors are authorized to work in solenoid control panels. (True/False)

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Description

Test your knowledge on the acrylamide production process with this quiz. Covering important concepts such as inhibitors, catalysts, and safety protocols, this assessment is perfect for those studying chemical engineering or polymer science. Prepare to explore various technical aspects related to acrylamide and its production equipment.

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