Chemical Engineering Quiz
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Questions and Answers

Which of the following statements about the use of caustic in a dissolution tank is true?

  • Caustic causes temperature to increase when charging a dissolution tank. (correct)
  • Caustic only reacts with solids.
  • Caustic has no effect on temperature.
  • Caustic decreases the temperature when added.

The granulator hopper measures weight by the use of a flow meter.

False (B)

What type of pump is used to transport aqueous phase solution to the reactors?

Centrifugal pump

The additive required for Product 934 SH is ______.

<p>BVE</p> Signup and view all the answers

Match the types of drying to their corresponding dryer numbers:

<p>Diffusion = Dryer 1 Evaporative = Dryer 2</p> Signup and view all the answers

What is the potential environmental impact of the finished product?

<p>Both A and C (B)</p> Signup and view all the answers

Thermal catalyst should be added to the reactor during the propagation process.

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

What by-product is generated from the process of making post hydro?

<p>Carbon dioxide</p> Signup and view all the answers

The equipment used to measure the amount of product transferred to the reactor is called a ______.

<p>Flow meter</p> Signup and view all the answers

Match the following inhibitors with their types:

<p>Acrylic acid = Inhibitor used in acrylamide Copper = Inhibitor used in acrylamide Urea = Inhibitor used in acrylamide Salt = Inhibitor used in acrylamide</p> Signup and view all the answers

Acrylamide is most dangerous in crystallization (solid) form.

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

Which of the following statements about MEHQ is true?

<p>It is considered a known carcinogen in polymerization. (C)</p> Signup and view all the answers

What is the maximum amount of catalyst approved to be present in the plant?

<p>48 hours worth</p> Signup and view all the answers

The average moisture range for product exiting dryer 2 on UP1 and LP2 is _____%.

<p>10-12</p> Signup and view all the answers

Match the following dryers with their average moisture ranges:

<p>Dryer 1 = 28-30% Dryer 2 = 10-12% Dryer 3 = 9-10%</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

Anionic products have a negative charge.

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

When should dissolution tank samples be discarded?

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

We add ______ to the dissolution tank when we use BVE.

<p>Antifoam</p> Signup and view all the answers

Match the following components with their descriptions:

<p>Anionic products = Negative charge Dissolution tank samples = Discarded when QC is confirmed BVE = Creates more foam Rotary valve motor = Controls valve motion</p> Signup and view all the answers

What is the primary function of dryer cyclones?

<p>To allow the dryer air to vent out through the ducts and stack, while returning the product to the dryers. (B)</p> Signup and view all the answers

Increasing redox catalyst will slow down the kinetic process.

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

What could cause product to emit from the stack?

<p>A plugged cyclone, clogged duct work, or high pressure during unloading.</p> Signup and view all the answers

The dryer moistures are important to ensure __________ of all rotors.

<p>compatibility</p> Signup and view all the answers

Match the following components with their related functions in a dryer:

<p>Cyclone = Ventilation and product retention Redox catalyst = Accelerates kinetic processes Moisture control = Maintains product quality Air flow = Causes vibration in certain dryer systems</p> Signup and view all the answers

What is the primary purpose of conducting a reactor pressure test?

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

Over sparging can lead to inadequate mixing of catalysts.

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

List the three main steps in reaction curve polymerization.

<p>Initiation, propagation, and termination.</p> Signup and view all the answers

Acetic acid is used when adjusting pH on post hydro products to ensure that ______ will not be adversely affected.

<p>anionicity</p> Signup and view all the answers

Match the following scenarios with their corresponding consequences:

<p>Insufficient hypo added = Slower reaction curve Reactor set to 0 degrees C = Product consistency may be affected Excessive sparging = Inadequate catalyst mixing Dissolution tanks set to -2 degrees C = Prevention of auto-polymerization</p> Signup and view all the answers

Draining faster than normal is considered a problem in the process.

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

What is the purpose of adding acetic acid, caustic, and acrylic acid in the process?

<p>To adjust the pH of the solution (B)</p> Signup and view all the answers

Over drying products can cause _____ to fail.

<p>filter ratio</p> Signup and view all the answers

What chemical process describes the breakdown of a compound by reaction with water?

<p>Hydrolysis</p> Signup and view all the answers

Match each process with their function:

<p>Granulator = Prevents damage to blades Centrifuge = Separates components based on density Catalyst pitch = Contains addition of water Oiling reactors = Facilitates draining gel</p> Signup and view all the answers

Empty catalyst bags should be discarded.

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

What could cause high amperage in a granulator?

<p>Not enough oil flow (B)</p> Signup and view all the answers

What does a brownish gel color signify in the production process?

<p>Too much Mohr's salt is being applied to product (A)</p> Signup and view all the answers

What should be checked first if oversize particles are coming out of the dryer?

<p>granulator screen</p> Signup and view all the answers

Mixing catalyst for too long can cause chemicals to lose potency.

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

What type of reactors are used at SNF Flopam?

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

Too much product in a dryer can cause the flame not to light due to ______.

<p>insufficient airflow</p> Signup and view all the answers

Match the following terminology to their definitions:

<p>Flocculation = Separation of a solution, commonly removal of sediment from a fluid Dissolution tank = Container used for dissolving solid materials into liquids On/off solenoid = Device controlling the flow of air to actuators Granulator = Machine that reduces material size for processing</p> Signup and view all the answers

If moisture levels are high coming out of dryer 1, the operator could be using the _____ drying conditions.

<p>wrong</p> Signup and view all the answers

Match the following components with their functions:

<p>Atomizer = Used to enable lower flow rate of oil Photo eye = Used to sense the presence of flame Pressure regulator = Controls pressure in the system Flow meter = Measures the flow of liquid or gas</p> Signup and view all the answers

If the pressure in the dryer is too low, which of the following could be a consequence?

<p>High moistures (B), Problem with product exiting (C)</p> Signup and view all the answers

The VHM signifies Very High Molecular Weight.

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

What inhibitors are commonly used in acrylic acid?

<p>MEHQ and oxygen</p> Signup and view all the answers

The potential cause for a batch not starting could be that the operator skipped adding the ______.

<p>thermo-catalyst</p> Signup and view all the answers

Match the substances stored in the process lab flammable cabinet with their reasons:

<p>TBHP = Can cause a fire if it comes in contact with a reducer Oxygen = Can cause discoloration if it comes in contact with TBHP MEHQ = Used to inhibit polymerization in acrylic acid</p> Signup and view all the answers

Flashcards

Granulator screens and Amps

Smaller granulator screens can cause high amps to occur due to increased resistance to the flow of material.

Centrifugal pumps in aqueous transport

Centrifugal pumps are commonly used to move aqueous solutions in chemical processes. They exert force on the liquid by spinning a rotor, creating pressure that propels the solution.

Product 934 SH and Additive BVE

Additive BVE is required for the production of Product 934 SH. This additive is carefully added to achieve desired product properties.

Caustic and temperature increase

Caustic is a strong base. When added to a dissolution tank, it reacts with water, generating heat and raising the temperature of the solution.

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Aqueous solutions and containment

Aqueous solutions are potentially hazardous and must be confined within a dike, preventing spills from contaminating the environment. Proper containment allows for safe disposal.

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Free Monomer

The amount of unreacted or unpolymerized monomers that remain in the polyacrylamide gel after polymerization.

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By-product of post-hydrolysis

A by-product of the post-hydrolysis process, where amide groups in the polyacrylamide polymer are converted to carboxyl groups.

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Flow Meter

A device that measures the flow rate of fluids, allowing for precise monitoring of the amount of product transferred to the reactor.

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Thermal catalyst addition

A critical process step in the production of polyacrylamide, where heat is applied to accelerate the polymerization reaction.

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Inhibitor

A chemical used to prevent unwanted reactions from occurring, ensuring a stable polymerization process.

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Is acrylamide more dangerous in crystallization (solid) form?

Acrylamide is a chemical that can be found in different states. It is most dangerous in its solid form, called crystallization.

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Is it safe to use homemade tools to clear equipment clogs?

Using homemade tools can be dangerous and lead to equipment damage and potential injuries. Always use approved and safe tools for maintenance.

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Is MEHQ a known carcinogen?

MEHQ is a chemical used in the polymerization process. It is classified as a known carcinogen, meaning it can cause cancer.

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Is 48 hours worth of catalyst allowed in the plant at any given time?

The amount of catalyst allowed in the plant at any given time is strictly controlled for safety reasons. The approved amount is typically much less than 48 hours worth.

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Is nitrogen a flammable gas?

Nitrogen is an inert gas, meaning it does not readily burn. It is commonly used for pressurizing and purging systems.

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Anionic Product Charge

A type of product with a negative charge.

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Antifoam

A substance used in the dissolution tank to prevent excessive foam formation.

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Sample Discard Time

The point at which a sample taken from the dissolution tank is deemed unusable for analysis.

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Gel Sample

A sample collected from the dissolution tank when product quality fails to meet specifications.

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BVE Dissolving

A method using BVE (butyl vinyl ether) that can lead to increased foam generation in the dissolution tank.

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What is Hydrolysis?

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

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How is catalyst amount determined?

The amount of catalyst needed in a batch is determined by the production sheet.

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Why is oiling the reactor important?

The purpose of oiling reactors is to help drain the gel more easily.

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What is the role of Caustic?

Caustic is a strong base that gives products a charge.

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What happens if products are overdried?

Over-drying products can cause the filter ratio to fail.

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What is the purpose of dryer cyclones?

Dryer cyclones are responsible for separating the product from the dryer air. They allow air to vent out through ducts and a stack, while returning the product back into the dryer.

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What is the effect of increasing redox catalyst?

Increasing the redox catalyst speeds up the chemical reaction, leading to faster kinetics.

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If product is emitting from the stack what could be the problem?

Product emitting from the stack could indicate a blocked cyclone, clogged ductwork, or high pressure during loading or unloading. This could be any or all of these issues.

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Why are dryer moistures important?

Dryer moisture readings are important for maintaining consistent production and preventing production of products outside desired specifications.

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What two parts makes the kason vibrate?

The Kason vibrates due to the air flow from dryer cyclones and the center spiral gasket.

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Empty catalyst bags

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

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Dissolution tank samples

Samples are taken from dissolution tanks to monitor the process and identify any issues that might be impacting drying. This helps ensure the product meets quality standards.

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Closing manual valves

Closing manual valves on reactors and dissolution tanks allows the system to reach the desired draw-down temperature effectively, ensuring the product is processed correctly.

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Acrylamide leakage

Acrylamide leaking from a valve could contaminate the product, making it unsafe and causing it to fail quality tests.

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Oversize particles in dryer

If large particles are found in the dryer (Kason), it's likely the granulator screen has a problem and needs to be inspected first.

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Reactor Pressure Test

The process that prevents leaks in a reactor, ensuring safety and a consistent environment for chemical reactions. This plays a critical role in preventing hazardous spills and maintaining the integrity of the reaction process.

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Reaction Curve Polymerization Steps

A key step in polymerization where three distinct stages determine the formation and structure of polymers. This process involves building chains of molecules through specific chemical reactions.

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Acetic Acid

A chemical used during the pH adjustment of post hydro products. It selectively impacts anionicity, ensuring that the product retains its desired properties and avoids unwanted side reactions.

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Dissolution Tank Temperature

A critical safety measure to prevent unwanted and potentially dangerous polymerization before it begins. This ensures product quality and maintains stable manufacturing conditions.

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Sparging

A method used to improve catalyst mixing and ensure consistent reactions. If overdone, it can negatively impact catalyst distribution and lead to inconsistent product quality.

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What type of reactors are used at SNT FLOPA?

The reactor at SNT FLOPA uses tubes to facilitate the chemical reaction process. Think of it like a network of pipes where the reaction takes place.

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What are the possible causes of high moisture in the dryer output?

If the dryer isn't working properly, it can cause a high moisture content in the product, and the operator might need to adjust the drying conditions.

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What does a brownish gel color signify?

A brownish gel color indicates potential leakage of glycol through the heat exchanger. Think of it like a colored marker leaking into your water glass.

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Why won't the burner flame light?

When the burner flame doesn't light, it could be a sign the photo eye needs replacement. Think of it as the "eye" that senses the flame and needs a replacement.

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Why should you avoid over-mixing the catalyst?

Excessive catalyst mixing can decrease its effectiveness, like over-mixing cookie dough can make it tough.

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Low Dryer Pressure: What's the problem?

The dryer's pressure being too low could result in the product exiting the dryer incorrectly or leading to an issue with the product's moisture content.

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Why is the dryer's pressure low?

A clogged pressure transmitter could be the reason for a false low pressure reading, causing the dryer to operate inefficiently.

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What does VHM stand for?

VHM refers to Very High Molecular Weight, indicating a polymer with very large molecules.

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Inhibitors in Acrylic Acid

Inhibitors are used to prevent unwanted reactions in acrylic acid, like polymerization, ensuring its stability. Common inhibitors include MEHQ and oxygen.

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Why won't a batch start?

Several factors can cause a batch to fail to start, including a missing thermal catalyst, excess foam, or an improper pH.

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Study Notes

True/False Questions

  • Smaller granulator screens can cause high amps to occur. (True/False)
  • Centrifugal is the type of pump we use 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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Test your knowledge on various chemical engineering concepts, including the use of caustics, catalysts, and drying processes. This quiz covers equipment, environmental impacts, and safety considerations associated with chemical production. Perfect for students and professionals in the field of chemical engineering!

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