DEPARTMENT OF CHEMICAL ENGINEERING

QUESTION BANK

Name of the Faculty : Dr.S.Karunakaran

Subject : Mechanical Operation

Regulations : R 2021

Course Code : U21CH303

Branch : Chemical Engineering

Year & Semester : IIrd Year & IV SEM

Academic Year : 2022-2023 (ODD Semester)

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 UNIT-1 PARTICLE CHARACTERISATION AND MEASUREMENT

PART-A

1. Show the significance of physical operations and chemical conversions in chemical

engineering.

a) To increase the surface in order to increase the rate of physical or chemical process.

b) To effect the separation of two constituents in cases where one is dispersed in small
isolated pockets

c) To improve distillation rate, solubility binding strength and dispersion properties

2. Define the terms friction and frictional loss.

A) Friction

It is the force resisting the relative motion of solid surfaces, fluid layers and material elements
sliding against each other.

B) Frictional loss

In fluid flow, the frictional loss of pressure or head that occurs in pipe or duct flow due to the effect
of fluids viscosity near the surface of pipe or duct.

3. How do you determine the nature of the feed for size reduction?

Solids appear in variety of forms-angular pieces, continuous sheets, and finely divided powders.

They may be hard and abrasive tough and rubbery, softer or fragile, dusty, cohesive, free flowing
or sticky

4. What is meant by screen effectiveness?

It is a measure of success of the screen in closely separating undersize and oversize material .The
screen effectiveness is based on the oversize material is the ratio of amount of oversize material A
that is actually in the overflow to the amount of oversize material A in the feed.

5. List out any two mechanical operations that you come across in everyday life.

• To cutting is extract juice we squeeze the fruit or we crush it.

• Also a mechanical operation, we used to cut the vegetables etc.

6. Define sphericity and friability.

Sphericity – the shape of the individual particle is conveniently expressed in terms of sphericity
(ɸs)=(6/Dp)/(Sp/Vp)

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Friability – it the tendency for a tablet to chip, crumble or break following compression. This
tendency is normally confined to uncoated tablets and surfaces during handling or subsequent
storage

7. What is shape factor of particulate solids?

For a given particle shape, volume of any particle is proportional to its diameter cubed.

V=aDp3

Where, a = volume shape factor.

8. What are the factors that affect capacity and efficiency of the screen?

Method of feeding, screening surfaces, screen slope, vibration amplitude and frequency, moisture
in feed.

9. what is sauter mean diameter?

The volume surface mean diameter is also called as sauter mean diameter Ds which is related to
the resitricted to the specific surface area Aw

Ds=6/Dpøsρp

10. Contrast between ideal screen and actual screen.

Sl No Ideal Actual
1 Yield sharp separation Does not yield sharp separation
2. Efficiency of the screen is 100 % Efficiency of the screen is less than 100 %
3. Such screen don’t found in Such screens are available in practice.
practice

11. What is blinding of screen?

It is phenomenon where in elongated sticky etc particle become wedged into the opening during
screenings and thus prevent the other particles ffrom passing through it .

12. List out the importance of separation based on particle size.

Particle size distribution can greatly affect the efficiency of any collection device,

A) settling chamber will normally only collect a very large particle,those that can be separated
using sieve trays

B) centrifugal collectors will normally collect particle down to about 20 µm .Higher efficiency
models can collect particles down to 10µm .

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 C) frabic filters are one of the most efficient and cost effective types of dust collectors
available and can achieve a collection efficiency of more than 99% of very fine particles

13. List out the general characteristics of solids.

Solids are generally characterised by their shape ,size and density .inter molecular distances are
short, intermoleculaer forces are strong.

PART B

1. Derive the related expression for the material balance ,effectiveness ,efficiency and the
effect of mesh size on capacity of actual screen.(16M)
2. Discuss the different techniques applied for determining particle size distribution.(8m)
3. Explain general characteristics of solids and their behavior under different forces.(8M)
4. The screen analysis of a sample of a crushed quartz is given. The density of the particle is
2650 kg/m3and the shape factor are (a=0.8 and ɸs =0.571) for the material between 4 – mesh
and 200- mesh in particle size. Calculate
A) Aw in mm2/gm
B) Nw in particles /gm
C) Dv
D)Ds
E) Dw
F) Ni for 150/200 mesh increment
G) what fraction of total number of particles in the 150/200 mesh increment(related problems
will be asked.(16M)

5. Explain briefly the different types of screening equipments(16M)

6. Explain the factors affecting the performance of the screen(8M).

7. Compare actual and ideal screen with graph(8M).

8. Explain with a neat sketch the working principle of vibrating screen(8M0

9. A quartz mixture having a certain screen analysis is screened through a standard 10 mesh
screen. Calculate a) the mass ratio of overflow and underflow to feed

B) Effectiveness of screen. Dp =Dpc=1.651mm ,Xf =0.47, Xd=0.85 ,Xb=0.195(related problems

will be asked).(16M).

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 UNIT II PARTICLE SIZE REDUCTION AND SIZE ENLARGEMENT

PART A

1. What are the importance of size reduction?

a) To increase the surface in order to increase the rate of physical or chemical process.

b) To effect the separation of two constituents in cases where one is dispersed in small
isolated pockets

c) To improve distillation rate , solubility binding strength and dispersion properties .

2. Define work index.

The amount of energy in kwatt-hrs per tones of the feed material,required to reduce a very large
feed to such a size that 80% of the product passes through a 100 µm screen.
3. What is crushing efficiency ?
It is the ratio of surface energy created by crushing to the energy absorbed by the solids.
ηc=es (Ab – Aa) /Wn
where,

ηc= Crushing efficiency

es=surface energy per unit area

Ab= area of product

Aa= area of feed

Wn= energy absorbed by material
4. What is mechanical efficiency ?
It is a ratio of energy absorbed to the engery input
ηm= W/Wn
where
ηm= mechanical efficiency
W=energy input to the machine
Wn = energy absorbed by the material.
5. Define size reduction or comminution.
It is a mechanical process of breakdown of solids into smaller size particle without altering the
state of aggregation of solids. It is also called as communition.
6. Name the four common ways of breaking solids in size reduction machines.
1)Compression
2)Impact
3) Ultrafine grinders
4) cutting machines
What are the types of size reduction equipments ?
a) crushes b) grinders c)ultrafine grinders d)cutting machines.

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7. Define angle of nip.
Angle of nip formed by the tangers to the roll faces at the point of contact with a particles to be
crushed
8. What is centrifuging ?
If the mill is operated at very high speed , the balls are carried right round in contact if the
sides of mill and the mill is said to be centrifuging .

9. Define critical speed of ball mill.

If the mill is operated at very high speed , the balls are carried right round in contact if the sides
of mill and the mill is said to be centrifuging . The minimum speed at which the centrifuging
occurs is called critical speed of mill.

10. Give the formula of calculating the critical speed of ball mill.
𝑁𝑐 = 1 √g
2 √𝑅−𝑟

11. Name some industries where size reduction operations are carried out.
A) Coal washers

B) Ore processing industries

C) Chemical industries

D) Paint industry

E) Cement industry

F) Food processing industry

PART B

1. Explain the empirical relationship between Ritinger’s law and kick’s law(8M).
2. Discuss briefly the criterion for comminuting(8M).
3. What is power required to crush 150 tonne per hour of lime stone if 85% of the feed passes in
2inch screen and 85% of the product in a 1/8 inch screen?(refer related problems)(8M)
4. Explain the laws of crushing(6M)>
5. Explain the construction and working of tumbling mill(10m)
6. With the help of neat sketch explain the operation of conical ball mill.(6M)
7. Classify the equipment used for the size reduction ,discuss their basic principles(10M).
8. Derive an expression to find critical speed of ball mill.(10M)
9. Derive an expression to related diameter of rolls with size of the feed for a smooth roll crusher.
10. Explain the construction and working principle of a jaw and blake jaw crusher.

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 UNIT III – PARTICLE SEPARATION

PART- A

1. Define stokes Law.

The force of viscosity on a small sphere moving through a viscous fluid is given by:
Fd = 6πμRV, Where: Fd is the frictional force – known as Stokes' drag – acting on the interface
between the fluid and the particle, μ is the dynamic viscosity, R is the radius of the spherical
object is the flow velocity relative to the object.

2. Contrast between filtration and centrifugation.

The separation of solid from a suspension in a liquid with the help of a porous medium or
screen which retains the solids and allows the liquid to pass is termed as filtration.
Centrifugation is a process by which a centrifuge machine is used to separate desired
constituents of a complex liquid mixture/slurry.
3. What are known to be thickeners?
Industrially sedimentation operations may be carried out batch wise or continuously in
equipment called thickener. A thickener consists of a relatively shallow tank from the top of
which a clear liquid is taken off and the thickened liquid is withdrawn from the bottom.
4. What is the principle of separation in magnetic separators?
In this method material having different magnetic attract ability is separated by passing
them through a magnetic field. The difference in magnetic properties of the different materials
is responsible for such a separation.
5. Define the term Brownian movement and when it is significant in settling of solids.
Brownian motion is the random motion of particles suspended in a fluid (a liquid ora
gas) resulting from their collision with the fast-moving atoms or molecules in the gas or liquid.
6. Define terminal settling velocity.
If a particle is allowed to settle in a fluid under the influence of gravity, it will increase in
velocity until the accelerating force is exactly balanced by the resisting force.
7. Name some industrial dust collectors.
Cyclone separators, fabric filters, electrostatic precipitator and unit collectors

8. How does the preparation of colloids take place?

i) By condensation ii) Dispersion iii) Peptization
9. Define the types of settling.
Free settling: It is the settling of the particle unaffected by the other particles and the wall
of the container.
Hindered settling: It is the settling of the particle impeded by the other particles and the
wall of the container.

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10. Contrast between settling and sedimentation.
Settling is the process by which particulates settle to the bottom of a liquid and form
a sediment. Particles that experience a force, either due to gravity or due to centrifugal motion
will tend to move in a uniform manner in the direction exerted by that force. Sedimentation
is the tendency for particles in suspension to settle out of the fluid in which they are entrained
and come to rest against a barrier. This is due to their motion through the fluid in response to
the forces acting on them: these forces can be due to gravity, centrifugal acceleration, or
electromagnetism.
11. Name some flocculating agents.
Ferric chloride, Polyacrylamide, APAM , Polyaluminium chloride etc,.
12. Compare between Jigging and Tabling.
Jigging: A process of gravity concentration where solids are separated based upon the
difference the behavior of particles through a moving fluid which in turn, depends upon
densities.
Tabling: Type of separation that utilizes difference in densities of materials. Process can be
performed either wet or dry with dry tabling have broader particles range.
13. Recall the principle of elutriation.
Elutriation is a process for separating particles based on their size, shape and density, using
a stream of gas or liquid flowing in a direction usually opposite to the direction of
sedimentation. This method is mainly used for particles smaller than 1 μm.
14. Summarize the functions of floatation agents.
Flocculation and coagulation treatment chemicals are used in effluent water treatment
processes for solids removal, water clarification, lime softening, sludge thickening, and solids
dewatering.
15. When is wet sieving employed?
When silt and clay are used then wet sieving must be employed for better results.
Washing of soil particles ensure fine particles separated from coarse particles.

PART – B

1. Explain how to design a thickener using a batch sedimentation test? (12 M)

2. Elaborate briefly about separation by magnetic and impingement method. (6 M)
3. Compile short notes on Heavy media separations and floatation (10 M)
4. Explain briefly the characteristics of membranes and their applications. (8 M)
5. Explain briefly about the process of floatation and floating agents. (6 M)
6. Discuss the settling characteristics of fine solids from liquid using batch sedimentation test.
7. Construct a short notes on Jigging (8 M)
8. Explain the working principle of a cyclone separator. (12 M)
9. Illustrate how will you separate the particles based on the electrical properties? (12 M)
10. Explain briefly the different classifiers. (16 M)
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 UNIT IV- FILTRATION AND FILTRATION EQUIPMENTS
PART – A
1. What are filter aids? Give some examples.
A filter aid is a granular or fibrous material which packs to form a bed of very high voidage.
Because of this, they are capable of increasing the porosity of the filter cake. Diatomaceous
earth, expanded pearlite, asbestos fibers are some examples of filter aids.
2. Where do you employ centrifugal filtration?
In case of slurries containing coarse granular or crystalline solids forming a porous cake
the filtration operation can be carried by using centrifugal force rather than pressure force.
3. What are the factors affecting the rate of filtration?
i) Pressure drop across the feed inlet and far side of the filter medium
ii) Area of the filtering surface
iii) Viscosity of the filtrate
iv) Resistance of the filter cake
4. What are the types of filtration?
Cake filtration and deep bed filtration
5. Contrast between constant rate and constant pressure filtration
Inconstant pressure filtration pressure drop over the filter is held constant so that the rate
of filtration is maximum at start and continuously decreases towards the end whereas in
constant rate filtration the pressure drop is varied usually minimum at start maximum at end
of the filtration.

6. What are clarifying filters? Mention its industrial application.

Clarifying filters also called as deep bed filters are used to remove small amounts of
solids to produce sparkling clear liquids whereas cake filters separates large amount of solids
in the form of cake of crystals. Clarifying filters find application in water treatment.
7. What is specific cake resistance?
 Pc A
A specific cake resistance is defined by the equation  = where, ∆Pc is the
 um

pressure drop over cake, A is the filter area, u is the linear velocity, and μ is the viscosity.

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8. What is compressibility coefficient?
The specific cake resistance can be related to the pressure drop by the equation
α = αo (∆P)s
9. List few characteristics of a filter medium.
i) It should retain the solids to be filter
ii) It should not plug or blind
iii) It should be mechanically strong
iv) It should be resistant to corrosive fluid.
10. What are sand filters?
Sand filters or clarifying filters are used for water treatment water purification. Sand filter
may include the layer of activated the carbon.
11. What are the different types of sand filters?
Rapid sand filter, slow sand filters, pressure filters and up flow sand filters.
12. Define pressure filters?
Filter which operate with super atmospheric pressure and upstream side and atmospheric
pressure at the downstream side of the filter medium are teamed as pressures filters.
13. What are vacuum filters?
Filters which operate with less than atmospheric pressure on the downstream side and
atmospheric pressure on the upstream of the filter medium are teamed as vacuum filters.
14. How do you classify the industrial cake filters?
i) Batch filters
ii) Continuous pressure filters
iii) Batch vacuum filters
iv) Continuous vacuum filters and v) Centrifugal filters.

PART - B

1. Categories the continuous filters. (4 M)

2. Simplify what are pressure filters. (8 M)
3. Classify horizontal filters. (8 M)
4. Compose a short note on filter aids and filter media. (8 M)
5. Discuss the basic principle of centrifugal filtration. (8 M)
6. Explain briefly the characteristics of membranes and their applications. (8 M)

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7. Construct and explain the Dorr thickener. (12 M)
8. Formulate a neat sketch of basket centrifuge and explain its construction. (16 M)
9. Explain the construction and working of a plate and frame filter press. (16 M)
10. Develop an expression to find the overall pressure drop across the filter.
11. What is continuous filtration? Derive an expression to find the rate of solids production (16).
12. Explain with neat sketch the working principle of a rotary drum dryer. (16 M)
13. Explain the different types of filters. (12 M)
14. Explain how to design a thickener using a batch sedimentation test. (16 M)

UNIT V- MIXING AND PARTICLE HANDLING

PART – A
1. List at least four types of conveyors.
Pneumatic conveyor systems, Vibrating conveyor systems, Flexible conveyor systems,
Vertical conveyor systems and spiral conveyors, Heavy duty rear conveyors
2. Infer the factors which influence ‘Rate of Mixing’.
Particle size , shape , charge, nature of the particle, relative density , viscosity, surface
tension of liquids, moisture, temperature, flow characteristics, liquid quality, type of mixer,
mixing speed.
3. Relate the significance of storage and conveying with respect to chemical industries.
Storage equipment is used for holding or buffering materials over a period of time.
Minimizing handling costs, material easily accessible.
4. What are the purposes of agitation?
Blending of miscible liquids, dispersing a gas in the liquid, dispersing or contacting
immiscible liquids, promoting heat transfer between the liquid.
5. Name the agitator which is suitable for mixing low viscous liquids.
Propeller agitators are commonly made of three bladed attached to the main shaft. They are
flexible in operations and mostly used in mechanical mixing of low to medium viscosity fluids.
6. Define power number and mixing index.
Power number is one which used to calculate the power required for an impeller to rotate. Np
= (P/ N3 Da5 ρ)
7. Which conveyor will be used for carrying sticky/paste materials?
Shaft less screw conveyors are the perfect solution and designed to efficiently convey semi-
fluid and sticky bulk materials.

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8. Find the principle of pneumatic conveying.
A pneumatic conveying system transfers powders, granules, and other dry bulk materials
through an enclosed pipeline. The motive force for this transfer comes from a combination
of pressure differential and the flow of a gas, such as air or nitrogen.
9. Contrast between Bin and Silo.
A silo is tall, skinny, seals tight and holds moisture. They traditionally store silage, which
is grass or other fodder harvested green and wet, primarily to feed dairy cattle. Bins are vented,
silver, corrugated steel structures fatter in diameter than silos and have varying heights. They
generally store dry corn and soybeans, which meet domestic or export market demand for
feed, food and fuel use.
10. What are the types of conveyors used for vertical transportation of materials?
Vertical conveyor system and Spiral conveyor system
11. How will you define Reynolds number of agitator inside and agitated tank with agitator
speed, N?
Reynolds number can be defined as NRe = (N Da2 ρ/μ)
12. Contrast between agitation and mixing.
Agitation refers to the induced motion of material in a circulatory pattern inside a tank or
vessel, while mixing is the random distribution into and through one another of two or more
initially separate phases.
13. Outline the significance of power number of agitation.
Power number is significant in the calculation of the power required to rotate an impeller
and is the function of the Reynolds number and Froude number.
14. List out industrial solid conveyors.
Pneumatic conveyor systems, Vibrating conveyor systems, Flexible conveyor systems,
Vertical conveyor systems and spiral conveyors, Heavy duty rear conveyors
15. What are the general specifications about pneumatic conveying?
Every pneumatic system makes use of pipes or ducts called transportation lines that carry
a mixture of materials and a stream of air. These materials are such as dry pulverized or free
flowing or light powdery materials like cement, fly ash etc. These materials can be transported
conveniently to various destinations by means of a stream of high velocity air through pipe
lines.

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16. What are the dimensionless numbers applied in mixing operations?
Power number Np = (P/ N3 Da5 ρ), Reynolds number NRe = (N Da2 ρ/μ) and Froude
number NFr = (N2 Da/ ρ).

PART – B
1. Compose a brief discussion on Mixers Extruders. (8 M)
2. Compile short notes on a) Muller mixers b) Tumbling mills c) Pug mills d) Ribbon mixers
3. A three bladed marine propeller (pitch = 2) is used to agitate a solutions= of specific gravity
1.3 and viscosity 12.5 CP in a unbaffled tank of 1 m with the solution and impeller diameter
0.3 Dtank is set at one impeller if power consumed to drive it is 0.34 KW.
4. List out at least four types of conveyors. What are bulk conveyors? (8M)
5. Perceive the significance of storage and conveying in chemical industries. (8 M)
6. Propose a short notes on a) Kneaders and masticators b) Pug mill (8 M)
7. Explain the method of calculating power required by an agitator for a given mixture. (8 M)
8. Discuss in detail the various types of mixing impellers used. (8 M)
9. Discuss the different types of conveyors used in industries to transport solids. (12 M)
10. Examine which conveyor is most suitable for transportation of sticky material? Why? (4 M)

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