Professional Documents
Culture Documents
01. Define Boiler Feed Water. What are the requirements of Boiler Feed Water?
Boiler Feed Water: The water fed into boiler for the production of steam is called
boiler feed water.
It should be free from turbidity, oil, dissolved gases, alkali and hardness
producing substances.
Requirements of Boiler Feed Water:
i). It should has zero hardness.
If hardness present in boiler feed water, it produces scales and sludges, which
prevents efficient heat transfer.
ii). It must free from dissolved gases like O2 and CO2.
Heat exchangers:A device for transferring heat from one medium to another.
Heat exchangers are designed to remove excess heat from aircraft
engines, optics, x-ray tubes, lasers, power supplies, military
equipment, and many other types of equipment that require cooling
beyond what air-cooled heat sinks can provide.
Formation of deposits: Scale and sludge formation.
Scale:If the precipitate forms hard and adherent coating on the inner walls of the boiler is known as
Scales may sometimes deposit in the valves and condensers of the boiler and choke then
partially. This results in decrease in efficiency of the boiler.
(iii). Boiler Explosion:
When thick scales crack due to uneven expansion, the water comes suddenly in contact
with over-heated iron plates. This causes in formation of a large amount of steam suddenly. So
sudden high-pressure is developed, which may even cause explosion of the boiler.
05. What are the disadvantages using hard water in boilers?
Disadvantages:
1. Scale and sludge formation.
2. Priming and Foaming.
3. Caustic Embrittlement.
4. Boiler Corrosion.
[seeQ.No: 3]
[seeQ.No: 10]
[seeQ.No: 7]
[seeQ.No: 9]
In low-pressure boilers, scale formation can be avoided by adding organic substances like
kerosene ,tannin, agar-agar (a gel), etc., which get coated over the scale forming precipitates,
thereby yielding non-sticky and loose deposits, which can easily be removed by pre-determined
blow-down operations.
(ii). Phosphate conditioning:
Three types of phosphates- mono, di and trisodium phosphates are employed in phosphate
conditioning. The advantages of phosphate conditioning over carborateconditioning are (i).It can be
applied to high pressure boilers and
(ii) It can be used for softening/ conditioning acidic, neutral or alkaline water sample.
In low pressure boilers, calcium ions are converted into soft and loose sludge by adding
sodium carbonate solution. It forms soft CaCO3 which can be removed by blow-down operation.
precipitation of scale forming salt. The complexNa2[Na4(PO3)6] is soluble in water and no problem
for its sludge disposal.
Corrosion.
Dissolved CO2:
--- FeCl 2 + H 2
Prevention: It is controlled by
1) Controlling the velocity of steam
2) Keeping the water level lower
3) Good boiler design
4) Using treated water
2) Foaming:
The formation of stable bubbles above the surface of water is called foaming These
bubbles are carried over by steam leading to excessive priming.
It is caused by
i) Presence of oil and grease
ii) Presence of finely divided particles.
It can be prevented by
i). Adding coagulants like sodium aluminate
ii).Adding anti-foaming agents like synthetic polyamides.
Brackish water = Water containing dissolved salts with a peculiar salty taste. Ex: Sea water
Reverse Osmosis(RO):
When a pressure greater than osmotic pressure applied on the concentrated side, the solvent flow
takes place from higher concentration to lower concentration is known as reverse osmosis.
Process:
1) In this RO process, Pure water is separated from salt water.
2) This RO process is also known as Super filtration or Hyper filtration
3) When the pressure is applied from the higher concentration side, the solvent flow takes
place to lower side and these two concentrations are separated by semipermeable
membrane, the salt water is converted into pure water.
4) The membranes used as cellulose acetate, polyamide and some polymers.
Advantages & RO method:
1. Low capital cost, easy operating.
2. It is used for converting sea water into drinking water
3. It removes all types of impurities like non-ionic and colloidal
4. The life time of membrane is high and it can be replaced within few minutes.
Applications:
(i) To calculate electrode potential of unknown metal
(ii)
Application of emf series
(iii)
Corrosion tendency of methods can be predicted
Oxidation occurs first at the surface of the metal and the resulting metal oxide scale forms a
barrier that tends to restrict either further oxidation. For oxidation to continue either the metal must
diffuse outwards through the scale to the surface or the oxygen must diffuse inwards through the
scale, to the underlying metal.
Both transfer occurs, but the outward metal diffusion is generally, much more rapid than the
inward diffusion of oxygen. Since the metal ion is appreciably smaller than the oxygen ion and
consequently of much higher mobility.
02. PILLING BEDWORTH RULE:
The ratio of the volume of the oxide formed to the volume of the metal consumed is pilling
bed worth rule.
03. Corrosion by other gases Hydrogen.
i) At ordinary Temperature : Hydrogen Embrittlement.
The process of formation of cracks and blisters on the metal surface, due to high pressure of
hydrogen gas is called hydrogen embrittlement
(i) Metal direct contact with H2s and forms atomic hydrogen
(ii) Atomic hydrogen diffuses readily into metal to form molecular hydrogen
2) At high temperature Decarburization
The process of decrease in carbon content in steel is termed as decarburization of steel.
04) Liquid
metal corrosion
This is due to the chemical action of following liquid metal at high temperature.
The corrosion reaction involves
(i)
Either dissolution of a solid metal by a liquid metal.
(ii)
Liquid metal may penetrate into the solid metal.
Chemical corrosion
It occurs dry state
Local attack to metal by environment
Homogeneous metal surface gets
corroded
Corrosion products accumulate in the
same place, where corrosion occurs
Chemical corrosion is self-controlled
It follows adsorption mechanism
Ex: formation of mild scale on iron surface
3 types. i). Oxidation corrosion
ii). Corrosion by other gases- H2
iii). Liquid Metal corrosion.
Electrochemical corrosion
Wet state (i.e) presence in moisture
Large number of cathodic and anodic areas
Heterogeneous surface
(i.e) Bimetallic contact.
Corrosion occurs at the anode, while the
products formed else where
It is continuous process
It follows electrochemical reaction
Ex: rusting of iron in moisture
2 types.
i). Galvanic corrosion.
ii). Differential aeration corrosion.
a). Position in emf series: Metals above hydrogen in emf series, corroded easily.
Metals have high ve reduction potential undergoes corrosion.
b) Relative areas of the anode and cathode: Rate of the corrosion has higher % in anodic area, the
rate of corrosion will be more, when the cathodic area is larger.
c) Purity of the metal: The 100% pure will not undergo any type of corrosion.
If impurity present in higher percentage, corrosion takes places at anode.
d) Over voltage:Corrosive environment is inversely proportional to corrosion rate.
e) Nature of the surface film: It is known as pilling- bed worth rule.
f) Nature of the corrosion product:Corrosion is faster when the corrosion product is soluble in
corroding medium. If the corrosion product is volatile, the corrosion rate will be faster.
ii). Nature of the environment:
09. Explain the Sacrificial anode and impressed current techniques for the preventions
ofcorrosion.
i)
Sacrificial anode method:
i). The application of sacrificial anodes in cathodic protection is based on the differences in
electrochemical reactivity of metals.
ii). In this method, the metal to be protected from corrosion is connected to more activemetal
which acts as an anode.
iii). In a redox reaction involving iron and zinc, the zinc will serve as the anode, and iron the
cathode.
iv). The zinc anode will oxidize and provide electrons for the reduction of Fe 2+ to elemental
iron.
v).This is called cathodic protection. The zinc anode is termed a sacrificial anode.
vi). Iron pipes buried in the ground, and designed to carry water, would normally be expected
to rust pretty quickly.
vii).If they are buried along with a piece of zinc, and connected by a wire the zinc will provide
cathodic protection.
2. Corrosion control through Impressed current method:
An alternative method of providing the current to protect a system is to use some sort of
external power supply. As with the sacrificial system , the structure to be protected is made the
cathode, the difference being that the driving force. Behind the current is not the difference in
potential between the anode and cathode of the system but from the power supply.
Both these types of cathodic protection may be applied to buried pipelines and to steel
hulled ships. For oil drilling platforms, however the method employed is sacrificial in the vast
majority of cases in the north sea.
This technique is useful for protecting large structures like water tanks, underground oil
collers, laid up ships,etc.
10. What is paint? What are the constituents and their functions in paint?
Paint: paint is a mechanical dispersion of one or more finely divided pigments in a medium (thinner
+ vehicle) . When paint is applied to a metal surface, the thinner evaporates, while the vehicle
undergoes slow oxidation forming a pigmented film.
Constituents:
1. Pigments. 2. Vehicle or drying oil. 3. Thinner. 4. Drier. 5. Filler or extender. 6. Plasticizer
7. Antiskinnig agent.
i) Pigments: They are colour producing substances in paint.
Ex: white colour- white lead, black=- carben black red-indian red, green chromium
oxide.
Function: i). It gives colour and opacity to the film.
ii). It also provides strength to the film.
iii). It provides weather resistance of the film.
ii) Vehicle (or) drying oil:This is a non-volatile portion of a medium and film forming constituent of
the paint. These are high molecular weight fatty acids present in vegetable and animal oils. Ex:
Linseed oil, castor oil.
Function:
i) They form a protective film by the oxidation and polymerization of the oil
ii) They hold the pigment particles together on the metal surface
iii) They impart water repellency , toughness and durability to the film.
iii) Thinners or solvents: Thinner is a volatile substance present in the medium.
Ex:
turpentine, toluol, xylol etc.
Function:
I) It increases the elasticity of the film
II) It helps easy drying of the paint film
III) It increases the penetrating power of the vehicle.
iv) Extenders or fillers: These are colourless (white) pigments which improve the quality of the
paint. Ex: Gypsum, Jal ,china clay, silica, etc.
Functions:
i) It reduces the cost of paint
ii) It prevents the cracking and shrinkage of the film
iii) It modifies the shades of the pigments
v).Driers: these are the substances, used to accelerate the process of crying.
Ex: metallic soaps.
Functions: i).They are oxygen carriers (or) catalists.
ii). They provide oxygen , which is essential for oxidation, polymerization of drying oil.
vi).Plasticisers: these are chemicals added to the paint to provide elasticity to the film and to
prevent cracking of the film. Ex: triphenyl phosphate, tricresyl phosphate, etc.
vii). Antiskinning agents:These are chemicals added to the paint to prevent gelling and skinning of
the paint. Ex: polyhydhroxy phenol.
NiCl2.6H2O
NaH2PO2H2O
(sodium hypophosphite)
Sodium succinate
Sodium acetate
85-95oc
4-6
30 g/l
10 g/l
10 g/l
10 g/l
The pretreated object is immersed in the plating bath for the required time during which the
following reduction reaction will occur and the Ni gets coated over the object.
Nuclear fusion
No chain reaction
5. Emits neutron
Emits positron
6. It can be controlled
It cannot be controlled.
02. Define Nuclear fission reaction. Explain with one example in detail.
03. Explain Nuclear Reactor-Power Generator with neat diagram./ Light Water Reactor
Nuclear Reactor: A device used for power generation, in which a nuclear chain reaction
is initiated, maintained and controlled to produce the heat energy is
known as nuclear reactor
.
Converted Thermal Energy
Converted
Nuclear Energy
Electrical Energy
(or)
Heat Energy
Components:
1) Fuel Rods:
the
gets
It produces noise.
It produces unwanted sound.
Affects birds life.
Affected to the radio signals.
08. Explain Alkaline Battery with neat diagram and cell reactions.
Anode
Cathode
Electrolyte
Zinc body
Carbon rod / Graphite rod
Powdered KOH, MnO2 in the form of paste.
Alkaline battery consists of electrolyte KOH and a Zinc cylinder filled with powdered Zn, KOH and
MnO2 in the form of paste using starch and water. A carbon rod [Graphite] acts as a cathode and it
is immersed in the electrolyte in the centre of the cell. The outside cylindrical zinc body acts as an
anode.
At Anode
: Zn+2OH -
--- Zn(OH)2 + 2e -
Advantages:
i.
Zinc doesnt dissolve in a basic medium.
ii.
Its life is longer than dry battery because there is no corrosion on Zn.
iii.
It maintains its voltage, when the current is drawn from it.
Uses:
It is used in calculators and watches.
Pb/Pb(SO)4//H2(SO)4(aq)/PbO2/Pb
Anode
Cathode
Electrolyte
Lead - Pb
Lead Oxide PbO2
Sulphuric acid - H2(SO)4
At Anode
: Pb(S) +SO 42
PbSO 4 + 2e -
Overall
: Pb(S) PbO 2(S) 2H 2SO4( aq )
2PbSO 4( S ) 2H 2O Energy
-----------------------------------------------------------------------------------------------
Advantages:
(i). It is made easily.
Uses:
(i). Used in automobiles like Car, Bus, Van, Lorry, Bike etc.
(ii). Used in Hospitals, Power stations, Telephone exchanges etc.
Cd/Cd(OH)2//KOH(aq)/NiO2/Ni
Anode
Cadmium (Cd)
Cathode
Electrolyte
KOH
Cell Reaction:
At Anode
: Cd(S) +2OH -
discharging
Cd(OH)2 +2e-
charging
discharging
charging
Ni(OH)2 +2OH -
discharging
Overall
: Cd(S) NiO 2(S) 2H 2O
Cd(OH)2 Ni(OH)2 Energy
charging
----------------------------------------------------------------------------------------------Recharging: When an current is passed opposite direction, the cell reaction is reversed. As a
result, Cd gets deposited on anode and NiO2 on cathode.
Charging
Discharging
Cd(S) NiO2(S) 2H 2O
Advantages:
(i). It is smaller and lighter.
(ii). It has longer life than lead storage cell.
Uses:
(i). It is used in calculators, Electronic devices.
(ii). Used in transistors, cordless appliances.
Anode
Lithium (Li)
TiS2
Polymer
Li+ + e-
: Li(S)
Li++ TiS-2
LiTiS2
Discharging:
When the anode is connected to cathode, Li+ ions move from anode to cathode.
Anode is Li and cathode is TiS2 and the electrolyte is solid polymer. The cathode is a material
capable of receiving the Lithium ions and electrons.
Recharging:
LiTiS2
Li+ + TiS-2
12. Explain Hydrogen- Oxygen Fuel cell / [H2 O2] Fuel cell.
Fuel Cell: It is a device in which the chemical energy of the fuel hydrogen is directly
converted into electricity without combustion.
Anode
Hydrogen
Cathode
Oxygen ( oxidizer)
Electrolyte
At Anode
: H 2 +2OH -
--- 2H 2 O+ 2e -
1
O +H 2O+2e --- 2OH 2 2
---------------------------------------------------------------------1
Overall
: H 2 O2
--- H 2 O
2
--------------------------------------------------------------------At Cathode :
02. Write short notes on (i). Grinding Wheel (ii).Abrasive paper and cloth.
(i). Grinding Wheel : It is manufactured by mixing abrasive grains with binder. The mixture
ismoulded and heated and cured.
Uses: It is used for the removal of scales from iron surfaces, cutting
tool sharpening.
(ii). Abrasive paper and cloth: The role of paper or cloth is made to pass through a series of
rollers and a thin coating of glue is applied on its upper side.
It is then passed then under a hopper from which the grit of
abrasive is allowed to fall and spread evenly on the glued
paper or cloth. Then it is dried in warm drying room. Finally it
is allowed to age for few days so that the glue sets firmly.
03. Define refractories. What are its characteristics? Explain with classification and
itsproperties.
Refractories: Refractories are materials that can withstand very high temperature without
softening or decomposition in shape.
(i). Drying Zone: Upper part of the kiln - About 400oc, water in slurry gets evaporated.
(ii). Calcination zone: Center part of the kiln - About 1000oc, limestone gets decomposed
intoCaO and CO2. CaCO3 ----- CaO + CO2
(iii). Clinkering Zone: Lowest part of the kiln - About 1350-1500oc, limestone reacts with
clay to form Bogue compounds. C2S,C3S,C3A,C4AF.
The Bogue compounds fuse together to form small, hard, grayish
coloured stone like mass called cement clinkers.
3. Grinding : The hot clinkers are cooled with atmospheric air and then pulverized together
with 2-3% gypsum in ball mills. Gypsum act as retarding agent for quick setting
cement.
4. Storage and Packing: The cement coming out of the grinding mill is stored in a concrete
storage silos. Then the cement is packed in jute bags by automatic
machine.
Chemical reactions:
(i). Flash set When cement is mixed with water, hydration of C3A takes place and the paste
becomes quite rigid within a short time.(1 Day)
C3 A + 6H2O C3A.6H2O
(II). Formation of Tobermonite gel: After the hydration of C3A, C3S begins to hydrate to give
Tobermonite gel and crystalline Ca(OH)2. This is responsible for the development of initial strength
of cement. The hydration of C3S gets completed within 7 days. It does not contribute much to the
strength of cement.
C4 AF + 7H2O C3A.6H2O
Thus the final setting and hardening of cement is due to the formation of tobermonite gel plus
crystallization of Ca(OH)2 and hydrated tricalcium aluminate.
08. Write short notes on special cements like waterproof and white cement.
(i). Waterproof cement:
It is obtained by adding water- proof materials like calcium stearate, aluminium stearate and
gypsum with tannic acid to ordinary Portland cement during grinding.
Functions:
Properties:
(i). It is more expensive than ordinary Portland cement.
(ii). It act as pore-blocking and water- repelling agent.
Uses:
(i). Used in the construction bridges and structures under water.
(ii) Volatile matter: After the analysis of moisture content, the crucible with residual coal sample is
converted with lid & it is heated upto 950C for 7 minutes.
% of Volatilemater incoal=
(iii) Ash content: After the analysis of volatile matter the crucible with coal sample is heated without
lidupto 750C for 30 minutes.
(iv)Fixed carbon: It is determined by the subtracting the sum total of moisture, volatile & ash
content from 100.
% of fixed carbon in coal = 100 - % of (moisture content + volatile matter + ash content)
H2O
% of Hydrogen in coal =
18
2. Nitrogen: It is carried out by Kjeldahls method.A known amount of coal is heated with Con.
H2SO4 in presence of K2 SO4 catalyst in a long necked flask called Kjeldahls flask. Nitrogen is
converted into ammonium sulphate. Then it is heated with NaOH& absorbed by HCl.
% of Nitrogen in coal = 1.4 X
3. Sulphur: A known amount of coal is completely burnt in a bomb calorimeter. Here sulphur is
converted into sulphate& treated with BaCl2, BaSO4 is obtained.
BaCl 2
S+O 2 SO4-
BaSO4 % of Sulphur in coal = weight ofBaSO4obtained X 32 X 100
Weight of coal sample
233
32
233
In order to (i) Increase the thermal efficiency of the carbonization process &
(ii) Recover the valuable by products by this method.
This oven consists of a number of silica chambers.
Each chamber is about 10-12 m long, 3-4 m height & 0.4 0.45m wide.
Coal is introduced into the silica chambers & heated 1200C by air & producer gas.
I & IV regenerators are heated by hot flue gases & II & III regenerators are heated by
incoming air &producergas.
When the process is complete, the coke is removed & cool by with water.
Time taken for this process is 12-20 hours.
The yield of the coke is about 70%
From out coming flue gas, it gives valuable products like Tar, ammonia, benzene. H 2S are
obtained.
Recovery of by products:
(i) Tar: the flue gases are first passed through a tower, in which liq. NH 3 is sprayed, tar is
collected at the bottom of the tank.
(ii) Ammonia: The gases are then passed through 2nd tower, in which water is sprayed & NH3
gets in the form of NH4OH.
(iii) Naphthalene: The gases are again passed through next tower, cooled water is sprayed,
Naphthalene gets & condensed.
(iv) Benzene: The gases are passed through next tower, petroleum oil is sprayed, benzene gets
condensed.
(v) H2S gas: The remaining gases are then passed through a purifier, H2S gas is obtained.
The final gas left out is called coal gas.
Advantages:
(i) Valuable by product like NH3, benzene, etc are obtained.
(ii) The carbonization time is less.(iii) Heating is done by extremely by producer gas.
Input
Powdered coal + Ni Oleate catalyst + Heavy oil are made into paste + H2
Heating in
400 - 450C.
Pressure
200-250atm.
The water gas producer consists of a tall steel vessel, lined with refractory bricks.
It is provided with cup & cone feeder at the top & side opening for water gas exists.
At the bottom it is provided with 2 inlet pipes for passing air & steam.
When steam & little air is passed alternatively over a red hot coke maintained
at about 900-1000C in a reactor, water gas is produced.
Two steps of reaction in production of water gas:
Step 1: C
+ H2O
CO + H2. ENDOTHERMIC
Coke
steam
water gas
Here the steam is passed through red hot coke, where CO & H2 gases are produced.
The reaction is endothermic.
Step 2: C + O2
CO2. EXOTHERMIC.
Uses:
1. It is used for preparation of power alcohol.
2. For the production of H2& in synthesis of NH3.
3. To manufacture synthesis petrol in Fischer Tropsh process.
The producer gas producer consists of a tall steel vessel, lined inside with refractory bricks.
It is provided with cup & cone feeder at the top & side opening for producer gas exit.
At the bottom it is provided with an one inlet for passing air & steam.
When a mixture of air & steam is passed over a red hot coke at 1100C in a reactor,
the producer gas is produced.
C
+
Coke
(O2 +N2)
from air
CO + N2.
producer gas
Uses:
It is a used as a reducing agent in metallurgical operations.
Apparatus: It consists a horizontal tube. At one end this tube, U tube containing fused CaCl2 is
connected through 3 way stop cock. The other end is connected with a graduated burette. The
horizontal tube is also connected with 3 different absorption bulbs I, II, III for absorbing CO2, CO
and O2.
I bulb: It contains KOH solutions & it absorbs CO2 only.
II bulb: It contains Alkalinepyrogallol solution & it absorbs CO2, & O2
III bulb: It contains Ammoniacal cuprous chloride solution & it absorbs CO 2,CO& O2
The 3 way stop cock is connected with flue gas supply & it is sucked into the burette & it is
adjusted by 100cc. then the 3 way stop cock is closed. In bulb I, co 2 is absorbed by KOH solution
& I is closed & II stopcock is opened, O2 is absorbed by alkaline pyrogallol solution. Now II is
closed & III is opened. CO is absorbed by ammonical cuprous chloride. The decrease in volume
of the flue gas in the burette indicates the volume of I CO2, II O2,
III COrespectively.
Significance: It gives an clear idea about the complete or incomplete process.