Prepared by: Von Joby Romero; Roel Deduyo

CPI Question Bank Controls fermentation in making wine

Carbon monoxide Powerful poison and major product in
(CO) synthesis gas
Quiz 1
Produced by heating NH4NO3 used as
INDUSTRIAL GASES Nitrous oxide (N2O)
anesthetics
pertains to the production and use of
Cryogenics CHLORO-ALKALI INDUSTRIES; SODA ASH,
extremely cold at temperature below -100oC
solid form used for refrigerating and freezing CAUSTIC SODA AND CHLORINE
CO2
food against bacteria spoilage Present synthetic process for the
Solvay process
Carbonated manufacture of soda ash
largest use of liquid form of CO2
beverages Process that uses salt, limestone and coke
synthesis gas in NH3 production, production with NH3 cyclic reagent
CO2 manufacturing of SNG, production of ethanol by Past method in soda ash manufacture by
LeBlanc process
fermentation, recovery from natural wells roasting salt cake with carbon and limestone
important gaseous material for chemical and Caustic soda
H2 Produced by causticization of soda ash
petroleum industries (NaOH)
derived from carbonaceous material, Process in the production of Cl2 by treating
Deacon process
hydrocarbons and water HCl
electrolysis of water, steam-hydrocarbon Process in the production of Cl2 which uses
Weldon process
H2 manufacturing reforming, partial oxidation, coal gasification, expensive MnO2
ammonia cracking, catalyst Chlorine Use entirely for bleaching processes
Consist of passing direct current through an Baking soda Produced by treating soda with CO2 in
Electrolysis
aqueous solution (NaHCO3) contacting tower
Nickel Catalyst for H2 production Electrolysis of Process used in production of caustic soda
Process in H2 production that can accept brine and chlorine at same time
Partial oxidation
liquid hydrocarbon feedstock Major advantage is that it can run on dilute,
Diaphragm cell
O2 Major use in production of steel fairly impure brine
Produced by liquefaction and rectification of Operates on a more concentrated brine
Membrane cell
air; less in electrolysis of water produces purer and concentrated product
Major use is gaseous blanket free from O2 Mercury cell Cell operation that does not require energy
N2
gas Sodium Employed as a disinfectant that is produced
Largest consumption is the production of hypochlorite by the reaction of Cl2 with caustic soda
ammonia Has 2.5 times bleaching power than chlorine
preserves the flavour of packed foods by Sodium chlorite produced from reaction of Cl2 with calcium
reducing chemical action chlorate
Air rare gases Argon, neon, krypton and xenon PETROLEUM PROCESSING
Produced by distillation of liquid air Product of natural changes in organic
Argon Used in metallurgic processes Petroleum
materials over millennia
Neon Filler in gas for display lights Shale oil chemically combined with rock
Krypton Light bulbs filler Kerogen
material
Helium, acetylene, sulfur dioxide, carbon Most desirable petroleum component anti-
Other gases Iso-paraffin
monoxide, nitrous oxide knocking property
Used in aerospace application because of its n-paraffin Have poor anti-knocking properties
Helium
lifting power Petroleum constituent that is produced in
Prevents nitrogen narcosis Olefin
cracking
Used with oxygen to give high welding Lack instability and reactivity because of the
Acetylene (C2H2) temperature and in the manufacture of Cycloalkanes
molecular configuration
industrial chemicals Aromatic Has very excellent anti-knocking property
Reaction of CaC2 with water; cracking of Sulfur Undesirable component of petroleum
natural gas Bottle gas Compressed gas stored in cylinders
Sulfur dioxide Aviation gasoline, motor gasoline, napthas,
Burning of sulfur in sulfur ores Light distillates
(SO2) petroleum solvent and kerosene
Prepared by: Von Joby Romero; Roel Deduyo
Intermediate hydroxide procedures similar to those for NaOH
Furnace oils, diesel fuels and gas oils
distillate Potassium its greatest use is in photographic emulsion
Lubricating oil, waxes, heavy oil and cracking bromide and photoengraving
Heavy distillate the fruit residue left after pressing fruits for
stock Pomace
juice
It includes asphalt, residual fuel oil, coke and
Residues the major ingredient of fertilizers which make
petrolatum Fixed nitrogen
intensive food production possible
Separation and It is the base from which virtually all nitrogen-
Two branches involved in refining process Ammonia
conversion containing products are derived
Breaking down of large hydrocarbon to Haber process use in ammonia synthesis
Cracking is the volume of gases, corrected to standard
smaller molecule by heat
Space velocity conditions that pass over one volume of
Polymerization Linking of similar molecules
catalyst per unit time
Union of olefin with aromatic or paraffinic It has the highest nitrogen content available
Alkylation
hydrocarbon in a solid fertilizer (46%). Used as a protein
Urea (NH2CONH2)
Mild process in the presence of hydrogen, food supplement for ruminants, in melamine
Hydrotreating and desulfurizes improves color, reduces productions
metallic contamination It is a mixture of TNT and granular
Amatol
Conversion of hydrocarbon into aromatic ammonium nitrate
Catalytic reforming
compounds
Hydrogen fluoride
Catalyst used in alkylation Quiz 3
and sulfuric acid
CERAMIC INDUSTRIES
Pottery making One of the most ancient of human industries
Quiz 2 Clay Ceramic product used as fillers
POTASSIUM, PHOSPHORUS AND NITROGEN Clay, feldspar and Raw materials used in ceramic products,
sand known as triaxial
INDUSTRIES Kaolinite Basic clay mineral
Stomach poisons are lethal to insects which ingest the Bentonite Clay used when very high plasticity is desired
Contact Potash, soda, lime Three common type of feldspar
kill following simple bodily contact
insecticides Mullite Only stable compound of alumina and silica
Fumigants act on the insect’s respiratory system Refractories Ceramic products that are resistant to heat
use of hormones that cause abnormalities to Based on selected grades of clay bonded
Genetic control Whitewares
develop, ultimately causing the insect’s death together
hydrocyanic acid most widely used fumigant Process in producing ceramic products with
Used inside plastic tents for treating citrus Glazing
high luster
trees and is highly effective in the glass Mixing equipment used in manufacture of
house Ball mill/ blunger
cements where clay and cement are mixed
sylvite KCl Equipment for the removal of iron contents of
halite NaCl Magnetic separator
slurry used for ceramic
langeinite K2SO4·2MgSO4 Process for the mass production of simple
a natural mixture of sylvite and halite and Jiggering round objects ceramics like cups, saucers
sylvinite
langbeinite and plates
selectively remove potassium from soil, Ceramic industries Alumina, Borax, other mineral materials
Plants acting as potash concentrators and denuding
the soil of potassium
PORTLAND CEMENTS, CALCIUM, AND
Metallic potassium prepared by electrolysis of fused KOH COMPOUND MAGNESIUM
Muriate potash potassium chloride at 97% purity Type of materials use in production of
Calcium and silica
Salt separators use to removed suspended salts from liquors Portland cement
used in refining sylvinite to produce Chief strength producing constituent of
Flotation Tricalcium silicate
potassium chloride cement
prepared by the reaction of potassium Portland cement Cement for general construction
Potassium
sulphate with sulfuric acid. Used as a flux for
bisulfate Lime Product of calcination of lime
ceramics.
Potassium is made by the electrolysis of KCl using Gypsum Hydrated calcium sulfate, a mineral that
Prepared by: Von Joby Romero; Roel Deduyo
occurs in large scale deposit throughout the Agar-agar A mucilaginous substance extracted from
world (Japanese gelatin) seaweed
Lime industries CaO, CaCO3, gypsum, concrete Animal gelatin Obtained by hydrolysis from collagen
GLASS INDUSTRIES Animal glue Oldest type of adhesives
Widely applied in woodworking industry and
Soda ash, salt
Casein glue in the manufacture of drinking cups, straws,
cake, limestone In manufacture of glass, the required flux are
etc.
and silica
Albumin adhesives Adhesive made from both eggs and blood
Process of holding a mass of glass above a
Annealing certain critical temperature low enough to Glues first used for large-scale industrial
Starch adhesive
reduce internal strain by plastic flow application
It is a rigid undercool liquid having no definite PULP AND PAPER INDUSTRIES
Glass melting point and sufficiently high viscosity to Major component of woody plants and is
Cellulose
prevent crystallization constantly replaceable
Sand, lime and Papyrus First paper appeared
Major ingredient of glass
soda ash Uses sulfate as make-up chemical for
Kraft process
Allowing molten glass sufficient time for cooking liquor
Finning bubbles to rise and leave or dissolved in Lignin Matrix that cements cellulose fibers together
glass Cannot be used because of difficulty to be
Bark
bleached
Softwood
Quiz 4 Preferred because it has longer fibers
(coniferous)
FOOD AND FOOD BY-PRODUCT Citric acid Product not obtained from wood
Added to paper to improve resistance to
PROCESSING INDUSTRIES Sizing
penetration of liquids
Converting sugar from its plant source to
Refining Sulfite pulping Pulping process that produces white pulp
common food product
Constituent of wood that is made of
Process of converting grain into flour by Hemicellulose
Milling disordered array of several sugar polymer
mechanical means
NSSC Use less chemical in pulping
Long term storage by heat treatment and
Canning Makes the paper stronger, more uniform,
sealing into air-tight containers Beating
denser, and more opaque
Processes that partially dehydrates foods
Concentration Added to paper to improve resistance to
that has high percentage of water Sizing
penetration of liquids
Process conditions severe enough to kill or
Sterilization completely inactivate all microorganisms by
intense heat treatment
Pasteurization Partial sterilization of food products
Fermentation Decomposition of carbohydrates
Involves the action of microorganism on
Putrefaction
protein
Radiation without causing undesirable protein
Irradiation
denaturation or appreciably altering the taste
Use to treat fruits before drying to prevent
SO2
browning
Food processing that prevent deterioration
Packaging
during storage by insects, molds and yeast
Leather One of the oldest commodities known
Leather, gelatin,
Food by-products
adhesives
Process of treating animal skin to produce
Chrome tanning
leather
Organic nitrogenous, colloidal protein
Gelatin
substance
Prepared by: Von Joby Romero; Roel Deduyo
Problem solving
In problem solving, one must be familiar with the process involved.
Also, some terms asked were too ambiguous leading to missing path
in solving the problem. Here are some terms essential in solving
problems in CPI.
CONVERSION
Conversion is amount of reactant reacted per amount fed.
YIELD
Yield is the amount of product formed per amount of product must be
formed at complete conversion of reactant.
SELECTIVITY
Selectivity is the amount of desired product formed per amount of
undesired products formed.
EFFICIENCY OF UTILIZATION
It is the amount of reacted reactant per amount of fresh reactant fed.
Sometimes, problem solving in ammonia industry involve terms such
as active oxygen, fixed nitrogen and free nitrogen.
 Active oxygen – these are oxygen present in the product
side in the form of nitrogen oxides (e.g. NO2, N2O4, NO3)
and oxygen gas (O2)
 Fixed nitrogen – nitrogen from nitrogen oxides
 Free nitrogen – nitrogen from nitrogen gas (N2)
TECHNIQUES
One technique usually used in industrial process calculation is the
ratio method. In this process, the ratio of the composition will serve
as the correcting factor in order to obtain the desired specie. For
example, given that O2 and N2 formed in stream X is 22.5% and
18.5% respectively and given that N2 is a tie component (not reacted)
in the process with a feed rate of 77.6 mol/s, then
( )
Some problems require atomic balances especially when producing
streams that have different products formed. However, the problem
with this type of solution is that it must satisfy the required degrees of
freedom in order to form solvable equations. The degrees of freedom
equation is given below.
Some solved problems related to industrial application are shown
below.
PROBLEM 1. CAUSTICIZATION OF SODA ASH
The caustization of soda ash follows the reaction
Na2CO3 + CaO + H2O  NaOH + CaCO3
1000 kg of 30% (wt) aq Na2CO3 reacts with excess CaO. After the
reaction, the CaCO3 sludge is separated from the NaOH liquor.
Assuming complete reaction and negligible amount of Ca(OH)2 in the
resulting liquor, what is the percentage wt NaOH in the resulting
liquor.
PROBLEM 2. COMBUSTION
200 moles of C2H6 was burned using 200 moles of O2 with 50%
conversion of the limiting reactant. How much of each reactant and
product is present at the end?
PROBLEM 3. CEMENT INDUSTRIES
Cement reactant feed containing 20% clay and 80% limestone are
fed in a kiln to form Portland cement. The clay has a composition of
72% SiO2, 16% As2O3, 7% Fe2O3, 1.7% K2O and 3.3% Na2O. On the
other hand, the limestone is 95% CaCO3 with balanced impurities.
Upon reaction, it was found out that CO2 evolved at a rate of 1250
m3/h at a condition of 1000oC and 1 atm. Calculate the feed rate of
the clay, feed rate of limestone and wt% of Fe2O3 in the Portland
cement.
PROBLEM 4. AMMONIA SYNTHESIS
In ammonia synthesis, ammonia achieves a hundred per cent
conversion to form N2 and H2 at 293 K and 1.8 atm. The volume of
liquid ammonia used, with a specific gravity of 0.817, is 50 L.
Calculate the resulting volume of N2 and H2 produced.
PROBLEM 5. AMMONIA SYNTHESIS
Fresh feed with a composition of 75.8% H2, 23.7% N2 and 0.5% inert
are fed into converter. After converting to ammonia, it will be fed to
an absorber where essentially, all NH3 are absorbed. The resulting
stream containing 10% N2 is recycled back and mixed with the fresh
feed. The stream before the converter has a composition of 15.5%
N2. Calculate the efficiency of utilization and % conversion of N2.
PROBLEM 6. AMMONIA CONVERSION
Ammonia is converted to nitrogen oxides in the presence of air. From
the analysis of the product, it was found out that it contains 8.92%
NO, 1.05% NO2, 4.98% O2, 69.9% N2 and 15.15% H2O. Find the
Prepared by: Von Joby Romero; Roel Deduyo
amount of fixed N2 per 100 mol of free N2 and find the amount of
active O2 per 100 mol of free N2.

PROBLEM 7. CEMENT INDUSTRY

Limestone with composition 51.5% CaO, 2.6% MgO, 43.4% CO2 and
1.1% H2O is fed and burned to a kiln with natural gas containing 94%
CH4 and 6% C2H6. The resulting kiln gas has a composition of
18.57% CO2, 1.93% O2 and 79.5% N2. The lime product is 93.6%
MgO + CaO and 6.4% CO2. Calculate the kg of lime produced per m3
of natural gas used for burning. The natural gas is at STP.

PROBLEM 8. FOOD INDUSTRY

Fresh orange juice contains 12.0 wt% solids and the balance water
and concentrated orange juice contains 42.0% wt solids. Initially, a
single evaporation process was used for the concentration but
volatile constituents of the juice escaped with the water leaving the
concentrate with a flat taste. The present process overcomes this
problem by bypassing the evaporator with a fraction of the fresh
juice; the juice that enters the evaporator is concentrated to 58.0 wt%
solids and the product is mixed with the bypassed fresh juice to
achieve the desired final concentration of solids. Calculate the
amount of concentrated juice produced per 100 kg of fresh juice fed
and the fraction of the feed that passed the evaporator.

Flow Chart
In drawing flow charts, one must consider all the given conditions.
Also, one must be strict from what is stated. In contrast, one should
also explore process either by adding or modifying streams that
should be ‘understood’ even no stated. For instance, it is stated that
sludge is filtered, and the resulting solid is burned on another unit
operation. It should be noted that addition of filtrate (liquid) stream
must be included although not stated.