60+ Deccan Fine Chemicals Interview Questions and Answers

Distillate product purity is influenced by factors such as feed composition, operating conditions, column design, and efficiency of separation processes.

• Feed composition - The composition of the feed entering the distillation column will directly impact the purity of the distillate product.

• Operating conditions - Factors such as temperature, pressure, and flow rates play a crucial role in determining the purity of the distillate product.

• Column design - The design of the distil...read more

To increase scrubber capacity, consider upgrading equipment, optimizing process parameters, and expanding physical space.

• Upgrade existing scrubber equipment to handle higher capacities

• Optimize process parameters such as flow rates and chemical dosages

• Expand physical space to accommodate larger scrubber units

• Consider implementing advanced technologies like automation and monitoring systems

• Consult with experts in the field for recommendations and best practices

To increase pump head without modifying existing pump, adjust system parameters like pipe diameter, pump speed, or impeller size.

• Increase pump speed to increase head

• Use a larger impeller to increase head

• Reduce pipe diameter to increase head

• Optimize system layout to reduce head losses

Boiling point of unknown liquid can be measured using a variety of methods including distillation, gas chromatography, and boiling point apparatus.

• Use a distillation setup to heat the liquid and collect the vapor at different temperatures to determine the boiling point.

• Perform gas chromatography to separate the components of the liquid and identify the boiling point of the unknown liquid.

• Utilize a boiling point apparatus which heats the liquid gradually until it reaches its b...read more

I am interested in research areas related to sustainable energy, process optimization, and materials science.

• Sustainable energy

• Process optimization

• Materials science

An orifice meter is a device used to measure the flow rate of a fluid, while valves and distillation columns are important components in process engineering.

• Orifice meter is a type of flow meter that uses a constriction in the flow path to create a pressure drop, which is then used to calculate the flow rate.

• Different types of valves include gate valves, globe valves, ball valves, butterfly valves, and check valves. Each type has its own specific applications and characterist...read more

Different types of flow reactors include continuous stirred tank reactors, plug flow reactors, and packed bed reactors.

• Continuous stirred tank reactors (CSTR) have continuous flow and well-mixed contents.

• Plug flow reactors have a uniform flow with minimal mixing.

• Packed bed reactors contain catalyst particles packed in a bed through which the reactants flow.

• Other types include tubular reactors, fluidized bed reactors, and membrane reactors.

The number of plates in a distillation column can be found using the McCabe-Thiele method.

• The McCabe-Thiele method involves constructing a graph of the distillation process and determining the number of theoretical plates required for separation.

• The method takes into account the vapor-liquid equilibrium data and the reflux ratio of the column.

• The number of plates can also be estimated using empirical correlations or simulation software.

• The actual number of plates required may...read more

Shaft balancing in accordance with ISO 21940-11 and ISO 21940-12 standards involves reducing vibrations by adjusting the mass distribution along the shaft.

• Shaft balancing aims to minimize vibrations in rotating machinery by adjusting the mass distribution along the shaft.

• ISO 21940-11 specifies the balancing process for rigid rotors, while ISO 21940-12 covers the balancing of flexible rotors.

• Balancing involves adding or removing weight from specific locations on the shaft to a...read more

Conduction is heat transfer through direct contact, convection is heat transfer through fluid movement, and radiation is heat transfer through electromagnetic waves.

• Conduction: Heat transfer through direct contact of particles. Example: Touching a hot pan.

• Convection: Heat transfer through fluid movement. Example: Boiling water in a pot.

• Radiation: Heat transfer through electromagnetic waves. Example: Feeling the warmth of the sun.

Net Positive Suction Head (NPSH) is the difference between the absolute pressure at the suction of the pump and the vapor pressure of the liquid.

• NPSH is a critical parameter in pump design and operation.

• It determines whether the pump will cavitate or not.

• Cavitation can cause damage to the pump and reduce its efficiency.

• NPSH is affected by factors such as fluid properties, pump speed, and suction piping design.

• NPSH can be calculated using various methods such as empirical equa...read more

Mass transfer operations involve the movement of one or more components from one phase to another.

• Distillation

• Absorption

• Extraction

• Adsorption

• Membrane separation

• Crystallization

• Drying

pH is a measure of acidity or alkalinity in a substance. Acids donate protons, bases accept protons, and chromatography techniques separate mixtures.

• pH is a scale from 0-14 to measure acidity or alkalinity

• Acids donate protons, lowering pH (0-6.9)

• Bases accept protons, raising pH (7.1-14)

• Chromatography techniques like HPLC and GC separate mixtures based on different properties

• Examples of acids: hydrochloric acid (HCl), citric acid

• Examples of bases: sodium hydroxide (NaOH), ammo...read more

A dryer is a device used to remove moisture or water content from a substance or material.

• There are several types of dryers, including air dryers, rotary dryers, spray dryers, and freeze dryers.

• Air dryers use hot air to remove moisture from materials.

• Rotary dryers use rotating drums to dry substances.

• Spray dryers use a spray nozzle to atomize liquid into a hot drying medium.

• Freeze dryers freeze materials and then remove the ice by sublimation.

• Other types of dryers include dru...read more

Equipment and safety precautions are followed for chemicals charging.

• Equipment such as pumps, hoses, and tanks are used for charging chemicals.

• Safety precautions include wearing personal protective equipment (PPE) such as gloves, goggles, and respirators.

• Chemicals are stored and handled in accordance with Material Safety Data Sheets (MSDS).

• Proper ventilation is maintained to prevent exposure to hazardous fumes.

• Spill containment measures are in place in case of accidental spil...read more

An Agitated Nutsche Filter Dryer is a type of equipment used for solid-liquid separation and drying of pharmaceuticals, chemicals, and food products.

• It is a batch filter with a mechanical agitation system

• It is used for filtration, washing, and drying of solids

• It is commonly used in the pharmaceutical industry for the production of antibiotics and other drugs

• It is also used in the chemical industry for the production of pigments, dyes, and catalysts

• It is designed to handle tox...read more

The least count diameter refers to the smallest increment that can be measured on a diameter scale.

• Least count diameter is the smallest division that can be measured on a diameter scale.

• It is typically determined by the precision of the measuring instrument being used.

• For example, if a micrometer has a least count of 0.01 mm, it means that it can measure diameter increments in 0.01 mm intervals.

Strength of materials, thermal, hydraulics, and projects

• Strength of materials refers to the study of how materials behave under different forces and loads

• Types of materials commonly studied include metals, ceramics, polymers, and composites

• Thermal engineering deals with the transfer of heat and the design of systems to control temperature

• Hydraulics involves the study of fluid behavior and the use of pumps to move and control fluids

• Projects in this context may refer to practic...read more

DC series motor needs load to limit the current flow and prevent damage.

• DC series motor has high starting torque and low resistance.

• Without load, the motor will draw excessive current and overheat.

• The load limits the current flow and prevents damage to the motor.

• Starting without load can also damage the driven equipment.

• Examples of DC series motor applications include cranes, hoists, and electric trains.

There are various types of dryers used in process engineering such as rotary, fluidized bed, spray, freeze, and vacuum dryers. Rotameter is a flow measuring device.

• Rotary dryers are used for drying materials by direct contact with hot gas.

• Fluidized bed dryers use hot air to suspend and fluidize the material to be dried.

• Spray dryers use a nozzle to atomize the liquid feed into a fine mist which is then dried by hot air.

• Freeze dryers use a process called sublimation to remove m...read more

Distillation column design principles involve understanding the separation process, heat transfer, and fluid dynamics.

• Understanding the separation process is crucial for designing an efficient distillation column.

• Consider the heat transfer requirements to ensure proper temperature control within the column.

• Fluid dynamics play a key role in determining the flow patterns and efficiency of the distillation process.

Equipment alignment involves ensuring that all components of a machine are properly positioned and oriented to work efficiently and accurately.

• Ensuring that all parts of the equipment are correctly positioned relative to each other

• Checking and adjusting the alignment of shafts, belts, gears, and other components

• Using precision tools such as laser alignment systems to achieve accurate alignment

• Proper alignment helps prevent premature wear and damage to equipment

• Examples: Align...read more

MEE flow diagram and ATFD MEE operation are related to the process of treating wastewater.

• MEE flow diagram refers to the process flow diagram of a Multiple Effect Evaporator (MEE) used in wastewater treatment.

• ATFD MEE operation refers to the operation of an Advanced Thermal Fracture Distillation (ATFD) system in conjunction with MEE.

• MEE is used to concentrate the wastewater by evaporating the water content, while ATFD is used to separate the concentrated wastewater into clean...read more

Number of theoretical plates can be calculated using the plate theory or the distillation column design equation.

• The plate theory method involves using the equilibrium data for the components being separated and the operating conditions of the column.

• The distillation column design equation method involves using the height equivalent to a theoretical plate (HETP) and the total number of plates in the column.

• Example: For a distillation column with a HETP of 0.5 ft and a total h...read more

Syanide chemical bonding involves a triple bond between carbon and nitrogen, and is highly toxic to humans.

• Syanide is a highly toxic chemical compound that can be found in various forms such as hydrogen cyanide and potassium cyanide.

• It works by inhibiting the body's ability to use oxygen, leading to cellular asphyxiation.

• Syanide poisoning can occur through ingestion, inhalation, or absorption through the skin.

• Symptoms of syanide poisoning include headache, dizziness, nausea, ...read more

Maintaining parameters of an RO plant involves regular monitoring, calibration, and cleaning to ensure optimal performance.

• Regularly monitor key parameters such as flow rate, pressure, and TDS levels to ensure they are within acceptable ranges.

• Calibrate sensors and instruments periodically to maintain accuracy in measurement.

• Perform routine maintenance tasks such as cleaning filters, membranes, and pumps to prevent clogging and ensure efficient operation.

• Keep a log of mainten...read more

The vapour compressor cycle is a thermodynamic cycle used in refrigeration systems to remove heat from a low-temperature region and transfer it to a high-temperature region.

• The cycle consists of four main components: compressor, condenser, expansion valve, and evaporator.

• During the cycle, the refrigerant undergoes phase changes from vapor to liquid and back to vapor.

• Latent heat refers to the heat absorbed or released during phase changes, such as during condensation or evapor...read more

ISO 28721-1.2019 is a code used for establishing a framework for implementing reliability-centered maintenance (RCM) in engineering.

• ISO 28721-1.2019 provides guidelines for developing maintenance strategies based on reliability-centered maintenance principles.

• It helps in identifying the most effective maintenance tasks to ensure equipment reliability and safety.

• The code outlines the process of analyzing potential failure modes, consequences, and suitable maintenance actions.

• I...read more

There are several types of electrical motors, including AC motors, DC motors, stepper motors, and servo motors.

• AC motors are commonly used in household appliances and industrial machinery.

• DC motors are often used in electric vehicles and robotics.

• Stepper motors are used in printers, scanners, and other precision equipment.

• Servo motors are used in robotics and automation applications.

• Other types of motors include linear motors, gear motors, and brushless motors.

Heat exchanger design involves determining the size, shape, and materials of the exchanger to efficiently transfer heat between two fluids.

• Consider the heat transfer rate required for the specific application

• Select the appropriate type of heat exchanger (e.g. shell and tube, plate, finned)

• Calculate the surface area needed for effective heat transfer

• Choose materials that can withstand the temperature and pressure conditions

• Optimize the flow patterns of the fluids to maximize h...read more

An ETP flow diagram and technical explanation

• ETP stands for Effluent Treatment Plant

• The flow diagram shows the process of treating wastewater before it is discharged into the environment

• The technical explanation includes the equipment and processes used in the ETP

• Examples of equipment used in ETPs include screens, clarifiers, and biological treatment systems

Distillation types include simple, fractional, and steam distillation. Drying methods include air-drying, freeze-drying, and spray-drying.

• Simple distillation is used for separating liquids with different boiling points.

• Fractional distillation is used for separating liquids with similar boiling points.

• Steam distillation is used for separating volatile compounds from non-volatile compounds.

• Air-drying involves drying a substance in the open air.

• Freeze-drying involves freezing a ...read more

Hydroquinone is a chemical compound with the formula C6H4(OH)2, commonly used in skincare products for its skin-lightening properties.

• Chemical formula: C6H4(OH)2

• Consists of two hydroxyl groups attached to a benzene ring

• Used in skincare products to lighten dark spots and hyperpigmentation

Critical speed of ball mill is the speed at which the centrifugal forces equal gravitational forces at the mill shell's inside surface.

• Critical speed is calculated by the formula: Nc = 1/(2*pi*sqrt(D/g)) where Nc is the critical speed, D is the diameter of the mill in meters, and g is the acceleration due to gravity (9.81 m/s^2).

• At critical speed, the grinding media in the mill starts rotating with the mill shell and no longer falls back, but stays on the perimeter of the mil...read more

API 510 is used for pressure vessel inspection and maintenance in accordance with industry standards.

• API 510 is a widely recognized standard for the inspection, repair, alteration, and rerating of pressure vessels.

• It ensures that pressure vessels are maintained in a safe and reliable condition.

• By following API 510 guidelines, maintenance engineers can ensure compliance with industry standards and regulations.

• Using API 510 helps in identifying potential issues early and preven...read more

A filler gauge is a tool used to measure the gap between two objects.

• Filler gauges are commonly used in maintenance to check clearances between parts

• They are typically made of a set of thin metal blades of varying thickness

• The user selects the appropriate blade that fits snugly in the gap being measured

• Filler gauges are useful for ensuring proper tolerances in machinery and equipment

I am responsible for maintaining and repairing various parts in the machinery and equipment.

• I am familiar with the different types of bearings used in machinery such as ball bearings, roller bearings, and sleeve bearings.

• I have experience in troubleshooting and replacing faulty bearings to ensure smooth operation of the equipment.

• I work closely with the procurement team to ensure we have an adequate supply of bearings in stock.

• I regularly inspect bearings for signs of wear an...read more

Heat transfer is the process of energy moving from a warmer object to a cooler object.

• Heat transfer can occur through conduction, convection, or radiation.

• Conduction is the transfer of heat through direct contact, like a metal spoon getting hot in a pot of soup.

• Convection is the transfer of heat through the movement of fluids, like boiling water in a pot.

• Radiation is the transfer of heat through electromagnetic waves, like the heat from the sun reaching the Earth.

Distillation column separates components of a liquid mixture based on differences in boiling points.

• Works on the principle of vapor-liquid equilibrium

• Liquid mixture is heated to create vapor, which rises through column

• Vapor condenses at different heights based on boiling points, separating components

• Components are collected at different points of the column

• Commonly used in oil refineries to separate crude oil into different fractions

Induction motor works on the principle of electromagnetic induction to produce rotational motion.

• A rotating magnetic field is produced by the stator winding

• This magnetic field induces current in the rotor winding

• The interaction between the magnetic field and the induced current produces torque, which causes the rotor to rotate

• The speed of the rotor is slightly less than the speed of the rotating magnetic field

• Induction motors are widely used in various applications such as fa...read more

Predictive maintenance involves using data and analytics to predict when equipment failure may occur, allowing for timely maintenance to prevent breakdowns.

• Uses data and analytics to predict when equipment failure may occur

• Helps in scheduling maintenance activities before breakdowns occur

• Reduces downtime and increases equipment reliability

• Examples include vibration analysis, oil analysis, and thermography

Extractor is a device used to remove substances from a mixture. Types of pumps include centrifugal, reciprocating, and rotary pumps. Flow refers to the rate at which a fluid moves.

• Extractor is commonly used in industries such as chemical, pharmaceutical, and food processing.

• Centrifugal pumps are commonly used for low viscosity fluids, while reciprocating pumps are used for high pressure applications.

• Flow can be measured in terms of gallons per minute (GPM) or liters per secon...read more

Relays are electrically operated switches that control high power circuits with low power signals. Types include electromechanical, solid state, and reed relays.

• Relays work by using an electromagnet to mechanically switch contacts open or closed.

• Types of relays include electromechanical relays, solid state relays, and reed relays.

• Electromechanical relays use an electromagnet to operate mechanical contacts.

• Solid state relays use semiconductor devices to switch the circuit on a...read more

ANFD problems and maintenance involve troubleshooting and maintaining equipment used in the Agitated Thin Film Dryer process.

• Regular inspection and cleaning of ANFD equipment to prevent buildup and clogging

• Monitoring temperature and pressure levels to ensure optimal operation

• Replacing worn out parts or components to prevent breakdowns

• Calibrating sensors and instruments for accurate readings

• Training staff on proper operation and maintenance procedures

• Implementing preventive ma...read more

A single line diagram is a simplified diagram that shows the electrical connections and components of a power system in a single line.

• It is used to represent the electrical system in a simplified manner.

• It shows the connections between various components like generators, transformers, circuit breakers, etc.

• It helps in understanding the overall layout of the system and how different components are interconnected.

• It is commonly used in power distribution systems and industrial ...read more

The Seandmeya reaction is a chemical reaction used in organic chemistry to synthesize aldehydes from alkynes.

• The Seandmeya reaction involves the hydroboration-oxidation of an alkyne to form an enol intermediate, which tautomerizes to the aldehyde.

• The reaction is often used in the synthesis of complex molecules and natural products.

• An example of the Seandmeya reaction is the conversion of 1-octyne to octanal using BH3 and H2O2.

• The reaction mechanism typically proceeds through ...read more

Batch distillation is a process of separating components of a mixture based on their boiling points.

• It involves heating a mixture in a batch still and collecting the vapor as it condenses.

• The components with lower boiling points will vaporize first and can be collected separately.

• The process is repeated multiple times to achieve higher purity of the desired component.

• It is commonly used in the production of alcoholic beverages and essential oils.

• Batch distillation is less eff...read more

The future of HR involves leveraging technology, focusing on employee experience, and adapting to changing workforce demographics.

• Increased use of AI and automation for recruitment and performance management

• Shift towards remote work and flexible work arrangements

• Focus on employee well-being and mental health

• Emphasis on diversity, equity, and inclusion initiatives

• Utilization of data analytics for decision-making in HR processes

Absorption is the process of taking in or soaking up something.

• Absorption can refer to the process of a substance being taken in by another substance, such as a sponge absorbing water.

• In the context of finance, absorption costing is a method of allocating all costs to the cost of production.

• In the context of pharmacology, absorption refers to the movement of a drug from its site of administration into the bloodstream.

Centrifuge problems can range from imbalance to motor issues, affecting sample separation and overall performance.

• Check for proper balance of samples in the rotor

• Inspect the motor for any signs of damage or malfunction

• Ensure the centrifuge is on a level surface to prevent imbalance

• Clean and maintain the centrifuge regularly to prevent buildup of debris

• Consult the manufacturer's manual for troubleshooting tips

Mechanical seals are devices that help prevent leakage between two surfaces in relative motion.

• Mechanical seals are commonly used in pumps, compressors, and other rotating equipment to prevent leakage of fluids.

• They consist of two main parts - a stationary element and a rotating element, which are held together by tension to create a seal.

• The seal faces are typically made of materials like carbon, ceramic, or tungsten carbide to withstand the friction and heat generated durin...read more

The cost of bearing parts can vary depending on the type, size, and quality of the bearing.

• Bearing parts can range from a few dollars to hundreds of dollars, depending on the specific requirements.

• Factors such as material, size, precision, and brand can all impact the cost of bearing parts.

• For example, a standard ball bearing for a small appliance may cost around $5, while a high-precision ceramic bearing for a specialized industrial machine could cost hundreds of dollars.

Accidents can be controlled through proper training, hazard identification, safety protocols, and regular inspections.

• Provide comprehensive safety training to all employees

• Conduct regular hazard assessments to identify potential risks

• Implement and enforce strict safety protocols and procedures

• Perform regular safety inspections and audits to ensure compliance

• Encourage reporting of near misses and incidents for continuous improvement

• Invest in safety equipment and technology to ...read more

Transformers are of two types - Step-up and Step-down transformers.

• Step-up transformers increase voltage while decreasing current.

• Step-down transformers decrease voltage while increasing current.

• Other types include isolation transformers, autotransformers, and instrument transformers.

• Isolation transformers are used to isolate a circuit from the power source.

• Autotransformers have a single winding and are used for voltage regulation.

• Instrument transformers are used to measure v...read more

Handle acidic chemicals with proper protective equipment and in a well-ventilated area.

• Wear appropriate personal protective equipment such as gloves, goggles, and lab coat.

• Work in a well-ventilated area to prevent inhalation of fumes.

• Use a fume hood or chemical safety cabinet when working with concentrated acids.

• Always add acid to water, not water to acid, to prevent splashing and potential burns.

• Have a neutralizing agent on hand in case of spills, such as baking soda or a co...read more

API STD 610 is a standard for centrifugal pumps for petroleum, petrochemical, and natural gas industries.

• API STD 610 specifies requirements for centrifugal pumps used in the petroleum, petrochemical, and natural gas industries.

• It covers design, materials, testing, and performance of centrifugal pumps.

• The standard also includes guidelines for pump selection, installation, operation, and maintenance.

• API STD 610 helps ensure safe and efficient operation of centrifugal pumps in t...read more

HIRA stands for Hazard Identification and Risk Assessment, while HAZOP stands for Hazard and Operability Study.

• HIRA is a systematic process for identifying hazards and assessing risks associated with a process or operation.

• HAZOP is a structured and systematic examination of a planned or existing process or operation to identify and evaluate problems that may represent risks to personnel or equipment.

• HIRA involves identifying potential hazards, analyzing the risks, and impleme...read more

Heat exchangers are devices used to transfer heat between two or more fluids.

• Heat exchangers are commonly used in various industries such as power plants, chemical plants, and HVAC systems.

• There are several types of heat exchangers including shell and tube, plate, and finned tube heat exchangers.

• Shell and tube heat exchangers consist of a shell with multiple tubes inside, allowing one fluid to flow through the tubes while the other fluid flows around them.

• Plate heat exchanger...read more

Refrigeration system is a mechanical system that removes heat from a space to lower its temperature.

• Refrigeration systems use a refrigerant to absorb and release heat.

• The basic components of a refrigeration system include a compressor, condenser, expansion valve, and evaporator.

• Examples of refrigeration systems include air conditioning units, refrigerators, and freezers.

Starters are used to control the starting and stopping of motors. Types include DOL, star-delta, soft starters, and VFDs.

• Direct-On-Line (DOL) starters provide full voltage to the motor at start-up

• Star-Delta starters reduce the voltage during start-up to reduce inrush current

• Soft starters gradually increase the voltage to the motor to reduce inrush current and mechanical stress

• Variable Frequency Drives (VFDs) control the speed and torque of the motor by varying the frequency a...read more

Types of level transmitters include ultrasonic, radar, capacitance, and differential pressure.

• Ultrasonic level transmitters use sound waves to measure the distance between the sensor and the liquid surface.

• Radar level transmitters use electromagnetic waves to determine the level of the liquid.

• Capacitance level transmitters measure the change in capacitance between two electrodes as the liquid level changes.

• Differential pressure level transmitters measure the pressure differen...read more

Unit operation involves physical changes while unit process involves chemical changes in a system.

• Unit operation involves physical changes like separation, filtration, etc.

• Unit process involves chemical changes like reactions, synthesis, etc.

• Unit operation is a single step in a process while unit process involves multiple steps.

• Examples of unit operations include distillation, crystallization, etc.

• Examples of unit processes include oxidation, hydrolysis, etc.

The part of a lanyard that attaches to the wearer's clothing or equipment.

• The part of a lanyard that attaches to the wearer's clothing or equipment is called a clip or hook.

• It is important for the clip or hook to be secure and properly attached to prevent accidents.

• Examples of clips or hooks used on lanyards include carabiners, snap hooks, and swivel hooks.