Ipca Laboratories Process Engineer Interview Questions and Answers

Q1. Scale up technology
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Q2. Reaction kinetic
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Q3. Crystallisations and about PAT tool
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Q4. Heat and mass balance
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Q5. PFD and P&ID drawing along with BFD
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Just basic questions for first round, no second round

Q1. Aptitude test and other behavioral questions
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Q1. 1. Filtration rate calculation 2. Distillation time calculation 3. Case studies
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Q1. Explain about chemical engineering thermodynamics
Ans. 
Chemical engineering thermodynamics is the study of energy and its transformations in chemical processes.
• It involves the application of thermodynamic principles to chemical systems and processes.

• It focuses on understanding and predicting the behavior of chemical reactions and the flow of energy in chemical systems.

• It helps in designing and optimizing chemical processes for efficient energy utilization.

• It includes topic...read more
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Q1. Distillation, process calculation, unit process,unit operation
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About aptitude and core related such as mass heat and fluid operations

Q1. Why you want to place in this job
Ans. 
I am interested in this job because it aligns with my skills and interests in process management.
• I have a strong background in process management and have successfully implemented process improvements in my previous roles.

• I am highly organized and detail-oriented, which are essential skills for a Process Associate.

• I enjoy analyzing data and identifying areas for improvement in processes.

• I am motivated by the opportunit...read more
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Q2. What are you future plans after hiring you
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I plan to grow within the company and take on more responsibilities.
• I aim to develop my skills and knowledge in the process associate role.

• I would like to take on additional tasks and projects to contribute more to the team.

• I hope to build strong relationships with colleagues and learn from their expertise.

• I am open to opportunities for advancement and promotion within the company.

• I will actively seek feedback and work...read more
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30 Min test related to organic chemistry and Medicinal Chemistry.

Q1. Different Chemical reactions their Mechanism of action. NMR, Mass spectroscopy etc.
Ans. 
Chemical reactions involve the breaking and forming of chemical bonds to create new substances. NMR and mass spectroscopy are analytical techniques used to study these reactions.
• Chemical reactions involve the breaking and forming of chemical bonds between atoms.

• Nuclear Magnetic Resonance (NMR) spectroscopy is used to study the structure and dynamics of molecules by analyzing the magnetic properties of atomic nuclei.

• Mas...read more
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Q1. What is tip speed, and how do you calculate it from the laboratory to the pilot plant?
Ans. 
Tip speed is the speed at the outer edge of a rotating object, calculated by multiplying the radius by the angular velocity.
• Tip speed is the speed at the outer edge of a rotating object.

• It is calculated by multiplying the radius of the object by the angular velocity.

• In the laboratory, tip speed can be calculated using the formula: Tip Speed = 2 * π * Radius * RPM.

• In the pilot plant, the same formula can be used to calc...read more
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Q2. What are heat transfer and mass transfer, and what is their significance?
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Heat transfer is the movement of heat from one place to another, while mass transfer is the movement of mass from one place to another. Both are important in various engineering processes.
• Heat transfer involves conduction, convection, and radiation.

• Mass transfer involves diffusion, convection, and molecular diffusion.

• Significance of heat transfer includes maintaining temperature in chemical reactors, HVAC systems, etc.

• ...read more
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Q3. What actions have you taken in troubleshooting?
Ans. 
I have taken various actions in troubleshooting, including analyzing data, conducting experiments, and collaborating with team members.
• Analyze data to identify potential issues

• Conduct experiments to test hypotheses

• Collaborate with team members to brainstorm solutions

• Utilize problem-solving skills to troubleshoot complex problems
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Q4. What are Power Number and Flow Number?
Ans. 
Power Number and Flow Number are dimensionless numbers used in fluid mechanics to characterize the flow behavior of fluids in different systems.
• Power Number is a dimensionless number used to characterize the power consumption in a mixing system. It is defined as the ratio of the power input to the fluid to the product of the impeller speed, impeller diameter, and fluid density.

• Flow Number is a dimensionless number used...read more
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Q5. How do the P/V ratio and tip speed affect the selection of scale-up, and what criteria do you use for this selection?
Ans. 
P/V ratio and tip speed impact scale-up selection in process engineering.
• P/V ratio affects the level of shear stress in the system, influencing mixing and reaction rates.

• Higher tip speeds can lead to increased shear forces and heat generation, impacting product quality.

• Selection criteria include desired mixing intensity, heat transfer requirements, and shear sensitivity of the product.

• For example, in pharmaceutical man...read more
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Q6. What is HAZAOP, and what is the procedure for it?
Ans. 
HAZOP stands for Hazard and Operability Study, a systematic method to identify potential hazards and operability issues in a process.
• HAZOP is a structured and systematic examination of a process to identify potential hazards and operability issues.

• It involves a team of experts analyzing the process step by step to identify deviations from the design intent.

• The team uses guide words such as 'no', 'more', 'less', 'as wel...read more
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Q7. What is your job role?
Ans. 
As a Process Engineer, my job role involves designing, implementing, and optimizing industrial processes to ensure efficiency and quality.
• Designing and implementing processes to improve efficiency and quality

• Optimizing existing processes to reduce costs and increase productivity

• Troubleshooting issues and implementing solutions to improve process performance

• Collaborating with cross-functional teams to ensure smooth oper...read more
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Q8. What calculations do you perform when transferring a new product from the lab to the plant?
Ans. 
Calculations include scale-up factors, equipment sizing, material compatibility, process optimization, and cost analysis.
• Determine scale-up factors to ensure the lab process can be replicated in the plant

• Size equipment appropriately for the larger scale production

• Check material compatibility with plant equipment and process conditions

• Optimize the process parameters for efficiency and quality

• Conduct cost analysis to det
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Q9. How to calculate distillation rate?
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Distillation rate can be calculated by dividing the amount of distillate collected by the time taken to collect it.
• Calculate the amount of distillate collected in a given time period.

• Divide the amount of distillate by the time taken to collect it to get the distillation rate.

• Express the distillation rate in units such as liters per hour or gallons per minute.
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