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CHEMICAL ENGINEERING REFRESHER COURSE

UNIT OPERATIONS II

1. When a stream of bulk solids enters a screener, the solids are spread across the screen deck as a result of the vibratory or gyratory
motion of the device. For a particle to pass through the screen, the particle must first pass through the bed of solids to be presented
to an aperture on the screen deck. The overall probability of passage of a given particle size through the screen is
𝒙 𝟐
𝒘 𝟏−
where: Po = PaPbPc Pa = Pb = [ 𝒘
𝒅 ] Pc = (%F)
𝒍𝒑 𝟏+
𝒘
w = aperture size
lp = thickness of particle layer
x = particle size
d = wire size
F = fines
Calculate the expected time for passage if a screener is operating at 60 Hz with a 400 μm particle through a 26 mesh TBC screen
where the percentage of fines is 83% and the layer thickness on the screen is 12 mm. For a 26 mesh TBC screen, the aperture
size is 787 μm and the wire size is 190.5 μm.
A. 2 s C. 15 s
B. 10 s D. 20 s
2. A zinc mineral slurry consists of ore particles and water in the volumetric ratio of 1:4. The volumetric ratio of zinc mineral (specific
gravity = 3.8) to ore particles (specific gravity = 2.6) is 0.4. The mineral particles are 0.009 inch in diameter. If the particles of
zinc minerals are settling under gravity and take the viscosity of water as μ = 8.1 x 10-4 lb/ft-s, the terminal velocity of the particle is
A. 0.34 ft/s C. 0.063 ft/s
B. 0.036 ft/s D. 0.088 ft/s

3. For a solid spherical particle of 0.8 mm in diameter and a density of 2,600 kg/m 3 that is immersed in a fluid of density 1,200 kg/m3
and a viscosity of 1.0 cp, the terminal velocity is
A. 8.39 m/s C. 9.75 m/s
B. 0.0975m/s D. 0.00839 m/s

4. Partition ratios can be particularly sensitive to temperature when mutual solubility between the feed and extraction solvent involves
hydrogen bonding. An interesting example is the extraction of citric acid from water using 1-butoxy-2-propanol as a solvent. Its
partition ratio at a temperature of 40°C is
A. 0.6 C. 0.3
B. 0.4 D. 0.25

5. A substance added to a dispersion of fine particles in a liquid to promote the formation of aggregate of particles is called
A. (A). flocculant C. collectors
B. (B). frothers D. modifiers

6. A crusher is fed with limestone having particles of 2.0 cm median equivalent diameter and discharges a product consisting of 0.5 cm
median equivalent diameter. The equipment operates at a capacity of 1.2 x 10 4 kg/h consuming a power of 10 Hp. If the
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requirements of the process demand a finer size of product (0.4 cm of median equivalent diameter) decreasing the capacity to 1.0 x
104 kg/h, the theoretical consumption under the new conditions using Kick’s law is
A. 0.746 kW C. 7.2 kW
B. 8.2 kW D. 5.8 kW
7. What is the bowl diameter of a tubular type sedimenting centrifuge with the following specifications and performance characteristics:
speed = 15,000 rev/min, liquid throughput rate = 0.2 – 20 gal/min and typical motor size = 3 Hp?
A. 4.125 in C. 1.75 in
B. 5.0 in D. 6 in
8. A mixture of oil (specific gravity = 0.88) and air consists of drops of oil with a diameter of 4.5 x 10 -5 ft. If a settling time of 80
seconds is allowed, find the maximum height of the chamber required for the oil drops to settle. Take density and viscosity of
air as 0.075 lb/ft3 and 1.2 x 10-5 lb/ft-s respectively.
A. 0.68 ft. C. 2.9 ft
B. 1.52 ft. D. 1.32 ft
9. The oil-solvent solution obtained by leaching of vegetable seeds is
A. miscible liquid C. carrier solvent
B. adhering solution D. miscella
10. The power required to move an empty belt conveyor is
𝑳
P= 𝑪𝟏 𝑽𝑩𝑺 + 0.0295 (0.4 + ) 𝝎 + 𝟗. 𝟔𝟗 𝒙 𝟏𝟎−𝟑 ∆𝒁 𝝎
91.42
Where: P = total power requirement in kW
C1 = constant for specific belt width and length
VBS = speed of belt in m/s
L = horizontal length of the conveyor in meters
𝜔 = mass flow rate of solid material in kg/s
A cement clinker solid with a bulk density of 1600 kg/m3 is to be transported a horizontal distance of 365 m up an incline of 5°. The
troughed belt conveyor has been selected to handle 101 kg/s of this material with a running angle of repose of 19°. A 0.61 m
troughed belt conveyor with an indicated slope angle of 20° and operating at a normal speed of 1.52 m/s has a capacity of 99.9
kg/s. If C1 = 4.6 kW-s/m, the power requirement in kW for this solids transport is
A. 45.3 C. 61.4
B. 51.3 D. 38.3
Problems 11 to 13 are based on the following information:
A vertical tank with an 6 ft. inside diameter contains 15 tons of ground coke. The ground coke is 60 mesh (0.0098 inch in diameter)
and has a density of 80 lb/ft3. The minimum porosity for fluidization, Ɛf for a particle size of 60 mesh is 0.6. If the coke is to be
fluidized with air of density ρ = 0.583 lb/ft3 and viscosity μ = 2.2 x 10-5 lb/ft-s, calculate the following:
11. The minimum height of the bed is
A. 25 ft. C. 18 ft
B. 33.2ft D. 10 ft
12. The pressure drop in the bed is
A. 6.5 psi C. 4.6 psi
B. 7.32 psi D. 5.5 psi
13. The critical velocity of air for the fluidization is
A. 1.79 ft/s C. 0.28 ft/s
B. 0.82 ft/s D. 1.31 ft/s
14. A type of fluidization where the fluidized bed resembles a liquid with rising gas bubbles and a sedimentation velocity higher than the
bulk of bed with hindered sedimentation.
A. Turbulent fluidization C. Particulate fluidization
B. Aggregative fluidization D. Continuous fluidization

15. Particles of sphalerite (specific gravity = 4.0) are settling under the force of gravity in carbon tetrachloride (CCl 4) at 20°C (specific
gravity = 1.594 and viscosity = 1.03 cp). The diameter of the sphalerite particles is 0.1 mm. The volume fraction of sphalerite in
CCl4 is 0.2. The hindered settling velocity of the sphalerite is
A. 7 cm/s B. 4 cm/s
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C. 8 cm/s D. 2 cm/s

16. The step in mineral ore flotation where low concentrated product is returned for repeated flotation.
A. scavenger concentrate C. rougher flotation
B. scavenger flotation D. final concentrate

17. Permeability or permeability factor maybe predicted from particle size (surface-volume average) and packing voidage. It is also a
function of gas viscosity and its uniformity. A course material such as wheat has a high permeability with no air retention capability.
The permeability factor of wheat is
A. 0.1 C. 0.1 to 1.0
B. 0.01 – 0.1 to 1.0 D. > 1.0

18. The mutual solubility of two salts can be plotted on the X and Y axes with temperatures as isotherm lines. If both solid-phase KCl
and NaCl are present, the solution composition at equilibrium can only be represented by the invariant point (at constant pressure).
The solubility ratios in parts per 100 parts water of KCl and NaCl at 100°C are:
A. 34.3 and 27 C. 35 and 27.5
B. 20.4 and 28.4 D. 22.6 and 31.4

19. It is desired to recover lead from an ore containing 10% lead sulfide (PbS) and the balance assumed to be silica, 500 tons of ore
being treated per 24 hr-day. It is assumed that the concentrate from a single cell is of acceptable purity but the tailings are to be
retreated in scavenger cells with return of scavenger concentrate to the rougher. Laboratory findings indicate that if the water to
solids ratio L/S = 2.0 and the contact time is 8 min in the rougher and L/S = 4.0 for 15 min in scavenger with mechanically agitated
machines of the Denver type. The following compositions will be found for the various products:
PbS SiO2
Feed 10% 90%
Final Concentrate 80% 20%
Rougher Tailings 2% 98%
Scavenger Concentrate 11% 89%
Final Tailings 0.5% 99.5%
The densities of PbS and SiO2 are 7.5 and 2.65 g/cc respectively.
The volume needed in the rougher is
A. 420 ft3 C. 240 ft3
B. 650 ft 3 D. 350 ft3

20. A concentrate from an evaporator system is 5,870 kg/h of 35 wt. % MgSO 4 at 83°C and 173 kPa. It is mixed with 10,500 kg/h of
saturated aqueous recycle filtrate of MgSO4 at 27°C and 173 kPa. The mixture is sent to a vacuum crystallizer operating at 30°C
and 4 kPa, to produce steam and magma of 25 wt.% crystals and 75 wt.% saturated solution of 28 wt.% MgSO 4. The MgSO4 is
crystallized as heptahydrate. At 83°C, the solubility of MgSO4 is 39 wt.% and at 27°C, the solubility of MgSO4 in water is 27.5 wt. %.
The water evaporated is
A. 1,490 kg/h C. 3,720 kg/h
B. 11,30 kg/h D. 11,160 kg/h

Problems 21 and 22 are based on the following information:

It is desired to separate a mixture of crystals into three fractions, a coarse fraction retained on an 8 mesh screen, a middle fraction
passing an 8 mesh but retained on a 14 mesh screen and a fine fraction passing a 14 mesh. Two screens in series are used, an 8
mesh and 14 mesh, conforming to the Tyler standard. Screen analyses of feed, coarse, medium and fine fractions are shown in the
table below.
The aperture for mesh numbers 8 and 14 are 2.362 mm and 1.168 mm respectively.
Screen Mesh Feed Coarse fraction Middle fraction Fine fraction
3/4 to 6/8 46 88 40 ----
8/14 39.5 12 49.1 46.7
14/20 to 35/48 14.5 ---- 10.9 53.3
Total 100 100 100 100
On the basis of 100 MT of feed to the first screen per hour,
21. The mass of the intermediate material produce per hour is
A. 29.4 MT C. 60.2 MT
B. 41.9 MT D. 14.5 MT
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22. The area required for the bottom screen if the shaking screen has a capacity of 4 MT per hr-m2-mm is
A. 11.6 m2 C. 26.1 m2
B. 10.6 m 2 D. 16.1 m2

23. A method for the determination of specific surface of a granular material, based on measurement of adsorption of a neutral gas at
low temperature
A. BET C. Langmuir
B. Freundlich D. Toth

24. A spherical tank 20 ft. in diameter is subjected to a maximum wind load of 90 miles per hour. The force exerted on the tank by the
wind, if the viscosity of the air is 0.017 cp.; the density of the air is 0.073 lb/ft3 and that the area exposed to the force is the flat end
of a horizontally positioned cylindrical tank 20 ft. in diameter is
A. 1520 lb C. 1240 lb
B. 960 lb D. 1450 lb

25. The average work index of lead sulfide in kWh/ton is

A. 25.17 C. 9.76
B. 12.77 D. 10.19

26. A counter-current leaching equipment is to be used to extract NaOH from a feed consisting of 80 kg NaOH, 400 kg water and
100 kg CaCO3 using water as solvent. The final extract solution will contain 10% NaOH with the recovery of 95% of the NaOH.
Setting the underflow constant at 3.0 kg solution per kg CaCO3, the number of ideal stages required is
A. 4.0 C. 7.0
B. 2.0 D. 5.0

27. The data below were obtained on the operation of a 6-mesh (square) hummer screen at the tipple of a coal mine. The screening
was done to separate a very fine refuse from a fine coal stream so that it could be reprocessed.
Feed to Screen, 131 tons per hour Underflow from Screen, 9.8 tons
(Approximately 5% Moisture) Overflow from Screen per hour (Dry Solids)
Size Sample Weight Size Sample Weight Size Sample, %
+1/4 in 3825 grams +1/4 in 2905 grams ¼ x 6 mesh 11.3
¼ x 6 mesh 1006 ¼ x 6 mesh 767 6x8 7.8
6 x 14 750 6 x 14 405 8 x 14 6.9
14 x 28 303 14 x 28 117 14 x 28 8.6
28 x 48 219 28 x 48 68 28 x 48 3.3
48 x 0 807 48 x 0 278 48 x 0 62.1

The screen effectiveness is

A. 34.14% C. 44.13%
B. 54.6% D. 78.3%
28. A crystallizer that is characterized by the production of supersaturation in a circulating stream of liquor is
A. evaporative C. scraped surface
B. oslo surface cooled D. classified suspension

Problems 29 and 30 are based on the following information:

A recycled furfural stream is used to extract benzene from a cyclohexane product stream. The product stream flows at 100kg/h and
contains 10% by weight benzene. The solvent stream flows at 150 kg/h and contains 0.01 weight % benzene. The distribution
coefficient for benzene in the two phases is 0.68, based on the mass fraction of solute. It is desired to reduce the benzene content
in the product stream to less than 1.0 weight % benzene. Assume cyclohexane and furfural are immiscible.
29. The composition of raffinate in a single stage extraction is most nearly
A. 6.8 weight % benzene and 93.2 weight % furfural
B. 6.8 weight % benzene and 93.2 weight % cyclohexane
C. 5.0 weight % benzene and 95 weight % cyclohexane
D. 7.35 weight % benzene and 92.65 weight % furfural
30. The raffinate flow rate in a single stage extraction is most nearly
A. 155 kg/h C. 96.6 kg/h
B. 107.4 kg/h D. 94.7 kg/h
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31. It is desired to extract aniline from water using toluene as extraction solvent at 25°C. The partition ratio is
A. 39.8 C. 2.2
B. 12.9 D. 36

32. A tube of 0.05 m2 cross sectional area is packed with spherical particles to a height of 0.25 m. The porosity of the bed is 0.35. It is
desired to fluidize the particles with water (ρ = 1000 kg/m3, µ = 10-3 Pa-s). The minimum velocity of fluidization is given by the
Ergun’s equation:
∆P 𝑫𝒑 𝝐𝟑 𝟏𝟓𝟎 𝝁 (𝟏 − 𝝐)
= + 𝟏. 𝟕𝟓
𝑳 𝝆 𝒇 𝒗𝟐 𝟏 − 𝝐 𝑫𝒑 𝝆𝒇 𝒗
Data: Diameter of particles = 0.01 m
Density of solid particles = 2600 kg/m3
The minimum velocity of fluidization in m/s is
A. 0.059 C. 0.56
B. 0.035 D. 0.0035

33. A solution of NH4Cl is saturated at 70°C. Calculate the temperature to which this solution must be cooled to crystallized out 45% of
the NH4Cl. The solubilities of NH4Cl in water are:
Temperature °C 70 10 0
Solubility, g/100 g H2O 60.2 33.3 29.4

A. 11.5 °C C. 5.3 °C
B. 9.5 °C D. 15.3 °C

34. The work index of galena material with an impact crushing resistance of 21.21 ft-lbf per in of thickness that is fed to a jaw crusher is
A. 18.45 kW-h/ton C. 9.76 kW-h/ton
B. 10.19 kW-h/ton D. 12.37 kW-h/ton

35. Ten kg of a solid containing 45% of a soluble material were treated with 15 kg of a solvent containing the same solute at 2%
concentration in a vessel under constant agitation. After a long time, the solution and solid were separated by pressing. The solid
analyzed contain 0.8 kg of solvent per kg of inert solid. The extract quantity obtained in kg was therefore
A. 14.8 C. 13.7
B. 15.1 D. 18.4

36. A solution of Na2SO4 in water is saturated at 50°C. When a saturated solution of Na2SO4 is cooled, crystals of Na2SO410H2O
separate from the solution.
Temperature °C Solubility of Na2SO4, g/100 g H2O
50 46.7
10 9.0

If 1000 kg of this solution is cooled to 10 °C, the percentage yield obtained is nearly
A. 91 C. 75
B. 90 D. 80
37. The solubility of dibasic potassium phosphate in water at 25°C is _____parts per 100 parts water.
A. 53 C. 25
B. 33 D. 48
38. In a determination of solution retention data, the mass fraction of the solute in the extract was determined to be 0.7. The
corresponding underflow analysis showed a retention of 0.5 kg solvent per kg of the inert solid. The mass fraction of the solute in
the underflow is most likely
A. 0.68 C. 0.23
B. 0.78 D. 0.44

39. The terminal settling velocity in water at 70°F of a particle with a specific gravity of 2.0 and diameter of 100 microns is ____ ft/s
A. 0.0135 C. 0.081
B. 0.00175 D. 0.018
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40. The viscosity of methyl propionate is ____cp at 40°C

A. 0.24 C. 0.65
B. 0.38 D. 0.55

41. The data on a leaching system show that the locus of the underflow compositions is a straight line and passes through the vertex
representing the solute. Which of the following statement is true?
A. The solvent retained by the inert in kg per kg of inert is constant.
B. The solution retained by the inert in kg per kg of inert is constant.
C. The system is non-ideal and there is solute adsorption by the inert.
D. The tie lines will not pass through origin in representing inert (I= 1.0).

42. A suspension of glass beads in ethylene glycol has a hindered settling velocity of 17 mm/s while the terminal settling velocity in a
single glass bead in ethylene glycol is 1.7 mm/s. If the Richardson and Zaki hindered settling index is 4.5, the void fraction of solids
in the suspension is
A. 0.1 C. 0.61
B. 0.4 D. 0.9

43. The composition of feed and underflow (percent solids) in the design of a typical thickener for the flue gas desulfurization sludge
process are
A. 0.2 – 2.0 and 30 - 70 C. 3 -4 and 45 - 50
B. 6 - 8 and 50 - 54 D. 3 - 12 and 20 – 45

44. The following tie line data were obtained for a ternary system of solute B, extract solvent S and raffinate solvent A at a temperature
of 25 °C.
Raffinate Layer, Weight % Extract Layer, weight%
B 35 52.5
S 57.5 24.6
A 7.5 22.9
The selectivity at this tie line is very nearly
A. 3.51 C. 0.68
B. 6.74 D. 1.0

45. The terminal velocity of spherical air bubbles with an average diameter of 1 mm rising in pure water is _____cm/s
A. 14 C. 5.0
B. 22 D. 41

46. A certain circular plate of diameter, D and thickness, t has a sphericity of 0.594. The ratio of t to D is
A. 0.333 C. 1.333
B. 0.166 D. 0.666

47. The surface area and sorptive capacity of bituminous coal based carbon adsorbent are between ______km 2/kg dry solid and
between ______ kg/kg dry solid respectively
A. 0.9 to 1.2 and 0.4 C. 0.8 to 1.6 and 0.5
B. 0.4 to 0.7 and 0.3 D. 0.8 to 1.6 and 0.4

48. We wish to extract nicotine from water using kerosene. If we have 100 kg of 2% nicotine solution extracted once with 200 kg
kerosene, what percentage of the nicotine will be extracted? Given that at equilibrium:
𝑘𝑔 𝑛𝑖𝑐𝑜𝑡𝑖𝑛𝑒 𝑘𝑔 𝑛𝑖𝑐𝑜𝑡𝑖𝑛𝑒
𝑦, = 0.9 𝑥,
𝑘𝑔 𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 𝑘𝑔 𝑤𝑎𝑡𝑒𝑟
A. 56.5% C. 46.5%
B. 64.75% D. 74.6%

49. In order to produce fine solid particles between 5 and 10 microns, the appropriate size reduction equipment is
A. fluid energy mill C. jaw crusher
B. hammer mill D. smooth roll mill
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50. An oil water separator for coconut oil mill is being designed by the plant’s chemical engineer to remove coconut oil from the mill’s
effluent water. Experiments have shown that with the specific gravity differential between coconut oil and water the rising velocity of
coconut oil globules in water is 0.0945 m/min. Practice has shown that for the separator to be effective the following parameters hold:
Water velocity along the separator, Vh = 0.91 m/min
Depth of water separator, D = 0.3 B
(where B is the width of the separator)
If 230 m3 of effluent water is to be handled per hour, the length of the separator in meters is
A. 11 m C. 9 m
B. 15 m D. 1.125 m

51. The following equilibrium relationship was obtained during the treatment of an aqueous solution of a valuable solute by decolorizing
carbon for removal of coloring impurities: Y = 8.91 x 10-5 X1.66
where X = adsorbate concentration per kg of carbon and Y = equilibrium color units per kg of solution measured on an arbitrary
scale proportional to the concentration of the colored impurity.
It is proposed to reduce the color of the solution to 20% of its original value of 9.0. The quantity of fresh carbon required per 100 kg
of the solution in single stage operation is
A. 4.18 kg C. 7.2 kg
B. 5.6 kg D. 1.84 kg

52. A tower having a diameter of 0.1524 m is being fluidized with water at 20.2°C. Water at 20.2°C has a density = 997.5 kg/m3 and
viscosity = 1 x 10-3 Pa-s. The uniform spherical beads in the tower bed have a diameter of 4.42 mm and a density of 1603 kg/m3.
The minimum fluidizing velocity is
A. 0.52 m/s
B. 0.026 m/s
C. 0.312 m/s
D. 0.082 m/s

Problems 53 to 55 are based on the following information:

A viscous solution containing particles with a density of 1461 kg/m3 is to be clarified by centrifugation. The solution density is
801 kg/m3 and its viscosity is 100 cp. The centrifuge has bowl with r2 = 0.02225 m,r1 = 0.00716 m and bowl height of 0.197 m.
The centrifuge rotates at 23,000 rev/min and the flow rate is0.002832 m3/h.

53. The critical particle diameter of the largest particle in the exit stream is
A. 0.747 μm
B. 0.537 μm
C. 0.868 μm
D. 0.477 μm

54. The physical characteristic of the centrifuge (area of the gravitational settler), Σ is
A. 169.1 m2
B. 196.1 m2
C. 296.1 m2
D. 259.1 m2

55. A new centrifuge having the following dimensions is to be used: r 2 = 0.0445 m, r1 = 0.01432 m, b = 0.394 m and N = 26,000 rev/min.
The new scale up flow rate using the same solution is
A. 5.08 x 10-4 m3/s
B. 8.77 x 10-5 m3/s
C. 8.05 x 10-3 m3/s
D. 8.05 x 10-6 m3/s