Chemical Reaction Engineering (CRE) – Technical & Situational Questions

Interviewer:

1. What is the difference between homogeneous and heterogeneous reactions?

Candidate:

• Homogeneous reactions occur in a single phase (e.g., gas-phase combustion).

• Heterogeneous reactions occur in multiple phases (e.g., catalytic cracking).

Interviewer:

2. Define rate of reaction and write its general expression.

Candidate:
The rate of reaction is the change in concentration of reactants or products per unit
time.

For a reaction A→BA \to B:

r=kCAnr = k C_A^n

where kk = rate constant, CAC_A = concentration of reactant, and nn = reaction order.

Interviewer:

3. What are the different types of reaction orders?

Candidate:

1. Zero Order – Rate is independent of reactant concentration (r=kr = k).

2. First Order – Rate is proportional to concentration (r=kCAr = k C_A).

3. Second Order – Rate depends on the square of the concentration (r=kCA2r = k

C_A^2).

4. Fractional Order – Order is a non-integer value.

5. Negative Order – Rate decreases as concentration increases.

Interviewer:

4. What is the Arrhenius equation and its significance?

Candidate:
The Arrhenius equation gives the temperature dependence of reaction rate:

k=Ae−EaRTk = A e^{-\frac{E_a}{RT}}

where:

• AA = Pre-exponential factor

• EaE_a = Activation energy

• RR = Universal gas constant

• TT = Temperature in Kelvin

It shows that higher temperature increases reaction rate.

Interviewer:

5. What is the difference between elementary and non-elementary reactions?

Candidate:

• Elementary reaction: Follows stoichiometry directly (reaction order =

molecularity).

• Non-elementary reaction: Involves complex mechanisms with intermediate

steps.

Example:

• Elementary: A+B→CA + B \to C, Rate = kCACBk C_A C_B.

• Non-elementary: Acid-catalyzed hydrolysis, where intermediates form.

Interviewer:

6. What is activation energy?

Candidate:
Activation energy (EaE_a) is the minimum energy required for reactants to form
products.

Interviewer:

7. What is pseudo-first-order reaction?

Candidate:
A reaction that is actually of higher order but appears to be first order due to an excess
of one reactant.

Example: Hydrolysis of esters (CAC_A = limiting, CBC_B = in large excess).

Interviewer:

8. What is collision theory?

Candidate:
Reaction rate depends on:

1. Number of collisions between molecules.

2. Proper orientation of reactants.

3. Sufficient energy to overcome activation barrier.

Higher temperature and concentration increase collisions, boosting the reaction rate.

Interviewer:

9. What is the difference between molecularity and order of reaction?

Candidate:

• Molecularity: The number of molecules involved in a single-step reaction

(integer value).

• Order: Experimentally determined dependence of rate on reactant

concentration (can be fractional).

Interviewer:

10. What is the difference between batch, continuous-stirred tank reactor (CSTR),
and plug flow reactor (PFR)?

Candidate:

• Batch Reactor: No inflow/outflow, used for small-scale or batch processing.

• CSTR: Well-mixed, uniform concentration, used for liquid-phase reactions.

• PFR: Flow moves in one direction, used for high-efficiency reactions.

Interviewer:

11. What is the Thiele modulus?

Candidate:
The Thiele modulus is a dimensionless number used in heterogeneous catalysis to
determine internal diffusion limitations.

ϕ=LDk\phi = \frac{L}{D} \sqrt{k}

If ϕ>1\phi > 1 → Reaction is diffusion-limited.

If ϕ<1\phi < 1 → Reaction is kinetically controlled.

Interviewer:

12. What is the Weisz-Prater criterion?

Candidate:
It checks if a catalytic reaction is limited by diffusion by comparing the observed
reaction rate to the rate expected if diffusion were limiting.

Interviewer:

13. What is a Damköhler number?

Candidate:
The Damköhler number (Da) is the ratio of reaction rate to transport rate.

Da=Reaction RateConvective Mass Transfer RateDa = \frac{\text{Reaction

Rate}}{\text{Convective Mass Transfer Rate}}

• Da≫1Da \gg 1 → Reaction limited.

• Da≪1Da \ll 1 → Transport limited.

Interviewer:

14. What is the effectiveness factor in catalysis?

Candidate:
Effectiveness factor (η\eta) measures how effectively a catalyst is used:

η=Actual reaction rateRate if no diffusion limitations\eta = \frac{\text{Actual reaction

rate}}{\text{Rate if no diffusion limitations}}

• η=1\eta = 1 → No diffusion resistance.

 • η<1\eta < 1 → Internal diffusion limiting reaction.

Interviewer:

15. What is the difference between external and internal mass transfer in catalysis?

Candidate:

• External mass transfer: Resistance in moving reactants from bulk fluid to

catalyst surface.

• Internal mass transfer: Resistance within catalyst pores.

Situational Questions – CRE

Interviewer:

16. You observe that increasing temperature does not significantly increase reaction
rate. What could be the reason?

Candidate:
Possible reasons:

• Mass transfer limitations (external or internal diffusion).

• Enzyme or catalyst deactivation at high temperatures.

• Reversible reaction approaching equilibrium.

Interviewer:

17. Your reactor’s conversion is lower than expected. What would you check?

Candidate:

• Residence time – Short residence may lead to incomplete reaction.

• Mixing efficiency – Poor mixing can cause concentration variations.

• Temperature control – Suboptimal temperatures slow reactions.

• Catalyst activity – Catalyst may be deactivated or poisoned.

Interviewer:
 18. A reaction is not achieving expected conversion in a PFR. What could be the
issue?

Candidate:

• Short residence time – Need longer reactor length.

• Flow maldistribution – Poor velocity profile.

• Diffusion limitations – Reaction might be transport-limited.

• Incorrect kinetics assumption – Verify reaction rate expression.

Interviewer:

19. You are designing a reactor for an exothermic reaction. What factors must you
consider?

Candidate:

• Heat removal – To prevent runaway reaction.

• Temperature control – Cooling jackets, heat exchangers.

• Safety interlocks – To handle emergencies.

• Residence time – To avoid thermal hotspots.

Interviewer:

20. You need to maximize conversion in a reactor. Would you choose a PFR or CSTR?

Candidate:

• For first-order reactions → PFR is better because it maintains high reactant

concentration.

• For reactions with side reactions → CSTR is better as it provides better control.

This covers Chemical Reaction Engineering (CRE) concepts, technical details, and
troubleshooting scenarios.

Next, do you want to move into reactor-specific questions?

Reactor-Specific Questions (Technical & Situational)

1. General Reactor Knowledge

Interviewer: What are the main types of chemical reactors?

Candidate:

1. Batch Reactor – No inflow/outflow, used for batch processing.

2. Continuous Stirred Tank Reactor (CSTR) – Well-mixed, steady-state operation.

3. Plug Flow Reactor (PFR) – Flow moves in one direction, no mixing in axial
direction.

4. Packed Bed Reactor (PBR) – Catalyst-packed reactor, used in heterogeneous

catalysis.

5. Fluidized Bed Reactor – Solids behave like a fluid, enhancing mixing and heat
transfer.

6. Trickle Bed Reactor – Gas-liquid-solid reactions over a catalyst bed.

7. Membrane Reactor – Selective separation of products during reaction.

2. Batch vs. Continuous Reactors

Interviewer: When would you prefer a batch reactor over a continuous reactor?

Candidate:

• Batch reactors are preferred for small-scale, high-purity, or multi-step

reactions.

• Continuous reactors are used for large-scale, steady-state production with

consistent quality.

3. CSTR vs. PFR

Interviewer: What are the key differences between a CSTR and a PFR?

Candidate:

• CSTR: Well-mixed, lower conversion per unit volume, easier temperature

control.

• PFR: No back-mixing, higher conversion per unit volume, better for high-order
reactions.
4. Ideal Reactor Performance

Interviewer: What are the design equations for CSTR and PFR?

Candidate:

• CSTR:

V=FA0−FA−rAV = \frac{F_{A0} - F_A}{-r_A}

• PFR:

∫dFA−rA=V\int \frac{dF_A}{-r_A} = V

where VV = reactor volume, FAF_A = molar flow rate, rAr_A = reaction rate.

5. Reactor Sizing

Interviewer: How do you determine the required volume of a reactor?

Candidate:
By integrating the rate law over the required conversion and using the design equation
for the specific reactor type.

6. Residence Time and Space Time

Interviewer: Define residence time and space time in reactors.

Candidate:

• Residence Time (τ\tau) = Time a molecule spends inside the reactor.

τ=VQ\tau = \frac{V}{Q}

• Space Time (τs\tau_s) = Theoretical time for the feed to fill the reactor.

τs=VFA0\tau_s = \frac{V}{F_{A0}}

7. Multiple CSTRs vs. a Single Large CSTR

Interviewer: Why are multiple CSTRs in series sometimes preferred over a single large
CSTR?

Candidate:

• Higher conversion than a single reactor of the same total volume.

 • Better temperature control.

• Flexibility in operation and maintenance.

8. Reactor Selection for Exothermic Reactions

Interviewer: What type of reactor is preferred for highly exothermic reactions?

Candidate:

• CSTRs with cooling jackets for better temperature control.

• Fluidized bed reactors for uniform heat distribution.

• Multi-stage reactors to gradually control temperature.

9. Reactor Temperature Control

Interviewer: How do you prevent thermal runaway in a reactor?

Candidate:

• Use of cooling jackets or heat exchangers.

• Feed dilution to reduce reactant concentration.

• Intermediate cooling stages in multi-stage reactors.

• Emergency shutdown systems.

10. Packed Bed Reactor Challenges

Interviewer: What are the common problems in packed bed reactors?

Candidate:

• Pressure drop across the bed.

• Catalyst deactivation due to fouling or sintering.

• Hot spots leading to thermal runaway.

• Mass transfer limitations affecting reaction efficiency.

11. Fluidized Bed Reactor Advantages

Interviewer: Why are fluidized bed reactors preferred over packed bed reactors in some
applications?

Candidate:

• Better mixing and heat transfer.

• Reduced pressure drop.

• Self-cleaning nature prevents catalyst fouling.

• Uniform temperature distribution.

12. Reversible Reaction Reactor Selection

Interviewer: What reactor type is best for a reversible reaction where high conversion is
required?

Candidate:

• PFR for high conversion per unit volume.

• Membrane reactors to remove products and shift equilibrium forward.

• Reactors with interstage separation to remove products continuously.

13. Reactor Troubleshooting – Low Conversion

Interviewer: Your reactor is giving lower conversion than expected. What could be the
reasons?

Candidate:

• Short residence time (Increase reactor volume or reduce flow rate).

• Temperature is too low (Increase reaction temperature).

• Catalyst deactivation (Check for poisoning or sintering).

• Mass transfer limitations (Improve mixing, use a different reactor type).

14. Gas-Phase vs. Liquid-Phase Reactors

Interviewer: How do gas-phase and liquid-phase reactors differ in design?

Candidate:

• Gas-phase reactors need pressure control and proper gas mixing.

 • Liquid-phase reactors require effective agitation and heat transfer control.

15. Non-Ideal Reactor Behavior

Interviewer: What factors cause non-ideal behavior in real reactors?

Candidate:

• Dead zones or stagnant regions.

• Short-circuiting or bypassing of reactants.

• Non-uniform mixing in CSTRs.

• Axial dispersion in PFRs.

Situational Questions – Reactors

16. Reactor Failure Scenario

Interviewer: Your plant’s CSTR temperature suddenly rises beyond control limits. What
actions would you take?

Candidate:

• Immediately shut down feed supply.

• Increase cooling capacity via cooling jacket or emergency quenching.

• Check if a runaway reaction is occurring due to catalyst deactivation or

excessive reactant accumulation.

• Assess emergency pressure relief systems.

17. PFR vs. CSTR Choice

Interviewer: You are given a high-pressure gas-phase reaction. Would you prefer a PFR
or a CSTR?

Candidate:
A PFR is preferable because:

• It provides higher conversion per unit volume.

• It avoids back-mixing, maintaining high reactant concentration.

• It has better pressure handling than a CSTR.

18. Catalyst Deactivation Problem

Interviewer: Your packed bed reactor shows a steady decline in conversion. What
could be the issue?

Candidate:

• Catalyst poisoning from contaminants.

• Sintering due to high temperature.

• Coking due to carbon buildup.

• Leaching of active catalyst material.

Solution: Regenerate or replace the catalyst.

19. Heat Transfer in Reactors

Interviewer: How do you enhance heat transfer in exothermic reactors?

Candidate:

• Use external heat exchangers.

• Increase surface area with internal coils.

• Improve mixing using baffles or agitation.

• Use a fluidized bed to ensure uniform temperature.

20. Choosing a Reactor for a Slow Reaction

Interviewer: You need to design a reactor for a very slow reaction. What would you
choose?

Candidate:

• CSTR with long residence time for continuous operation.

• PFR with recycle to increase conversion.

• Batch reactor for better control over reaction time.

This concludes reactor-specific questions covering design, operation,

troubleshooting, and selection.
Reactor-Specific Questions (Technical & Situational)

1. General Reactor Knowledge

Interviewer: What are the main types of chemical reactors?

Candidate:

1. Batch Reactor – No inflow/outflow, used for batch processing.

2. Continuous Stirred Tank Reactor (CSTR) – Well-mixed, steady-state operation.

3. Plug Flow Reactor (PFR) – Flow moves in one direction, no mixing in axial
direction.

4. Packed Bed Reactor (PBR) – Catalyst-packed reactor, used in heterogeneous

catalysis.

5. Fluidized Bed Reactor – Solids behave like a fluid, enhancing mixing and heat
transfer.

6. Trickle Bed Reactor – Gas-liquid-solid reactions over a catalyst bed.

7. Membrane Reactor – Selective separation of products during reaction.

2. Batch vs. Continuous Reactors

Interviewer: When would you prefer a batch reactor over a continuous reactor?

Candidate:

• Batch reactors are preferred for small-scale, high-purity, or multi-step

reactions.

• Continuous reactors are used for large-scale, steady-state production with

consistent quality.

3. CSTR vs. PFR

Interviewer: What are the key differences between a CSTR and a PFR?

Candidate:

• CSTR: Well-mixed, lower conversion per unit volume, easier temperature

control.
 • PFR: No back-mixing, higher conversion per unit volume, better for high-order
reactions.

4. Ideal Reactor Performance

Interviewer: What are the design equations for CSTR and PFR?

Candidate:

• CSTR:

V=FA0−FA−rAV = \frac{F_{A0} - F_A}{-r_A}

• PFR:

∫dFA−rA=V\int \frac{dF_A}{-r_A} = V

where VV = reactor volume, FAF_A = molar flow rate, rAr_A = reaction rate.

5. Reactor Sizing

Interviewer: How do you determine the required volume of a reactor?

Candidate:
By integrating the rate law over the required conversion and using the design equation
for the specific reactor type.

6. Residence Time and Space Time

Interviewer: Define residence time and space time in reactors.

Candidate:

• Residence Time (τ\tau) = Time a molecule spends inside the reactor.

τ=VQ\tau = \frac{V}{Q}

• Space Time (τs\tau_s) = Theoretical time for the feed to fill the reactor.

τs=VFA0\tau_s = \frac{V}{F_{A0}}

7. Multiple CSTRs vs. a Single Large CSTR

Interviewer: Why are multiple CSTRs in series sometimes preferred over a single large
CSTR?
Candidate:

• Higher conversion than a single reactor of the same total volume.

• Better temperature control.

• Flexibility in operation and maintenance.

8. Reactor Selection for Exothermic Reactions

Interviewer: What type of reactor is preferred for highly exothermic reactions?

Candidate:

• CSTRs with cooling jackets for better temperature control.

• Fluidized bed reactors for uniform heat distribution.

• Multi-stage reactors to gradually control temperature.

9. Reactor Temperature Control

Interviewer: How do you prevent thermal runaway in a reactor?

Candidate:

• Use of cooling jackets or heat exchangers.

• Feed dilution to reduce reactant concentration.

• Intermediate cooling stages in multi-stage reactors.

• Emergency shutdown systems.

10. Packed Bed Reactor Challenges

Interviewer: What are the common problems in packed bed reactors?

Candidate:

• Pressure drop across the bed.

• Catalyst deactivation due to fouling or sintering.

• Hot spots leading to thermal runaway.

• Mass transfer limitations affecting reaction efficiency.

11. Fluidized Bed Reactor Advantages

Interviewer: Why are fluidized bed reactors preferred over packed bed reactors in some
applications?

Candidate:

• Better mixing and heat transfer.

• Reduced pressure drop.

• Self-cleaning nature prevents catalyst fouling.

• Uniform temperature distribution.

12. Reversible Reaction Reactor Selection

Interviewer: What reactor type is best for a reversible reaction where high conversion is
required?

Candidate:

• PFR for high conversion per unit volume.

• Membrane reactors to remove products and shift equilibrium forward.

• Reactors with interstage separation to remove products continuously.

13. Reactor Troubleshooting – Low Conversion

Interviewer: Your reactor is giving lower conversion than expected. What could be the
reasons?

Candidate:

• Short residence time (Increase reactor volume or reduce flow rate).

• Temperature is too low (Increase reaction temperature).

• Catalyst deactivation (Check for poisoning or sintering).

• Mass transfer limitations (Improve mixing, use a different reactor type).

14. Gas-Phase vs. Liquid-Phase Reactors

Interviewer: How do gas-phase and liquid-phase reactors differ in design?

Candidate:
 • Gas-phase reactors need pressure control and proper gas mixing.

• Liquid-phase reactors require effective agitation and heat transfer control.

15. Non-Ideal Reactor Behavior

Interviewer: What factors cause non-ideal behavior in real reactors?

Candidate:

• Dead zones or stagnant regions.

• Short-circuiting or bypassing of reactants.

• Non-uniform mixing in CSTRs.

• Axial dispersion in PFRs.

Situational Questions – Reactors

16. Reactor Failure Scenario

Interviewer: Your plant’s CSTR temperature suddenly rises beyond control limits. What
actions would you take?

Candidate:

• Immediately shut down feed supply.

• Increase cooling capacity via cooling jacket or emergency quenching.

• Check if a runaway reaction is occurring due to catalyst deactivation or

excessive reactant accumulation.

• Assess emergency pressure relief systems.

17. PFR vs. CSTR Choice

Interviewer: You are given a high-pressure gas-phase reaction. Would you prefer a PFR
or a CSTR?

Candidate:
A PFR is preferable because:

• It provides higher conversion per unit volume.

• It avoids back-mixing, maintaining high reactant concentration.

 • It has better pressure handling than a CSTR.

18. Catalyst Deactivation Problem

Interviewer: Your packed bed reactor shows a steady decline in conversion. What
could be the issue?

Candidate:

• Catalyst poisoning from contaminants.

• Sintering due to high temperature.

• Coking due to carbon buildup.

• Leaching of active catalyst material.

Solution: Regenerate or replace the catalyst.

19. Heat Transfer in Reactors

Interviewer: How do you enhance heat transfer in exothermic reactors?

Candidate:

• Use external heat exchangers.

• Increase surface area with internal coils.

• Improve mixing using baffles or agitation.

• Use a fluidized bed to ensure uniform temperature.

20. Choosing a Reactor for a Slow Reaction

Interviewer: You need to design a reactor for a very slow reaction. What would you
choose?

Candidate:

• CSTR with long residence time for continuous operation.

• PFR with recycle to increase conversion.

• Batch reactor for better control over reaction time.

This concludes reactor-specific questions covering design, operation,
troubleshooting, and selection.

Would you like to move on to reaction kinetics with real-life case studies next?
Great! Let's move on to Heat Transfer questions.

Interviewer:

1. What are the three modes of heat transfer?

Candidate:
The three modes are conduction (heat transfer through solids), convection (heat
transfer through fluids), and radiation (heat transfer via electromagnetic waves).

Interviewer:

2. What is Fourier’s Law of heat conduction?

Candidate:
Fourier’s Law states that the rate of heat conduction is proportional to the temperature
gradient and the thermal conductivity of the material:

q=−kdTdxq = -k \frac{dT}{dx}

where qq is heat flux, kk is thermal conductivity, and dT/dxdT/dx is the temperature

gradient.

Interviewer:

3. How does thermal conductivity affect heat transfer?

Candidate:
Higher thermal conductivity means faster heat transfer through a material. Metals like
copper have high conductivity, while insulators like wood have low conductivity.

Interviewer:

4. What is Newton’s Law of Cooling?

Candidate:
It states that the rate of heat loss of a body is proportional to the temperature difference
between the body and its surroundings:

q=hA(Ts−T∞)q = hA(T_s - T_\infty)

where hh is the heat transfer coefficient, AA is the surface area, TsT_s is surface
temperature, and T∞T_\infty is ambient temperature.
Interviewer:

5. What factors affect convective heat transfer?

Candidate:
Key factors include fluid velocity, fluid properties (viscosity, density, thermal
conductivity), surface geometry, and temperature difference between the fluid and
surface.

Interviewer:

6. What is the difference between natural and forced convection?

Candidate:
Natural convection occurs due to density differences caused by temperature variation,
while forced convection occurs when an external force (e.g., a fan or pump) moves the
fluid.

Interviewer:

7. What is the Nusselt number and why is it important?

Candidate:
The Nusselt number (NuNu) is a dimensionless quantity that represents the ratio of
convective to conductive heat transfer:

Nu=hLkNu = \frac{hL}{k}

where hh is the heat transfer coefficient, LL is characteristic length, and kk is thermal

conductivity. It helps determine the effectiveness of convection.

Interviewer:

8. What is the Stefan-Boltzmann Law of radiation?

Candidate:
It states that the thermal radiation emitted by a black body is proportional to the fourth
power of its absolute temperature:

q=σT4q = \sigma T^4

where σ\sigma is the Stefan-Boltzmann constant.

Interviewer:

9. What is the difference between black body and gray body radiation?

Candidate:
A black body absorbs and emits radiation perfectly (ε=1\varepsilon = 1), while a gray
body has an emissivity ε<1\varepsilon < 1, meaning it does not emit or absorb all
incident radiation.

Interviewer:

10. What is the role of heat exchangers in chemical processes?

Candidate:
Heat exchangers transfer heat between two fluids without mixing them, improving
energy efficiency in processes like distillation, cooling, and heating.

Interviewer:

11. What are the different types of heat exchangers?

Candidate:
Common types include shell-and-tube, plate, finned-tube, and air-cooled heat
exchangers. Selection depends on heat transfer efficiency, pressure drop, and space
constraints.

Interviewer:

12. What is the Log Mean Temperature Difference (LMTD) method?

Candidate:
LMTD is used to calculate the temperature driving force in heat exchangers:

LMTD=ΔT1−ΔT2ln⁡(ΔT1/ΔT2)LMTD = \frac{\Delta T_1 - \Delta T_2}{\ln(\Delta T_1 / \Delta

T_2)}

where ΔT1\Delta T_1 and ΔT2\Delta T_2 are temperature differences at two ends.

Interviewer:

13. How does the effectiveness-NTU method work?

Candidate:
It determines heat exchanger performance using effectiveness (ε\varepsilon) and the
Number of Transfer Units (NTU) without needing outlet temperatures.

Interviewer:

14. What is thermal resistance and how is it calculated?

Candidate:
Thermal resistance is the opposition to heat flow, calculated as:

R=LkAR = \frac{L}{kA}

where LL is thickness, kk is thermal conductivity, and AA is surface area.

Interviewer:

15. What is a finned surface and why is it used?

Candidate:
Fins increase the surface area for heat transfer, enhancing cooling or heating in
applications like radiators and heat sinks.

Interviewer:

16. What are the different types of boiling?

Candidate:
Types include nucleate boiling (bubble formation on heated surface), film boiling (vapor
film formation), and critical heat flux (maximum heat transfer before film boiling).

Interviewer:

17. What is the Leidenfrost effect?

Candidate:
It occurs when a liquid droplet hovers over a hot surface due to vapor formation,
reducing heat transfer efficiency.

Interviewer:

18. What is thermal expansion?

Candidate:
Thermal expansion is the increase in volume of a material when heated, which must be
considered in piping and equipment design to prevent stress and failure.

Interviewer:

19. What is the difference between heat capacity and specific heat?

Candidate:
Heat capacity is the total heat required to change a substance’s temperature, while
specific heat is the heat required per unit mass to raise the temperature by one degree.

Interviewer:

20. What is Prandtl’s number and why is it important?

Candidate:
Prandtl number (PrPr) is the ratio of momentum diffusivity to thermal diffusivity:

Pr=μCpkPr = \frac{\mu C_p}{k}

It indicates whether heat transfer is dominated by conduction or convection.

Interviewer:

21. What is the significance of the Reynolds number in heat transfer?

Candidate:
Reynolds number (ReRe) determines flow type:

• Re<2000Re < 2000 (laminar) – conduction dominates

• Re>4000Re > 4000 (turbulent) – convection dominates

Interviewer:

22. How do you calculate the overall heat transfer coefficient?

Candidate:

U=1(1h1+Lk+1h2)U = \frac{1}{\left( \frac{1}{h_1} + \frac{L}{k} + \frac{1}{h_2} \right)}

where h1h_1 and h2h_2 are heat transfer coefficients, LL is wall thickness, and kk is
thermal conductivity.
Interviewer:

23. What is the difference between steady-state and transient heat transfer?

Candidate:
Steady-state heat transfer occurs when temperatures do not change over time, while
transient heat transfer involves time-dependent temperature changes.

Interviewer:

24. What is the role of insulation in heat transfer?

Candidate:
Insulation reduces heat loss or gain by increasing thermal resistance, improving energy
efficiency in industrial processes and buildings.

Interviewer:

25. How does phase change affect heat transfer?

Candidate:
Phase changes (melting, evaporation, condensation) involve latent heat, allowing heat
transfer without temperature change, crucial in distillation and refrigeration.

Interviewer:

26. How does fouling affect heat exchanger performance?

Candidate:
Fouling (deposition of unwanted materials on surfaces) reduces heat transfer efficiency,
increases pressure drop, and requires maintenance.

Interviewer:

27. What is the purpose of cooling towers in industrial plants?

Candidate:
Cooling towers dissipate excess heat by evaporating water, maintaining process
temperatures in chemical plants, refineries, and power plants.
Interviewer:

28. How does cryogenic heat transfer differ from conventional heat transfer?

Candidate:
Cryogenic heat transfer deals with extremely low temperatures, requiring specialized
materials and insulation to minimize heat leaks.

Great! Let's move on to Heat Transfer questions.

Interviewer:

1. What are the three modes of heat transfer?

Candidate:
The three modes are conduction (heat transfer through solids), convection (heat
transfer through fluids), and radiation (heat transfer via electromagnetic waves).

Interviewer:

2. What is Fourier’s Law of heat conduction?

Candidate:
Fourier’s Law states that the rate of heat conduction is proportional to the temperature
gradient and the thermal conductivity of the material:

q=−kdTdxq = -k \frac{dT}{dx}

where qq is heat flux, kk is thermal conductivity, and dT/dxdT/dx is the temperature

gradient.

Interviewer:

3. How does thermal conductivity affect heat transfer?

Candidate:
Higher thermal conductivity means faster heat transfer through a material. Metals like
copper have high conductivity, while insulators like wood have low conductivity.

Interviewer:

4. What is Newton’s Law of Cooling?

Candidate:
It states that the rate of heat loss of a body is proportional to the temperature difference
between the body and its surroundings:

q=hA(Ts−T∞)q = hA(T_s - T_\infty)

where hh is the heat transfer coefficient, AA is the surface area, TsT_s is surface
temperature, and T∞T_\infty is ambient temperature.

Interviewer:

5. What factors affect convective heat transfer?

Candidate:
Key factors include fluid velocity, fluid properties (viscosity, density, thermal
conductivity), surface geometry, and temperature difference between the fluid and
surface.

Interviewer:

6. What is the difference between natural and forced convection?

Candidate:
Natural convection occurs due to density differences caused by temperature variation,
while forced convection occurs when an external force (e.g., a fan or pump) moves the
fluid.

Interviewer:

7. What is the Nusselt number and why is it important?

Candidate:
The Nusselt number (NuNu) is a dimensionless quantity that represents the ratio of
convective to conductive heat transfer:

Nu=hLkNu = \frac{hL}{k}

where hh is the heat transfer coefficient, LL is characteristic length, and kk is thermal

conductivity. It helps determine the effectiveness of convection.

Interviewer:

8. What is the Stefan-Boltzmann Law of radiation?

Candidate:
It states that the thermal radiation emitted by a black body is proportional to the fourth
power of its absolute temperature:

q=σT4q = \sigma T^4

where σ\sigma is the Stefan-Boltzmann constant.

Interviewer:

9. What is the difference between black body and gray body radiation?

Candidate:
A black body absorbs and emits radiation perfectly (ε=1\varepsilon = 1), while a gray
body has an emissivity ε<1\varepsilon < 1, meaning it does not emit or absorb all
incident radiation.

Interviewer:

10. What is the role of heat exchangers in chemical processes?

Candidate:
Heat exchangers transfer heat between two fluids without mixing them, improving
energy efficiency in processes like distillation, cooling, and heating.

Interviewer:

11. What are the different types of heat exchangers?

Candidate:
Common types include shell-and-tube, plate, finned-tube, and air-cooled heat
exchangers. Selection depends on heat transfer efficiency, pressure drop, and space
constraints.

Interviewer:

12. What is the Log Mean Temperature Difference (LMTD) method?

Candidate:
LMTD is used to calculate the temperature driving force in heat exchangers:

LMTD=ΔT1−ΔT2ln⁡(ΔT1/ΔT2)LMTD = \frac{\Delta T_1 - \Delta T_2}{\ln(\Delta T_1 / \Delta

T_2)}
where ΔT1\Delta T_1 and ΔT2\Delta T_2 are temperature differences at two ends.

Interviewer:

13. How does the effectiveness-NTU method work?

Candidate:
It determines heat exchanger performance using effectiveness (ε\varepsilon) and the
Number of Transfer Units (NTU) without needing outlet temperatures.

Interviewer:

14. What is thermal resistance and how is it calculated?

Candidate:
Thermal resistance is the opposition to heat flow, calculated as:

R=LkAR = \frac{L}{kA}

where LL is thickness, kk is thermal conductivity, and AA is surface area.

Interviewer:

15. What is a finned surface and why is it used?

Candidate:
Fins increase the surface area for heat transfer, enhancing cooling or heating in
applications like radiators and heat sinks.

Interviewer:

16. What are the different types of boiling?

Candidate:
Types include nucleate boiling (bubble formation on heated surface), film boiling (vapor
film formation), and critical heat flux (maximum heat transfer before film boiling).

Interviewer:

17. What is the Leidenfrost effect?

Candidate:
It occurs when a liquid droplet hovers over a hot surface due to vapor formation,
reducing heat transfer efficiency.

Interviewer:

18. What is thermal expansion?

Candidate:
Thermal expansion is the increase in volume of a material when heated, which must be
considered in piping and equipment design to prevent stress and failure.

Interviewer:

19. What is the difference between heat capacity and specific heat?

Candidate:
Heat capacity is the total heat required to change a substance’s temperature, while
specific heat is the heat required per unit mass to raise the temperature by one degree.

Interviewer:

20. What is Prandtl’s number and why is it important?

Candidate:
Prandtl number (PrPr) is the ratio of momentum diffusivity to thermal diffusivity:

Pr=μCpkPr = \frac{\mu C_p}{k}

It indicates whether heat transfer is dominated by conduction or convection.

Interviewer:

21. What is the significance of the Reynolds number in heat transfer?

Candidate:
Reynolds number (ReRe) determines flow type:

• Re<2000Re < 2000 (laminar) – conduction dominates

• Re>4000Re > 4000 (turbulent) – convection dominates

Interviewer:

22. How do you calculate the overall heat transfer coefficient?

Candidate:

U=1(1h1+Lk+1h2)U = \frac{1}{\left( \frac{1}{h_1} + \frac{L}{k} + \frac{1}{h_2} \right)}

where h1h_1 and h2h_2 are heat transfer coefficients, LL is wall thickness, and kk is
thermal conductivity.

Interviewer:

23. What is the difference between steady-state and transient heat transfer?

Candidate:
Steady-state heat transfer occurs when temperatures do not change over time, while
transient heat transfer involves time-dependent temperature changes.

Interviewer:

24. What is the role of insulation in heat transfer?

Candidate:
Insulation reduces heat loss or gain by increasing thermal resistance, improving energy
efficiency in industrial processes and buildings.

Interviewer:

25. How does phase change affect heat transfer?

Candidate:
Phase changes (melting, evaporation, condensation) involve latent heat, allowing heat
transfer without temperature change, crucial in distillation and refrigeration.

Interviewer:

26. How does fouling affect heat exchanger performance?

Candidate:
Fouling (deposition of unwanted materials on surfaces) reduces heat transfer efficiency,
increases pressure drop, and requires maintenance.
Interviewer:

27. What is the purpose of cooling towers in industrial plants?

Candidate:
Cooling towers dissipate excess heat by evaporating water, maintaining process
temperatures in chemical plants, refineries, and power plants.

Interviewer:

28. How does cryogenic heat transfer differ from conventional heat transfer?

Candidate:
Cryogenic heat transfer deals with extremely low temperatures, requiring specialized
materials and insulation to minimize heat leaks.

Would you like me to continue or focus on specific areas?

Sure! Let’s continue with more questions:

Interviewer:

1. Can you explain the difference between a centrifugal and a reciprocating

compressor?

Candidate:
Centrifugal compressors use rotational force to increase gas velocity and pressure,
while reciprocating compressors use pistons to compress gas in a cylinder.

Interviewer:
2. What is the primary advantage of using a screw compressor?

Candidate:
Screw compressors are more efficient at handling continuous flow and moderate
pressures, offering smoother operation and less pulsation compared to reciprocating
compressors.

Interviewer:
3. What is surge in a compressor system?

Candidate:
Surge is a condition where the compressor stalls due to a sudden drop in flow, causing
a reversal of gas flow and potentially damaging the compressor.

Interviewer:
4. What are the main causes of compressor failure?

Candidate:
Common causes include wear and tear of components, poor maintenance, excessive
heat, contamination, and incorrect operating conditions.

Interviewer:
5. How would you handle a compressor that’s overheating?

Candidate:
Check for clogged air filters, low coolant levels, excessive load, or improper lubrication.
Address the issue by correcting the cause and ensuring proper maintenance.
Interviewer:
6. What is a typical material used for compressor seals?

Candidate:
Common materials for compressor seals include elastomers like nitrile rubber or
fluorocarbon and metals like stainless steel for high-temperature applications.

Interviewer:
7. What is the impact of improper lubrication in a compressor?

Candidate:
Improper lubrication can lead to excessive wear, overheating, and mechanical failure
due to increased friction between moving parts.

Interviewer:
8. How do you calculate the capacity of a compressor?

Candidate:
Compressor capacity is calculated based on the volume of gas compressed per unit
time, typically measured in cubic feet per minute (CFM) or liters per second (L/s).

Interviewer:
9. What is the role of the intercooler in a multi-stage compressor?

Candidate:
An intercooler reduces the temperature of the compressed gas between stages to
increase efficiency and prevent overheating.

Interviewer:
10. Can you explain the concept of pressure ratio in compressors?

Candidate:
The pressure ratio is the ratio of the discharge pressure to the inlet pressure, indicating
the compressor's ability to compress the gas.

Interviewer:
11. How would you prevent compressor cavitation?
Candidate:
To prevent cavitation, ensure proper suction pressure, maintain adequate flow rates,
and avoid operating below the manufacturer’s minimum flow conditions.

Interviewer:
12. What is a "blow-off valve" in a compressor system?

Candidate:
A blow-off valve is used to release excess pressure or air from the system to prevent
damage to the compressor and maintain safe operating conditions.

Interviewer:
13. What types of compressors are typically used for refrigeration?

Candidate:
Reciprocating, screw, and centrifugal compressors are commonly used in refrigeration
systems depending on the size and capacity requirements.

Interviewer:
14. How does a compressor affect energy consumption in a plant?

Candidate:
Compressors are energy-intensive. Their efficiency impacts overall energy
consumption; more efficient compressors consume less energy while maintaining
output.

Interviewer:
15. What is the function of a compressor discharge valve?

Candidate:
The discharge valve controls the release of compressed gas from the compressor,
maintaining pressure and regulating the gas flow into the system.

Interviewer:
16. How do you prevent oil contamination in a compressor?

Candidate:
Regular oil changes, using the correct oil grade, ensuring proper filtration, and
monitoring oil quality are key to preventing oil contamination.
Interviewer:
17. What is "flooded lubrication" in a compressor?

Candidate:
Flooded lubrication is a method where the compressor’s moving parts are continuously
submerged in oil to reduce friction and cooling issues.

Interviewer:
18. What maintenance checks would you perform regularly on a compressor?

Candidate:
I’d check oil levels, filter conditions, seal integrity, vibration levels, and ensure proper
cooling and pressure levels.

Interviewer:
19. What is a "backflow" in a compressor system, and how is it prevented?

Candidate:
Backflow is the reversal of gas flow, typically caused by surge or a valve malfunction. It
can be prevented by ensuring proper flow rates and pressure settings.

Interviewer:
20. What role do sensors play in compressor operations?

Candidate:
Sensors monitor parameters like pressure, temperature, and vibration, helping detect
inefficiencies and alerting operators to potential failures.

Interviewer:
21. How do you deal with a compressor that is vibrating excessively?

Candidate:
Excessive vibration may indicate misalignment, unbalanced components, or wear. I’d
inspect for damage and ensure proper alignment and balance of moving parts.

Interviewer:
22. Can you explain the term "volumetric efficiency"?
Candidate:
Volumetric efficiency is the ratio of the actual volume of gas delivered by the
compressor to the theoretical volume it should deliver, reflecting how well the
compressor fills its cylinders.

Interviewer:
23. What is a common issue with centrifugal compressors at low flow rates?

Candidate:
At low flow rates, centrifugal compressors can experience surge or inefficient operation
due to the mismatch between the flow rate and the compressor’s design.

Interviewer:
24. What is the typical lifespan of a well-maintained compressor?

Candidate:
A well-maintained compressor can last anywhere from 10 to 20 years, depending on
usage, maintenance, and operating conditions.

Interviewer:
25. How would you improve the efficiency of an existing compressor system?

Candidate:
By implementing variable speed drives, performing regular maintenance, upgrading to
more energy-efficient models, and optimizing operating conditions.

Interviewer:
26. What is the difference between a compressor and a pump?

Candidate:
A compressor is designed to increase the pressure of gases, while a pump is used to
transport liquids by increasing their pressure or flow.

Interviewer:
27. What is the purpose of an air receiver in a compressed air system?

Candidate:
An air receiver stores compressed air, stabilizing pressure and allowing for intermittent
demand without overloading the compressor.
Pump-Specific Interview Questions (Chemical Engineering Focus)

These questions cover pump selection, operation, troubleshooting, and efficiency—

critical for Engro’s fertilizer, petrochemical, and LNG operations.

1. Basic Pump Types

Interviewer: What are the main types of pumps used in industrial applications?

Candidate:

1. Centrifugal Pumps – Used for large flow rates and low-viscosity fluids (e.g.,
water, chemicals, hydrocarbons).

2. Positive Displacement Pumps – Used for high-viscosity or precise flow rate

applications (e.g., slurries, polymers).

o Reciprocating Pumps (piston, diaphragm) – High-pressure applications.

o Rotary Pumps (gear, lobe, screw) – Viscous fluid transport.

3. Jet Pumps – Uses the Venturi effect for fluid movement.

4. Multistage Pumps – Used for high-pressure applications (e.g., boiler feed

water).

2. Centrifugal vs. Positive Displacement Pumps

Interviewer: How do you decide whether to use a centrifugal or a positive displacement

pump?

Candidate:

• Centrifugal pumps: Best for low-viscosity fluids and high flow rates at
relatively constant pressure.

• Positive displacement pumps: Best for high-viscosity fluids and precise flow
control.

Example:

• Engro’s cooling water and hydrocarbon transport systems use centrifugal

pumps.

• Engro’s slurry transport in fertilizer production uses positive displacement

pumps.
3. Net Positive Suction Head (NPSH) & Cavitation

Interviewer: What is Net Positive Suction Head (NPSH), and why is it important?

Candidate:
NPSH is the absolute pressure at the pump suction needed to prevent cavitation.

NPSHavailable=Patm−Pvapor−friction lossesNPSH_{\text{available}} = P_{\text{atm}} -

P_{\text{vapor}} - \text{friction losses}
NPSHavailable>NPSHrequiredNPSH_{\text{available}} > NPSH_{\text{required}}

• If NPSHavailableNPSH_{\text{available}} is too low, cavitation occurs—forming

vapor bubbles that collapse violently, causing:

o Impeller damage

o Noise and vibration

o Reduced efficiency

4. Pump Performance Curves

Interviewer: How do you interpret a centrifugal pump performance curve?

Candidate: A performance curve includes:

• Head vs. Flow rate – Shows how head decreases as flow increases.

• Efficiency curve – Identifies Best Efficiency Point (BEP).

• Power consumption – Indicates how motor power changes with flow rate.

• NPSH curve – Ensures NPSH is sufficient to avoid cavitation.

Engro optimizes pump operation by operating close to BEP to minimize energy

consumption and wear.

5. Affinity Laws for Pumps

Interviewer: What are the Affinity Laws for centrifugal pumps?

Candidate: Affinity laws show how pump performance changes with speed and
impeller diameter.

1. Flow rate vs. Speed

Q2=Q1×N2N1Q_2 = Q_1 \times \frac{N_2}{N_1}

2. Head vs. Speed

H2=H1×(N2N1)2H_2 = H_1 \times \left( \frac{N_2}{N_1} \right)^2

3. Power vs. Speed

P2=P1×(N2N1)3P_2 = P_1 \times \left( \frac{N_2}{N_1} \right)^3

If Engro needs to increase flow rate, they may increase pump speed, but must check
if NPSH is sufficient.

6. Cavitation in Pumps

Interviewer: How can you prevent cavitation in a pump?

Candidate:

1. Increase suction pressure (higher liquid level in the suction tank).

2. Reduce suction pipe length to decrease friction losses.

3. Increase pipe diameter to lower velocity and pressure drop.

4. Install an inducer to increase suction pressure.

5. Use a pump with lower NPSH requirement.

Cavitation is critical in LNG and ammonia transport, where pumps handle low-
temperature fluids.

7. Pump Priming

Interviewer: Why do some pumps need priming, and how is it done?

Candidate:

• Centrifugal pumps require priming because they cannot pump air.

• Priming methods:

1. Filling the suction pipe and pump casing with liquid.

2. Using a vacuum pump to remove air.

3. Self-priming pumps (have built-in priming chambers).

Engro uses self-priming pumps in stormwater drainage and process applications.

8. Pump Efficiency Factors

Interviewer: What factors affect pump efficiency?

Candidate:

1. Operating away from BEP increases energy loss.

2. Pump wear (erosion, corrosion) reduces efficiency.

3. Poor suction conditions cause cavitation.

4. Incorrect impeller size may cause excess power consumption.

5. Frictional losses in pipes increase system resistance.

Engro optimizes pump efficiency using Variable Frequency Drives (VFDs) and
predictive maintenance.

9. Pump Maintenance Strategies

Interviewer: What are common pump maintenance strategies?

Candidate:

1. Preventive maintenance – Regular inspections, lubrication, vibration analysis.

2. Predictive maintenance – Monitoring vibration, temperature, and power

consumption.

3. Corrective maintenance – Repairs after failures (less efficient).

Engro uses vibration monitoring to predict failures before breakdowns occur.

10. Seal & Bearing Failures

Interviewer: What are common causes of seal and bearing failures in pumps?

Candidate:

1. Mechanical seal failure:

o Dry running – No lubrication causes overheating.

o Cavitation – Pressure fluctuations damage seals.

o Misalignment – Uneven load distribution.

2. Bearing failure:

o Poor lubrication – Causes overheating and wear.

o Excessive vibration – Indicates misalignment or imbalance.

Engro’s condition monitoring systems help prevent unexpected failures.

11. Pump Startup & Shutdown Procedures

Interviewer: What steps should be followed for safe pump startup and shutdown?

Candidate:

Startup:

1. Check lubrication in bearings and seals.

2. Ensure suction valve is open and priming is done.

3. Start the pump with discharge valve closed (reduces motor load).

4. Gradually open the discharge valve after pump reaches operating speed.

Shutdown:

1. Slowly close the discharge valve to prevent pressure surges.

2. Turn off the motor and allow the pump to stop completely.

3. Close the suction valve if needed.

In Engro’s high-pressure ammonia pumps, following correct startup and shutdown

procedures prevents water hammer and mechanical damage.

12. Special Pumps in Engro’s Operations

Interviewer: What specialized pumps are used in Engro’s operations?

Candidate:

1. Cryogenic pumps – For LNG and ammonia transport.

2. Slurry pumps – For phosphate rock and urea production.

3. High-pressure reciprocating pumps – For fertilizer feed systems.

4. Diaphragm pumps – For chemical dosing in petrochemical plants.

Advanced Pump Questions for a Chemical Engineering Interview at Engro

Here are more in-depth pump questions covering design, troubleshooting, energy
efficiency, and real-world applications in Engro’s fertilizer, petrochemical, and LNG
operations.
1. Pump Classification & Selection

Interviewer: How do you select the right pump for a chemical process?

Candidate: Pump selection depends on:

1. Fluid Properties – Viscosity, corrosiveness, temperature, and presence of

solids.

2. Flow Rate & Head Requirements – Determines pump type and size.

3. Operating Conditions – Continuous vs. intermittent operation.

4. Efficiency & Energy Considerations – Choosing an efficient pump minimizes

operating costs.

5. Process Safety Requirements – Ensuring compatibility with hazardous fluids

(e.g., ammonia, LNG).

Example:
For Engro’s liquid ammonia transport, a cryogenic centrifugal pump is preferred
due to its low-temperature handling capabilities.

2. Suction & Discharge Conditions

Interviewer: What factors affect suction and discharge conditions in a pump

system?

Candidate:

1. Suction Side:

o Suction lift – If a pump is above the fluid level, priming is required.

o Suction pipe diameter – Too small causes excessive friction loss.

o Air entrainment – Leads to cavitation.

2. Discharge Side:

o System resistance – Includes friction losses, fittings, and elevation

changes.

o Valve position – Sudden closure can cause water hammer.

o Backpressure – Can overload the pump motor.

3. Pump Start-Up Failures

Interviewer: What could cause a pump to fail to start?

Candidate: Possible reasons include:

1. Electrical Issues – Faulty motor, tripped circuit breaker.

2. Mechanical Blockages – Foreign objects in impeller or pipes.

3. Airlock in Pump Casing – Requires venting or priming.

4. Suction Line Blockage – Strainer clogged or valve closed.

Example:
At Engro’s fertilizer plant, solid precipitation in slurry pumps can block suction
lines, requiring regular flushing.

4. Pump Performance Curve Interpretation

Interviewer: How do you use a pump performance curve to diagnose operational

issues?

Candidate:

1. Operating at a flow rate higher than BEP → Excessive vibration and wear.

2. Operating at a flow rate lower than BEP → Overheating and recirculation

losses.

3. High power consumption → Pump running at higher-than-required speed.

4. Flow rate lower than expected → Suction blockage or impeller damage.

5. Pump Efficiency Improvement Strategies

Interviewer: How can we improve pump efficiency in an industrial plant?

Candidate:

1. Operate near Best Efficiency Point (BEP).

2. Use Variable Frequency Drives (VFDs) to match process demand.

3. Reduce pipe friction losses (optimize pipe size, reduce bends).

4. Use energy-efficient motors.

5. Regular maintenance to avoid wear and leaks.

Engro optimizes energy use in fertilizer production by employing high-efficiency
pumps with VFDs.

6. Special Considerations for Corrosive Fluids

Interviewer: What factors should be considered when pumping corrosive fluids?

Candidate:

1. Material Selection – Stainless steel, Hastelloy, or polymer coatings.

2. Sealing System – Mechanical seals with corrosion-resistant materials.

3. Pump Design – Avoiding dead zones where corrosive fluids can accumulate.

4. Monitoring pH & temperature – Corrosion rates increase at high

temperatures.

Example:
In Engro’s urea production, pumps handling highly corrosive ammonium
carbamate require specialized coatings and seal materials.

7. Effect of Impeller Diameter on Pump Performance

Interviewer: What happens if the impeller diameter is changed?

Candidate:

• Larger impeller → Increases flow rate and head but may overload the motor.

• Smaller impeller → Reduces flow rate and energy consumption.

• Affinity Laws Apply:

Q∝DQ \propto D H∝D2H \propto D^2 P∝D3P \propto D^3

Engro uses trimming impellers to fine-tune pump performance in cooling water

circulation systems.

8. Water Hammer in Pumping Systems

Interviewer: What is water hammer, and how do you prevent it?

Candidate:
Water hammer is a pressure surge caused by the sudden closing of a valve or
stopping of a pump.
Prevention Methods:

1. Slow-closing valves to avoid pressure spikes.

2. Surge tanks or accumulators to absorb shock.

3. Variable speed drive (VSD) pumps for smooth start/stop operation.

4. Proper pipe support and anchoring to reduce vibration.

Example:
Engro prevents water hammer in firefighting water pumps by using pressure relief
valves.

9. Mechanical Seals vs. Gland Packing

Interviewer: What is the difference between mechanical seals and gland packing?

Candidate:

1. Gland Packing:

o Uses rope-like material to seal the shaft.

o Higher leakage but simple to maintain.

o Used in low-cost, non-hazardous applications.

2. Mechanical Seal:

o Uses polished rotating faces to prevent leakage.

o More reliable, lower leakage.

o Used for hazardous or high-pressure fluids (e.g., ammonia, LNG).

Example:
Engro uses mechanical seals in LNG pumps to prevent cryogenic fluid leakage.

10. Pumps in Series vs. Pumps in Parallel

Interviewer: When would you use pumps in series vs. parallel?

Candidate:

1. Pumps in Series – Used when high head is required but flow rate is moderate.

o Example: Boiler feed pumps in power plants.

 2. Pumps in Parallel – Used when high flow rate is needed at the same
pressure.

o Example: Cooling water pumps in Engro’s fertilizer plant.

11. Dry Running in Pumps

Interviewer: Why is dry running a problem in pumps?

Candidate:
Dry running means operating a pump without fluid, which causes:

1. Seal damage due to overheating.

2. Excessive friction & wear in impeller and bearings.

3. Loss of lubrication in mechanical seals.

Prevention:

• Liquid level sensors to shut down the pump automatically.

• Self-priming pumps in intermittent flow applications.

12. How Do You Handle Slurries in Pumping Systems?

Interviewer: What design modifications are needed for slurry pumps?

Candidate:

1. Larger clearances to prevent clogging.

2. Wear-resistant materials (ceramic coatings, hardened steel).

3. Lower operating speeds to reduce erosion.

4. Settling prevention – Avoid long horizontal runs to prevent solid deposition.

Engro uses centrifugal slurry pumps in phosphate rock transport for fertilizer
production.

13. What Causes High Vibration in Pumps?

Interviewer: What are the main causes of high vibration in pumps?

Candidate:

1. Pump misalignment.
 2. Worn bearings or impeller imbalance.

3. Cavitation or air entrainment.

4. Operating away from BEP.

5. Loose pipe supports.

Engro monitors pump vibration using predictive maintenance systems.

Basic Chemical Engineering Questions – Fluid Mechanics

These questions focus on fundamental fluid mechanics concepts relevant to Engro’s

industries (fertilizers, petrochemicals, LNG, and industrial processes).

1. Fluid Properties & Classification

Interviewer: Can you explain the difference between Newtonian and non-Newtonian
fluids?

Candidate:

• Newtonian fluids have a constant viscosity independent of shear rate (e.g.,

water, air, ethanol).

• Non-Newtonian fluids have a viscosity that changes with shear rate.

Examples:

o Shear-thinning (pseudoplastic): Viscosity decreases with shear (e.g.,

paint, blood).

o Shear-thickening (dilatant): Viscosity increases with shear (e.g.,

cornstarch-water mixture).

o Bingham plastic: Needs a yield stress before it starts flowing (e.g.,

toothpaste).

2. Bernoulli’s Equation & Energy Conservation

Interviewer: How would you use Bernoulli’s equation to analyze flow in a pipeline?

Candidate: Bernoulli’s equation is:

P1+12ρv12+ρgh1=P2+12ρv22+ρgh2+lossesP_1 + \frac{1}{2} \rho v_1^2 + \rho g h_1 =

P_2 + \frac{1}{2} \rho v_2^2 + \rho g h_2 + \text{losses}

I would use it to:

1. Calculate pressure drop in long pipelines (important for gas transport in

Engro’s fertilizer plants).

2. Determine velocity variations in pump systems.

3. Estimate head loss due to pipe friction using the Darcy-Weisbach equation.

4. Optimize flow rate to reduce energy consumption in Engro’s processing units.

3. Pressure Drop & Pipe Flow

Interviewer: How do you calculate pressure drop in a pipeline?

Candidate:
I use the Darcy-Weisbach equation:

ΔP=fLDρv22\Delta P = f \frac{L}{D} \frac{\rho v^2}{2}

Where:

• ff = Friction factor (from Moody chart or Colebrook equation).

• LL = Pipe length, DD = Diameter.

• vv = Flow velocity, ρ\rho = Density.

For laminar flow (Re<2000Re < 2000):

f=64Ref = \frac{64}{Re}

For turbulent flow (Re>4000Re > 4000):

Use Moody chart or Colebrook equation.

Engro’s gas transport pipelines require pressure drop analysis to optimize compressor
power and minimize energy losses.

4. Reynolds Number & Flow Regimes

Interviewer: What is Reynolds number, and why is it important in industrial fluid flow?

Candidate:
Reynolds number (ReRe) is:

Re=ρvDμRe = \frac{\rho v D}{\mu}

• If Re<2000Re < 2000: Laminar flow (smooth, low mixing, predictable).

• If Re>4000Re > 4000: Turbulent flow (chaotic, high mixing, better heat & mass
transfer).

• Between 2000 and 4000: Transition region (unstable).

In Engro’s chemical plants, knowing the flow regime helps in:

• Designing heat exchangers (turbulent flow for high efficiency).

• Sizing pipes and pumps (laminar flow to minimize frictional losses in certain
applications).

• Mixing operations in reactors and fluidized beds.

5. Pump Selection & NPSH

Interviewer: What factors do you consider when selecting a pump for an industrial
process?

Candidate: I consider:

1. Flow rate & head requirement – Using pump performance curves.

2. NPSH (Net Positive Suction Head) – Avoiding cavitation.

NPSHavailable>NPSHrequiredNPSH_{\text{available}} > NPSH_{\text{required}}

3. Pump type:

o Centrifugal pumps (for low-viscosity liquids).

o Positive displacement pumps (for high-viscosity fluids like slurries).

4. Material compatibility – Ensuring corrosion resistance in acidic or alkaline

environments.

5. Energy efficiency – Choosing a pump with optimal efficiency at operating

conditions.

Engro’s fertilizer and petrochemical plants use centrifugal pumps for large fluid
transport and reciprocating pumps for high-pressure applications.

6. Flow Measurement Techniques

Interviewer: What are the different methods of measuring fluid flow in an industrial
setting?

Candidate: Flow can be measured using:

1. Differential pressure meters (Bernoulli’s principle):

o Orifice plate – Simple, but causes pressure loss.

o Venturi meter – More efficient, less pressure drop.

2. Positive displacement meters (piston or gear-type).

3. Electromagnetic flow meters (for conductive liquids like water).

4. Ultrasonic flow meters (non-invasive, used in large pipelines).

5. Coriolis mass flow meters (for high-accuracy mass flow measurement).

For gas and liquid transport at Engro, Venturi meters and Coriolis meters are
commonly used.

7. Fluidization & Multiphase Flow

Interviewer: Engro uses fluidized beds in chemical processes. What are the key
advantages of fluidized bed reactors?

Candidate: Fluidized beds are used for solid-gas reactions in catalytic cracking and
coal gasification. Key advantages include:

• Enhanced heat transfer – Uniform temperature distribution.

• Improved mass transfer – More efficient reactant-catalyst interaction.

• High reaction rates – More surface area for reaction.

• Easier catalyst replacement – Continuous operation without shutdown.

8. Cavitation in Pumps & Pipes

Interviewer: What is cavitation, and how can it be prevented in industrial pumps?

Candidate:
Cavitation occurs when liquid pressure drops below vapor pressure, forming
bubbles that collapse violently, causing:

• Pump damage (erosion of impellers).

• Reduced efficiency.

• Excessive vibration & noise.

Prevention methods:

1. Increase suction pressure (ensure adequate NPSH).

2. Reduce fluid velocity to avoid localized pressure drops.

3. Use larger diameter suction pipes to minimize frictional losses.

4. Install an inducer in pumps to increase suction head.

Cavitation is critical in Engro’s fertilizer and LNG plants, where pumps operate under
high-pressure conditions.

9. Compressible vs. Incompressible Flow

Interviewer: How do you determine if a fluid is compressible or incompressible?

Candidate:
A fluid is compressible if density changes significantly due to pressure variations,
typically when Mach number (MaMa) > 0.3:

Ma=vcMa = \frac{v}{c}

where cc is the speed of sound in the fluid.

• Incompressible flow: Liquids and slow-moving gases (Ma<0.3Ma < 0.3).

• Compressible flow: High-speed gas flows (e.g., Engro’s LNG and ammonia
transport systems).

10. Two-Phase Flow & Slurry Transport

Interviewer: Engro transports slurries in pipelines. What are the challenges in slurry
transport?

Candidate: Slurry transport challenges include:

• Settling of solids – Requires higher velocities to maintain suspension.

• Erosion of pipeline walls – Needs wear-resistant materials.

• Pumping difficulties – Using positive displacement or specialized slurry

pumps.

• High energy consumption – Due to increased friction and turbulence.

What is a Boundary Layer?

The boundary layer is the thin region of fluid near a solid surface where the effects of
viscosity are significant. It forms when a fluid flows over a solid surface, and its velocity
transitions from zero at the surface (due to the no-slip condition) to the free-stream
velocity outside the boundary layer.

Types of Boundary Layers

1. Laminar Boundary Layer – Smooth, orderly flow with minimal mixing.

2. Turbulent Boundary Layer – Chaotic, with vortices and increased mixing,

forming at higher Reynolds numbers.