International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

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www.journalspub.com eISSN: 2455-5576 International Journal of Chemical Engineering & Processing IJCEP Jul–Dec 2016

Transcript of International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

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eISSN: 2455-5576

International Journal of

Chemical Engineering & Processing

IJCEP

Jul–Dec 2016

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International Journal of Chemical

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PUBLICATION MANAGEMENT TEAM

INTERNAL MEMBERS

Associate Manager

ChairmanMr. Puneet Mehrotra

Managing Director,JournalsPub,

New Delhi

Hidam Renubala

Ankita Singh

Deepika Bhadauria

Rekha Rani

Commissioning Editors

Dr. Chhavi Goel

Manisha Dhoble

Page 6: International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

EDITORIAL BOARD MEMBERS

Alexander RussellMechanical Process Engineering, University of

Magdeburg, Germany.

Dr. Animes K GolderDepartment of Chemical Engineering,

Indian Institute of Technology, Assam, India.

Dr. Asif MahmoodDepartment of Chemical Engineering,

King Saud University, Riyadh, Saudi Arabia.

Prof. Ateeq Rahman Department of Chemistry, Bindura University

of Science Education, Bindura, Zimbabwe.

Dr. Bharat ModheraDepartment of Chemical Engineering,

Maulana Azad National Institute of Technology, Bhopal, India.

Prof. C. M. NarayananDepartment of Chemical Engineering,

National Institute of Technology, Durgapur, India.

Dr. Chandi Charan MalakarDepartment of Chemistry, National Institute of

Technology, Imphal, India.

Prof. Chang-Yu SunChina University of Petroleum, Beijing,

China.

Dr. Dharam PalDepartment of Chemical Engineering,

National Institute of Technology, Raipur, India.

Dr. Didik PrasetyokoDepartment of Chemistry, Faculty of

Mathematics and Sciences, ITS, Surabaya, Indonesia.

Dr. M. Jhansi L. KishoreDepartment of Chemical Engineering,

Institute of Technology, Nirma University, Ahmedabad, India.

Dr. Mohamed AbasharDepartment of Chemical Engineering,

College of Engineering, King Saud University, Saudi Arabia.

Dr. Nagamalleswara Rao KanidarapuBapatla Engineering College (Autonomous),

Bapatla, Andhra Pradesh, India.

Dr. Nanda Gopal SahooDepartment of Chemistry, Nanoscience and Nanotechnology Centre D. S. B. Campus,Kumaun University, Uttarakhand, India.

Dr. P. A. PawarDepartment of Chemical Technology,

Sant Gadge Baba Amravati University, Amravati, India.

Prof. Radha DasDepartment of Chemical Engineering,West Bengal University of Technology,

India.

Dr. Rajendrasinh JadejaDepartment of Chemistry,

The M.S. University of Baroda, Vadodara, India.

Saeed SoltanaliResearch Institute of Petroleum Industry

(RIPI), Iran.

Mr. Sanjay L BhagatPravara Rural Engineering College,

Maharashtra, India.

Dr. Shi-Peng SunNational University of Singapore,

Singapore.

Page 7: International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

EDITORIAL BOARD MEMBERS

Dr. Shivkumar RanganathanR & D (Battery), Su-Kam Power Systems

Limited, Apparel Park Cum Industrial Area, Himachal Pradesh, India.

Dr. Soumitra Kumar ChoudhuriDepartment of In Vitro Carcinogenesis,Chittaranjan National Cancer Institute,

Calcutta, India.

Dr. Srinivasan AnandanCenter for Nano-materials, International Advanced Research Centre for Powder

Metallurgy & New Materials (ARCI), Bolapur, Hyderabad, India.

Dr. Stoyan Novakov NedeltchevHelmholtz Zentrum Dresden-Rossendorf

Institute of Fluid Dynamics,Germany.

Dr. Suryya K RanaDungarpur College of Engineering &

Technology, India.

Dr. Suyogkumar V. TaralkarChemical Engineering Department,

MIT Academy of Engineering, Pune, India.

Dr. T. K. RadhakrishnanDepartment of Chemical Engineering, National

Institute of Technology, iruchirappalli, India.

Dr. V. Venkata Basava RaoFaculty of Technology, Principal Investigator for Centre of Excellence TEQIP Coordinator,

University College of Technology (A),Osmania University Hyderabad, India.

Dr. Vangalapati MeenaDepartment of Chemical Engineering,

A. U. C. E (A), Andhra University, Andhra Pradesh, India.

Prof. Velluru SrideviDepartment of Chemical Engineering,A. U. College of Engineering, Andhra

University, India.

Dr. Vijaya Kumar BulasaraDepartment of Chemical Engineering,

Thapar University, Patiala, India.

Dr. Vipan Kumar SohpalDepartment of Chemical Engineering &

Biotechnology, Beant College of Engineering & Technology, Punjab, India.

Dr Wenming YangNational University of Singapore,

Singapore.

Dr. Zhi ShangLouisiana State University,

United States.

Page 8: International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

From the Editor's Desk

Dear Readers,

We would like to present, with great pleasure, the inaugural volume of a new scholarly

journal, International Journal of Chemical Engineering & Processing. This journal is part

of the Applied Sciences, and is devoted to the scope of present Chemical Engineering

issues, from theoretical aspects to application-dependent studies and the validation of emerging

technologies.

This new journal was planned and established to represent the growing needs of Chemical Engineering &

Processing as an emerging and increasingly vital field, now widely recognized as an integral part of

scientific and technical investigations. Its mission is to become a voice of the Chemical Engineering

community, addressing researchers and practitioners in this area.

The core vision of International Journal of Chemical Engineering & Processing in JournalsPub is to

propagate novel awareness and know-how for the profit of mankind ranging from the academic and

professional research societies to industry practitioners in a range of topics in Chemical Engineering &

Processing in general. JournalsPub acts as a pathfinder for the scientific community to publish their papers

at excellently, well-time & successfully.

International Journal of Chemical Engineering & Processing focuses on original high-quality research in

the realm of Alternative energy conversion & transport mechanisms, Thermodynamics, Chemical reaction

engineering, Polymer Science and Engineering, Modern instrumental analysis, Colloidal and interfacial

science, Molecular dynamics & Chemical kinetics, and many more.

Many scientists and researchers have contributed to the creation and the success of the Chemical

Engineering & Processing. We are very thankful to everybody within that community who supported the idea

of creating an innovative platform. We are certain that this issue will be followed by many others, reporting

new developments in the field of Chemical Engineering.

This issue would not have been possible without the great support of the Editorial Board members, and we

would like to express our sincere thanks to all of them. We also like to express our gratitude to the editorial

staff of JournalsPub, who supported us at every stage of the project.

It is our hope that this fine collection of articles will be a valuable resource for Chemical Engineering

readers and will stimulate further research into the vibrant area of Chemical Engineering and Processing.

Puneet Mehrotra

Managing Director

Page 9: International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

1. Induced Codeposition of Ni–W Alloy Coatings Using Glycerol as Additive and Their Characterization L. Elias, A. Chitharanjan Hegde 1

2. A Customized Wireless Supervisory Infrastructure for Integration and Explicit Multiparametric MPC-Based Control of Laboratory Processes K. Velswamy, T.K. Radhakrishnan 10

3. Electrolytic Deposition of Zn–Ni Alloy from Acidic Sulphate Bath and Their CharacterizationR.S. Bhat, J. Nayak, A.C. Hegde 19

4. Kinetic and Thermodynamic Studies of Adsorption of Pb (II) by Using Ferrous Sulphide as an AdsorbentD. Kamalakar, C.V. Subrahmanayam, P. Rohinikumar, L. Nageswara Rao 33

5. Investigation of High Corrosion Rate in Oil Production Carbon Steel PipelinesA.A.L. Zaabi, S. Feroz, L. Nageswara Rao 42

Contents

Page 10: International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

IJCEP (2016) 1–9 © JournalsPub 2016. All Rights Reserved Page 1

International Journal of Chemical Engineering and Processing eISSN: 2455-5576

Vol. 2: Issue 2

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Induced Codeposition of Ni–W Alloy Coatings Using Glycerol as

Additive and Their Characterization

L. Elias, A. Chitharanjan Hegde* Electrochemistry Research Laboratory, Department of Chemistry, National Institute of Technology Karnataka,

Srinivasnagar, India

ABSTRACT

As a promising coating material to replace hard chromium coating, the development of

nickel–tungsten (Ni–W) alloy coatings of good corrosion protection is of great interest in

surface coating technology. Further, the effect of plating variables, including additive on the

composition of alloys of induced co-deposition is more vagarious than in other types of alloy

deposition. In this context, an alkaline citrate bath has been formulated for electrodeposition

of Ni–W alloy through conventional Hull cell process, using glycerol as an additive.

Electrodeposition following the induced type of codeposition of Ni–W alloy was carried out

onto mild steel (MS) substrate at different current densities (c.d.’s) at room temperature,

taking a basic bath. Influence of bath constituents and functional parameters on appearance,

thickness, hardness and composition of the deposits were analyzed as a degree of their

performance against corrosion. Corrosion behaviors of Ni–W coatings having hard-adherent

mirror bright appearance were investigated using Tafel’s polarization and electrochemical

impedance spectroscopy (EIS) techniques in 5 wt.% NaCl solution. Experimental results

revealed that corrosion protection efficacy of Ni–W coatings increased with deposition c.d.,

in proportion of its W content. The coating developed at 4.0 A dm2

was found to exhibit the

least corrosion rate (5.3 × 102

mm y1

), compared to those at other c.d.’s. The process and

product of electrodeposition have been studied using different instrumental methods, such as

Cyclic voltammetry (CV), Scanning electron microscopy (SEM), Energy dispersive

spectroscopy (EDS) and X-ray diffraction (XRD) study. Experimental observations were

analyzed in the light of induced codeposition of Ni–W alloy due to stimulation by Ni+2

ions,

and results are discussed.

Keywords: bath optimization, corrosion behavior, electrodeposition, glycerol, Ni–W alloy

INTRODUCTION

The properties like enhanced hardness,

corrosion and wear resistance, low

hydrogen overvoltage, magnetic,

electrical, electro-erosion properties of

electrodeposited Ni–W alloy coatings are

of considerable interest due to their wide

spread industrial applications.[1]

These

properties are due to combination of two

constituent metals, i.e., hardest and high

melting metal tungsten (W) with nickel

(Ni). Hence, electrodeposited Ni–W

alloys, also known as high-temperature

alloys find their applications in turbine

blades operating at high temperature.[2,3]

Even though concentration of W in

electroplated alloys is rather less, it has a

major impact on various properties, such

as hardness, wear-resistance and improved

corrosion resistance even at high

temperature.[4,5]

Page 11: International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

IJCEP (2016) 10–18 © JournalsPub 2016. All Rights Reserved Page 10

International Journal of Chemical Engineering and Processing eISSN: 2455-5576

Vol. 2: Issue 2

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A Customized Wireless Supervisory Infrastructure for

Integration and Explicit Multiparametric MPC-Based Control of

Laboratory Processes

K. Velswamy1, T.K. Radhakrishnan

2*

1Lennox India Technology Centre, India

2Department of Chemical Engineering, NIT Trichy, India

ABSTRACT

In this study, a custom, embedded wireless (Zigbee) supervisory infrastructure aimed at

integration of laboratory processes is reported. A microcontroller based field control unit

(FCU) implements closed loop control on experiments via ADAM 5000/485 data acquisition

module. Data from the process (sensor/manipulation) are broadcasted from FCU using a

wireless access point (WAP). A MATLAB graphic user interface (GUI) updates the data

(obtained using a remote monitoring unit (RMU)) graphically. Multiparametric model

predictive controllers (mpMPC) provide constrained and optimal explicit control structure. A

benchmark spherical tank process (STP) is the control loops considered. From the linearized

first principle model, gain scheduled mpMPC’s for STP are designed and deployed using

FCU firmware. Servo tracking and regulatory experiments conducted on STP approves the

viability of such custom infrastructure and also proves from metrics that mpMPC

outperforms conventional control techniques.

Keywords: gain scheduling, model predictive control, multiparametric, nonlinear, Zigbee

INTRODUCTION

Energy efficient process systems are being

researched extensively. Initial methods to

improve existing process systems involved

a careful selection of sensors and

actuators.[1]

The intermediate element, the

controller currently provides a huge scope

in terms of contributing to overall

efficiency of process systems and

operations. The regulatory systems in the

bottom layer of distributed control were

governed by supervisory mechanisms on

higher layers to ensure product quality and

performance.[2]

From an end of the line

user perspective, ease of maintenance (ad-

hoc tuning in conventional controller

terms) is almost eliminated owing to the

complex structure of the model based

controllers. Model based controllers

provide performance that can easily

deteriorate with increased model

uncertainties. To overcome this, such

controllers require constant maintenance

and fine tuning without which its

performance benefits may never be

sustained.[3]

Thus, preventing wide spread

adaptation of such controls in small scale

industries.[4]

The initial class of regulators derived from

quadratic programming based objectives

focused on unconstrained optimization

with very less regard for stability of such

systems. Later, terminal constraint cost

based stability was implemented in such

quadratic programming (QP) based

controls.[5]

Page 12: International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

IJCEP (2016) 19–32 © JournalsPub 2016. All Rights Reserved Page 19

International Journal of Chemical Engineering and Processing eISSN: 2455-5576

Vol. 2: Issue 2

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Electrolytic Deposition of Zn–Ni Alloy from Acidic Sulphate Bath

and Their Characterization

R.S. Bhat1*

, J. Nayak1, A.C. Hegde

2

1Department of Chemistry, Nitte Mahalinga Adyanthaya Memorial Institution of Technology Karnataka, Nitte,

India 2Electrochemistry Laboratory, Department of Chemistry, National Institute of Technology Karnataka,

Srinivasnagar, India

ABSTRACT

A bath containing ZnSO4.7H2O, NiSO4.7H2O, thiamine hydrochloride (THC) and citric acid

(CA) has been proposed. Bright Zn–Ni alloy coatings were developed galvanostatically onto

mild steel (MS) and their corrosion resistance and other physical properties were studied.

THC was found to improve the brightness and homogeneity of the deposit. The dependency of

bath composition, current density (c.d.), pH and temperature, agitation on wt.% Ni were

tested. Deposition was carried out under different c.d. and molar ratio of [Ni+2

]/[Zn+2

]. No

transition c.d., at which codeposition behaviour changed from anomalous to normal type,

was detected. Studies of the factors such as temperature, agitation, pH and [Ni+2

]/[Zn+2

]

which influence the wt.% Ni in the deposit were made. Influence of wt.%Ni on corrosion

resistance, hardness, adhesion and glossiness were studied. The wt.% Ni in the deposit was

determined calorimetrically and cross-examined by EDX analysis. The morphological

variation in deposit patterns with c.d. were examined by Scanning Electron Microscopy

(SEM). Good corrosion resistance at optimized c.d. (3.0 A/dm2) is attributed to the capacitive

reactance at the interface, evidenced by Nyquist plot having large polarization resistance.

The XRD analysis was carried out to identify the phase structures of the deposits.

Keywords: citric acid, sulphate bath, thiamine hydrochloride, XRD, Zn–Ni alloy

INTRODUCTION

The most widely used corrosion protective

coatings for steel is zinc which is applied

either by hot-dipping or electroplating

processes. However, corrosion stability of

zinc coatings can be improved markedly

by alloying it with Fe group metals,

namely Ni, Co and Fe for automotive

industry. Many reports are available for

showing the improved corrosion resistance

property of Zn–Ni alloys, developed under

different conditions of both bath and

current densities (Bajat et al. 2000; Brooks

et al. 2001; Muller et al. 2002;

Shivakumara et al. 2007).[1–4]

Those

depositions were carried out in acidic

baths such as chloride bath, sulphate bath,

sulphate-chloride bath, and aqueous

acetate bath, as well as in some alkaline

baths, either cyanide bath or non-cyanide

bath, etc. (Roventi et al. 2000; Ebothe et

al. 2000; Ashassi-Sorkhabi et al. 2001;

Koura et al. 2003; Wang 2005).[5–9]

Similarly, many extensive research works

have been reported on deposition of Zn–Ni

alloys, concentrating on anomalous

codeposition mechanism and dependency

of deposit characters on bath constitutions

and operating parameters.

Gomez et al. (2001)[10]

found that the

presence of particular additives in the bath

Page 13: International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

IJCEP (2016) 33–41 © JournalsPub 2016. All Rights Reserved Page 33

International Journal of Chemical Engineering and Processing eISSN: 2455-5576

Vol. 2: Issue 2

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Kinetic and Thermodynamic Studies of Adsorption of Pb (II) by

Using Ferrous Sulphide as an Adsorbent

D. Kamalakar1, C.V. Subrahmanayam

1, P. Rohinikumar

1, L. Nageswara Rao

2*

1Department of Chemical Engineering, R.V.R. and J.C. College of Engineering (A), Chowdavaram, Guntur,

Andhra Pradesh, India 2Caledonian College of Engineering, Sultanate of Oman, Oman

ABSTRACT

Poisoning of lead is causing a serious threat to the environment. In the present study the

adsorption behaviour of lead was studied in detail by ferrous sulphide in granular form.

Ferrous sulphide has the magnetic properties and makes it a better candidate for lead

removal. Batch adsorption experiments were carried out by varying different process

parameters such as contact time, adsorbent dose, pH, and temperature. Lead adsorption by

ferrous sulphide was found to be highly pH sensitive. Maximum lead was adsorbed at around

pH 6.8. Study of temperature effect on lead adsorption confirmed the endothermic nature of

the process. Other thermodynamic properties were also calculated and found that physical

adsorption was dominant with activation energy of 213.254 kJ/mol. Kinetic study revealed

that the pseudo second order model was followed by the adsorption process having

regression coefficient (R2) 0.99.

Keywords: adsorption, equilibrium, ferrous sulphide, kinetic and thermodynamic studies,

lead

INTRODUCTION

Environmental effluence by heavy metals

can occur by many alternative ways, either

directly or indirectly. Soils, water and

plants are contaminated by material from

the air or by direct deposition of

pollutants. Heavy metals are introduced

into the eco-system by the manufacturers

and the use of materials containing heavy

metals as well as the disposal of this waste.

Heavy metals in air, soil, and water are

global problems that are a growing threat

to the environment. There are many

sources of heavy metal pollution,

including the coal, natural gas, paper, and

industries.[1,2]

Metals are spread in the environment

through two main routes viz., atmosphere

and flowing waters. Under normal

circumstances, the end result of migration

is the sediments, soil and underground

waters. Heavy metals may enter the food

chain as a result of their uptake by edible

plants. The interaction of metals with solid

phases of soils, soil water and air either

within or above the soil; is dependent on a

variety of chemical factors. Absorption of

metals from soil water to soil particles is

the most important chemical determinant

that limits mobility in soils.[3–5]

The accumulation of these contaminants is

aided by the capability of soil to bind them

with clay minerals or organic substances.

Heavy metals are natural components of

soil. Most elements are only present in

minimal, insignificant eco-toxicological

Page 14: International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

IJCEP (2016) 42-51 © JournalsPub 2016. All Rights Reserved Page 42

International Journal of Chemical Engineering and Processing eISSN: 2455-5576

Vol. 2: Issue 2

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Investigation of High Corrosion Rate in Oil Production Carbon

Steel Pipelines

Ahmed Al Zaabi, Shaik Feroz, Lakkimsetty Nageswara Rao* Caledonian College of Engineering, Seeb, Sultanate of Oman

ABSTRACT

A comprehensive study to identify the causes and the types of internal corrosion of a 16 inch

oily water production piping from production wells, which was found to be severely corroded

(corrosion rate ≈5.5 mm/year) was considered. The study involves collecting and analyzing

of different parameters like production data, flow velocity, CO2 partial pressure, water

quantities and water species contents, gas species contents, scale chemical elements, etc. This

study is based on real time data where the internal corrosion was measured after two years

from the commissioning date.

Keywords: CO2 corrosion, flow velocity, internal corrosion, scale contents, water contents

INTRODUCTION Corrosion is the destructive attack of a

material after it reacts with the

environment or any natural potential

hazard. Almost every aqueous

environment can promote corrosion, which

is commonly found under complex

conditions in oil and gas production,

processing, and pipeline systems. Today,

corrosion has become one of the

outstanding challenging problems in the

industrial sector.

It is important to take into consideration

the effect of corrosion on the life-span of

the equipments used for industrial purpose.

Many industries have lost billions of

dollars because of corrosion.[1]

Crude oil and natural gas carry several

high-impurity products like carbon dioxide

(CO2), hydrogen sulfide (H2S), and free

water which are inherently corrosive.

Continual extraction of CO2, H2S, and free

water through oil and gas components

cause corrosion in the internal lining of the

pipelines.[2]

Various researchers[3–15]

studied the effects

of flow parameters in scale-free CO2

corrosion, but no one much reported in the

real situation where the actual corrosion

anomalies were measured for pipes.

FAILURE ANALYSIS

METHODOLOGY

Failure analysis is a vast concept that

includes different fields such as

electronics, mechanics, metallurgy,

corrosion, etc. While performing corrosion

studies, failure analysis is defined as the

study of a specific case of component

and/or equipment failure caused by

mechanical aspects of corrosion. These

studies are conducted to analyze the root

causes that lead to such failure and

undertake measures to overcome them.

The methodology of the corrosion failure

analysis was performed as per the

following steps:

Collecting and analyzing information

related to the pipeline’s history

Page 15: International Journal of Chemical Engineering and Processing - Vol 2_Issue 2

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Chemical Engineering & Processing

IJCEP

Jul–Dec 2016