Process Engineering
Interview Questions
DISTILLATION COLUMN
FUNDAMENTAL PRINCIPLES
Q1: What is the fundamental principle behind distillation?
A: Separates components based on boiling point differences. Heat vaporizes
lower-boiling components first, vapor is condensed and collected separately.
Q2: What is relative volatility and why important?
A: α = (yi/xi)/(yj/xj). Indicates separation ease. Higher α = easier separation.
When α = 1, no separation possible.
Q3: Define bubble point and dew point temperatures.
A: Bubble point: Temperature where first vapor bubble forms. Dew point:
Temperature where first liquid drop forms from vapor.
Q4: What are the key components of distillation setup?
A: • Distillation column with trays/packing
• Reboiler for vapor generation
• Condenser for vapor condensation
• Reflux drum and feed system
• Product withdrawal systems
• Control and instrumentation
Q5: What is the driving force for separation?
A: Difference in chemical potential between vapor and liquid phases,
manifesting as boiling point and vapor pressure differences.
TYPES OF DISTILLATION
Q6: Simple vs Fractional Distillation?
A: Simple: Components with >50°C boiling point difference, single stage
Fractional: Close-boiling components, multiple equilibrium stages
Q7: When to use vacuum distillation?
A: • Thermally sensitive components
• High boiling point materials
• Energy savings required
• Reduces boiling points by lowering pressure
Q8: Batch vs Continuous Distillation?
A: Batch: Fixed feed, composition changes with time, small quantities
Continuous: Steady streams, constant composition, large-scale
Q9: What is extractive distillation?
A: Uses selective solvent (entrainer) to alter relative volatility when α <
1.05 for conventional distillation
Q10: Steam distillation applications?
A: For temperature-sensitive compounds, essential oils, aromatics using
steam below normal boiling points
DESIGN PARAMETERS
Q11: What is reflux ratio and its effect?
A: R = L/D (liquid returned/distillate). Higher R improves purity but increases
energy consumption
Q12: Define minimum reflux ratio.
A: Rmin = lowest reflux ratio for desired separation with infinite stages.
Typical operation: R = 1.2-1.5 × Rmin
Q13: How to calculate theoretical stages?
A: McCabe-Thiele method, Fenske equation, Gilliland correlation, computer
simulation
Q14: Factors affecting column efficiency?
A: • Number of theoretical stages
• Reflux ratio and feed condition
• Operating pressure and tray design
• Vapor-liquid contact efficiency
Q15: How does pressure affect distillation?
A: Higher pressure → higher boiling points → reduced relative volatility →
more difficult separation. Vacuum operation improves separation but
increases equipment size.
OPERATIONS
Q16: Effect of feed location on performance?
A: Optimal feed at q-line intersection. Feed too high → insufficient
stripping. Feed too low → insufficient rectification
Q17: How to optimize reflux ratio economically?
A: Ropt = 1.2-1.5 × Rmin. Balance energy costs vs column size. Consider
capital and operating costs
Q18: What is boil-up ratio?
A: V/B = vapor generated in reboiler/bottom product flow. Controls
stripping section separation
Q19: How do temperature and pressure profiles indicate performance?
A: Temperature profile: Smooth curve indicates good efficiency. Sudden
changes = problems
Pressure profile: High ΔP = flooding, Low ΔP = weeping
Q20: Safety considerations in distillation?
A: • High pressure/temperature operation
• Flammable materials and explosion risk
• Overpressure protection systems
• Emergency shutdown procedures
• Personnel safety training
Q21: What is flooding and how to prevent it?
A: Liquid flow exceeds column capacity. Symptoms: high pressure drop,
unstable levels, poor separation. Prevent: proper design margins, control
rates
Q22: What is weeping and its causes?
A: Liquid falls through tray holes due to insufficient vapor flow. Causes: low
vapor rates, damaged trays. Solution: increase vapor flow, repair trays
TROUBLESHOOTING
Q23: What is entrainment and its effects?
A: Liquid droplets carried by vapor. Causes: excessive vapor velocity,
foaming. Effects: reduced separation. Solutions: reduce vapor rates, anti-
foam agents
Q24: How to troubleshoot poor product quality?
A: Check: insufficient stages/reflux, feed quality changes, tray damage,
operating deviations, control problems
Q25: What causes pressure drop variations?
A: Flooding/weeping, tray damage, fouling, control problems, feed changes.
Monitor trends vs design values
ADVANCED TOPICS
Q26: How do azeotropes affect distillation?
A: Constant-boiling mixtures impossible to separate by simple distillation.
Solutions: pressure-swing, extractive distillation, membrane separation
Q27: Advantages of high-performance trays?
A: 15-30% higher capacity, better turndown, improved efficiency, lower
pressure drop, reduced fouling
Q28: How do control systems improve operation?
A: • Composition control using analyzers
• Model predictive control (MPC)
• Feed-forward control and optimization
• Benefits: improved quality, energy savings
Q29: Modern innovations in distillation?
A: Dividing wall columns, heat integration, membrane distillation, reactive
distillation, process intensification
Q30: How to select materials for distillation equipment?
A: Consider:
• Corrosion resistance to process fluids
• Temperature and pressure ratings
• Thermal expansion properties
• Cost factors and fabrication requirements
• Common materials: stainless steel, carbon steel with lining, exotic alloys
for severe service
KEY FORMULAS AND EQUATIONS
• Relative Volatility: α = (yi/xi) / (yj/xj)
• Reflux Ratio: R = L/D
• Boil-up Ratio: V/B = vapor flow / bottom product flow
• Fenske Equation: Nmin = log[(xD/xB)(xB,f/xD,f)] / log(α)
• Underwood Equation for minimum reflux ratio
• McCabe-Thiele Graphical Method for theoretical stages
• Pressure Drop: ΔP = f(vapor velocity, liquid rate, tray design)
• Antoine Equation: log P = A - B/(C + T)
INTERVIEW PREPARATION TIPS
• Master fundamental principles and definitions
• Understand equipment components and their functions
• Practice problem-solving with calculations
• Know troubleshooting procedures for common problems
• Be familiar with different types of distillation
• Understand economic optimization concepts
• Stay updated with modern technologies and innovations
• Prepare real-world examples from your experience
• Review process flow diagrams and P&IDs
• Practice explaining complex concepts simply
COMMON INTERVIEW TOPICS
• Distillation fundamentals and principles
• Column design and sizing calculations
• Operating parameter optimization
• Troubleshooting and problem diagnosis
• Safety and environmental considerations
• Economic factors and cost optimization
• Process control and automation
• Materials of construction
• Energy integration and efficiency
• Regulatory compliance and standards
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