Agro Processing Plant Design Questions and Answers

Q: Consider the following statements about plant capacity: 1. A seasonal plant is sized on the peak arrival rate of raw material. 2. Its utilisation factor is inherently low. 3. Utilisation can be raised by increasing the rated capacity. Which of the statements given above is or are correct?

Correct answer: 1 and 2 onlyStatements 1 and 2 are correct, and the second follows from the first. Statement 3 has it backwards: increasing the rated capacity lowers the utilisation factor, since utilisation is actual output divided by rated output. Utilisation rises only by processing more, or for longer.

Q: Consider the following statements about layout: 1. Product layout suits high volume and a narrow range. 2. Process layout suits low volume and a wide range. 3. Layout determines the plant's rated throughput. Which of the statements given above is or are correct?

Correct answer: 1 and 2 onlyStatements 1 and 2 correctly describe when each layout suits. Statement 3 is false - throughput is set by the machines’ capacities, not by their arrangement. A poor layout can waste capacity through handling and delay, but it cannot create any.

Q: Consider the following statements about cost estimation: 1. The Lang factor scales equipment cost to fixed capital investment. 2. The six-tenths rule scales cost between capacities. 3. Payback period accounts for the time value of money. Which of the statements given above is or are correct?

Correct answer: 1 and 2 onlyStatements 1 and 2 describe the two scaling tools correctly. Statement 3 is false: payback uses undiscounted cash flows and takes no account of the time value of money - which, with its blindness to everything after the payback point, is its central weakness.

Q: Consider the following statements about breakeven: 1. It is the output at which revenue equals total cost. 2. A higher fixed cost raises the breakeven output. 3. A higher selling price raises the breakeven output. Which of the statements given above is or are correct?

Correct answer: 1 and 2 onlyStatements 1 and 2 are right. Statement 3 is the wrong way round: a higher selling price increases the contribution per tonne, so fewer tonnes are needed to cover the fixed costs and breakeven falls.

Q: Match each design document in List I with what it defines in List II. List I A. Process flow sheet B. Material balance C. Layout drawing D. Equipment list List II 1. Quantities of every stream in the process 2. Sequence of unit operations and the streams between them 3. Ratings, sizes and connected loads of the machines 4. Physical positions of equipment on the site Select the correct match.

Correct answer: A-2, B-1, C-4, D-3The flow sheet gives the sequence of operations and the streams between them (2); the material balance puts quantities on those streams (1); the layout places the equipment on the site (4); and the equipment list records ratings, sizes and connected loads (3). Each is derived from the one before.

Q: Match each estimating tool in List I with its use in List II. List I A. Lang factor B. Six-tenths rule C. Breakeven analysis D. Payback period List II 1. Scaling a plant cost to a different capacity 2. Scaling equipment cost to fixed capital investment 3. Time for cumulative inflow to equal the outlay 4. Output at which revenue equals total cost Select the correct match.

Correct answer: A-2, B-1, C-4, D-3Lang factor: equipment cost to fixed capital (2). Six-tenths rule: one capacity to another (1). Breakeven: the output where revenue meets cost (4). Payback: the time for cumulative inflow to equal the outlay (3).

Q: Match each cost item in List I with its category in List II. List I A. Process equipment B. Raw material stocks C. Wages and utilities D. Depreciation List II 1. Working capital 2. Fixed capital 3. Accounting recovery of fixed capital 4. Operating cost Select the correct match.

Correct answer: A-2, B-1, C-4, D-3Process equipment is fixed capital (2); raw material stocks are working capital (1); wages and utilities are operating costs (4); and depreciation is the accounting recovery of fixed capital over time (3) - a charge against profit rather than a category of capital or a cash outlay.

Q: Match each layout objective in List I with the measure that achieves it in List II. List I A. Preventing cross-contamination B. Reducing handling cost C. Reliable cleaning D. Avoiding bottlenecks List II 1. Short, direct material paths 2. Unidirectional flow from raw to finished 3. Balanced stage capacities 4. Drainable, crevice-free equipment Select the correct match.

Correct answer: A-2, B-1, C-4, D-3Unidirectional flow prevents cross-contamination (2); short direct paths reduce handling cost (1); drainable, crevice-free equipment makes cleaning reliable (4); and balanced stage capacities avoid bottlenecks (3).

Q: Which of the following is NOT part of fixed capital investment?

Correct answer: Raw material stocksRaw material stocks are working capital - money tied up in goods and recovered when they are sold. Equipment, buildings and installation are all fixed capital, spent once and written down over the plant’s life.

81.

Assertion (A): A pilot plant is built before committing to full scale.

Reason (R): Scale-up rarely behaves exactly as calculation predicts.

Select the correct answer from the options below.

A.Both A and R are true, and R is the correct explanation of A
B.Both A and R are true, but R is not the correct explanation of A
C.A is true but R is false
D.A is false but R is true

Answer: A

Correct answer: Both A and R are true, and R is the correct explanation of A

Because scale-up rarely behaves as calculated - heat transfer, mixing, handling and fouling all change with size - an intermediate step is worth its cost. The pilot plant is where those surprises are found cheaply, which is precisely why it is built.

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82.

Consider the following statements about plant capacity:

1. A seasonal plant is sized on the peak arrival rate of raw material.

2. Its utilisation factor is inherently low.

3. Utilisation can be raised by increasing the rated capacity.

Which of the statements given above is or are correct?

A.1, 2 and 3
B.1 and 2 only
C.1 and 3 only
D.2 and 3 only

Answer: B

Correct answer: 1 and 2 only

Statements 1 and 2 are correct, and the second follows from the first. Statement 3 has it backwards: increasing the rated capacity lowers the utilisation factor, since utilisation is actual output divided by rated output. Utilisation rises only by processing more, or for longer.

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83.

Consider the following statements about layout:

1. Product layout suits high volume and a narrow range.

2. Process layout suits low volume and a wide range.

3. Layout determines the plant's rated throughput.

Which of the statements given above is or are correct?

A.2 and 3 only
B.1, 2 and 3
C.1 and 2 only
D.1 and 3 only

Answer: C

Correct answer: 1 and 2 only

Statements 1 and 2 correctly describe when each layout suits. Statement 3 is false - throughput is set by the machines’ capacities, not by their arrangement. A poor layout can waste capacity through handling and delay, but it cannot create any.

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84.

Consider the following statements about cost estimation:

1. The Lang factor scales equipment cost to fixed capital investment.

2. The six-tenths rule scales cost between capacities.

3. Payback period accounts for the time value of money.

Which of the statements given above is or are correct?

A.1 and 3 only
B.2 and 3 only
C.1, 2 and 3
D.1 and 2 only

Answer: D

Correct answer: 1 and 2 only

Statements 1 and 2 describe the two scaling tools correctly. Statement 3 is false: payback uses undiscounted cash flows and takes no account of the time value of money - which, with its blindness to everything after the payback point, is its central weakness.

Discuss in Forum

85.

Consider the following statements about breakeven:

1. It is the output at which revenue equals total cost.

2. A higher fixed cost raises the breakeven output.

3. A higher selling price raises the breakeven output.

Which of the statements given above is or are correct?

A.1 and 2 only
B.1 and 3 only
C.2 and 3 only
D.1, 2 and 3

Answer: A

Correct answer: 1 and 2 only

Statements 1 and 2 are right. Statement 3 is the wrong way round: a higher selling price increases the contribution per tonne, so fewer tonnes are needed to cover the fixed costs and breakeven falls.

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86.

Match each design document in List I with what it defines in List II.

List I

A. Process flow sheet

B. Material balance

C. Layout drawing

D. Equipment list

List II

1. Quantities of every stream in the process

2. Sequence of unit operations and the streams between them

3. Ratings, sizes and connected loads of the machines

4. Physical positions of equipment on the site

Select the correct match.

A.A-3, B-1, C-4, D-2
B.A-2, B-1, C-4, D-3
C.A-1, B-2, C-4, D-3
D.A-2, B-4, C-1, D-3

Answer: B

Correct answer: A-2, B-1, C-4, D-3

The flow sheet gives the sequence of operations and the streams between them (2); the material balance puts quantities on those streams (1); the layout places the equipment on the site (4); and the equipment list records ratings, sizes and connected loads (3). Each is derived from the one before.

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87.

Match each estimating tool in List I with its use in List II.

List I

A. Lang factor

B. Six-tenths rule

C. Breakeven analysis

D. Payback period

List II

1. Scaling a plant cost to a different capacity

2. Scaling equipment cost to fixed capital investment

3. Time for cumulative inflow to equal the outlay

4. Output at which revenue equals total cost

Select the correct match.

A.A-2, B-4, C-1, D-3
B.A-3, B-1, C-4, D-2
C.A-2, B-1, C-4, D-3
D.A-1, B-2, C-4, D-3

Answer: C

Correct answer: A-2, B-1, C-4, D-3

Lang factor: equipment cost to fixed capital (2). Six-tenths rule: one capacity to another (1). Breakeven: the output where revenue meets cost (4). Payback: the time for cumulative inflow to equal the outlay (3).

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88.

Match each cost item in List I with its category in List II.

List I

A. Process equipment

B. Raw material stocks

C. Wages and utilities

D. Depreciation

List II

1. Working capital

2. Fixed capital

3. Accounting recovery of fixed capital

4. Operating cost

Select the correct match.

A.A-1, B-2, C-4, D-3
B.A-2, B-4, C-1, D-3
C.A-3, B-1, C-4, D-2
D.A-2, B-1, C-4, D-3

Answer: D

Correct answer: A-2, B-1, C-4, D-3

Process equipment is fixed capital (2); raw material stocks are working capital (1); wages and utilities are operating costs (4); and depreciation is the accounting recovery of fixed capital over time (3) - a charge against profit rather than a category of capital or a cash outlay.

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89.

Match each layout objective in List I with the measure that achieves it in List II.

List I

A. Preventing cross-contamination

B. Reducing handling cost

C. Reliable cleaning

D. Avoiding bottlenecks

List II

1. Short, direct material paths

2. Unidirectional flow from raw to finished

3. Balanced stage capacities

4. Drainable, crevice-free equipment

Select the correct match.

A.A-2, B-1, C-4, D-3
B.A-1, B-2, C-4, D-3
C.A-2, B-4, C-1, D-3
D.A-3, B-1, C-4, D-2

Answer: A

Correct answer: A-2, B-1, C-4, D-3

Unidirectional flow prevents cross-contamination (2); short direct paths reduce handling cost (1); drainable, crevice-free equipment makes cleaning reliable (4); and balanced stage capacities avoid bottlenecks (3).

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90.

Which of the following is NOT part of fixed capital investment?

A.Equipment installation
B.Raw material stocks
C.Process equipment
D.Buildings

Answer: B

Correct answer: Raw material stocks

Raw material stocks are working capital - money tied up in goods and recovered when they are sold. Equipment, buildings and installation are all fixed capital, spent once and written down over the plant’s life.

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