CONFIDENTIAL UNIVERSITI KUALA LUMPUR Malaysian Institute Of Chemical & Bioengineering Technology FINAL EXAMINATION JANUARY 2012 SESSION SUBJECT CODE : CLB 10904 SUBJECT TITLE : CHEMICAL PROCESS PRINCIPLES. LEVEL : DEGREE TIME | DURATION : 3HOURS Ss INSTRUCTIONS TO CANDIDATES . Please read CAREFULLY the instructions given in the question paper. . This question paper has information printed on both sides of the paper. . This question paper consists of one section only. |. There are FIVE (5) questions in this QUESTION BOOKLET, Answer FOUR (4) questions only, Write your answers in the answer booklet provided. ‘THERE ARE 9 PAGES OF QUESTIONS, EXCLUDING THIS PAGE, $$JANUARY 2012 CONFIDENTIAL, INSTRUCTION: Answer only FOUR questions. Please use the answer booklet provided. Question 1 (a) The thermal conductivity k of a liquid metal is predicted via the empirical equation as follows: R= Aexplb/T) where & is in Ji(s)(m}(K) and T is temperature. A and b are constant. The above equation is dimensionally consistent. Determine the units of A and b (3 marks) The following table (Table 1) shows the annual inputs of phosphorus to Lake Erie: Table 1 Metric Tonsiyr Source Lake Huron 2240 Land drainage 6740 Municipal waste 48080 Industrial waste 2030 30100 Ouifiow 4500 Retained 25600, Convert the retained phosphorus to concentration in micrograms per liter assuming that Lake Erie contains 1.2 * 10" gal of water and that the average Phosphorus retention time is 2.60 yr (marks) Calculate the percentage of the input comes from detergents, assuming they represent 70% of the municipal waste. (3 marks)JANUARY 2012 (ch CONFIDENTIAL Perchloric acid (HCIO.) is a strong acid that mainly produced as @ precursor to ammonium perchlorate, which is used as rocket fuel. The growth in rocketry has led to increased production of perchloric acid, ‘A perchioric acid production process consists of a reactor and a separator as shown in the figure below. Suifuric acid is supplied in 20% excess to react with Ba(CiO,)z in the reaction BaXC1O,); + H,SO, + BaSO, + 2HCIO, ‘The production rate of perchloric acid is 17,400 Ibn and 6125 Ib./h unreacted Ba(CiQ,); is recycled to join the fresh feed, (MW: Ba(CIO,), = 336, BaSO, = 233; H-SO, = 98; HCIO,= 100.5) Note; 20% excess H;SO, is based on the total Ba(CiO,), entering the reactor, FA 100% HS. | M E Pi | 100% H,SO; 2 90 wt% Ba(ClO,}> Resco 10 wt% HCIO, R 100% Ba(ClO.). ‘Separator 3 + 100% BaSO, 100% HCIO, i Calculate the Ib, of HCIO, leaving the separator per lbp, of fresh feed (7 marks) i Calculate the motar flaw rate (Ib-mole/h) of sulfuric acid fed to the reactor. li, Caleulate the overall conversion of Ba(CIO.)>. (S marks) (2 marks)JANUARY 2012 CONFIDENTIAL Question 2 ‘Chlorobenzene (CsH;C!), an important solvent and intermediate in the production of many other chemicals, is produced by bubbling chlorine gas through liquid benzene in the presence of ferric chloride catalyst. in an undesired side reaction, the product is further chlorinated to dichlorobenzene, and in a third reaction the dichlorobenzene is chlorinated to trichlorobenzene. ‘The feed to @ chlorination reactor consists of essentially pure liquid benzene and a technical grade of chlorine gas (Cl; and the balance are gaseous impurities). The liquid output from the reactor contains 73.2 mole% CzH;, 25.0 mole% CHCl, 1.8 mole% CcHCl, and 0.3 mol@% CsHsCls, The gaseous output contains only HCI and the impurities that entered with the chlorine (@) (b) ) i) te) (fh) Taking a basis of 100 mol/h of the liquid output, draw and label a complete flowehart. (6 marks) Calculate the molar flow rate for all the species in all streams (except the gaseous impurities) (6 marks) Caloulate the percentage by which benzene is fed in excess (4 marks) Calculate the fractional conversion of benzene. (2 marks) Calculate the fractional yield of chlorobenzene. (3 marks) Explain why would benzene be fed in excess and the fractional conversion kept low. (4 marks)JANUARY 2012 CONFIDENTIAL Question 3 ‘A gas stream containing 36.37 mole% n-hexane is fed to a condenser at 75'C and 3.0 atm. The product gas emerges at 0°C and 3.0 atm at a rate of 100.0 kmotih. The liquid product stream contains 100% n-hexane. A flowchart for the process is given below. H=mhexane ___ Gas product, 0'C, 30 atm 75°C, 3.0.atm TED ete a Ne Liquid product 0, 30atm “Taking [Ni(g, 25°C), rehexanet|, 0°6)] as reference for enthalpy calculations, prepare and fill in the inlet-outlet enthalpy table and calculate the rate (kd/h) at which heat must be transferred from the condenser. (Neglect the effects of pressure changes on enthalpies) (25 marks) Question 4 fa) ASO mL vessel contains § g of dry ice (solid CO,) is heated to 1000K, Calculate the pressure in the vessel using the compressibility factor equation of state. (12 marks) (b) A gas containing nitrogen, benzene, and toluene is in equilibrium with a liquid consisting of 36 mole% benzene, and the remainder toluene at 85°C and 10.0 atm Determine the gas composition (mole fractions) using Reoult’s law and assuming ideal gas behavior. (13 marks)JANUARY 2012 CONFIDENTIAL Question 5 Ethylene oxide is produced by the catalytic oxidation of the ethylene CH da)* FON @) > CH O18) ‘An undesired competing reaction is the combustion of ethylene to form carbon dioxide and ‘water vapor. ‘The feed to @ reactor contains 2 mol G,Hyth and 1 mol Oyh as mixture. The conversion of ethylene is 25% and 0.35 mol of CzH.Osh is produced. The reactor inlet and outlet streams are each at 450°C, (2) Draw and label a flowchart of the pracess, (3marks) ‘White the stoichiometric equation for the undesired competing reaction. Calculate the molar flow rate of flue stack gas using Extent of Reaction method (8 marks) Taking elemental species [C{s), O.(g), Hi(g)] at 25°C as reference for enthalpy calculations, prepare and fill in the inlet-outtet enthalpy table and calculate the heat requirement (kJrh) far the reactor. Data for C:H.O(g): AMY = 51.00 kl /mot C,ful(mol.K) = - 4.69 + 0.2061 T- 9.995 x 10° F (14 marks) END OF QUESTIONJANUARY 2012 CONFIDENTIAL APPENDIX 1 T(K)=T(0CC)+273.15 TCR) = T(°F) + 459.67 LF 18° 18F eC TPR) =1.8TUK) eC 1K TPR TOF) =1.87(°C)+ M=dy, Wan, EVE f= moles reacted/moles fed ct reactant output from proces Overall Conversion = H6tant input to process — reactant output from Process yyy, reactant input to process —reaetant output fh e101 Single Pass. Conversion = iia input to reactor — reactant autpet fom renee 94 reactant input to reactor The SRI equation of state: aa Fb VWs) m= 0.48508 + 1.55171@ 0.156107 The virial equation of state truncat he second term: e BM yy a-ha, +0) B, = 0.139 iesJANUARY 2012 (CONFIDENTIAL Tem yaa + YeTea to Fa ylist Yuba te B= 9,P= pT) P.=)P=pi (Ty) Pa YaP = XRT) 52.) =P 5 100% “ PT) 1 All fo,(nar O-W, =AH+AE, +AE, it a? = Shnllariy)— Shejladis) aft = Zila] Tila) pone AH = EMBO Sp Flay — Daf AH=DaH,-YaA,CONFIDENTIAL APPENDIX 2 ‘The Gas Constant 8.314 m’.Pa/ (moLK) | 0.08344 L.bar/ (mol.k) |.0.08206 Latm /(mol.K) | 62.36 L.mm Mg / (mol.K) [0.7302 fe atm / (Ib-mole."R)_| 10.73 ft*.psia / (Ib-mote.°R) | 8.314 JJ (mol) _| 4,987 cal f (mol. K) 1,987 Btu /(Ib-mole.°RJANUARY 2012 CONFIDENTIAL APPENDIX 3 FACTORS FOR UNIT CONVERSIONS a SsSSSsSs Quantity Equivalent Values Mass 1kg = 1000.9 = 0.004 metric ton = 2.20462 Ib, = 3.27392 oz dibs = 16 oz = 5x 10“ ton = 453.593 g = 0.453593 kg Length Tm = 100 em = 1000. mm = 10° microns (um) = 10" angstroms (4) = 39.37 in = 3.2808 ft = 1.0936 yd = 0.008214 mite TA = 12 in = 1/8 yd = 0.8048 m = 30.48 em Volume = im? = 1000 liters = 10% cm? = 10 mi 6 = 35,3145 ft’ = 220.83 imperial gallons = 264.17 gal = 1056.68 qt 1f° = 1728 in! = 7.4805 gal = 0.028317 m’ = 28.317 liters = 28317 om? Force 1N = 1kg.m/s*= 10° dynes = 10° g.cm/s? = 0.22481 Ib, 1b) = 32.174 lb, ft/s? = 4.4482 N = 4.4482 x 10° dynes Pressure =i atm = 1.01325 x 10° Nim® (Pa) = 101,325 KPa = 1.01325 bars 1.01325 x 10° dynesicm* = 760 mm Hg at 0°C (torr) = 10.333 m HAO at 426 9 = 14.696 Ibyin? (psi) = 33.9 fh HO at 4° = 28.921 in Hg at O° Energy 1J | =1N.m= 107 ergs = 107 dyne.cm = 2778x107 kW.n= 0.23001 cal = 0.7376 filby= 9.486 x 10°* Btu Power 1W dis = 0.23901 calls = 0.7376 fi.lbys = 9.486 x 10-* Btu's 341 x10" hp ee