Chemical Engineering Calculations Compiled by Mary Rose B.

Flores

2. MATERIAL BALANCES

2.1 Fundamentals of Material Balances

A. Introduction

In Chemical Engineering, a process is an operation or series of operations that causes a

physical or chemical change in a substance.

The streams The streams

entering are Process Unit leaving are the
the input or output or
feed streams product streams

Figure 2. Schematic Diagram of a Process.

Figure 2 shows the schematic diagram of a process showing the flows of process materials. In
any process, inventory of material is a must to evaluate the performance of the process unit and
the entire process in general. This is accomplished by setting up mass balances or material
balances based on the Law of Conservation of Mass.

B. Process classification

1. Batch Process

A process is considered to be a batch process when no material is transferred across the

system boundaries during the time interval of interest. The feed is charged to the process
unit at the beginning of the process and the products are removed all at once sometime
later.

2. Continuous Process

A continuous process is one in which there is a continuous flow of outputs and inputs throughout
the duration of the process.

3. Semibatch or Semicontinuous Process

A process that neither fits the description of batch and continuous process is considered as
semibatch or semicontinuous.

If the values of all the process variables (flows, pressures, temperature, etc.) do not
change with time, the process is considered to be operating under steady state
conditions. Otherwise the process is said to be unsteady state or transient. Batch and

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

semibatch processes are classified to be transient processes while continuous process

may be either steady or unsteady state process.

C. The General Balance Equation

Material Balances are based on the Law of Conservation of Mass - that is, mass can
neither be created nor destroyed.

A material balance accounts for the material which enters, leaves or accumulates in a
system and for the material which is generated or consumed by chemical reaction in
the system.

The general balance equation may be written as:

Input + Generation - Output - Consumption = Accumulation (82)

The above equation may be written as an inventory of material in a single unit, a

collection of units or an entire process. The general balance equation can be applied to
the total mass of the material or to any molecular or atomic species involved in the
process.

D. Types of material balances

1. Differential balances. These are balances that indicate what is going on in a system at an
instant of time. Since these balances are dependent of time, each term of the balance equation
is then a rate (rate of input, rate of consumption, rate of accumulation, etc.) and has units of
the balanced quantity unit divided by a time unit (people/yr., g CO 2/s, tons of oil/day).
Differential balances are usually applied to a continuous process.

2. Integral balances. These are balances that depict what happens between two instants of
time. Since the balances are independent of time, each term of the equation is then an amount
of the balanced quantity and has the corresponding unit (people, g CO2, tons of oil). This type
of balance is usually applied to a batch process, wherein the two instants of time being
considered are the time after the input takes place and the time before the product is
withdrawn.

E. Balances on the different types of processes

1. Balances on continuous steady-state processes

For a continuous steady state process, every component of the system must appear in the input
and output streams. The accumulation term in a balance on every component must be equal to

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

zero; if it did not, the amount of any component in the process system would necessarily
change with time, and the process would then by definition not be at steady-state. Thus, the
general balance equation simplifies to:

Input + Generation = Output + Consumption (83)

2. Integral balances on batch processes

For batch process, there are no input and output streams, thus from the general balance
equation, generation - consumption = accumulation. But the quantity of any material that
builds up (accumulates) in the system between two instants of time is simply, the final amount
minus the initial amount of that material. The same reasoning may be used to any substance
participating in a batch process to obtain

Accumulation = final output - initial input (by definition)

= generation - consumption (from the general balance equation) (84)

Combining these two expressions for the accumulation yields

Initial input + generation = final output + consumption (85)

Take note that the above equation is similar to that for continuous steady-state process derived
above except that in this case the input and output terms represent the initial and final
amounts of the balanced substance rather than flow rates of the balanced substance in
continuous feed and product streams.

3. Balances if there is no chemical reaction:

Since there is no chemical reaction, Generation and Consumption terms are zero. The material
balance equation will be:

Accumulation = Input – Output (86)

F. Material Balance Calculations

All material balance problems are variations on a single theme, that are given the
values of some input and output stream variables, calculate values of unknown
variables.

Procedure for Material Balance Calculations

1. Draw a flowchart of the problem and label all streams (known and unknown
variables).

2. Choose a convenient basis of calculation.

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

3. Write down the independent equations.

4. Solve the equations

2.2. Material balances on non-reactive systems

The following rules in writing a material balance are applicable to systems without
chemical reactions:

1. For a non-reactive system, the maximum number of independent equations that can
be derived by writing material balances equals the number of chemical species in
the input and output streams.

2. The unknown variables would be easier to determine if balances with the fewest
unknowns are solved first.

A. Material Balance on a Single Unit

Feed 1, F1
Components A, C, E
Mass fractions xA1, x C1, x E1 Process Unit Product, P
Components A, B, C, E
Feed 2, F2 Mass fractions xA, x B,
x C, x E
Components A, B, C
Mass fractions xA2, x B2, x C2

Figure 3. Steady State Process on a Single Unit.

Consider Figure 3, since there are four components in the input and output streams, four
independent material balance equations may be written. These are:

A Balance:
xA1F1 + xA2 F2 = xA P (87)

B balance:
xB2 F2 = xB P (88)

C Balance:
xC1F1 + xC2 F2 = xC P (89)

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

E Balance:
xE1 F1 = xE P (90)
Or

Overall Material Balance

F1 + F2 = P (91)

DRYING
Example: A wet paper pulp contains 68% wt H2O. After the pulp was dried, it was found that
55% of the original H2O in the wet pulp was removed. Calculate the composition of the dried
pulp and weight for a feed of 1000kg/min of wet pulp.

drying
Wet paper pulp,W dried pulp
1000 kg/min % H2O
68 wt % H2O D

55% H2O removal

H
Required: %H2O or D
Solution:
OMB: W = H + D = 1000 (1)

H2O balance: 0.68(1000) = H + %H2O D (2)

0.68(1000) = (0.55)-H (3)

pulp balance: (1-0.68)(1000) = (1-%H2O) D (4)

Eq’n (2) & (3)

0.68(1000) = 0.68(0.55)(1000) + %H2O D

680 = 374 + %H2O D
306 = %H2O D
%H2O = 306/D
320 = (1- 306/D)D
321 = D – 306
D = 626 kg/min

%H2O = 306/626 x 100 = 46.88%

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

MIXING
A mixed acid containing 40% H2SO4, 43% HNO3, 17% H2O is made by blending the
following:

a. spend acid containing 33% H2SO4, 36% HNO3, 31% H2O

b. concentrated H2SO4 containing 95% H2SO4
c. concentrated HNO3 containing 78% HNO3
How much of the said mixtures will be added to come up with the mixed acid of the aid
composition
95% H2SO4 (H)
5% H2O

spent acid (S) mixed acid (A)

33% H2SO4 mixer 40% H2SO4
36% HNO3 43% HNO3
31% H2O 17% H2O

(N)
conc. HNO3
78% HNO3
22% H2O

OMB: S + H + N = A = 100kg (1)

Basis: 100kg

H2SO4 balance : 0.33S + 0.95H = 0.40(100)

0.33S + 0.95H = 40

HNO3 balance : 0.36 S + 0.78N = 0.43(100) (2)

0.36S + 0.78N = 43

H2O balance: 0.31S + 0.05 H + 0.22N = 0.17(100)

0.31S + 0.05H + 0.22N = 17 (3)

Combine (1) & (2)

0.33S + 0.95H = 40
0.36S + 0.78N = 43
(0.69S + 0.95H + 0.78N = 83)0.31 = 0.2139S + 0.2945H + 0.2418N = 25.73
0.31S + 0.05H + 0.22N = 17)0.69 = -0.2139S + 0.0345H + 0.1518N = 11.73
0.26H + 0.09N = 14 (6)

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

(4) & (3)

0.05S + 0.05H + 0.05N = 5
-0.31S + 0.05H = 0.22N = 17
(0.26S + 0.17N = 12) 0.36 (5)
(0.36S + 0.78N = 43) 0.26 (2)
-0.0936S + 0.0612N = 4.32
- 0.0936S + 0.2028N = 11.18
= 0.1416N = 6.86

N = 48.4463kg

0.36S + 0.78 (48.4463) = 43

S = 14.4775 kg

(0.33)(14.4775) + 0.95H = 40
H = 37.0762 kg

FERTILIZER PROBLEM
NPK, 2-12-10
2%N2, 12% P2O5, 10% K2O

murate of potash KCl (C)

filter (D) 1000kg NPK

Mixer 2-12-10

Ca3(PO4)2 NaNO3
(A) (B)

OMB: 1000kg = A + B + C + D

N2 balance: 0.02(1000) = B ( 1 N2 ) 2NaNO3 2Na+ + N2 + 3O2

(2 NaNO3) Ca3(PO4)2 Ca+ + P2O5 + 3/2 O2

P2O5 balance : 0.12(1000kgmole) = A x 1P2O5 KCl K+ + Cl-

1Ca3(PO4)2 K2O 2K+ + O-

K2O balance : 0.1(1000 kgmole) = 0.97 (C) x 1K+ x 1K20

Murate of potash or KCl 2K+
A = 120 B = 40 C = 206.1856

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

1000kg = 120 + 40 + 206.1856 + D

D = 633.8144 kgmole

N2 balance: 0.02(1000) = B x 1N2;MW=28

2NaNO3;MW=84.9898
B = 121.4329

P2O5 balance = 0.12(1000) = A x 1P2O5;MW=141.9476

1Ca3(PO4)2;MW=310.1816
A = 262.2378

K2O balance = 0.1(1000) = C x 1K+ x 1K2O = 1K2O;MW=94.1966

1KCl 2K+ 2KCl;MW=74.551
100 = C x 94.1966
74.551(2)

100 = C (0.6318) (0.97)

100 (158.2779) = C (0.6128)
C = 163.1854

1000kg = A + B + C + D
1000kg = 262.2378 + 121.4329 + 163.1854 + D
D = 453.1459
Drying

5% moisture (wet basis) = 5 parts H2O

5 parts H2O + 95 parts bone dry solid

5% moisture (dry basis) = 5 parts H2O

100 parts bone dry solid

wet basis = 5 parts H2O

100 parts BDs + 5 parts H2O

H2O (W)

Wet mat’l Drier dry mat’l (D)

1000kg/hr 9% H2O
30% H2O (wet basis) (dry basis)

9 parts H2O = 8.256%

100+9

OMB = 1000 = W + D

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

H2O balance : 0.3 (1000) = W + 0.0856D

Solid Balance : 0.7 (1000) = (1-0.0856)D

D = 762.9927 kg/hr

W = 1000 – 762.9927 kg/hr

W = 237.0073 kg/hr

EVAPORATOR
1. Single Effect Evaporator
Vapor (V)

S, Steam

F, thin liquor thick liquor (L)

Condensate (C)
OMB = F = V + L
S=C
2. Double Effect Evaporator

V1 V2

F L1 L2

C1
C2

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

A solution containing 15% dissolved solids is to be concentrated to 60% dissolved solids. If

the evaporator will evaporate 20,000 kg of water/hr, what must be the feed rate? How much
product is obtained per hour?

H2O vapor = 20000kg/hr

F, Feed thin liquor Evaporator thick liquor

15% solids product, L
60% solid

OMB : F = 20000 + L

Solid balance : 0.15(F) = 0.6L

H2O balance : 0.85(F) = 20000kg + 0.4L

F = 4L

4L = 20000 + L

3L = 20000

L = 6666.6667

F = 20000 + 6666.6667 kg/hr

F = 26666.6667 kg/hr

DISTILLATION
Condenser

distillate

Feed

reboiler

bottoms B

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

%recovery = amt. of MVC in D

amt. of MVC in F

%loss = amt. of MVC in B

amt. of MVC in F

A mixture containing 70% methanol and 30% H2O is to be distilled. If the distillate product is
to contain 99.9% methanol and the bottom product 0.004% methanol, how much distillate
and bottoms product are obtained / 100 kg of feed distilled.

99.9% methanol
0.1% H2O

F 100 kg feed

70% methanol
30% H2O

0.002 % CH3OH
99.996 H2O

OMB : F = D + B = 100 kg

CH3OH balance : 0.7(100) = 0.999D + 0.00004B

H2O balance = 0.3(100) = 0.001D + 0.99996 H2O(B)

0.7(100) = 0.999D + 0.00004B = (0.001)
0.3(100) = 0.001 D + 0.99996B = (0.999)

(100 = D + B) 0.999
99.9 = 0.999D + 0.999B
70 = 0.999D + 0.00004B
29.9 = 0.99896B
B = 29.9311 kg

100 = D + 29.9311 kg
D = 70.0689 kg

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

CRYSTALLIZATION
H2O

Mother liquor
magma
crystallizer

crystals

Solubility- amount of soluble present in a given amount of solvent of solution based on a

temperateure.

Example:
1000kg of a 64% NaNO3 solution in water is at a temperature of 100 0C. This is sent to a
crystallizer where it is cooled to 300C. At this temperature the solubility of NaNO3 is 96 parts
per 100 parts of water (the solubility of NaNO3 is maximum amount of NaNO3 that can stay
in solution, the rest crystallizes out). Calculate the amount of crystals precipitates out if
a. No water evaporates during cooling
b. 5% of the original water evaporates during cooling

Solution:

Feed crystallizer solution

64% NaNO3 ( mother liquor)

NaNO3 crystals

a. OMB = 1000 = C + M

NaNO3 balance: 0.64 (1000) = crystal or NaNO3 M + C

H2O balance : 0.36 ( 1000) = H2O M

NaNO3 M = 0.36 (1000) x 96kg NaNO3 = 345.6 kg NaNO3 in M

100kg H2O
Substitute NaNO3 M in NaNO3 balance

0.64 ( 1000) = 345.6 + C

C = 294.4 kg

b. OMB : F = E + C + M

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

E acts as an H2O evaporated

E = 0.36 (1000) (0.05) = 18 kg H2O

H2O balance : 0.36 (1000) = 18 + H2O M

NaNO3 balance : 0.64 (1000) = C + M x 96

100+96
640 = C + M 0.489795918
1000 = 18 + C + M
M = 1000 – 18 –C
M = 982 – C

Substitute M to NaNO3 balance

NaNO3 balance: 0.64 (1000) = C + (982-C) (0.489795918)

C = 311.68 kg

B. Balances on Multiple Unit Processes

Most of industrial chemical processes are comprised of not just one process unit.
There might be one or more chemical reactors present, as there are units for mixing
reactants, blending products, heating and cooling process streams, and separating
products from each other and from unused reactants. The chemical engineer’s job
includes keeping track of materials that flow from one unit to another unit within the
process.

When several process units are involved in the process, the systems on which material
balances may be written are:

a. The whole process –material balances made on the whole process are known as
overall balances.

b. An interconnected portion of more than one process units

c. A single process unit

d. Mixing point - A point at which two or more streams are mixed

e. Split point- A point at which a single stream is split

The determination of all unknown stream flow rates (or amounts) and compositions for
a multiple unit process usually require choosing several such systems and successively
writing balances on each of them.

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

Feed 2
a
b c d e

Feed 1 Unit 1 Unit 2 Product 1

Product 2 Product 3 Feed 3

Figure 4. Multiple Unit Process.

Consider the multiple unit process in Figure 4. The dashed lines denote boundaries of
systems about which balances can be written. The procedure for solving material
balance problems is essentially the same whether a single unit or multiple unit
processes are involved. However, in processes involving multiple units, you may have
to isolate and write balances on several subsystems (b,c,d, & e in Figure D - 4) to
obtain enough equations to determine all the unknown stream variables. Generally, it is
recommended to set up overall balances first to determine unknown process feed and
product streams variables; after that, balances on various process subsystems may be
used to solve for interior stream variables.

When choosing subsystems on which to write balances, consider first the boundaries
that intersect streams containing the fewest unknown variables.

1. Establish overall unit balance.

2. Establish individual unit balance.
3. Establish material balance on mixing points and splitting points.
4. Make a solution.

Example: Multi-Unit system

3-47
/137
A double effect evaporator is to concentrate 1000 000 kg/day oaf a liquor containing
5% solids to 40% solids. Assuming equal evaporations are obtained from such effect,
calculate the composition of the solution from the first effect and the flowrate of the product
in kg/hr. how much evaporation is obtained?

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

V1 V2

E1 E2

F L1 L2 40% solid
C1 C2

1 000 000 kg/day

5% solid

OMB:
S + 1 000 000 = C1 + C2 + V2 + L2 ; E1 : S = C1
1 000 000 = C2 + V2 + L2
E1 : 1 000 000 = V1 + L1
E2 : L1 = V2 + L2 ; V1 + C2

Solute Balance in L2:

0.05(1000 000kg/day) = 0.4L2

L2 = 125 000 kg/ day  1 day = 5 208.3333kg/hr

24 hr
V 1 = V 2 = C2
1000 000 = C2 + V2 + L2
1000 000 = 2V2 + 125 000
V1 = V2 = C2 = 437 500 kg/day

L 1 = V2 + L 2
L1 = 437 500 + 125 000
L1 = 562 500 kg/day

Solute Balance in L1:

0.05(1000 000) = x(562 500)
x = 0.0889
solute in L1 = 8.89%

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

2.3. Material Balances on Reactive Systems

Stoichiometry
- stoicheion; Greek word which means elementary constituents
- metrein; Greek word which means to measure

Stoichiometric Calculation
- calculation of the weights of substances involved in chemical reactions

Balanced in Chemical Reaction

- a chemical equation expresses wht happens during a chemical reaction.

Example: CH4 + 2O2  CO2 + 2H2O

Chemical or Gravimetric Factors

aA + bB  cC + dD

Setting up mass ratios:

1. mass A = aMWA 3. mass C = cMWC
mass C cMWC mass B bMWB
2. mass D = dMWD
massB bMWB

Example:
4FeS2 + 11O2  2Fe2O3 + 8SO2
150 kg

Molecular Weight:
FeS2 = 119.979 kg/mol
O2 = 32 kg/mol
Fe2O3 = 159.649 kg/mol
SO2 = 64.066 kg/mol

O2 : 150 kg FeS2  1 mol FeS2  11 mol O2  32 kg O2 = 110.0192 kg O2

119.979 kg 4 mol FeS2 1 mol O2

Fe2O3 :150 kg FeS2  1 mol FeS2  2 mol Fe2O3  159.649 kg Fe2O3 =

119.979 kg 4 mol FeS2 1 mol Fe2O3
= 99.8262kg Fe2O3

SO2 : 150 kg FeS2  1 mol FeS2  8 mol SO2  64.066 kg SO2

119.979 kg 4 mol FeS2 1 mol SO2
= 160.193 kg SO2

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

Chemical Reactions in Industrial Processes (Complex Reaction)

Consecutive (Series) Reaction

A BC

Parallel (side or competing reaction)

A B A S
A S BS
A+BD A+BE

Reversible Reaction
A+BC+D A+B  C+D
C+D A+B

Mixed reaction – combination of any kind of complex reaction

Factors that reduce the yield

Undesired side reaction
Incomplete reaction
Chemical equilibrium

Comparison of Ideal and Industrial Reactions

Ideal ( Theoretical Reaction ) Industrial Reaction

Complete reaction Seldom reaction
Stoichiometric amounts of reactants are used
Some reactants are in excess
Pure materials are used or are assumed to be
Raw materials are impure or mixed with other
used substances
Assumed to occur at only one condition Occurs over a wide range of temperature,
pressure and concentration
No competing side reactions are involved Several reactions may occur simultaneously
Stoichiometric amounts of products are The products will contain side products and
obtained unreacted or excess products

A. Reaction Stoichiometry

For the chemical reaction,

aA + bB cC + dD (92)

a, b, c, d are the stoichiometric coefficients, representing the molar balance of the equation
--that is, a moles of A react with b moles of B to form c moles of C and d moles of D.

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

In writing the balance equations involving reactions, there is a need to quantify the extent of
the reactions. This will require the following concepts:

1. Limiting reactant

This is the reactant in the smallest stoichiometric amount, thus it would disappear first if a
reaction proceeded to completion.

Suppose x moles of A and y moles of B are mixed and A and B react according to the above
reaction.

If If
x a x a
 
y b y b
then A is the limiting reactant then B is the limiting reactant

If all of the reactants are present in stoichiometric proportion, then no reactant is limiting.

2. Excess reactants

The reactants other than the limiting reactant are called excess reactant. The percentage
excess of this reactant is defined as:

moles fed - moles required

% Excess = x 100 (93)
moles required

where moles required is based on the moles required to react with the limiting reactant.

3. Fractional Conversion, f

Fractional conversion is the fraction of the feed or any component in the feed that is
converted into products. It is defined as:

moles reacted
f = (94)
amount fed

The basis of the conversion must be clearly stated because the conversion of one component
may not be the same as the conversion of another.

B. Multiple Reactions, Yield and Selectivity

The terms yield and selectivity are used to measure the degree to which a desired reaction
proceeds relative to competing side or undesirable reactions.

Yield is defined in three ways:

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

moles of desired product formed

Yield (based on maximum = (95)
production) moles that would have been formed if
there were no side reactions and the
limiting reactant had reacted completely

moles of desired product formed

Yield (based on feed) = (96)
moles of limiting reactant fed

moles of desired product formed

Yield (based on reactant consumed) = (97)
moles of limiting reactant consumed
From the above definitions, there are three types of yield. If the type of yield is not specified,
it is assumed that it is the yield based on maximum production.
Selectivity is defined as:
moles of desired product formed
Selectivity = (98)
moles of undesired product formed

If C is the desired product and D is an undesired product, we then refer to the selectivity of C
relative to D. High values of yield and selectivity indicate that the desired reactions
predominates over competing side reactions.

C. Balances on Atomic and Molecular Species

In a chemical reaction, balances on atomic species may be written. For atomic balance,
the general balance equation will be simplified into input = output, since atoms can
neither be created nor destroyed (generation and consumption = 0).

Both methods must lead to the same result; however, one is frequently more convenient
than the other, so it is a good idea to become at ease in using both methods.

Generally, balances on atomic or molecular species are equally suitable to use when only
one chemical reaction takes place, while balances on atomic species are preferable if
several simultaneous reactions take place.

D. Product Separation and Recycle

In the analysis of chemical reactors with product separation and recycle of unused
reactants, there are two definitions of reactant conversion being used and these are:

1. Overall Conversion

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

= reactant input to process - reactant output from process (99)

reactant input to process

2. Single-pass Conversion

= reactant input to reactor - reactant output from reactor (100)

reactant input to reactor

The corresponding percentage conversions are obtained by multiplying these quantities

by 100%.

4-36
Ethylene dibromide is produced by the liquid phase bromination of ethylene. Ethylene
and bromine are fed in equimolar units into a vessel where they reacted at 35 to 85C and
atmospheric pressure. The reaction involved:

CH2=CH2 + Br2  BrCH2CH2Br

For every 1000kg of ethylene dibromide product, 860 kg of bromine is used. Two-
thirds of the ethylene dibromide liquid from the stripper is recycled to be used as the solvent
in the reactor. Another reaction that occur is

BrCH2CH2Br + Br2  BrCH2CHBr2 + HBr

What is the yield on the ethylene? the yield on the bromine? What is the composition
of the liquid that goes out of the main reactor?

R, 2/3 BrCH2CH2Br

Purge Stream

Reactor 1 000 kg Stripper

C2H4 860 kg BrCH2CH2Br 1/3
Br2 Br2 BrCH2CH2Br

CH2=CH2 + Br2  BrCH2CH2Br (main)

BrCH2CH2Br + Br2  BrCH2CHBr2 + HBr (side)

Molecular Weight:
CH2=CH2 = 28kg/mol
Br2 =159.808kg/mol
BrCH2CH2Br = 187.808kg/mol
BrCH2CHBr2 = 266.712kg/mol

Weight of Br2 needed:

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

= 1000kg C2H4Br2  1 kg mol  1kgmolBr2  159.808kgBr2

187.808kg 1kgmol 1kgmolBr2
= 850.9116 kgBr2

Excess Br2 = 860kg – 850.9116kg = 9.0884 kg Br2

Weight of C2H4 needed:

= 860kg Br2  1 kg mol  1kgmolC2H4  28 kg C2H4
159.808kg 1kgmol 1kgmolC2H4
= 150.6808 kg C2H4

Weight of C2H4 actually used:

= 1000kg C2H4Br2  1 kg mol  1kgmolC2H4  28 kg C2H4
187.808kg 1kgmol 1kgmol C2H4
= 149.0884 kg C2H4

Excess amount of C2H4:

= 150.6808kg – 149.0884 kg
= 1.5924 kg C2H4

Yield C2H4 = 149.0884kg  100 = 98.94%

159.6808

Yield Br2 = 850.9116kg  100 = 98.94%

860 kg

Composition in main reactor:

Component Weight %
Br2 9.0884kg 0.8992%
C2H4 1.5924kg 0.1576%
C2H4Br2 1000kg 98.94%
1010.6808 kg

R = (2/3)(1000) = 666.6667 kg

Weight of C2H4Br2 reacted with excess Br2:

= 9.0884 kgBr2  1 kg mol  1kgmolC2H4Br2  187.808 kg C2H4Br2
159.808kg 1kgmol 1kgmol C2H4Br2

= 10.6808 kg C2H4Br2

Excess C2H4Br2 = 666.6667 – 10.6808 = 655.9859 kg

Weight of C2H4Br3:

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

= 9.0884 kgBr2  1 kg mol  1kgmolC2H4Br3  266.712 kg C2H4Br3

159.808kg 1kgmol 1kgmol C2H4Br3

= 15.1682 kg C2H4Br3

Weight of HBr = 4.6011 kg

Composition in stripper:

Component Weight %
C2H4 1.5924kg 0.1576%
C2H4Br2 655.9859 + 333.3333kg 97.87%
C2H4Br3 15.1682kg 1.5%
HBr 4.6011kg 0.46%
1010.6808 kg

2.4. Recycle

Recycle stream is primarily used in a chemical process in order to recover and reuse
unconsumed reactants. However, this is not the only reason for using a recycle stream
in a process. Some of the other uses of recycle streams are the following: (1) to
recover catalyst, (2) to dilute a process stream, (3) to control a process variable and (4)
to circulate a working fluid. Figure 5 shows a process with recycle stream.

Feed Unit 1 Unit 2 Product

Recycle

Figure 5. Flow Chart of a Process with Recycle Stream.

1. Balance on the whole system.

2. Balance on the process with in the recycle loop.
3. Balance on the mixing point.
4. Balance on the splitting point.
5. Make a solution.
Recycle to fresh feed ratio=R/F
Total feed to fresh ratio= T/F

Example:

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

3-50
/137Air conditioning system supplies 1000m3/min of air containing 0.01mol H2O/mole dry
air. It is at 20C and 1atm. To conserve energy, part of the exhaust air containing 0.08mol
H2O/mol dry air is recycled and mixed with the fresh air from the air conditioner to produce a
gross air feed to the room containing 0.035 mol H2O/mol dry air. How many kg of water is
picked up by the air per minute? What is the volumetric flow rate of the recycle stream?
(27C, 99kPa).

Recycle (R)
20C, 1atm 0.08mol H2O
mol dry air
gross air feed (T)
Air Conditioning
F P
x
1000m3/min 0.035mol H2O
0.01mol H2O mol dry air
mol dry air H2O (W)

Req’d: W(kg); R(m3)

Sol’n:
n = PV = (1atm)(1000m3/min) .
atmm3
RT (0.08205 /kgmolK)(20+273.15)
n = 41.5749 kgmol/min

OMB:
41.5749 + W = P

Unit Balance: T + W = x
@ mixing point: 41.5749 + R = T
@ splitting point: x = P + R

0.01mol H2O  0.01mol H2O .= 0.0099 mol H2O/mol sol’n

mol dry air 0.01mol H2O + 1 mol dry air

0.035mol H2O  0.0338 mol H2O/mol sol’n

mol dry air

0.08mol H2O  0.0741 mol H2O/mol sol’n

mol dry air

Solute Balances:

OMB: 0.0099(41.5749) + W = 0.0741P

- 41.5749 +W =P a
P = 44.4576 kgmol/min
W = P – 41.5749
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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

W = 44.4576 - 41.5749 = 2.8827 kgmol/min  18kg H2O /kgmol H2O

W = 51.8886 kg/min

Solution Balance @ mixing point:

0.0099 (41.5749) + R(0.0741) = T(0.0338)
- 0.0338 (41.5749) + R(0.0338) = T(0.0338)
R = 24.6561 kgmol/min

R = 24.6561 kgmol/min
V = nRT = (24.6561kgmol/min)(0.08205atmm3/kmoK)(273.15 + 27)K
P (99kPa)(1atm/101.325kPa)

R(V) = 621.4737 m3/min

Another solutuion:
R = (24.6561kgmol/min)  (22.4m3/kgmol)  (273.15+27)  (101.325kPa)
273.15 99kPa
R(V) = 621.9740 m3/min

2.5. Bypass

Bypass is a procedure in which a fraction of the feed to a process unit is diverted

around the unit and combined with the output stream from the unit.

Consider a flow chart for a unit process shown below:

Feed Process Product

Unit

Bypass stream

Figure 6. Flow chart of a process with bypass stream

By varying the fraction of the feed, which is bypassed, the composition and properties
of the product can be varied.
1. Balance around the whole system.
2. Process with in the bypass loop.
3. Balance on splitting point & mixing point.
4. Make a solution.

Example. 3-48/137
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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

It is desired to produce 7% NaNO3 solution continuously.

NaNO3 (N)
Saturation (x) 0.07% NaNO3, P
Water, W 500kg/hr Process 47.9%
NaNO3

The water line (NaNO3 free) is split into two: 500kg/hr is sent to a tank where NaNO 3
is added. The mixture is stirred well to form a saturated solution of NaNO 3 (47.9%). The other
line bypasses the tank and is mixed with the 47.9% solution. What is the flow rate of the
bypass stream and the final product?

OMB: W + N = P

Process: 500 + N = x

Split point: W = B + 500

Mixing point: x + B = P

Solution Balance:

OMB: N = 0.07P

Process: N = 0.479x

Mixed point: 0.479x = 0.07P

500 + 0.479x = x
500 = (1 – 0.479)x
x = 959.6929kg/hr

N = 0.479x
N = 459.6929kg/hr

N = 0.07P
P = 6567.0414kg/hr

W+N=P
W = 6107.3485kg/hr

W = B + 500
B = 5607.3485kg/hr

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

2.6. Purge

Purge is a procedure used to prevent material build up in processes that involve recycling. If
a material that enters with the fresh feed or is produced in a reaction remains entirely in a
recycle stream, rather than being carried out in a process product, the substance would
continuously enter the process and would have no way of leaving. It would therefore steadily
accumulate, making the attainment of steady state impossible. To prevent this from
happening, a portion of the recycle stream must be withdrawn as a purge stream to rid the
process of the undesired material. Figure 7 shows a process with purge stream.

Fresh Feed Unit 1 Unit 2 Product

Recycle Purge Stream

Figure 7. Flow Chart of a Process with Recycle and Purge Streams.

Example:

Product 98%C2H6
2% C6H6
Distillate

reflux
_______ 30% of reflux, purge stream, (P)
_______
_______
100 kg/day ____
40%C2H6
60% C6H6

bottoms, 5% C2H6
(B)

Solution:

OMB: 100 = D + B + P

Solute balance (C2H6): 0.4(100) = 0.98D + 0.98P + 0.05B

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Chemical Engineering Calculations Compiled by Mary Rose B. Flores

Relationship: R/D = 3/5; P = 0.3R

R = 3D/5
P = (0.3)(3/5)D

100 = D + B + (0.3)(3/5)D  (100= 1.18D + B) (1)

40 = 0.98D + 0.05B + (0.98)(0.3)(3/5)D  (40 = 1.1564D + 0.05B) (2)

Eliminate equation (1) & (2):

Multiply (1) by 0.05

5 = 0.059D + 0.05B
- 40 = 1.1564D + 0.05B)
-35 = - 1.0974D
D = 31.8936kg/day
B = 62.3656kg/day
P = 5.7408kg/day

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