Solved Problems in Chemical Process Calculations

1. Orsat Analysis
2. Natural Gas - Flue Gas and Orsat Analysis
3. Recycle Reactor
4. Recycle Reactor - 2 separators
5. Humidity
6. CCl4 Removal by Humidification
7. Humidification - determining vapor pressure
8. Solvent Recovery
9. Drying
10. Evaporation
11. Distillation
12. Extraction
13. Heat of Sublimation
14. Heat Required
15. Evaporation - Steam Required
16. Adiabatic Flame Temperature

1. A hydrocarbon is burnt with excess air. The Orsat analysis of the flue gas shows 10.81%
CO2, 3.78% O2 and 85.40 N2. Calculate the atomic ratio of C: H in the hydrocarbon and the
% excess air.

Calculations:

100 moles of dry flue gas (i.e., excepting H2O)

The Orsat analysis shows the compositions of the flue gases by not taking into account of H 2O.

From the composition of air(mole %),

Here, nitrogen is the tie component.

79 mole of N2 and 21 mole of O2

Therefore, O2 that is entering the burner = 85.4 x 21/79 = 22.7

C + O2  CO2

1 mole of CO2 h 1 mole of O2 h 1 atom of C ( i.e.,1 mole of O2 reacts with 1 atom of C to produce 1
mole of CO2)

Therefore, O2 used up for reacting with carbon = 10.81 mole and,

Carbon in the hydrocarbon = 10.81 atoms

O2 reacted with Hydrogen in the hydrocarbon = 22.7 - (10.81 + 3.78) = 8.11

4H + O2  2H2O

1
1 mole of O2 reacts with 4 atoms of hydrogen.

Therefore, hydrogen in the hydrocarbon = 8.11 x 4 = 32.44 atoms.

C:H ratio in the hydrocarbon = 1 : 32.44/10.81 = 1 : 3

Theoretical air demand = air needed for complete conversion of carbon to carbon dioxide and
hydrogen to water vapor

% excess air = 100 x (actual air used - theoretical air demand) / theoretical air demand
= 100 x (22.7 - (10.81 + 8.11))/( 10.81 + 8.11) = 20%

2. Calculate the theoretical flame temperature of a gas having 20% CO and 80% N 2 when
burnt with 150% excess air. Both the reactants are at 25oC.

Data:

Hof of CO2 = -94052 cal/gmol

Hof of CO = -26412 cal/gmol

Mean heat capacities in cal/gmol.oC are CO2 = 12, O2 = 7.9, N2 = 7.55

Calculations:

Basis : 1 mole of gas (having 20% CO and 80% N2)

Combustion reaction:

CO + 1/2 O2  CO2

Heat of reaction at 25oC for the above reaction is calculated as:

Heat of reaction = heat of formation of products - heat of formation of reactants

= -94052 - (-26412) = -94052 + 26412

= -67640 cal/gmol of CO converted

This represents exothermic heat of reaction.

Total heat liberated = 67640 x 0.2 = 13528 cal.

If a base temperature of 25oC is assumed, enthalpy of reactants at 25oC = 0 cal

Total enthalpy of product stream = enthalpy of reactants + heat added by reaction = 0

+ 13528 = 13528 cal.

This enthalpy rise of product stream with respect to feed is accomplished by a

temperature increase, if the reaction is in adiabatic conditions.

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Constituents of product stream are estimated as follows:

CO2 in the product stream = 0.2 gmol

O2 theoretically needed = 0.2 x 0.5 = 0.1 gmol.
O2 actually entering (150% excess) = 0.1 x 2.5 = 0.25 gmol
N2 entering along with O2 in the air = 0.25 x 79/21 = 0.9405 gmol
O2 in the leaving gases (assuming complete combustion of CO to CO 2)
= 0.25 - 0.1 = 0.15 gmol

N2 in the leaving gases = 0.9405 + 0.8 = 1.7405 gmol.

Adiabatic temperature (T) is calculated as follows:

13528 = 0.2 x 12 x (T - 25) + 0.15 x 7.9 x (T - 25) + 1.7405 x 7.55 x (T - 25)

i.e., 13528 = 16.726 (T - 25)
808.8 = T - 25

T = 808.8 + 25 = 833.8oC

Theoretical or Adiabatic flame temperature = 833.8oC.

3. Air at 30oC and 150 kPa in a closed container is compressed and cooled. It is found that
the first droplet of water condenses at 200 kPa and 15 oC. Calculate the percent relative
humidity of the original air. The vapor pressures of water at 15 oC and 30oC are 1.7051 kPa
and 4.246 kPa respectively.

Calculations:

At 15oC, and 200 kPa water is at 100% humidity.

Percentage humidity or percentage absolute humidity

= 100 x [pA(p - pS)]/[ pS(p - pA)]
= 100
Therefore,
pA/(p - pA) = pS/(p - pS)
where: pA = partial pressure of water vapor;
pS = vapor pressure of water vapor
p = total pressure of system

No. of moles of water vapor per mole of dry air = 1.7051/(200 - 1.7051) = 0.0086

This ratio (moles of water vapor / mole of dry air) is not going to change for a closed
system. Therefore, partial pressure of A at 30oC and 150 kPa is found as follows:

pA/(p - pA) = 0.0086

pA/(150 - pA) = 0.0086
pA + 0.0086 pA = 1.29
pA = 1.29/1.0086 = 1.279 kPa

Percentage relative humidity of the original air:

percentage relative humidity = 100 x (pA/pS) = 100 x 1.279/4.246 = 30.12%

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4. Carbon tetra chloride is to be removed from a polymer solution by bubbling dry air
through it at 297 K. The resulting mixture has % relative humidity of 70. It is required to
remove 90% of carbon tetra chloride present by compressing to a suitable pressure and
cooling to 283 K. What this pressure should be?

Data: Vapor pressure of CCl4 at 297 K = 12.2 kN/m2 and at 283 K = 6 kN/m2

Calculations:

Initial conditions:

Temperature = 297 K
Total pressure = 101 kN/m2
Relative humidity = pA/pS = 0.70
pA = 0.7 x 12.2 = 8.54 kN/m2
moles of CCl4 / moles of dry air = 8.54 / (101.3 - 8.54) = 0.09207
CCl4 present per mole of dry air = 0.09207 mole

Final conditions:

Temperature = 283 K
Total pressure = to be determined
Relative humidity = 100 %
CCl4 to be present in the exit air per mole of dry air = 0.09207 x 0.1
= 0.009207 mole

If the partial pressure of a vapor is greater than its vapor pressure, it will condense till
its partial pressure is equal to vapor pressure.

6/(pT - 6) = 0.009207
pT = 657.71 kN/m2
that is, the air mixture has to be compressed to 657.71 kN/m2 and cooled to 283 K to
remove 90% of carbon tetra chloride.

5. A solution of ethyl alcohol containing 8.6% alcohol by weight is fed at the rate of 5000
kg/hr to a continuous fractionating column operating at atmospheric pressure. The
distillate which is the desired product contains 95.4% alcohol by weight and the residue
from the bottom of the column contains 0.1% alcohol by weight. Calculate the following:
i. the mass flow rates of the distillate and residue in kg/hr, and
ii. the percentage loss of alcohol.

Calculations:

Overall material balance:

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Feed = Distillate + Residue

F=D+R
D + R = 5000 (1)

Component balance for Alcohol:

FxF = DxD + RxR

Where x 's are the mole fraction of alcohol in various streams.

0.954 D + 0.001 R = 5000 x 0.086 = 430 (2)

Equations 1 and 2 contains 2 unknowns D and R, and that can be solved as follows:

Multiplying equation 1 by 0.001,

0.001D + 0.001 R = 5 (3)

Subtracting equation 3 from equation 2,

0.953 D = 425
D = 446 kg/hr
Distillate flow rate = 446 kg/hr

Therefore, R = 5000 - 446 = 4554 kg/hr

Residue flow rate = 4554 kg/hr

Ethanol leaving in the residue (i.e., ethanol lost) = 4554 x 0.001 = 4.554 kg/hr

Ethanol entering in the feed = 5000 x 0.086 = 430 kg/hr

Percentage loss of ethanol = 100 x (4.554 / 430) = 1.06

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6. A stock containing 1.526 kg moisture per kg dry solid is dried to 0.099 kg moisture per
kg dry solid by countercurrent air flow. Fresh air entering contains 0.0152 kg water per kg
dry sir and the exit air has 0.0526 kg water per kg dry air. What fraction of air is recycled if
52.5 kg of dry air flows per 1 kg of dry solid inside the drier?

Calculations:

Basis: 1 kg of dry solid

Material balance for moisture in air:

Water in stream M+ moisture added by drying of solid = Water in stream D

From the problem statement, 52.5 kg dry air is flowing per kg of dry solid and exit air is
having a water content of 0.0526 kg per kg of dry air.

Therefore, water in the air leaving the dryer = 52.5 x 0.0526 = 2.7615 kg

Water added by drying of solid = 1.562 - 0.099 = 1.463 kg

Water in the stream M = 2.7615 - 1.463 = 1.2985 kg

Water in stream F + water in stream R = water in stream M

0.0152 F + 0.0526 R = 1.2985 (1)

and balance for dry air:

F + R = 52.5 (2)

Multiplying equation 2 with 0.0152,

0.0152 F + 0.0152 R = 0.798 (3)

subtracting equation 3 from equation 1,

0.0374 R = 0.5005
R = 13.382 kg

Substituting for R in equation 2,

F = 52.5 - 13.382 = 39.118 kg

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Recycle ratio = Recycle amount / fresh feed = 13.382 / 39.118 = 0.342

7. An evaporator is fed with10000 kg/hr of a solution containing 1% solute by weight. It is

to be concentrated to 1.5% solute by weight. The feed is at a temperature of 37oC. The
water is evaporated by heating with steam available at a pressure of 1.34 atm absolute,
corresponding to a temperature of 108.3oC. The operating pressure in the vapor space is 1
atm absolute. Boiling point elevation and other effects can be neglected. The condensate
leaves at the condensing temperature. All the physical properties of the solution may be
taken to be same as that of water. What is the quantity of steam required per hour?

Data:
Enthalpy of feed = 38.1 kcal/kg
Enthalpy of solution inside the evaporator (at 100oC) = 98 kcal/kg
Enthalpy of vapor at 100oC = 644 kcal/kg
Latent heat of vaporization of steam = 540 kcal/kg

Calculations:

Basis: 10000 kg/hr of solution containing 1% solute by weight.

Let us denote the feed stream as F and Concentrated solution stream as P, and water
evaporated as W and the concentration of solute as x

Balance on solute:

Solute in the feed = solute in the concentrated liquor

Fx = Px
10000 x 0.01 = P x 0.015

Therefore, P = 6666.7 kg/hr.

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And water evaporated (W) = F - P = 10000 - 6666.7 = 3333.3 kg/hr.

Enthalpy balance:

FHF + S s = WHW + PHP

Where: HF = enthalpy of feed = 38.1 kcal/kg

HW = enthalpy of water vapor = 644 kcal/kg
HP = enthalpy of product = 98 kcal/kg
 s = Latent heat of steam = 540 kcal/kg

Therefore,

10000 x 38.1 + S x 540 = 3333.3 x 644 + 6666.7 x 98

S = 4479.6 kg/hr

steam required = 4479.6 kg/hr.

8. An evaporator is fed continuously with 25 kg/hr of a solution which contains 10% NaCl,
10% NaOH and 80% H2O. During evaporation, H2O is removed from the solution and NaCl
precipitates as crystals which is settled and removed. The concentrated liquor leaving the
evaporator contains 50% NaOH, 2% NaCl and 48% H2O. Calculate
(i)Weight of salt precipitated per hour. (6)
(ii) Weight of concentrated liquor leaving per hour. (6)

Calculations:

Data:
Flow rate of feed = 25 kg/hr
Composition of feed (F):
NaCl 10%
NaOH 10%
H2O 80%
Composition of concentrated liquor (P):
NaCl 2%
NaOH 48%
H2O 50%

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Balance for NaOH:

NaOH entering the in feed = NaOH leaving in concentrated liquor

0.1 x 25 = 0.50 P

Therefore, the mass flow rate of concentrated liquor (P) = 0.1 x 25 / 0.50 = 5 kg/hr

Balance for NaCl:

NaCl entering in the feed = 25 x 0.1 = 2.5 kg/hr

The entering NaCl is coming out as crystals and in the concentrated liquor.

NaCl leaving in the concentrated liquor = 0.02 P = 0.02 x 5 = 0.1 kg/hr

Therefore,

NaCl precipitated = 2.5 - 0.1 = 2.4 kg/hr.

9. A liquid containing 47.5% acetic acid and 52.5% water is to be separated by solvent
extraction using isopropanol. The solvent used is 1.3 kg per kg of feed. The final extract is
found to contain 82% acid on solvent free basis. The residue has 14% acid on solvent free
basis. Find the percentage extraction of acid from the feed.

Calculations:

Basis: 1 kg of solvent free acid.

Acetic acid in the feed = 0.475 kg
Water in the feed = 0.525 kg

Entering acid has to come out in the extract and residue (raffinate) phases.

9
Let as denote the streams with the following representation.
Feed: F
Extract: E
Residue: R
Solvent: S

And the mass fractions of acetic acid (on solvent free basis) in various streams:

Acetic acid in the feed: xF

Acetic acid in extract: xE
Acetic acid in residue xR

And the mass fraction of acetic acid in the solvent is zero, since the solvent is a pure
one.

Balance on acetic acid:

FxF = ExE + RxR

1 x 0.475 = E x 0.82 + R x 0.14
0.475 = 0.82 E + 0.14 R (1)

Similarly writing the balance for water,

0.525 = (1 - 0.82) E + (1 - 0.14) R

0.525 = 0.18 E + 0.86 R (2)

Solving equations 1 and 2,

E = 0.493 kg, and

R = 0.507 kg.

Amount of acetic acid in the extract = 0.493 x 0.82 = 0.4043 kg.

Percentage extraction of acetic acid = 100 x Acetic acid in the extract / Acetic acid In
feed

= 100 x 0.4043/0.475 = 85.12

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10. Calculate the enthalpy of sublimation of Iodine from the following data:
H2(g) + I2(s)  2 HI(g) HR = 51.9 kJ
H2(g) + I2(g)  2 HI(g) HR = -9.2 kJ

Calculations:

H2(g) + I2(s)  2 HI(g) -- I HR = 51.9 kJ

H2(g) + I2(g)  2 HI(g) -- II HR = -9.2 kJ

From Hess's law of constant heat of summation,

Subtracting equation II from I gives,

I2(s) - I2(g) = 0 HR = 51.9 - (-9.2) = 61.1 kJ

I2(s) = I2(g) HR = 61.1 kJ

That is enthalpy of sublimation (transformation of iodine from solid phase to directly

vapor phase) of iodine is 61.1 kJ

11. The analysis of 15000 liter of gas mixture at standard conditions is as follows:

CO2 = 9.5%; SO2 = 0.5% ; O2 = 12.0% ; N2 = 78.0%.

How much heat must be added to this gas to change its temperature from 25 oC to 700oC?

Data: Specific heat values in kcal/(kmol.oK)

Gas CO2 SO2 O2 N2

Cp at 25oC 8.884 9.54 7.017 6.961
Cp at 700oC 11.303 11.66 7.706 7.298

Calculations:

Basis: 15000 litre of gas

22.4 litre is occupied by 1 gmol of gas at at 0oC.

Therefore, number of gmol of gas in the volume of 15000 litre at 25 oC, is estimated as:
PV = nRT (Ideal gas equation)

From the above equation,

n2P1V1/T1 = n1P2V2/T2

Here P1 and P2 are the same.

Therefore,
n2 x 22.4 / 273 = 1 x 15000 / (273 + 25)

n2 = 613.5 gmol = 0.6135 kmol

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 Component Mole fraction No of moles, kmol

CO2 0.095 0.6135 x 0.095 = 0.0583

SO2 0.005 0.6135 x 0.005 = 0.0031

O2 0.12 0.6135 x 0.12 = 0.0736

N2 0.78 0.6135 x 0.78 = 0.4785

Heat required (H) to raise the temperature from 25oC to 700oC is given by,

H =  niCPmi(T2 - T1) =  niCPmi (700 - 25)

Where ni is the moles of component 'i', and CPmi is the mean molal specific heat of
component 'i'.

The calculations are shown in the following table.

CP at
CP at 25oC CPm
700oC
Heat to be
Component kmol
kcal/(kmol kcal/(kmol.o added, kcal
kcal/(k
.oK) K)
mol.oK)

0.0583 x
(8.884 +
10.0935 x
CO2 0.0583 8.884 11.303 11.303)/2 =
(700 - 25) =
10.0935
397.2

SO2 0.0031 9.54 11.66 10.6 22.18

O2 0.0736 7.017 7.706 7.3615 365.72

N2 0.4785 6.961 7.298 7.1295 2302.74

Total heat to be added 3087.84 kcal

12. Methanol vapor can be converted into formaldehyde by the following reaction
scheme:

CH3OH + 0.5 O2  HCHO + H2O

CH3OH  HCHO + H2

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The fresh feed to the process was 0.5 kmol / hr of O 2 and an excess methanol. All of the O2
reacts in the reactor. Formaldehyde and water are removed from the product stream first,
after which H2 is removed from the recycled methanol. The recycle flow rate of methanol
was 1 kmol/hr. The ratio of methanol reacting by decomposition to that by oxidation was
3. Draw the flow diagram and then calculate the per pass conversion of methanol in the
reactor and the fresh feed rate of methanol.

Calculations:

The flow diagram for the above process is as given below:

From the problem statements,

a. all of the O2 entering, reacts in the reactor and

b. the ratio of methanol reacting by decomposition to that by oxidation = 3.

The number of moles taking parts in the reactions are given below:

CH3OH + 0.5 O2  HCHO + H2O (1)

1 0.5 1 1

CH3OH  HCHO + H2 (2)

1 1 1

From reaction 1,

0.5 mole of O2 h 1 mole of CH3OH

Therefore, for complete conversion of oxygen, 0.5 mole/hr of O 2 needs 1 mole/hr of

CH3OH.
And from the ratio of methanol conversion, methanol reacting by decomposition = 3
times that by oxidation = 3 mole/hr of CH3OH.

Therefore,

Total methanol entering the reactor = Methanol reacted by oxidation + methanol reacted
by decomposition + recycle methanol = 1 + 3 + 1 = 5 kmol/hr.

Conversion per pass = 100 x (Total methanol reacted /Total methanol entering the
reactor)

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 = 100 x 4/5 = 80%

Fresh methanol rate = Total methanol entering the reactor - recycle methanol

= 5 - 1 = 4 kmol/hr.

13. Natural gas containing 80% CH4, 15% C2H6 and 5% C3H8 is burnt with 50% excess air.
Assuming that 90% of the carbon in the hydrocarbons are converted to CO2 and the rest to
CO, determine
i. Flue gas analysis
ii. Orsat analysis

Calculations:

Basis: 1 mole of natural gas

Component Mole Atoms of C Atoms of H

CH4 0.80 0.8 x 1 = 0.8 0.8 x 4 = 3.2

C2H6 0.15 0.15 x 2 = 0.3 0.15 x 6 = 0.9

C3H8 0.05 0.05 x 3 = 0.15 0.05 x 8 = 0.4

Total 1.0 1.25 4.5

Reactions:

C + O2  CO2 -- I
C + 1/2 O2  CO -- II
H + 1/4 O2  1/2 H2O -- III

90% of Carbon is converted by reaction I, and 10% of carbon is converted by II.

Amount of CO2 produced = 1.25 x 0.9 = 1.125 mole

Amount of CO produced = 1.25 x 0.1 = 0.125 mole
Amount of H2O produced = 4.5 / 2 = 2.25 mole
Amount of O2 used by hydrocarbon = O2 used by reactions I, II and III.
= 1.125 + 0.125 x (1/2) + 4.5 x (1/4) = 2.3125 mole

Theoretical O2 needed = Oxygen for complete conversion of C to CO2 and H to H2O.

= 1.25 + 4.5 x (1/4) = 2.375 mole

Oxygen entering = 150% of theoretical = 1.5 x 2.375 = 3.5625 mole

Therefore, nitrogen entering = 3.5625 x 79/21 = 13.4018 mole = N 2 in the flue gas
O2 in the flue gases = O2 entering - O2 used = 3.5625 - 2.3125 = 1.25 mole

Flue gas analysis:

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 Component Moles Mole %

CO2 1.125 6.20

CO 0.125 0.69

H2O 2.25 12.39

O2 1.25 6.89

N2 13.4018 73.83

Total 18.1518 100

Orsat analysis (Water free):

Component Moles Mole %

CO2 1.125 7.07

CO 0.125 0.79

O2 1.25 7.86

N2 13.4018 84.28

Total 15.9018 100

Balance of Individual Reactions:

Basis: 1 mole of Natural gas

CH4 0.80

C2H6 0.15

C3H8 0.05

Total 1.0

CH4 + 2 O2  CO2 + 2 H2O 1

CH4 + 3/2 O2  CO + 2 H2O 2
C2H6 + 7/2 O2  2 CO2 + 3 H2O 3
C2H6 + 5/2 O2  2 CO + 3 H2O 4
C3H8 + 5 O2  3 CO2 + 4 H2O 5
C3H8 + 7/2 O2  3 CO + 4 H2O 6

In the above reactions CO2 is produced from reactions 1, 3 and 5.

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Since 90% of Carbon is converted to CO2 and 10% to CO,

CO2 produced = (1 x 0.8 + 2 x 0.15 + 3 x 0.05) x 0.9 = 1.125 mole

Similarly CO is obtained from reactions 2, 4 and 6.

CO produced = (1 x 0.8 + 2 x 0.15 + 3 x 0.05) x 0.1 = 0.125 mole

H2O produced = (2 x 0.8 + 3 x 0.15 + 4 x 0.05) x 0.9 + (2 x 0.8 + 3 x 0.15 + 4 x 0.05)
x 0.1 = 2.25 mole
O2 used up in these reactions = (2 x 0.8 + 3.5 x 0.15 + 5 x 0.05) x 0.9 + (1.5 x 0.8 +
2.5 x 0.15 + 3.5 x 0.05) x 0.1
= 2.3125 mole

Theoretical O2 needed = moles of O2 needed for Conversion of C to CO2 and H to H2O.

= 2 x 0.8 + 3.5 x 0.15 + 5 x 0.05 = 2.375 mole

O2 entering = 50 % excess = 150% of theoretical = 2.375 x 1.5 = 3.5625 mole

N2 entering along with O2 in the air = 3.5625 x 79/21 = 13.4018 mole (sine air is 21%
O2 and 79% N2 by volume).

O2 in the flue gas = O2 entering - O2 used up = 3.5625 - 2.3125 = 1.25 mole

N2 in the flue gas = N2 entering = 13.4018 mole
Therefore, for 1 mole of Natural gas entering, the flue gas coming out are:

Component Moles

CO2 1.125

CO 0.125

H2O 2.25

O2 1.25

N2 13.4018

Total 18.1518

On comparing with the data obtained from atomic balance and balance of individual
reactions, it can be seen that the results are same from either method. But instead of
lengthy calculations for individual reactions, we can very well make use of atomic
balances.

14. Nitrogen from a cylinder is bubbled through acetone at 1.1 bar and 323 K at the rate of
2 x 10-4 m3/min. The nitrogen, saturated with acetone vapor leaves at 1.013 bar, 308 K at
the rate of 3.83 x 10-4 m3/min. What is the vapor pressure of acetone at 308 K?

Calculations:

Using Ideal gas law, molal flow rate of nitrogen is calculated as follows:

Molal density of nitrogen m = n/V = P/RT = 1.1 x 105/(8314 x 323)

16
 = 0.04096 kmol/m3

Therefore, molal flow rate = 2 x 10-4 x 0.04096 = 8.1934 x 10-6 kmol/min

Similarly the molal density of leaving gases = 1.013 x 105/(8314 x 308) = 0.03956
kmol/m3

And the molal flow rate of leaving gases = 3.83 x 10-4 x 0.03956
= 1.5151 x 10-5 kmol/min

Since the molal rate of nitrogen is not going to change,

Molal flow rate of acetone in the leaving gases = 1.5151 x 10-5 - 8.1934 x 10-6
= 6.9578 x 10-6 kmol/min

Mole fraction of acetone in the leaving gases = 6.9578 x 10-6 / 1.5151 x 10-5
= 0.4592

And partial pressure of acetone in the leaving gases = 0.4592 x 1.013

= 0.4652 Bar

At saturation conditions, partial pressure of vapor is equal to its vapor pressure.

Therefore, vapor pressure of acetone at 308 K = 0.4652 Bar.

15. A solvent recovery system delivers a gas saturated with benzene (C 6H6) vapor that
analyzes on a benzene free basis as follows: CO2 - 15%; O2 - 4% and N2 - 81%. This gas is at
21oC and 750 mm Hg pressure. It is compressed to 5 atmospheres and cooled to 21 oC after
compression. How many kilograms of benzene are condensed by this process per 1000 m 3
of the original mixture?

Data: Vapor pressure of benzene at 21oC = 75 mm Hg.

Calculations:

Basis: 100 moles of Benzene free vapor.

At saturation,

pA/(p - pA) = pS/(p - pS)

where: pA is the partial pressure of benzene;

p is the total pressure of the system;
pS is the vapor pressure of benzene at system temperature.
Therefore,
pA = pS = 75 mm Hg

Sum of the partial pressure of benzene free gases is = 750 - 75 = 675 mm Hg.

Moles of Benzene/mole of benzene free gases at a total pressure of 750 mm Hg

= 75/675 = 0.1111

At a total pressure of 5 atm ( = 5 x 760 = 3800 mm Hg),

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Moles of benzene per mole of benzene free gases in the gas phase
= 75/(3800 - 75) = 0.0201.

The remaining moles of benzene condense into liquid phase.

Initial mole fraction of benzene in the gas mixture = 75/750 = 0.1

Partial volume of benzene in the gas mixture at the initial conditions = 0.1 x 1000 = 100
m3

Number of moles of benzene in the gas mixture at the initial conditions:

Using ideal gas equation,

P1V1/n1T1 = P2V2/n2T2
760 x 22.4/(1 x 273) = 750 x 100/(n2 x 294)
n2 = 4.091 kmol.

No. of moles of benzene in the gas mixture = 4.0909 kmol

And the number of moles of benzene free gas in the gas mixture
= 40.909 - 4.0909 = 36.8181 kmol.

Number of moles of benzene condensed

= No of moles of benzene in the gas mixture at initial conditions - at final
conditions
= 4.0909 - 0.0201 x 36.8181 = 3.3509 kmol.

Mass of benzene condensed = 3.3509 x molecular weight of benzene

= 3.3509 x 78 = 261.4 kg

16. The reaction A  2B + C takes place in a catalytic reactor (diagram is given below). The
reactor effluent is sent to a separator. The overall conversion of A is 95%. The product
stream from the separator consists of B, C and 0.5% of A entering the separator, while the
recycle stream consists of the remainder of the unreacted A and 1% of B entering the
separator. Calculate the
a. single pass conversion of A in the reactor
b. molar ratio of recycle to feed.

Calculations:

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Basis: 1 mole of pure A in the feed

From the reaction, A  2B + C

1 mole of A produces 2 moles of B and 1 mole of C for complete conversion.

From the problem statement, overall conversion is 95%. Therefore, 1 mole of feed A will
produce
2 x 0.95 mole of B , 1 x 0.95 mole of C and the unreacted A is 0.05 mole.

Product stream contains:

A : 0.05 mole
B : 1.9 mole
C : 0.95 mole

Material Balance for the compound B:

From the problem statement, B in the recycle stream = 1% of B entering the separator.

Therefore, B in the product stream = 99% of B entering the separator = 1.9 mole

Total B entering the separator = 1.9/0.99 = 1.919 mole

And, amount of B in the recycle stream = 1.919 x 0.01 = 0.019 mole.

Material Balance for the compound A:

From the problem statement, A in the product stream = 0.5% of A entering the
separator.

A in the product stream = 0.5% of A entering the separator = 0.05 mole.

Therefore, amount of A entering the separator = 0.05/0.005 = 10 mole.

And, the amount of A in the recycle stream

= Amount of A entering the separator - Amount of A in the product stream
= 10 - 0.05 = 9.95 mole.

Amount of A entering the reactor = fresh A + recycle A = 1 + 9.95 = 10.95 mole.

Amount of A converted in the reactor = moles of A entering the reactor - moles of A

entering the separator = 10.95 - 10 = 0.95 mole

Single pass conversion of A in the reactor

= 100 x Amount of A converted in the reactor / Amount of A entering the reactor

= 100 x (0.95/10.95) = 8.676%

Total moles of recycle stream = moles of A in recycle stream + moles of B in recycle

stream
= 9.95 + 0.019 = 9.969 mole

Molar ratio of recycle to feed = 9.969/1 = 9.969

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