Balances on Chemical Processes 15

1 Third Lecture
2
3 ‫رن‬
Example 10.3-2 Ethane is dehydrogenated ‫الهيدروجي‬ ‫ نزع‬to ethylene and acetylene in the
4 following pair of catalytic reactions:

5
6 The reactions take place at 1 atm and proceed to a point such that the product gas
7 composition satisfies the following equilibrium conditions:
𝑦𝐶2 𝐻4 𝑦 𝐻2 𝑦𝐶2 𝐻2 𝑦𝐻22
8 = 3.75 ; = 0.135
𝑦𝐶2 𝐻6 𝑦𝐶2 𝐻6
9 Where yi is mole fraction. The product gas goes to a separation process that separates 95%
10 of the unreacted ethane and recycles to the reactor, and ethane feed to the reactor is 100
11 mol/s.
12 a) Set up the equations for all unknown stream variables,
13 b) Perform a df analysis on the process
14 c) Outline a manual calculation procedure to determine the compositions of all streams.
15 d) Determine the compositions of all streams and fill the Data Sheet Table.
16 Solution:

𝑛1,𝐶2 𝐻6 𝑛2, 𝐶2𝐻6 = 100 𝑛3 𝑛4

𝑛3,𝐶2 𝐻6 𝑛4,𝐶2 𝐻6
𝑛3,𝐶2 𝐻4 𝑛3,𝐶2 𝐻4
𝑛3,𝐶2 𝐻2 𝑛3,𝐶2 𝐻2
𝑛3,𝐻2 𝑛3,𝐻2
𝑛5,𝐶2 𝐻6
17
18
 Balances on Chemical Processes 16

1 a) The df analysis proceeds in the customary manner.

Mixing Point 2 Variables (𝒏𝟏,𝑪𝟐 𝑯𝟔 , 𝒏𝟓,𝑪𝟐 𝑯𝟔 )
- 1 Ethane Material Balance

1 Local df

Reactor 9 Variables (𝑛3 , 𝑛3,𝐶2 𝐻6 , 𝑛3,𝐶2 𝐻4 , 𝑛3,𝐶2 𝐻2 , 𝑛3,𝐻2 )

𝑦3,𝐶2𝐻6 , 𝑦3,𝐶2𝐻4 , 𝑦3,𝐶2 𝐻2 , 𝑦3,𝐻2
- 1 Total Material Balance
- 4 C2H6, C2H4 , C2H2 and H2 Material Balances
𝑛3,𝐶2 𝐻6
- 4 Mole fractions (physical constraints) for example 𝑦𝐶2 𝐻6 = 𝑛3
- 2 Equilibrium relations
𝑦𝐶2 𝐻4 𝑦 𝐻2 𝑦𝐶2 𝐻2 𝑦𝐻22
= 3.75 ; = 0.135
𝑦𝐶2 𝐻6 𝑦𝐶2 𝐻6
- 2 Chemical Reaction equation ‫عدد المعادالت بعدد التفاعالت‬
- 4 Local df

Separation 8 Variables (𝑛3 , 𝑛4 , 𝑛3,𝐶2 𝐻6 , 𝑛3,𝐶2 𝐻4 , 𝑛3,𝐶2 𝐻2 , 𝑛3,𝐻2 𝑛5,𝐶2 𝐻6 𝑛4,𝐶2𝐻6 )

Process -1 Total Material Balance
- 4 C2H6, C2H4 , C2H2 and H2 Material Balances
- 1 Additional relation (95% of the ethane fed leaves with the product)
2 Local df

Process - 1 Local df (1- 4 + 2)

- 6 Tie variables (𝑛3 , 𝑛3,𝐶2 𝐻6 , 𝑛3,𝐶2 𝐻4 , 𝑛3,𝐶2 𝐻2 , 𝑛3,𝐻2 𝑛5,𝐶2 𝐻6 )
- 7 Overall df
2
 Balances on Chemical Processes 17

1 b)
2 Mixing Point
3 100 = 𝒏𝟏,𝑪𝟐 𝑯𝟔 + 𝒏𝟓,𝑪𝟐 𝑯𝟔 (1)
4
5 Reactor
6 Chemical Reaction equation: We will use the extent of reaction method ],

7
‫ن‬
8 ‫موازنة المادة للمفاعل يف حالة عدم معرفة نسبة التحول‬
9 𝑛3,𝐶2 𝐻6 = 100 − 𝜉1 − 𝜉2 ‫الغي متفاعل‬
‫االيثان الخارج ر‬ (2)
10 𝑛3,𝐶2 𝐻4 = 𝜉1 ‫رن‬
‫االثيلي الناتج‬ (3)
11 𝑛3,𝐶2 𝐻4 = 𝜉2 ‫رن‬
‫االستيلي الناتج‬ (4)
12 𝑛3,𝐻2 = 𝜉1 + 2𝜉2 ‫رن‬
‫الهايدروجي الناتج‬ (5)

13 𝑛3 = 100 − 𝜉1 + 2𝜉2 ‫بالجمع‬ (6)

14 Mole fraction equations
𝑛3,𝐶2 𝐻6 100 − 𝜉1 − 𝜉2
15 𝑦𝐶2 𝐻6 = = (7)
𝑛3 100 − 𝜉1 + 2𝜉2
𝑛3,𝐶2 𝐻4 𝜉1
16 𝑦𝐶2 𝐻4 = = (8)
𝑛3 100 − 𝜉1 + 2𝜉2
𝑛3,𝐶2 𝐻2 𝜉2
17 𝑦𝐶2 𝐻2 = = (9)
𝑛3 100 − 𝜉1 + 2𝜉2
𝑛3,𝐻2 𝜉1 + 2𝜉2
18 𝑦𝐻2 = = (10)
𝑛3 100 − 𝜉1 + 2𝜉2
𝑦𝐶2 𝐻4 𝑦 𝐻2
19 = 3.75 (11)
𝑦𝐶2 𝐻6
𝑦𝐶2 𝐻2 𝑦𝐻22
20 = 0.135 (12)
𝑦𝐶2 𝐻6
21 It can be substituted into the given equilibrium relations to yield the following equations:

22 …………………. (A)

23 …………..…. (B)
 Balances on Chemical Processes 18

1 Separation Process
2 𝒏𝟑,𝑪𝟐𝑯𝟔 = 𝒏𝟓,𝑪𝟐 𝑯𝟔 + 𝒏𝟔,𝑪𝟐 𝑯𝟔 Ethane Material Balance (13)
3 𝒏𝟔,𝑪𝟐𝑯𝟔 = 0.95 × 𝒏𝟑,𝑪𝟐 𝑯𝟔 95% recovery (14)
4
5 c) Examining the 14 equations, we see that two are nonlinear (Equations A and B). Rewrite
6 each of the two equations (A and B) in the form f(ξ1, ξ2) = 0
7 Equation A becomes

8
9 Equation B becomes

10
11
12 d) These two equations may be solved simultaneously using an equation-solving program or
13 a numerical procedure like the Newton–Raphson method.
14 The solution is ξ1 = 83.06 mol, ξ2 = 6.127 mol.
15
16 Data Sheet

Stream No 1 2 3 4 5
C2H6 (mol/s) 89.73 100 10.81 95.32 10.27
C2H4 (mol/s) 0 0 83.06 83.06 0
C2H2 (mol/s) 0 0 6.13 6.13 0
H2 (mol/s) 0 0 95.32 95.32 0
Flow rate (mol/s) 89.73 100 195.32 279.83 10.27
Phase Gas Gas Gas Gas Gas
Pressure (atm) 1 1 1 1 1
17
 Balances on Chemical Processes 19

1 Example 10.1-2 Methanol may be produced from carbon monoxide and hydrogen in the
2 reaction

3
4 The fresh feed, (CO and H2), enters the process at a rate of 2.2 m3/s at 25 °C and 6.0 MPa
5 and combines adiabatically with a recycle stream. The combined stream is heated to 250 °C
6 and fed to the reactor. The reactor effluent emerges at the same temperature and is cooled
7 to 0 °C at P = 6.0 MPa in condenser, partially condensing the methanol product. The gas
8 leaving the condenser is saturated with methanol: 1% is taken off for process monitoring
9 purposes and the remainder is recycled. An overall CO conversion of 98% is achieved. The
10 ratio of H2 to CO is 2 mol H2/1 mol CO everywhere in the process system. Ideal gas behavior
11 may be assumed.
12 a) Carry out a df analysis for this process
13 b) Outline a manual calculation procedure to determine the compositions of all streams,
14 c) Compute the temperature after mixing point.
15 d) Compute the required heat duties for all process units,
16
17 Solution

18
19 ‫المثاىل‬ ‫رن‬
‫نستعي بقانون الغاز‬ ‫الموىل‬ ‫الحجم اىل‬ ‫لتحويل معدل الجريان‬ 
‫ي‬ ‫ي‬ ‫ي‬
20 .‫تغي بالطور‬
‫لمية المادة الداخلة نفسها الخارجة الي مبادل حراري اذا لان اليوجد ر‬ 
21 .‫متغية‬ ‫ر‬ 
‫ تجرى له موازنة طاقة الن درجة الحرارة ر‬adiabatic ‫اديباب‬
‫ي‬ ‫اي نظام‬
22 .‫النجري موازنة طاقة‬isothermal ‫اي نظام ثابت درجة الحرارة‬ 
23 ‫او‬.Purge ‫ او لتنقية النظام‬Sample ‫) لتحليلها ومعرفة المكونات‬%1 ‫احياننا نحتاج الخذ عينة من المجرى (مثال‬ 
24 .‫ الكمية قليلة فنتجاهلها بالحسابات‬.Injection ‫لحقن مادة معينة‬
 Balances on Chemical Processes 20

5
6 b) The solution of the system equations
7  Calculate n0 by the ideal gas equation.
8 Given P and T, solve for 𝑉̂ .
9  Calculate n3 from the specified overall CO conversion (Conversion f= (no – n3)/ no).
10  Calculate n6 by Raoult’s law at the condenser.
11  Calculate n5 from an overall carbon balance.
12  Calculate n1 and n2 by Balances on CO and CH3OH at the mixing point.
13 c) Calculate Ta by an energy balance at the mixing point.
14 d) (1) Calculate Qh by An energy balance on the preheater. (2) Calculate n4 from a
15 methanol balance on the condenser. (3) Calculate Qr and Qc by energy balances on the
16 reactor and the condenser, respectively.
 Balances on Chemical Processes 27

1 Revision of Material Balance on Reaction

2 (a) Fractional Conversion ‫ نسبة التحول‬of the reactant is :
𝑚𝑜𝑙𝑒𝑠 𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑛̇ 𝐴𝑜 − 𝑛̇ 𝐴
3 𝑓= = (4.6 − 2)
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑓𝑒𝑒𝑑 𝑛̇ 𝐴𝑜
4 Rearrangement,
5 𝑚𝑜𝑙𝑒𝑠 𝑢𝑛𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑛̇ 𝐴 = 𝑛̇ 𝐴𝑜 (1 − 𝑓)
6 ‫دائما تحسب للمادة المحددة التي تنفذ اوال‬
7 (b) Extent of Reaction (ξ) Molar flow rate of species i in the final state is, ‫امتداد التفاعل‬
8 ṅ𝑨 = ṅ𝑨𝒐 + 𝝂𝑨 𝝃 𝟒. 𝟔 − 𝟑
9 ṅA is molar flow rate of species A in the product, ‫موالت المادة الغير متفاعلة‬
10 ṅAo is molar flow rate of species A in the feed,
11 vA is stoichiometric coefficient, making it negative for reactants and positive for products.
12 ξ = ( ṅAo – ṅA )/ νA
13 ‫ " قيمة واحدة لكل تفاعل ودائما تحسب للمادة المحددة‬ξ

14 Example: N2 + 3H2 → 2NH3

15 The feed to a continuous reactor consists of 100 mol/s of nitrogen, 300 mol/s of hydrogen.
16 A fractional hydrogen conversion is 0.6. Calculate the outlet flow rate of hydrogen, nitrogen
17 and ammonia.
18
19 Solution
N2 + 3H2 → 2 NH3 ‫بعد الحسابات‬
In (Reactants) Out (Products) Results (mol/s)
𝑛̇ 𝑁2 = 100 mol/s 𝑛̇ 𝑁2 41
𝑛̇ 𝐻2 = 300 mol/s 𝑛̇ 𝐻2 120
𝑛̇ 𝑁𝐻3 = 0 𝑛̇ 𝑁𝐻3 121
𝜉 61
20
21 ṅ𝑨 = ṅ𝑨𝒐 + 𝝂𝑨 𝝃 𝟒. 𝟔 − 𝟑
22 𝑛̇ 𝐻2 = 300 − 3 𝜉 (1)
23 𝑛̇ 𝑁2 = 100 − 𝜉 (2)
24 𝑛̇ 𝑁𝐻3 = 2𝜉 (3)
25 𝒏̇ 𝑨 = 𝒏̇ 𝑨𝒐 (𝟏 − 𝒇) 𝟒. 𝟔 − 𝟐
26 𝑛̇ 𝐻2 = 300 (1 − 0.6) = 120 (4)
27 ‫اربع معادالت بأربع مجاهيل تحل اليجاد المجاهيل‬