+ Draw one box for each process unit. Label each box as a Mixer, Reactor, Splitter or Separator + Draw lines for input and output + One line for a stream that is mixture of compounds + Asystem can be a single process unit, a group of units, or an entire process + Group together several process units into a single system if you do not need to know anything about the process streams that connect the unitsChoose compounds as components if reaction with known stoichiometry Choose elements as components if reaction with unknown stoichiometry Choose composites as components if no reaction If there are N components in a stream, there are N stream variables. The N stream variables can be the quantities or flow rates of each of the N components, or they can be the total quantity or flow rate of the stream plus (N-1) mole or mass fraction. + Use moles if reaction with known stoichiometry + Use either mole or mass if there is no reaction or if elements are chosen as components.The input of raw material or the output of desired product is often a convenient basis Change basis based on need, and finally scale up or scale down as per final requirement For each reaction of known stoichiometry with N reactants and products, there are N system variables for generation + consumption and N-1 equations relating generation and consumption variables through stoichiometric coefficients. Accumulation is zero for continuous or steady state process+ Be careful for hidden specification, e.g. Splitter output streams have same composition + If there are N components in the system, there are N independent material balance equations + Abalance equation on total mass can replace one of the component material balance equations+ Solve the equation with the fewest number of unknown variables first + Don't skip this step ! + If you have used component material balance equation to solve the problem, use the total mass balance equation to check the solutionYour Job is to design a mixer to produce 200kg/day of battery acid. The mixer will operate continuously and at steady state. The battery acid products must contain 18.6 wt% H2SO4 in water. Raw materials available include a concentrated H2SO4 at 77wt% in water and pure water. Prepare PFD for the system. Your Job is to design a mixer to produce 200kg/day of battery acid. The mixer will operate continuously and at steady state. The battery acid products must contain 18.6 wt% H2S04 in water. Raw materials available include a concentrated H2SO4 at 77wt% in water and pure water. Prepare PFD for the system. Fl = 48.3 kg/d Wsi = 0.77, F3 = 200 kg/d F2 = 151.7 kg/d Ww2=1.0Ammonia Synthesis. A gas mixture of hydrogen an nitrogen is fed to a reactor, where they react to form ammonia. The nitrogen flow rate into the reactor is 150 gmol/h and hydrogen is fed at a ratio of 4gmol N2. Of the N2 fed to reactor 70% is consumed by reaction, The reactor operate at steady state. What is the flow rate (gmol/h) of N2, H2 and NH3 in outlet? Summarize your results in a table. Sr a ee aS oor) Pony PonyFruit juice is a complex mixture of water, fructose, pulp, citric and other acids, acetates and other chemicals. Fresh fruit juice from Fruity-fresh farm contains 88wt%water. A fruit juice processor buys a batch of 2680 kg fresh juice from Fruity-fresh and make concentrated juice by filling an evaporator with the fresh juice, evaporating 75% of water and then removing the concentrated juice. How much water must the evaporator remove? If processor pays Rs 9 per kg for the fresh juice and sells the concentrated juice at Rs50 per kg, can he make profit? Howmuch? 1770kg water Fresh juice Concentrated juice 2360kg water 590kg water 320kg solids 320kg solids1770kg water Fresh juice Concentrated juice 2360kg water 590kg water 320ka solids 320kq solids (910 kg conc juice * Rs 50 per kg) ~ (2680 kg fresh juice * Rs 9 per kg) = 45500- 24120 = Rs21380 Fresh farm squeezes 275 tons of juice per month at the Farm. They plan to sell 82% of their juice to processor, who will make frozen concentrated juice. The processor pays Rs7.5 per kg of juice solids. Some 17% of the juice will be bottled and sale in market for Rs30 for 2L bottle. The farm will keep remainder for themselves. What are the annual sale for the farm?You have a summer training with a company that is interested in building a plant to manufacture the painkiller ibuprofen [2- (p-isobutylphenyl) propionic acid, C13H802] using a new reaction scheme. Your assignment is to collect some data on one of the reactions, as a first step in designing a full-scale reactor. In one experiment you mix 134g of isobutylbenzene (IBB, C10H14) with 134 g acetic anhydride (AAn, C4H603) in a laboratory scale batch reactor, adjust the temperature and wait 1 hour, At the end of 1 hour you stop the reaction, collect. all the material in pot and send it for chemical analysis. The report comes back that the pot contains, IBB, Aan, isobutylacetophenone (IBA, C12H160) and acetic acid (Aac, CH3COOH). Unfortunately, someone spilled coffee on the report and all you can read is the amount of acetic acid:68g. Your boss is upset — he needs that data right away. Here is the opportunity to come to the rescue and impress your boss, can you? Elements as components, unknown stoichiometry 134g IBB 2 IBB 134g AAn ? Aan 21BA 68g AAc Gy = € put into reactor taken out of reactor Hy) =H putin reactor Hy = H taken out of reactor 0.) =O put into reactor Oy = O taken out of reactorWe know the grams of IB and AAn placed in the reactor, and the grams of AAc removed. But we don’t know the moles of each element. We calculate these values from the grams of compounds and the molar ‘mass and the chemical formula of each compound: m, wen where n,, = moles of element h in compound i, n, = moles of com- pound i, €,, = moles of element h per mole of compound i, m, = mass of compound i, and M, = molar mass of compound i. Itis easy to summarize these calculations in table form. My = Epi For stream m M fa Ma Emon Pk Compound (g)__(e/gmol) (gmol) (gmol) (gmol) TBB,CyH,, = 134134 10 10 414 o 0 AAn, CHO, 134102 452556 788 33.94 We simply sum up the correct column to find our stream variables: Cyy = 10 + 5.255 = 15.255 gmol Hy = 14 + 7.88 = 21.88 gmol Oy = 0 + 3.94 = 3.94 gmolFor stream 2: ee mM, fan fa Mar Compound __(g)__(w/emol) (gmol) (emo!) 1070) BB, CH M410 yp o 0 4 nsacy 3m ganz) AARCHO) Mmm «($12 4 Gq 3 aM mas miwaty BBACyH,O mang «175 ag 6 1 w@ 2 267 4 2226 Ade CHO, 68 Steps 6, 7, and 8. Define system variables, list specifications, write material ‘balances. Even though there are chemical reactions, we have cho- sen elements as our components, and elements cannot be generated or consumed. Therefore generation = consumption = 0. There is nothing in the reactor before the beginning of the experiment, and all is removed at the end, so accumulation = 0. There are no addi- tional specifications given. The material balance equations are quite simple: Gn = CaySteps 9.and 10. Solve and check By substituting into the material balance equations the expressions we derived for each stream variable, we end up with three equations in three unknowns, Lamang) + ag + 2267 Mm ip5.) | 8M rue J6miga, 21.88 = eh, ata 2 134 10. + 7g + 4.533 Smannay "nary <2 tag + 2267 ‘We solve simultaneously to find Misp(2) = 1.6 g Maani2)= 22.9 g Mair) = 175.5 9To check the solution, we check that the total mass in equals the total mass out: 134g + 134g = 16g + 22.984 1552+ 68g 268 g = 268 g Air is used throughout’ process plant to move control valves (special valves that regulate flow). Ifthe air is humid, it needs to be dried before being used. To pro- duce dry air for instrument use, filtered and compressed humid room air at 83°F and 1.1 atm pressure, containing 1.5 mol% HO (as vapor), is pumped through a tank at 2 flow rate of 100 ft'/min, The tank i filled with 60 Ibs of alumina (Al,0;) pellets. ‘The water vapor in the air adsorbs (sticks) onto the pellets. Dry instrument air, con- taining just 0.06 mol% H,O, exits from the tank. The maximum amount of water that can adsorb to the alumina pellets is 0.22 tb H,O per Ib alumina. How long can the tank be operated before the alumina pellets need to be replaced?