CHEE2001

Process Principles

Week 3 – Tutorial 1
Plan for Today

1. Psychrometric charts and air-water system

2. Multi-unit system mass balancing exercises

3. NaCl/KCl production problem

Warm up

What is this a photo of?

 Reading a psychrometric chart
Data at a point:
Red Dry bulb temperature (oC)
Yellow Moisture content (kg H2O/kg dry air)
Dew point temperature (oC)
Purple Relative humidity (%)
Blue Humid volume (m3/kg dry air) *
Green Enthalpy at saturation (kJ/kg dry air) *
Wet bulb temperature (oC)

Notes:
*volume of the (air + moisture) divided by the mass of dry air
*enthalpy of the (air + moisture) divided by the mass of dry air

CHEE2001
4
CRICOS code 00025B
 Q1: Psychrometric chart

Air at 25 oC and relative humidity of 20%.

a) Absolute humidity = 0.004 kg water/ kg dry air

b) Humid volume = 0.85 m3/kg dry air
Q2 : Air conditioner solution

Q2 a) Cool air
T2 = 23 oC
RH2 = 25%.
Hot humid air
V1 = 150 m3/h
Air
conditioner
T1 = 35 oC
RH1 = 40%

Water
Legend
V vol flowrate m3/h
T Temperature oC
RH Relative humidity %
 Q2: Air conditioner

Q2 b)
Stream 1 - Air at 35 oC and relative humidity of 40%
moist. content = 0.014 kg/kg dry air
humid volume = 0.892 m3/kg dry air

Stream 2 - Air at 23 oC and relative humidity of 25% 1

moist. content = 0.004 kg/kg dry air

2
Q2 : Air conditioner solution
Cool air
DA2
W2 Legend
V vol flowrate m3/h
DA mass flow dry air kg/h
Hot humid air V1 = 150 m3/h Air W mass flow water kg/h
DA1 = 168.2 conditioner
W1 = 2.35

Water
W3

Q2 c) Mass flowrate calcs:

Stream 1: Humid volume = 0.892 m3/kg dry air

so DA1 = (150 m3/h )* (1/0.892 m3/kg dry air) = 168.2 kg dry air/h
and W1 = (168.2 kg dry air/h) * 0.014 kg water/ kg dry air) = 2.35 kg water/h
Q2 : Air conditioner solution
Cool air
DA2
W2 Legend
V vol flowrate m3/h
DA mass flow dry air kg/h
Hot humid air V1 = 150 m3/h Air W mass flow water kg/h
DA1 = 168.2 conditioner
W1 = 2.35

Water
W3

d) DOF Analysis
# unknowns = 3 (DA2, W2, W3)
# component bal = 2 (DA, W)
# other equations = 1 (W2 = DA2 * 0.004)
DOF =0 therefore can be solved
Q2 : Air conditioner solution
Assumptions: Steady state so no accumulation
No reactions so no generation or consumption

General Mass Balance (GMB):

Accumulation = Input – Output + Generation – Consumption
Simplified GMB: 0 = Input – Output

Balances:
Dry air: 0 = 168.2 – DA2
Water: 0 = 2.35 - W2 - W3

Other equation: W2= 0.004 * DA2

Solving:
DA2 = 168.2 kg/h
W2 = 0.67 kg/h
W3 = 1.68 kg/h

e) Ans: Flowrate of water leaving the air conditioner = 1.68 kg/h

Q3: Orange juice solution
M4
xw4 = 1.0

M1 M2 M5 M6
Splitter Evaporator Mixer
xO1 = 0.12 xO2 = 0.12 xO5 = 0.58 xO6 = 0.42
xw1 = 0.88 xw2 = 0.88 xw5 = 0.42 xW6 = 0.58

M3
xO3 = 0.12
xw3 = 0.88
Legend
M mass kg
x mass fraction
O Orange juice solids
W Water
Orange juice solution

M4
xw4 = 1.0

M1 M2 M5 M6
Splitter Evaporator Mixer
xO1 = 0.12 xO2 = 0.12 xO5 = 0.58 xO6 = 0.42
xw1 = 0.88 xw2 = 0.88 xw5 = 0.42 xW6 = 0.58

M3
xO3 = 0.12
xw3 = 0.88
Legend
M mass kg
x mass fraction
DOF – Overall system O Orange juice solids
# unknowns = 3 (M1 M4 M6) W Water
# component bal = 2 (orange juice, water)
DOF =1 therefore underspecified
Orange juice solution
M4
xw4 = 1.0

M1 M2 M5 M6
Splitter Evaporator Mixer
xO1 = 0.12 xO2 = 0.12 xO5 = 0.58 xO6 = 0.42
xw1 = 0.88 xw2 = 0.88 xw5 = 0.42 xW6 = 0.58

M3
xO3 = 0.12
xw3 = 0.88
Legend
M mass kg
x mass fraction
DOF – Splitter O Orange juice solids
# unknowns = 3 (M2 M3) W Water
# ind. comp bal = 1 (orange juice)
DOF =2 underspecified, therefore can’t be solved
Orange juice solution
M4
xw4 = 1.0

M1 M2 M5 M6
Splitter Evaporator Mixer
xO1 = 0.12 xO2 = 0.12 xO5 = 0.58 xO6 = 0.42
xw1 = 0.88 xw2 = 0.88 xw5 = 0.42 xW6 = 0.58

M3
xO3 = 0.12
xw3 = 0.88
Legend
M mass kg
x mass fraction
DOF – Evaporator O Orange juice solids
# unknowns = 3 (M2 M4 M5) W Water
# component bal = 2 (orange juice, water)
DOF =1 therefore can’t be solved
Orange juice solution
M4
xw4 = 1.0

M1 M2 M5 M6
Splitter Evaporator Mixer
xO1 = 0.12 xO2 = 0.12 xO5 = 0.58 xO6 = 0.42
xw1 = 0.88 xw2 = 0.88 xw5 = 0.42 xW6 = 0.58

M3
xO3 = 0.12
xw3 = 0.88
Legend
M mass kg
x mass fraction
DOF – Mixer O Orange juice solids
# unknowns = 3 (M3 M5 M6) W Water
# component bal = 2 (orange juice, water)
DOF =1 therefore can’t be solved
 Orange juice solution
M4
xw4 = 1.0

M1 = 100 M2 M5 M6
Splitter Evaporator Mixer
xO1 = 0.12 xO2 = 0.12 xO5 = 0.58 xA6 = 0.42
xw1 = 0.88 xw2 = 0.88 xw5 = 0.42 xW6 = 0.58

M3
xO3 = 0.12
xw3 = 0.88
Legend
M mass kg
x mass fraction
O Orange juice solids
W Water
Assume a basis of 100kg feed, DOF for overall system = 0.
So, start mass balancing with the overall system.
Orange juice solution
General Mass Balance (GMB):
Accumulation = Input – Output + Generation – Consumption

Assumptions: Steady state, no generation, no consumption

Simplified GMB: 0 = Input – Output

Balances around whole system:

Overall: 0 = 100 – M4 – M6
Orange juice: 0 = 100 * 0.12 – M6* 0.42
Water: 0 = 100 * 0.88 – M4 - M6 * 0.58
Solving:
M4 = 71.4 kg
M6 = 28.6 kg

Ans c) So, 28.6 kg product produced per 100 kg feed

Orange juice solution
M4 = 71.4
xw4 = 1.0

M1 = 100 M2 M5 M6 = 28.6
Splitter Evaporator Mixer
xO1 = 0.12 xO2 = 0.12 xO5 = 0.58 xO6 = 0.42
xw1 = 0.88 xw2 = 0.88 xw5 = 0.42 xW6 = 0.58

M3
xO3 = 0.12
xw3 = 0.88
Legend
M mass kg
x mass fraction
Back to Mixer: O Orange juice solids
DOF – Mixer W Water
# unknowns = 2 (M3 M5 )
# component bal = 2 (orange juice, water)
DOF =0 therefore can be solved
Orange juice solution
General Mass Balance (GMB):
Accumulation = Input – Output + Generation – Consumption

Assumptions: Steady state, no generation, no consumption

Simplified GMB: 0 = Input – Output

Balances around Mixer:

Overall: 0 = M3 + M5 – 28.6
Orange juice: 0 = M3* 0.12 + M5* 0.58 – 28.6 * 0.42
Water: 0 = M3* 0.88 + M5* 0.42 – 28.6 * 0.58
Solving:
M3 = 9.95 kg
M5 = 18.65 kg
Orange juice solution
M4 = 71.4
xw4 = 1.0

M1 = 100 M2 M5 = 18.65 M6 = 28.6

Splitter Evaporator Mixer
xO1 = 0.12 xO2 = 0.12 xO5 = 0.58 xO6 = 0.42
xw1 = 0.88 xw2 = 0.88 xw5 = 0.42 xW6 = 0.58

M3 = 9.95
xO3 = 0.12
xw3 = 0.88
Legend
M mass kg
x mass fraction
Back to Splitter O Orange juice solids
DOF – Splitter W Water
# unknowns = 1 (M2)
# ind. comp bal = 1 (orange juice)
DOF =0 therefore can be solved
Orange juice solution
General Mass Balance (GMB):
Accumulation = Input – Output + Generation – Consumption

Assumptions: Steady state, no generation, no consumption

Simplified GMB: 0 = Input – Output

Balances around Splitter:

Overall: 0 = 100 – M2 – 9.95

Solving:
M2 = 90.05 kg

Ans d) Bypass rate = M3 / 100 = 9.95/100 = 10% of the fresh feed

 Q4: NaCl/KCl problem
Salt Production

You are the senior process engineer on this plant and the Managing Director has heard disturbing rumours that
production of the mixed sodium chloride/potassium chloride product is well below the target value of 900 tonnes
per day. You have 20 minutes before the Managing Director is going to phone and demand some specific
answers. You have hurriedly sent the junior engineer out onto the plant to obtain actual material flows and
compositions. He has just returned with the information which is printed underneath the flow sheet and claims
that this is sufficient information to produce a unique solution and a full mass balance.

1. Is the junior engineer correct in his claim about a unique solution and full solution to the mass balance?

2. What are you going to tell the Managing Director when he phones?

Remember - you have only 20 minutes to come up with the answers!

 NaCl/KCl Problem - Flowsheet
4 5 9
2 8

1 3 6 7 Thermal 10
Feed Solar Evap Solar Xtall’n Mixer KCl
Xtall’n
Xtall’n.
11 NaCl/KCl
product
12

14 13
Osmosis Purge

Stream 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Feed Water Solar Water NaCl Conc Mixer Water NaCl Brine NaCl/KCl To Purge Recycle
Evap brine out product osmosis
outlet
Flow (tpd) 100 000 2 000 900 ?
NaCl (wt%) 3 18 100 18 100 5 3
KCl (wt%) 1 5.5 18 95 3
MgCl2 (wt%) 0.2 1.3 12
Water (wt%) 95.8 100 100 64 100 82
NaCl/KCl Problem - Flowsheet

F4 F5
F2 F8 = 2000 t/d F9 = 900
XW4 = 1 XS5 = 1
XW2 = 1 XW8 = 1 t/d

XS9 = 1

F1 = 100 000 t/d F3 F6 F7 F10 F11

Solar Evap Solar Still Thermal
Mixer XS7 KCl
XS1 = 0.03 XS3 = 0.18 XS6 = 0.18 Still XS10 XS11 = 0.05
XK1 = 0.01 XK7 XK10 Still XK11 = 0.95
XK3 = 0.055 XK6 = 0.18
XM1 = 0.002 XM3 = 0.013 XM6 XM7 XM10
XW1 = 0.958 XW3 = 0.752 XW6 XW7 XW10

F12
XS12
XK12
XM12
XW12
Legend
F = Mass flow stream (t/d)
x = mass fraction F14 F13
S = Sodium chloride Osmosis XS13 = 0.03
XS14
K = Potassium chloride XK13 = 0.03
XK14
M = Magnesium chloride XM13 = 0.12
XM14
W = Water XW13 = 0.82
XW14

Need to determine if product stream (F11) is > 900 tonnes/d.

NaCl/KCl Problem - Flowsheet

F4 F5
F2 F8 = 2000 t/d F9 = 900
XW4 = 1 XS5 = 1
XW2 = 1 XW8 = 1 t/d

XS9 = 1

F1 = 100 000 t/d F3 F6 F7 F10 F11

Solar Evap Solar Still Thermal
Mixer XS7 KCl
XS1 = 0.03 XS3 = 0.18 XS6 = 0.18 Still XS10 XS11 = 0.05
XK1 = 0.01 XK7 XK10 Still XK11 = 0.95
XK3 = 0.055 XK6 = 0.18
XM1 = 0.002 XM3 = 0.013 XM6 XM7 XM10
XW1 = 0.958 XW3 = 0.752 XW6 XW7 XW10

F12
XS12
XK12
XM12
XW12

F14 F13
Osmosis XS13 = 0.03
XS14
XK14 XK13 = 0.03
XM14 XM13 = 0.12
XW14 XW13 = 0.82

Determine if product stream (F11) is > 900 tonnes/d.

NaCl/KCl Problem – Approach 1

F8 = 2000 t/d
F2 F4 F5
Could we solve XW8 = 1
XW2 = 1 XW4 = 1 XS5 = 1
for any
components?
F9 = 900
t/d

XS9 = 1

F11
Process
F1 = 100 000 t/d XS11 = 0.05
XK11 = 0.95
XS1 = 0.03
XK1 = 0.01
XM1 = 0.002 F13
XW1 = 0.958
XS13 = 0.03
XK13 = 0.03
XM13 = 0.12
XW13 = 0.82

Magnesium enters in 1 place and leaves in 1 place. We can solve for Magnesium

Once we solve for Magnesium we can solve for Potassium

 NaCl/KCl Problem – Approach 1
General Mass Balance (GMB):
Accumulation = Input – Output + Generation – Consumption

Assumptions: Steady state, no generation, no consumption

Simplified GMB: 0 = Input – Output

Balances around overall system

M: 0 = 100,000 * 0.002 – F13 * 0.12
K: 0 = 100,000 * 0.01 – F11 * 0.95 – F13 * 0.03

Solving: F11 = 1,000 t/d

F13 = 1,667 t/d

Answers:
a) No, not enough information to perform full mass balance (all streams) around the circuit.
b) The production rate of NaCl/KCl product (F11) > the target of 900 t/d.
NaCl/KCl Problem – Approach 2

F8 = 2000 t/d
Does it Matter F2 F4 F5
XW8 = 1
where Water XW2 = 1 XW4 = 1 XS5 = 1
Leaves the
Process? F9 = 900
t/d

XS9 = 1

F11
Process
F1 = 100 000 t/d XS11 = 0.05
XK11 = 0.95
XS1 = 0.03
XK1 = 0.01
XM1 = 0.002 F13
XW1 = 0.958
XS13 = 0.03
XK13 = 0.03
XM13 = 0.12
XW13 = 0.82

DOF analysis
# Unknowns: 5 (F2 F4 F5 F11 F13)
# Independent Balance Equations: 4 (S, K, M, W)
DOF = 1 Therefore underspecified – can’t solve.
NaCl/KCl Problem – Approach 2

F8 = 2000 t/d
Could we group F15 F5
XW8 = 1
water streams XW15 = 1 XS5 = 1
for this problem?
F9 = 900
t/d

XS9 = 1

F11
Process
F1 = 100 000 t/d XS11 = 0.05
XK11 = 0.95
XS1 = 0.03
XK1 = 0.01
XM1 = 0.002 F13
XW1 = 0.958
XS13 = 0.03
XK13 = 0.03
XM13 = 0.12
XW13 = 0.82

DOF analysis
# Unknowns: 4 (F15 F5 F11 F13)
# Independent Balance Equations: 4 (S, K, M, W)
DOF = 0 Therefore – Can Solve!
Q5: Multi-unit distillation exercise
A liquid mixture containing 30 mol% benzene (B), 25 mol% toluene (T) and the
balance xylene (X) is fed to a distillation column. The bottoms product contains 98
mol% X and no B and 96% of the X in the feed is recovered in this stream. The
overhead product is fed to a second distillation column. The overhead product from
the second column contains 97% of the B in the feed to this column. The
composition of this stream is 94 mol% B and the balance T.
a) Draw and label a flowchart for this process.
b) Perform a DOF analysis for the overall system and the two subsystems.
c) Calculate:
• the % benzene in the process feed that emerges in the overhead product from the second column, &
• the % toluene in the process feed that emerges in the bottom product of the second column.

a) Ans = 97 % benzene in feed reports to overhead

stream from second column
b) Ans = 90 % toluene in feed reports to bottoms
stream of second column

See solution on Blackboard

CHEE2001
Process Principles

Week 3 – Tutorial 2
CHEE2001 Project 1 Support

We will come around to each group. Show us your Project 1 draft

flowsheet.