Saint Louis University

SCHOOL OF ENGINEERING AND ARCHITECTURE

Department of Chemical Engineering

MODULE 6: MATERIAL BALANCE WITH CHEMICAL REACTION INVOLVING MULTIPLE-UNIT

SYSTEM AND SPECIAL PROCESSES (RECYCLE, BYPASS AND PURGE)

Topic Learning Outcomes: At the end of this module, each student should be able to:
TLO7: Analyze and solve material balance problems involving multiple equipment process
and special processes

PRODUCT SEPARATION and RECYCLE

Two definitions of reactant conversion are used in the analysis of chemical reactors with
product separation and recycle of unconsumed reactants:

Sample Problems:

1. Propane is dehydrogenated to form propylene in a catalytic reactor:

C3H8 → C3H6 + H2

The process is to be designed for a 95% overall conversion of propane. The reaction
products are separated into two streams: the first, which contains H2, C3H6 and 0.555%
of the propane that leaves the reactor, is taken off as product; the second stream,
which contains the balance of the unreacted propane and 5% of the propylene in the
first stream, is recycled to the reactor. Calculate (a) the composition of the product,

118
Property of and for the exclusive use of SLU. Reproduction, storing in a retrieval system, distributing, uploading or posting online, or transmitting in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise of any part of this document, without the prior written permission of SLU, is strictly prohibited.
ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

(b) the ratio (moles recycled) / (mole fresh feed), and (c) the single-pass conversion.

SOLUTION:
a) the composition of the product
C3H8 → C3H6 + H2
95 % Overall Conversion of propane

Carbon balance:

Hydrogen balance:

Composition of product:

Component No. of moles Mole %

n6, C3H8 5 mole 2.5641%

n7, C3H6 95 mole 48.7179%

n8 ,H2 95 mol 48.7179%

nt =195 mole

b) ratio (moles recycled) / (mole fresh feed)

But

119
Property of and for the exclusive use of SLU. Reproduction, storing in a retrieval system, distributing, uploading or posting online, or transmitting in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise of any part of this document, without the prior written permission of SLU, is strictly prohibited.
ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

c) Single-pass conversion
100 mole n3 mole C3H8
C3H8

R
n9 mole C3H8

( )

2. Methanol is produced in the reaction of carbon dioxide and hydrogen:

CO2 + H2 CH3OH + H2O

The fresh feed to the process contains hydrogen, carbon dioxide and 0.400 mole %
inerts (I). The reactor effluent passes to a condenser that removes essentially all of the
methanol and water formed and none of the reactants or inerts. The latter substances
are recycled to the reactor. To avoid buildup of the inerts in the system, a purge stream
is withdrawn from the recycle.
The feed to the reactor contains 28.0 mole% CO2, 70.0 mole % H2 and 2.00 mole %
inerts. The single pass conversion of hydrogen is 60%. Calculate (a) F, X, Z and R (b) n1,
n2, n3, n4, n9 and n10. (Basis: 100 moles entering the reactor)

120
Property of and for the exclusive use of SLU. Reproduction, storing in a retrieval system, distributing, uploading or posting online, or transmitting in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise of any part of this document, without the prior written permission of SLU, is strictly prohibited.
ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

SOLUTION:

CO2 + 3 H2 → CH3OH + H2O

Single- pass conversion of hydrogen is 60%

Y n1 mole CO2
100 mole REACTOR
28 mole CO2 n2 =28 mole H2
70 mole H2 n3 mole CH3OH
2 mole inert n4 mole H2O
2 mole inert

121
Property of and for the exclusive use of SLU. Reproduction, storing in a retrieval system, distributing, uploading or posting online, or transmitting in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise of any part of this document, without the prior written permission of SLU, is strictly prohibited.
ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

Around the condenser: There is no reaction at the condenser

Composition of Z = Composition of R

Component Mole Mole %

CO2 14 31.8182

H2 28 63.6364

Inert 2 4.5455

31.8182% CO2
63.6364 % H2
4.5455 % inert
R
TMB: 𝐹 𝑅
F
n9 mole CO2 100 mole
Inert Balance: 𝐹 𝑅= 2
n10 mole H2 2 mole inert
0.4mol % inert 28 mole CO2 𝑹 𝟑𝟖 𝟓𝟗𝟔𝟏 𝒎𝒐𝒍𝒆 𝑭 𝟔𝟏 𝟒𝟎𝟑𝟗 𝒎𝒐𝒍𝒆
70 mole H2

CO2 balance: →

H2 balance: →

Overall TMB: → →

122
Property of and for the exclusive use of SLU. Reproduction, storing in a retrieval system, distributing, uploading or posting online, or transmitting in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise of any part of this document, without the prior written permission of SLU, is strictly prohibited.
ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

ACTIVITY 1:

1. For the preparation of methyl iodide, 2000lb/day of hydroiodic acid are added to an
excess methanol
HI + CH3OH CH3I + H2O

If the product contains 81.6% along with the unreacted methanol and the waste
contains 82.65% Hl and the 17.35% H2O, calculate, assuming that the reaction is 40%
complete in the vessel:

a. The weight of the methanol added per day

b. The amount of Hl recycled

123
Property of and for the exclusive use of SLU. Reproduction, storing in a retrieval system, distributing, uploading or posting online, or transmitting in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise of any part of this document, without the prior written permission of SLU, is strictly prohibited.
ENGR. MYLENE M. OCASION