Industrial Process Calculations CHE 341

Industrial Process
Calculations
(CHE 341)
By
Engr. Dr. O.U. Osazuwa (AMIChemE)
Course Outline
• Introduction to equipment in a chemical plants (heat transfer, mass transfer
equipment and physical processes equipment).
• Chemical equation and stoichiometry: limiting reactant, excess reactant,
conversion, selectivity and yield.
• Material balances: Calculations for steady state systems involving inert, recycle,
by-pass and purges.
• Energy Balances: Forms of energy and overall energy balance for a chemical
system. Heat capacities. Calculation of enthalpy changes: heats of fusion,
vaporization, reaction, formation and combustion, solution and mixing.
• Combined material and energy balances. Enthalpy-concentration charts-
application and construction.
Introduction to process equipment in a chemical plants
For the purpose of this course: physical, heat & mass transfer equipment.
Industrial Process equipment: what are industrial process equipment?
• Uses physical or chemical methods to add value to a raw material or product.
Mass Transfer Equipment:
• Movement of mass in an equipment from one location to another (i.e., phase, stream, fraction or component).
• Mass transfer processes include evaporation, absorption, precipitation, membrane filtration, drying,
crystallization & distillation.
• Physical process equipment: Equipment where there exit material changes through a series of states.
Heat Transfer Equipment: what are heat transfer process equipment?
• Transfers heat from a hot fluid to cold fluid.
• Exchange of thermal energy between physical systems.
• Heat transfer indicates energy transfer from one place to another (temperature is a measure of the thermal
energy).
Class Engagement
1. Which of these processes is/are physical processes. (a)burning fuels, (b) dissolving salt
in water (c ) freezing water into ice.
2. Which of the following is/are physical processes?
(a) Change in shape with no bond breakage (b) change in state of matter (when ice
melts into water, or when water becomes a vapor) (c)hydrolysis of starch into water (d) both
(a) & (b).
Process Equipment in
industrial Chemical Plant
Phases Operations
contacting
• Mass transfer & heat transfer equipment,
physical process equipment.
Gas-liquid Distillation, gas absorption,
stripping, humidification
• Industrial processes operates as continuous
processes while small production process Liquid- Solvent extraction
use batch modes. liquid
• Turbulent mixing is needed while heating
Gas-solid Drying, Adsorption
& cooling are employed to maintain process
operating conditions. Liquid-solid Leaching, crystallization, ion
• Interphase mass transfer equipment are exchange
classified in 4 categories.
Reactor
• An equipment unit in a chemical
process.
• An enclosed volume where reaction
takes place (batch & continuous).
• Chemical reaction/transformation
takes place to generate desirable
products.
• Configuration & operating
conditions are selected to achieve
objectives (e.g., maximize profit/product, minimize
Distillation
column
• A unit equipment used to separate
two or more mixture into its
individual components.
• Multi components can also be
separated in a complex distillation
system.
• Reflux ratio: Ratio of the amount of
mole returned as reflux liquid to the
fractionating column & the amount of
moles of final product per unit time.
Gas Absorber
• Absorption process is a gas-liquid mass
transfer process where a component is
transferred from a gas phase to a liquid
phase.
• Used for the removal of one or more
component from a gas mixture using a
suitable liquid.
• Absorption can be physical & chemical
(read up).
• Absorption rate is determined by the rate
of molecular diffusion.
Compressor & Pumps
Compressor
• increases pressure of a gas by reducing its
volume.
• Axial flow or radial/centrifugal flow.
Pumps
• Used to move fluids.
• Increases the mechanical energy of the fluid,
thereby increasing the velocity (flowrate) &
Pressure (elevation).
Heat Exchanger
• Unit equipment built for

industrial processes to
efficiently transfer heat
from one fluid to another.
• E.g., include intercoolers,
boilers, pre-heaters,&
condensers.
Boiler
• Boiler is a closed vessel in

which water is heated to
produce steam.
• Thermal Energy released by
combustion of fuel is used to
make steam at the desired
temperature & pressure.
• The exit heated or vaporized
fluid from the boiler is used in
many processes or in heating
applications.
Electric Heater
• A device that converts
electric current to heat.
• Holds an electric element
(resistor) which works on
the principle of Joule
heating.
• Joule Heating: An electric
current passing through a
resistor will convert
electrical energy to heat
Cooling Tower
• Heat rejection device that expels waste

heat into the environment.
• Works by the cooling of water streams to
lower temperatures.
Cooling methods include:
• Evaporation (evaporators) of water to
remove the heat and cool the working
fluid to near the wet-bulb air temperature.
• Closed circuit dry cooling towers rely on
air to cool the working fluid to near the
dry bulb air temperature.
Assignment
• Identify & describe 3 equipment each in the 4 categories of

interphase mass transfer equipment. (to be submitted in the
next class).
• Identify & describe the working of 3 heat transfer equipment.
• Identify & describe the working of 3 physical process
equipment.
• What is the difference between a pump & compressor?
• Discuss wet bulb air & dry bulb air temperature utilized in
cooling towers.
Chemical equation and stoichiometry: limiting reactant, excess
reactant, conversion, selectivity and yield.
Signs of Chemical Reaction:

1. Evolution of gas
2. Change in properties like
color, odor, density
3. Release of absorption of
energy.
4. Formation of precipitates.
Chemical Reaction
• Changes that occur to form a new substance.

• Reactant : starting substance
• Product: new substance formed
• Chemical equation: short form of describing chemical reactions
E.g.
yields
𝐶 + 𝑂2 𝐶𝑂2
Stoichiometry
yields
𝐶 + 𝑂2 𝐶𝑂2
In terms of mol, & mass respectively:
1 mol of C reacts with 1 mol of O2 to give 1 mol of CO2.
12 g of C react with 32 g O2 to yield 44 g CO2.
Stoichiometry equation: relates the number of moles or mass
of reactants to those of the products of the reaction.
• For a valid stoichiometric equation: the sum of the masses of
the reactants must be equal to the mass of the product(s).
Stoichiometry
Note: read up:

Law of definite proportion, law of multiple proportion, law of reciprocal proportion & Dalton’s Atomic
Theory
Stoichiometry & industrial processes
In industrial processes reactants are not fed into the reactor in

stoichiometric proportions because:
• One reactant might be fed in excess of the other(s).
• One reactant may be depleted or used up faster than the
other.
• Reaction may not go to conclusion because of equilibrium of
rate considerations
• Competing reactions may exist thereby affecting the desired
product yield.
As a result of the deviation experienced in industrial processes some

definitions will be required:
Limiting reactant: This is the reactant that is depleted fastest.

yields
E.g., 𝐶 + 𝑂2 𝐶𝑂2
Assuming 2 mol of O2 is reacting, C will be the limiting reactant because it is
present in less than stoichiometric amount (1 mol of C as against 2 mols of
O2).
Excess reactant: This is the reactant in excess of the limiting reactant.

yields
E.g., 𝐶 + 𝑂2 𝐶𝑂2
Assuming 2 mol of O2 is reacting, O2 is the excess reactant because it is
present in less than stoichiometric amount (1 mol of C as against 2 mols of
O2).
% excess reactant =
𝑛𝑜.𝑜𝑓 𝒎𝒐𝒍𝒆𝒔 𝑜𝑓 𝒆𝒙𝒄𝒆𝒔𝒔 𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 −𝑛𝑜.𝑜𝑓 𝒎𝒐𝒍𝒆𝒔 𝑜𝑓 𝒍𝒊𝒎𝒊𝒕𝒊𝒏𝒈 𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡

𝑛𝑜 𝑜𝑓 𝒎𝒐𝒍𝒆𝒔 𝑜𝑓 𝒍𝒊𝒎𝒊𝒕𝒊𝒏𝒈 𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡
× 100
Fractional Conversion (X): fraction of a reactant that is converted into

product. % of the limiting reactant that is converted into products or
consumed .
consider
yields
𝐴+𝐵 𝐶+𝐷
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐴 𝑟𝑒𝑎𝑐𝑡𝑒𝑑 (𝑐𝑜𝑛𝑣𝑒𝑟𝑡𝑒𝑑 𝑡𝑜 𝑝𝑟𝑜𝑑𝑢𝑐𝑡)
Fractional conversion of A =𝑋𝐴 = 𝒎𝒐𝒍𝒆𝒔 𝑜𝑓 𝐴 𝑓𝑒𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑓𝑒𝑒𝑑 𝑐𝑜𝑛𝑣𝑒𝑟𝑡𝑒𝑑 𝑡𝑜 𝑝𝑟𝑜𝑑𝑢𝑐𝑡
Fractional conversion of the feed=𝑋𝐴+𝐵 =
𝒎𝒐𝒍𝒆𝒔 𝑜𝑓 𝐴+𝐵 𝑓𝑒𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟
if 10 moles of A is fed to a reactor and 6 moles reacted what is the fractional

conversion of A?
6
Ans: 𝑋𝐴 = = 0.6 × 100 = 60 %.
10
Selectivity & yield 𝐴 + 𝐵՜𝑪 +𝑫
𝑫 + 𝐴՜𝐸 + 𝐹
Assuming:
• C is the desired product & D is the undesired product.
• If D reacts with A to form more undesired product D is said to be competing
with C.
• Hence, there will be a net reduction of the selectivity & yield of the desired
product.
• The selectivity & yield show the extent to which the desired reaction
𝑚𝑎𝑠𝑠 𝑜𝑟 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝒅𝒆𝒔𝒊𝒓𝒆𝒅 𝑝𝑟𝑜𝑑𝑢𝑐𝑡

Selectivity= 𝑚𝑎𝑠𝑠 𝑜𝑟 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝒖𝒏𝒅𝒆𝒔𝒊𝒓𝒆𝒅 𝑝𝑟𝑜𝑑𝑢𝑐𝑡
𝑚𝑎𝑠𝑠 𝑜𝑟 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝒅𝒆𝒔𝒊𝒓𝒆𝒅 𝑝𝑟𝑜𝑑𝑢𝑐𝑡
Yield = 𝑚𝑎𝑠𝑠 𝑜𝑟 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟 𝒄𝒐𝒎𝒑𝒍𝒆𝒕𝒆 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛
Fundamentals of Material balances
Material balance- Accounting of material.

• Based on conservation of mass.
• Accounts for the material (in terms of composition. & mass flowrates) which enters and leaves
the system (non-reactive).
• Accounts for the material which enters, leaves, or accumulates, is generated or consumed by
chemical reaction in the system (reactive).
• Based on the principles of “law of conservation of mass”.
• Matter is neither created nor destroyed in the process, while the overall mass is unchanged.
Classification of Processes
Classes of Chemical Process: 2 classes.

1. batch, continuous or semi batch
2. Steady-state or unsteady state (transient).
Note
These classes must be identified before a material balance is obtained for a
process.
batch process: reactants (input) are fed into a vessel at the start of the
process and removed (unreacted & products) later.
Continuous process: reactants & products (input & output) flow continuously
through out the process.
semi batch process: neither batch nor continuous.

Steady state: when process variables does not change with time.
Unsteady state (transient) : when process variables changes with

time.
• Batch & semi batch processes are unsteady state operations. Why?
• Continuous processes may be steady-state or transient. Why?
Batch processes are used for small scale production & production is to be
carried out in single runs.
Continuous processes are suited to large production rates.
Continuous processes are operated at as close to steady state as possible,
however, unsteady state conditions exist at process start-up
Class engagement
Classify the following processes as batch, continuous or semi-batch & steady

state & unsteady state.
1. A balloon filled with air at a steady rate of 15 g min-1.
2. A bottle of milk removed from the refrigerator and left on a table.
3. Water is boiled in an open flask.
4. Carbon monoxide & steam are fed into a tubular reactor at a steady rate &
react to form carbon dioxide & hydrogen. Products & reactants are
withdrawn at the other end. The reactor contains air when the process is
started up. The temp. of the reactor is constant, & the composition &
flowrate of the entering reactants stream are independent of time. Classify
the process (a) initially , (b) after a long period of time has elapsed.
Balances: The General Balance Equation
H2 gas
𝑚 ሶ 𝑖𝑛𝑘𝑔/ℎ
Process Unit
H2 gas
𝑚ሶ 𝑜𝑢𝑡 𝑘𝑔/ℎ
H2 gas
𝑚 ሶ 𝑖𝑛𝑘𝑔/ℎ Process Unit
𝑚 ሶ 𝑖𝑛 𝑚ሶ 𝑜𝑢𝑡
≠ H2 gas
Possibilities for unequal mass flowrate of H2
1. H2 is consumed as a reactant or generated as a product.
2. H2 is accumulated in the unit.
3. H2 leakage
4. Wrong measurements
H2 gas
𝑚 ሶ 𝑖𝑛𝑘𝑔/ℎ Process Unit
𝑚 ሶ 𝑖𝑛 𝑚ሶ 𝑜𝑢𝑡
≠ H2 gas
Assuming the measurements are correct & there are no leaks, a
balance on a conserved quantity e.g., mass or energy in the system
(process unit) is:
𝑰𝒏𝒑𝒖𝒕 + generation – output – consumption = accumulation

𝑰𝒏𝒑𝒖𝒕 (enters) + generation (is produced) – output (leaves)– consumption (consumed) =

accumulation (built up)
Each year 50,000 people move into a city 75, 000 people move out,
22,000 are born, & 19,000 die. Write a balance on the population of
the city.
Let P represent People.
50,000 P/yr. (enters) + 22,000 p/yr. (is produced) – 75,000 (leaves)– 19,000 p/yr.
(consumed) =
accumulation (built up)
Accumulation = -22,000 p/yr.
Meaning each year population will decreases by 22,000 people.
Balances: Types of balances
1. Differential Balances:
• Balances related to a system performance at a particular instance or time.
• The balance eqn. term is a rate (e.g., rate of input, i.e., barrels/day etc).
• Applied to continuous processes.
2. Integral balances:
• Balances related to a system performance between two-time instances
(during input & output).
• The term in the balance eqn. is an amount of the balanced quantity & has
the corresponding unit (e.g., g CO2, barrels etc).
• Applied in a batch process.
Rules for material balance equation.
1. For total mass balance: generation = o, consumption = o. Except

for nuclear rxns.
2. For non-reactive species (no reactant or product): generation = o,
consumption = o.
3. Steady state system: accumulation =0, (in a steady state system
nothing can change with time).
Continuous steady-state processes (Differential balances).
1. For a steady state Continuous processes: accumulation = zero

𝑰𝒏𝒑𝒖𝒕 (enters) + generation (is produced) = output (leaves) + consumption (consumed)
2. For a non-reactive species or total mass: generation &

consumption terms = 0.
𝑰𝒏𝒑𝒖𝒕 (enters) = output (leaves)

Material balances on a Continuous distillation process.
1000 kg/hr of a mixture of benzene (B) & 450 kg B/h
toluene (T) containing 50 % benzene by

mሶ 1 kg T/h
mass is separated by distillation into two

fractions. The mass flow rate of benzene in
the top stream is 450 kg B/h & that of
500 kg B/h Distillation
toluene in the bottom stream is 475 kg T/h. 500 kg T/h column
The operation is at steady state. Write

balances on benzene & toluene to calculate
the unknown component flow rates in the 475 kg T/h
output streams. mሶ 2 kg B/h

For a steady state non-reactive Continuous processes: accumulation

= zero, consumption = o, generation = o.
𝑰𝒏𝒑𝒖𝒕 (enters) = output (leaves)

Benzene balance :
𝑰𝒏𝒑𝒖𝒕 (500 kg B/h) = output (450 kg B/h + 𝒎ሶ 𝟐)
𝒎ሶ 𝟐= 50 kg B/h
Toluene balance :
𝑰𝒏𝒑𝒖𝒕 (500 kg T/h) = output (475 kg T/h + 𝒎ሶ 𝟏)
𝒎ሶ 𝟏= 25 kg T/h
To check:
Total mass balance:
𝐼𝑛𝑝𝑢𝑡 (1000 kg/h) = output (450 + 475 + 𝑚ሶ 2(50) + 𝑚ሶ 1(25)) (kg/h)
1000 kg/h= 1000 kg/h

Batch processes (Integral balances).
1. For batch processes:

accumulation = final output – initial input (1)
= generation – consumption (2)
Initial input (enters) + generation (is produced) = Final output (leaves) + consumption
(consumed)
Material balance on a batch mixing process (integral balances).
Example :
Two methanol-water mixtures are contained in separate flasks.
The first mixture contains 40 wt.% methanol, and the second
contains 70 wt.% methanol. If 200 g of the first mixture is
combined with 150 g of the second, what are the mass and
composition of the product?
Initial streams Final streams
First mixture: 200g

0.4 g CH3OH/g
0.6 g H2O/g
m(g)
y g CH3OH/g
1-y g H2O/g
Second mixture: 150g
0.7 g CH3OH/g
0.3 g H2O/g
Since there is no reaction involved, no generation or consumption term, hence

input = output
From the given parameters, We will attempt:

1) a total mass balance
2) methanol balance
From the mass balance m is obtained (350 g) and inserted into

the methanol balance to find y.
Y = 0.529 g CH3OH/g
Total Mass Balance:

200 g + 150 g = m g
m = 350 g
Methanol Balance:
200 g x 0.4 g CH3OH/g + 150 g x 0.7 g CH3OH/g =
m (g) x y (g) CH3OH/g
Y = 0.529 g CH3OH/g
Material balance on a batch mixing process: Class activity
Carry out a water balance on the given example.
input = output
165 g H2O = 165 g H2O
Integral balances on semi-batch and continuous processes.
Two steps:
• Write a differential balance on the system.
• Integrate the system between two instants of time.
Example: n (kmol /min)

0.1 kmol C6H14/kmol
Air is bubbled through a drum of 0.9 kmol air/kmol
liquid hexane at a rate of 0.1 kmolmin-
1. The gas stream leaving the drum
contains 10 mole% hexane vapor. Air

may be considered insoluble in liquid
hexane. Use an integral balance to
estimate the time required to
vaporize 10 m3 of the liquid. (specific
gravity of hexane is 0.659). 0.1 kmol air/min
Differential balance on air (air is considered insoluble in

liquid hexane (i.e., neither reacts nor dissolves)):
accumulation and generation terms = 0
0.1 kmol air/ min = 0.9 kmol air/kmol x n kmol/min

flowrate of air exiting the system = 0.111 kmol min-1
Integral balance on hexane from t = 0 to tt (min)= time

required.
• Recall: Initial input (enters) + generation (is produced) =
Final output (leaves) + consumption (consumed)
• Accumulation = -output
Accumulation term: total change in the moles of hexane in

the system during tt (min)= time required.
• In this case accumulation is negative (hexane is removed).
Accumulation term:
Total moles of hexane evaporated = -10 m3 = -10,000 L
Density of Hexane = 0.659 kg/L
Mass = Volume x Density = - 6590 kg
Recall : molar mass of hexane = 86.2 g/mol.
accumulation = -76.45 kmol
Accumulation term: total change in the moles of hexane in
the system during tt (min)= time required.
• In this case accumulation is negative (hexane is removed).
Output term:
Mole fraction of gas stream leaving contains 10 mole%
hexane vapor = 0.1.
Flowrate of gas exiting the system = n = 0.111 kmol/min
tt (min)= time required to vapourize 10 m3 of hexane.
Accumulation = -output
Output term: rate at which hexane is leaving the system

-76.45 kmol C6H14 = -0.1 x 0.111 x tt (min).
tt = 6,887 min
Material Balance Calculations
All material balance problems involves:

• Given values of some input & output stream variables.
• Derived and solved eqns.
• Solving eqns. involves simple algebra.
• Deriving eqns. from a description of a process and a
collection of process data may be challenging.
• It may not be obvious from the problem statement what is
known and what is required.
Procedure: How to reduce the description of a process to a
set of eqns. That can be solved for unknown process
variables
Steps:
1. Draw a flowchart of the process to represent process
units (reactors, mixers, separation units etc.) using
boxes, & lines to represent inputs and outputs.
2. Fully label the flowchart at the initial stage with
values for known process variables & symbols for
unknown variables being written for each input &
output stream.
Procedure: contd.
• The flowchart functions as a score board for the

problem solution
• As each unknown variable is determined, the result is
filled in.
• The flowchart provides a continuous record of where the
solution stands & what must still be done.
Labeling a flowchart for material balance calculations
1. Write the values & units of all known stream variables at the
locations of the streams on the flowchart.
E.g.
A stream containing 21 mole% O2 and 79% N2 at 320 ℃ & 1.4 atm
flowing at a rate of 400 mol/h might be labeled.
400 mol/h
0.21 mol O2/mol
0.79 mol N2/mol
T = 320 ℃, P = 1.4 atm
2. Assign algebraic symbols to unknown stream variables

(e.g. m (kg solution/min), x (kmol C3H8) & write these
variable names & their associated units on the flowchart.
E.g.
n mol/h
0.21 mol O2/mol
Variable name
0.79 mol N2/mol Associated unit
T = 320 ℃, P = 1.4 atm
3. Derive & solve an eqn. for each unknown on the

flowchart.
4. Keep the no. of labeled unknowns to a minimum.
5. Variable names should be assigned to all but one
fraction, since the last one must be “1 – the sum of the
others”.
6. If volumetric flowrate of a stream is given, it is
preferable to label with the mass or molar flowrate of this
stream.
Procedure: How to reduce the description of a process to a
set of eqns. That can be solved for unknown process
variables
E.g. & class activity

Suppose a gas containing N2 & O2 is combined with propane
in a batch combustion chamber in which some (but not all)
of the O2 & C3H8 react to form CO2 & H2O, & the product
is then cooled, condensing the water. Draw the flowchart
of this two-unit process.
Solution: flowchart of a combustion-condensation process
d mol C3H8
e mol O2 d mol C3H8
a mol C3H8
e mol O2
Combustion
Condenser
Chamber
b mol O2 c mol N2 c mol N2

c mol N2 f mol CO2 f mol CO2
g mol H2O
g mol H2O
Class activity: Flowchart of an air humidification & oxygenation process.
An experiment on the growth rate of certain organisms requires an environment

of humid air enriched in oxygen. Three input streams are fed into an
evaporation chamber to produce an output stream with the desired composition.
a. Liquid water, fed at a rate of 20 cm3min-1
b. Air (21 mol % O2, the balance N2)
c. Pure oxygen, with a molar flowrate one-fifth of the molar flowrate of
stream B.
The output gas is analyzed and is found to contain 1.5 mole % water. Draw and
label a flowchart of the process & calculate all unknown stream variables.
Solution: calculating the unknown values
Tips:
• Label all stream flowrates on the basis of the given flowrate (20
cm3 H2O/min).
• Write the O2 flowrate (0.2 ň1) in terms of the air flowrate (ň1).
• Mole fractions of the components of any stream must add up to
1.
E.g. – in the outlet stream
mole fraction of H2O (0.015), O2 (y) & N2 (0.985-y) = 1
Solution: Flowchart of an air humidification & oxygenation process.
0.2 ň1 (mol O2 min-1)

ň3 (mol min-1)
ň1 (mol air min-1)
0.015 mol H2O mol-1
0.21 mol O2 mol-1 y (mol O2 mol-1)
0.79 mol N2 mol-1 (0.985 – y)(mol N2 mol-1)
20 cm3 H2O (L) min-1

ň2 (mol H2O min-1)
To find ň2 (molar flowrate- mol H2O min-1)

v = 20 cm3 min-1
Density of H2O = 1 g/cm3
(mass flowrate) = 20 g/ min-1
Recall: 1 mol – 18.02 g
ň2 = 1.11 mol H2O min-1
To find ň3 (molar flowrate- mol H2O min-1)

H2O balance
ň2 mol H2O min-1 = ň3 mol min-1 x 0.015 mol H2O mol-1
ň2 = 1.11 mol H2O min-1
ň3 = 74.1 mol min-1

To find ň1 (total molar flowrate- mol min-1)

total mole balance
0.2 ň1 + ň1 + ň2 = ň3
ň2 = 1.11 mol H2O min-1
ň3 = 74.1 mol min-1
ň1 = 60.8 mol min-1
To find y: total mole balance

N2 Balance
ň1 (mol min-1) x 0.79 mol N2 mol-1 = ň3 (mol min-1) x (0.985 – y)(mol
N2 mol-1)
ň3 = 74.1 mol min-1
ň1 = 60.8 mol min-1
Y = 0.337 mol O2 mol-1

Balancing a Process: for non-reactive processes
1. The Maximum number of independent equations

that can be derived by writing balances on a
nonreactive system equals the number of
chemical species in the input & output streams.
2. Write balances first that involve the fewest
unknown variables.
Degree of freedom Analysis
• The procedure for drawn & labelled flowchart is referred to as

degree of freedom analysis.
Procedure
1. Draw & label (completely) a flowchart.
2. Count the unknown variables on the flowchart
3. Count the independent eqns. relating them
4. Subtract the 3 from 2.
Result: no. of degrees of freedom of the process, ndf= n unknowns –n
indep. eqns.
Degree of freedom Analysis (ndf )- 3 possibilities exist
If ndf= 0,
• The problem can be solved (n unknowns & n independent eqns.).
If ndf > 0,
• Underspecified and has infinitely many solutions- can not be
solved (More unknowns than independent eqns.)
If ndf < 0,
• Flowchart is incompletely labeled or the problem is over specified
with redundant & inconsistent relations- can not be solved (more
independent eqns. than unknowns).
General procedure for process material balance calculations
1. Choose as a basis of calculation an amount or flow

rate of one of the process streams.
2. Draw a flowchart & fill in all known variable values,
including the basis of calculation. Label the unknown
stream variables on the flowchart.
3. Express what the problem statement asks you to
determine, in terms of the labeled variables.
4. If you are given mixed mass & mole units for a
stream convert all quantities to one basis.
General procedure for process material balance calculations
5. Do the degree of freedom analysis.

6. If the number of unknowns equals the number of eqns relating
them, write the eqns in an efficient order & circle the variables
for which you will solve. Start with eqns that only involve one
unknown variable, then pairs of simultaneous eqns containing two
unknown variables, & so on.
7. Solve the eqns.
8. Calculate the quantities requested in the problem statement if
they have not already been calculated.
Recycle & Bypass
Read up
Balances on reactive processes: Balances on Molecular & atomic species
The flowchart below shows the dehydrogenation of ethane in a steady state

continuous reactor. The reaction is:
C2H6 C2H4 + H2
One hundred kmol min-1 of ethane is fed to the reactor. The molar flow rate of
H2 in the product stream is 40 kmol min-1. write the various balances for the
chemical process & determine the molar flowrate of the exit C2H6 & C2H4.
40 kmol H2 min-1
100 kmol C2H6 min-1 ň1 kmol C2H6 min-1

ň2 kmol C2H4 min-14
Note:
The balance could be written for:
1. Atomic C & H balance (input = output)- atoms can neither be
created (generation =0) nor destroyed (consumption =0) in a
chemical rxn.
2. Molecular H2, C2H6, C2H4 (input +generation = output +
consumption).
• Generation term – (H2, C2H4 )
• Consumption term – (C2H6)
Recall: the general balance eq. for steady-state process:

Initial input (enters) + generation (is produced) = Final output
(leaves) + consumption (consumed)
C2H6 C2H4 + H2
For molecular H2 balance: Generation = output
Gen H2 ( mol H2 generated min -1) = 40 mol H min-1
2

C2H6 C2H4 + H2
For C2H6 balance: input = output + consumption
100 mol C2H6 min-1 = ň1 (mol C2H6 min-1) + Cons C H (mol C2H6
2 6
consumed min-1).

C2H6 C2H4 + H2
For C2H4 balance: Generation = output
Gen C2H4 ( mol H2 generated min -1) = ň (mol C H min-1)
2 2 6

Initial input (enters) + generation (is produced) = Final output (leaves) + consumption (consumed)
C2H6 C2H4 + H2
For C balance: input = output

From the reaction stoichiometry : 2 mol of C are in:
• Initial C2H6 , final C2H6 & produced C2H4
100 mol C2H6 min-1 x 2 mol C mol-1 C2H6 =
ň1 (mol C2H6 min-1) x 2 mol C mol-1 C2H6 + ň2 mol C2H4 min-1 x 2 mol C
mol-1 C2H4

C2H6 C2H4 + H2
For C balance: input = output

100 mol C min-1 = ň1 (mol C min-1) + ň2 (mol C min-1)

C2H6 C2H4 + H2
For atomic H balance: input = output

From the reaction stoichiometry : 6, 6, 4 & 2 mol of H are in:
• Initial C2H6 , final C2H6, produced C2H4 H2
100 mol C2H6 min-1 x 6 mol H mol-1 C2H6 = 40 (mol H2 min-1 ) x 2 (mol
H mol-1 H2) + ň1 (mol C2H6 min-1) x 6 mol H mol-1 C2H6 + ň2 mol C2H4
min-1 x 4 mol H mol-1 C2H4

C2H6 C2H4 + H2

600 mol H min-1 = 80 (mol H min-1) + 6ň1 (mol H min-1) + 4ň2 (mol H
min-1)

C2H6 C2H4 + H2

600 mol H min-1 = 80 (mol H min-1) + 6ň1 (mol H min-1) + 4ň2 (mol H
min-1)
Class Activity
• Solve for ň1 & ň2 using both the 3 molecular balances (in

conjunction with the stoichiometric eq.) & the 2 atomic balances.
ň1 = 60 kmol C2H6 min-1 & ň2 = 40 kmol C2H6 min-1

Molecular Species Balances
• Use to determine unknown stream variables for a reactive

process.
• The balances on the reactive species must contain generation
&/or consumption terms.
• No. of degree of freedom =
No. of unknown labeled variables + No. of independent chemical
rxns – No. of independent molecular species balances – No. of
other eqns. Relating the unknown variables.
Molecular Species Balances
• For e.g.: the dehydrogenation of ethane:

Degree of freedom analysis: 40 kmol H2 min-1

2 unknown labeled variable (ň1 & ň2) + 1 independent chemical

reaction – 3 independent molecular species balances (H2, C2H6,
C2H4) – 0 other eqs. relating unknown variables = 0 degrees of
freedom.
Atomic Species Balances
• Atoms can neither be generated nor consumed in chemical

species.
• Balances on atomic species take the form input = output.
No. degrees of freedom =
No. of unknown labeled variables – No. of independent
atomic species balances – No. of molecular balances on
independent nonreactive species - No. of other eqns.
Relating the unknown variables.
Atomic Species Balances


2 unknown labeled variables (ň1 & ň2) - 2 independent atomic

species balances (C & H), - 0 molecular balances on
independent nonreactive species – 0 other eqs. relating the
unknown variables = 0 degrees of freedom.
Summary
Systems with chemical reaction occurring can be analyzed using:

• Molecular species balances (used mainly for non-reactive systems)
• Atomic species balances (mainly used in reactive systems).
• Extents of reaction.
Note
Gives same results but convenience differ for different problems
Extent of reaction
No. degrees of freedom =

No. of unknown labeled variables + No. of independent reactions
(one extent of reaction for each) – No. of independent reactive
species (one equation for each species in terms of extents or rxn) –
No. of independent nonreactive species ( one balance eqn. for each)
- No. of other eqns. relating the unknown variables.
Extent of Reaction


2 unknown labeled variables (ň1 & ň2) + 1 independent reaction

– 3 independent reactive species (H2, C2H6, C2H4) - 0
independent nonreactive species – 0 other eqns. relating the
unknown variables = 0 degrees of freedom.
Assignment
• Use Extent of reaction method to solve the previous

example.
which technique to use for a given process ?
Atomic species balances

• Leads to straight forward solution procedure especially when
more than one reaction is involved.
Extents of reaction
• Convenient for chemical equilibrium problems.
• When eqn. solving software is to be used.
Molecular species balances
• Used for simple systems involving one rxn.
Limiting & Excess Reactants
Limiting reactant: the reactant that would run out of a

reaction.
Excess reactant: The left over reactants.
A reactant is limiting if it is present in less than its
stoichiometric proportion relative to every other reactant.
If (nA)feed = no. of moles of an excess reactant.
(nA)stoich = stoichiometric requirement of A
Limiting & Excess Reactants
Fractional excess of A =
((nA)feed - (nA)stoich )/ (nA)stoich
Example: hydrogenation of acetylene to form ethane.
C2H2 + 2H2 C2H6
20 kmolh-1 of acetylene & 50 kmolh-1 of H2 are fed to a reactor.
The stoichiometric ratio of H2 to acetylene is 2:1, & since the
ratio of H2 to C2H2 in the feed is 2.5 :1 (50:20), H2 is fed in a
greater than stoichiometric proportion to acetylene. Acetylene
is therefore the limiting reactant.
Determining the fractional excess
Since it would take 40 kmol H2 h-1 to react completely with all

the acetylene fed to the reactor.
(nH ) stoich = 40 kmolh-1
2
Recall:
Fractional excess of A =
((nA)feed - (nA)stoich )/ (nA)stoich
Fractional excess of H2 =
(50 - 40) kmolh-1 / 40 kmolh-1 = 0.25
Fractional Conversion
Fractional conversion (X) = moles reacted/moles fed

Fraction unreacted = 1-X
Example:
If 100 moles of reactant are fed & 90 moles react,
Fractional conversion = 0.9
Fraction unreacted = 0.1
Also, if 20 mol min-1 of a reactant is fed & the % conversion is
80%, then 20x(0.8) = 16 mol min-1 has reacted & 20x(1-0.8)
= 4 mol min-1 remains unreacted.
C2H2 + 2H2 C2H6
20 kmol of acetylene, 50 kmol of H2, & 50 kmol of ethane

are charged into a batch reactor. After a while, 30 kmol of
H2 reacted. How much of each species will be present in
the reactor at the moment?
C2H2 + 2H2 C2H6

• From 50 kmol of H2, 30 kmol reacts – 20 kmol H2 is
remaining/unreacted.
• From the stoichiometry, if 30 kmol of H2 reacts, 15 kmol of
C2H2 also reacts.
• Amount of C2H2 remaining: 20 – 15 = 5 kmol C2H2
• 30 kmol of H2 that reacts forms 15 kmol of C2H6
• Initial C2H6 (50 kmol) + produced C2H6 (15 kmol) = 65 kmol
C2H6
Extent of reaction (E)
C2H2 + 2H2 C2H6

nH2 = (nH2)0 – 2E
nC2H2 = (nC2H2 )0 – E
nC2H6 = (nC2H6 )0 + E
Once the amount of H2 or acetylene (C2H2) reacting or
the ethane (C2H6) formed is known, the E can be
calculated.
Extent of reaction (E)
In general : ni = nio + ViE
Vi = stoichiometric coefficient of the ith species in a chemical

reaction (- for reactants & + for products).
C2H2 + 2H2 C2H6
VC2H2 = -1, VH2 = -2, VC2H6 = +1
nio = mole (batch) or molar flow rate (continuous) of species i
in the feed to a batch or continuous steady state process.
Extent of reaction
Example.
Consider the ammonia formation reaction.
N2 + 3H2 2NH3
The feed to a continuous reactor consists of 100 mol s-1 of
nitrogen, 300 mol s-1 of hydrogen, & 1 mol s-1 of argon (inert
gas). Write the equations for the extent of reaction for this
process. For a fractional H2 conversion of 0.6, calculate the
outlet flow rate of H2, the extent of reaction, & the outlet
flow rates of N2 & NH3.
Limiting & Excess Reactants, fractional Conversion, & Extent of
reaction
Extent of Reaction (E): Fraction of H2 converted = 0.6

N2 + 3H2 2NH3 Fraction unreacted = 0.4
Outlet flowrate of H2 =0.4 x 300
nN2 = 100 mol s-1 –E = 120 mol s-1
nH2 = 300 mol s-1 – 3E E = 60 mol s-1
nNH3 = 2E Outlet flow rate of N2 =40 mol s-1

Outlet flowrate of NH3 = 120 mol s-1
nA = 1 mol s-1
Example : Incomplete Combustion of Methane
Methane is burned with air in a continuous steady-state combustion

reactor to yield a mixture of carbon monoxide, carbon dioxide &
water. The reactions taking place are
CH4 + 3/2O2 CO + 2H2O
CH4 + 2O2 CO2 + 2H2O
The feed to the reactor contains 7.80 mole % CH4, 19.4% O2, & 72.8 %
N2. The % conversion of CH4 is 90%, & the gas leaving the reactor
contains 8 mol CO2/mol CO. Carry out a degree of freedom analysis on
the process. Then calculate the molar composition of the product
stream using molecular species balances, atomic species balances, &
extents of reaction. Use 100 mol feed basis.
Example : Incomplete Combustion of Methane
nCH4 (mol CH4)

nCO (mol CO)
100 mol
8nCO (mol CO2)
nH2O (mol H2O)

0.078 mol CH4 mol-1
nO2 (mol O2)
0.194 mol O2 mol-1
nN2 (mol N2)
0.078 mol N2 mol-1
Example : Degree-of-Freedom Analysis
Molecular species balances –

• No. of degree of freedom =
No. of unknown labeled variables + No. of independent chemical
rxns – No. of independent molecular species balances – No. of
other eqns.
5 unknown variables + 2 independent reactions – 6 independent

molecular species balances (CH4, O2, N2, CO, CO2, H2O)- 1
specified methane conversion = 0 degrees of freedom.
Atomic species balances –

No. of degrees of freedom =
No. of unknown labeled variables – No. of independent atomic
species balances – No. of molecular balances on independent
nonreactive species - No. of other eqns.
5 unknown variables + 3 independent atomic species balances

(C,H,O)- 1 nonreactive molecular species balance (N2) - 1
specified methane conversion = 0 degrees of freedom.
Extent of reaction–
No. of degrees of freedom =
No. of unknown labeled variables + No. of independent reactions (one
extent of reaction for each) – No. of independent reactive species
(one equation for each species in terms of extents or rxn) –No. of
independent nonreactive species ( one balance eqn. for each) - No. of
other eqns. relating the unknown variables.
5 unknown labeled variables + 2 independent reactions - 5 expressions

for ni (E) (i = CH4, O2, CO, CO2, H2O) – 1 nonreactive molecular species
balance (N2) - 1 specified methane conversion = 0 degrees of freedom.
Example : Determining nCH4
Using 90 % CH4 conversion: (10 % remains unconverted)
nCH4 = 0.100 x 7.8 mol CH4 fed = 0.780 mol CH4

Example : Determining nN2
All 3 solution methods involve writing a balance on N2 (the

unreactive species in the process).
N2 Balance : input = output
nN2 = 72.8 mol N2
Determine nCO, nH2O, & nO2 using the 3 methods.
Molecular species balances
Atomic species balance
Extent of reaction
Energy Balances
• If a plant uses more energy than its competitors, its

product would be priced out of the market.
• Designing a process:
• Energy in & out of a process unit must be accounted for.
• Overall energy requirement for the process.
• Carried out in same way as material balances (account for
molar or mass flow).
Forms of Energy: First law of thermodynamics
Total energy of a system is of 3 components:

1. Kinetic Energy: Energy due to translational motion of a
system relative to some reference (earth surface).
2. Potential Energy: Energy due to the position of the
system in relational to a potential field.
3. Internal Energy: all other energy possessed by a
system
Forms of Energy: Energy transferred
For a closed system, energy may be transferred btw a

system & its surroundings in two ways:
1. As heat: Energy flowing as a result of temp gradient.
Note
• Heat flow from a higher temp to a lower one.
• Heat is +ve when it is transferred to the system from
the surroundings.
Forms of Energy: Energy transferred
2. As work (force x Distance): energy that flows in

response to any driving force other than temp diff .e.g. a
force or voltage.
Note
• Work is +ve when it is done by the system on the
surroundings.
Principle of Energy balances: First law of thermodynamics
Law of conservation of Energy:

• Energy can neither be created nor destroyed.
• The rate at which energy (kinetic + potential +internal) is
carried into a system by input streams plus the rate at which
it enters as heat, minus the rate at which it is transported
out of the system by the output stream, minus the rate at
which it leaves as work, equals the rate of accumulation of
energy in the system.
• Accumulation = input - output
Class Activity
Suppose the initial energy of a system (internal + kinetic +

potential) is Ei, the final energy is Ef, and amount of
energy Q is transferred from the environment to the
system as heat, & an amount W is transferred from the
system to the environment as work. According to the first
law of thermodynamics, what is the relationship btw Ei,
Ef, Q & W.
Forms of Energy: Kinetic & Potential Energy
The kinetic energy (Ek) (J)
Ek = ½ mu2 or Ḕk= 1/2ṁu2

Where:
m = mass of object (kg)
U = velocity of object (m/s) or uniform velocity of fluid
ṁ=mass flowrate of fluid (kg/s)
Forms of Energy: Kinetic & Potential Energy
The gravitational potential energy (Ep) of an object of mass m

Ep = mgz or Ḕp= ṁgz
Where:
m = mass of object (kg)
g = acceleration of gravity
z = height of the object above a reference plane at which Ep is zero.
ṁ = mass flowrate of fluid (kg/s)
Change in Ep when a body or fluid changes elevation
Ep2 – Ep1 = mg(z2-z1)
Energy Balances on Systems
A system can be:

• Open: mass crosses the system boundaries over time.
• Closed: mass is not allowed to cross the system
boundaries over time.
• Open system: semi batch & continuous system.
• Close system : batch process system.
Energy Balances on Closed Systems
An integral energy balance of a closed system btw time

intervals :
accumulation = input - output
Note: Energy can neither be created nor destroyed
(eliminating the generation & consumption terms).
Deriving the basic form of the first law of thermodynamics for
a Closed Systems
• Unlike the mass balance, for closed systems energy can

be transferred across boundaries as heat & work.
Final system energy – initial system energy = net energy

transferred to the system (in – out).
Initial system energy = Ui + Eki + Epi
Final system energy = Uf + Ekf +Epf
Energy transferred = Q - W
a Closed Systems
i & f = initial & final state of the system.

U =internal energy
Ek = kinetic energy
Ep = potential energy
Q = heat transferred to the system from its surroundings.
W = work done by the system on its surroundings.
(Uf – Ui) + (Ekf – Eki) + (Epf – Epi) = Q – W
ΔU + ΔEk + ΔEp = Q - W
a Closed Systems
Note
1. Internal energy in a closed system:
• depends on the chemical composition, state of aggregation
(solid, liquid & gas), & temp of the system materials.
• independent of the pressure for ideal gases & almost
independent of pressure for liquids & solids.
• If there are no temp changes, phase changes or chemical
rxns ΔU ≡ 0
a Closed Systems
Note
2. If the system is not accelerating ΔEk =0. if the system
is not rising or falling, then ΔEp = 0.
3. If a system & its surroundings are at the same
temperature or the system is perfectly insulated the Q =
0 (adiabatic).
a Closed Systems
Note
4. If there are no moving parts or electrical currents or
radiation at the system boundary, then W = 0.
Work done on or by a closed system is carried out by
movement of the system boundary against a resisting
force or the passage of an electrical current or radiation
across the system boundary.
Class Activity
1. What do the terms closed system & open system mean?

2. Define an adiabatic process.
3. If a closed system has an internal energy of 100 kcal at
the beginning of a process & 50 kcal at the end, what is
ΔU?
4. If 250 J is added to a system as heat, what is the value
of Q in the energy balance eqn? if 250 J of work is done
to the system, what is the value of W?
Energy Balance on a closed system: Example
A gas is contained in a cylinder fitted with a movable piston.

The initial gas temperature is 25 ℃. The cylinder is placed in boiling
water with the piston held in a fixed position. Heat in the amount of 2
kcal is transferred to the gas, which equilibrates at 100 ℃ ( & a
higher pressure). The piston is then released & the gas does 100 J of
work in moving the piston to its new equilibrium position. The final gas
temperature is 100 ℃.
Write the energy balance equation for each of the two stages of this
process, & in each case solve for the unknown energy term in the
equation.
A gas is contained in a cylinder fitted with a movable piston. In

solving this problem, consider the gas in the cylinder to be
system, neglect the change in potential energy of the gas as the
piston moves vertically, & assume the gas behaves ideally. Express
all energies in joules.
25℃ 100℃
Initial state Final state

Recall: ΔU + ΔEk + ΔEp = Q – W

ΔEk = 0 (the system is stationary)
ΔEp = 0 (no vertical displacement)
W = 0 (no moving boundaries)
ΔU = Q
Q = 2 kcal
Convert to Joules = 8370 J
ΔU = 8370 J
Recall: ΔU + ΔEk + ΔEp = Q – W

ΔEk = 0 (the system is stationary at
Initial & final state)
100℃ 100℃
ΔEp = 0 (assumed negligible)
Initial Final
ΔU = (dependent on T for an ideal gas state state
& T is constant)
Thus an additional 100 J of heat is
0 = Q - W
transferred to the gas as it expands
W = +100 J (why is it positive?) at 100 ℃.
Q = 100 J
Energy Balance on an open system at steady state
Open system:
• Has mass crossing its boundaries during the process.
• Work is done to push mass in, & work is done on the surroundings
by the emerging mass.
• Recall: The first law of thermodynamics for an open system at
steady state:
Input = Output
• What happens to the accumulation, generation, & consumption
terms of the general balance eqns?
Input= total rate of transport of kinetic energy, potential energy.

& internal energy by all process input streams + the rate at which
energy is transferred in as heat
Output = total rate of energy transport by the output streams +
the rate at which energy is transferred out as work.
If Ej = total rate of energy transport by the jth input or output

stream of a process.
Q & W = rate of flow of heat (into) & work (out) of the process.
Q + σ𝒊 Eji (summation of input stream) = σ𝒐 Ej𝒐 (summation of

output stream) + W
σ𝒐 Ej𝒐 - σ𝒊 Eji = Q – W
if mj, Ekj, & Uj = mass, kinetic energy, potential energy
& internal energy for the jth process stream.
Total rate at which energy is transported into & out of
the system is:
Ej = Uj + Ekj + Epj
Uj = mjuj
Ekj = ½ mjuj2
Epj = mjgzj
Ej = mj (Uj + ½ u2 + gz)
The total work (W) done by the system on its surroundings
equals the shaft work (Ws) + the flow work (Wfl)
Wfl =σ𝒐 Pj𝒐Vj𝒐 - σ𝒊 PjiVj𝒊
W =Ws + σ𝒐 Pj𝒐Vj𝒐 - σ𝒊 PjiVj𝒊
Substituting W =Ws + σ𝒐 Pj𝒐Vj𝒐 - σ𝒊 PjiVj𝒊

Ej = mj (Uj + ½ u2 + gz) into
σ𝒐 Ej𝒐 - σ𝒊 Eji = Q – W
σ𝒐 mjo[Ujo + PjoVjo + 1/2 u2 + gzjo] -σ𝒊 mji[Uji + PjiVji + 1/2 u2 + gzji]= Q – W
Recall: Hj = Uj + PjVj
H = specific enthalpy
Substituting Hj into the equation:
σ𝒐 mjo[Hjo + 1/2 u2 + gzjo] -σ𝒊 mji[Hji + 1/2 u2 + gzji]= Q – Ws
Let ΔH = σ𝒐 mjoHjo -σ𝒊 mjiHji

ΔEk = σ𝒐 1/2mjou2 -σ𝒊 1/2mji u2]
ΔEp = σ𝒐 mjogzjo -σ𝒊 mjigzji]
Net energy balance for an open system at steady state
ΔH + ΔEk + ΔEp = Q - Ws
Practice question on energy balance
1000 kg/h of steam drives a turbine. The steam enters the

turbine at 44 atm and 800 ℃ at a linear velocity of 800 m
h-1 and leaves at a point 10 m below the turbine inlet at
atmospheric pressure and a velocity of 3600 m h-1. The
turbine delivers shaft work at a rate of 100 kW, and the
heat loss from the turbine is estimated to be 170 kcal h-1.
calculate the specific enthalpy change.
Practice question on energy balance
Two streams of water are mixed to form the feed to a boiler. The process
data are as follows.
Feed stream 1 = 60 kg hr-1 at 30 ℃, specific enthalpy=125.7 kJ kg-1
Feed stream 2 =50 kg hr-1 at 65 ℃, specific enthalpy= 271.9 kJ kg-1
Boiler pressure = 17 bar (absolute)
Saturated stream: 204℃, specific enthalpy= 2793 kJ kg-1
Specific volume of saturated steam at 17 bar is 0.1166 m3 kg-1.
The exiting steam emerges from the boiler through a 50 cm ID pipe.
calculate the required heat input to the boiler in kilojoules per seconds if
the emerging steam is saturated at the boiler pressure. Assume the kinetic
energies of the liquid inlet stream is negligible.

Industrial Process Calculations CHE 341

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Industrial Process Calculations CHE 341

Uploaded by

Copyright:

Available Formats

Industrial Process

• Unit equipment built for

• Boiler is a closed vessel in

• Heat rejection device that expels waste

• Identify & describe 3 equipment each in the 4 categories of

Signs of Chemical Reaction:

• Changes that occur to form a new substance.

Note: read up:

In industrial processes reactants are not fed into the reactor in

As a result of the deviation experienced in industrial processes some

Limiting reactant: This is the reactant that is depleted fastest.

Excess reactant: This is the reactant in excess of the limiting reactant.

𝑛𝑜.𝑜𝑓 𝒎𝒐𝒍𝒆𝒔 𝑜𝑓 𝒆𝒙𝒄𝒆𝒔𝒔 𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 −𝑛𝑜.𝑜𝑓 𝒎𝒐𝒍𝒆𝒔 𝑜𝑓 𝒍𝒊𝒎𝒊𝒕𝒊𝒏𝒈 𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡

Fractional Conversion (X): fraction of a reactant that is converted into

if 10 moles of A is fed to a reactor and 6 moles reacted what is the fractional

Selectivity & yield 𝐴 + 𝐵՜𝑪 +𝑫

𝑚𝑎𝑠𝑠 𝑜𝑟 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝒅𝒆𝒔𝒊𝒓𝒆𝒅 𝑝𝑟𝑜𝑑𝑢𝑐𝑡

Material balance- Accounting of material.

Classes of Chemical Process: 2 classes.

semi batch process: neither batch nor continuous.

Unsteady state (transient) : when process variables changes with

Classify the following processes as batch, continuous or semi-batch & steady

𝑰𝒏𝒑𝒖𝒕 + generation – output – consumption = accumulation

𝑰𝒏𝒑𝒖𝒕 (enters) + generation (is produced) – output (leaves)– consumption (consumed) =

1. For total mass balance: generation = o, consumption = o. Except

1. For a steady state Continuous processes: accumulation = zero

2. For a non-reactive species or total mass: generation &

𝑰𝒏𝒑𝒖𝒕 (enters) = output (leaves)

1000 kg/hr of a mixture of benzene (B) & 450 kg B/h

toluene (T) containing 50 % benzene by

mass is separated by distillation into two

The operation is at steady state. Write

output streams. mሶ 2 kg B/h

For a steady state non-reactive Continuous processes: accumulation

𝑰𝒏𝒑𝒖𝒕 (enters) = output (leaves)

𝑰𝒏𝒑𝒖𝒕 (500 kg B/h) = output (450 kg B/h + 𝒎ሶ 𝟐)

𝑰𝒏𝒑𝒖𝒕 (500 kg T/h) = output (475 kg T/h + 𝒎ሶ 𝟏)

𝐼𝑛𝑝𝑢𝑡 (1000 kg/h) = output (450 + 475 + 𝑚ሶ 2(50) + 𝑚ሶ 1(25)) (kg/h)

1000 kg/h= 1000 kg/h

1. For batch processes:

Initial streams Final streams

First mixture: 200g

Since there is no reaction involved, no generation or consumption term, hence

From the given parameters, We will attempt:

From the mass balance m is obtained (350 g) and inserted into

Total Mass Balance:

Carry out a water balance on the given example.

Example: n (kmol /min)

contains 10 mole% hexane vapor. Air

Differential balance on air (air is considered insoluble in

0.1 kmol air/ min = 0.9 kmol air/kmol x n kmol/min

Integral balance on hexane from t = 0 to tt (min)= time

Accumulation term: total change in the moles of hexane in

Output term: rate at which hexane is leaving the system

-76.45 kmol C6H14 = -0.1 x 0.111 x tt (min).

All material balance problems involves:

• The flowchart functions as a score board for the

2. Assign algebraic symbols to unknown stream variables

3. Derive & solve an eqn. for each unknown on the

E.g. & class activity

b mol O2 c mol N2 c mol N2

An experiment on the growth rate of certain organisms requires an environment

0.2 ň1 (mol O2 min-1)

20 cm3 H2O (L) min-1