Material Balance For Reactive System Chapter 4

4.0 MATERIAL BALANCE FOR REACTIVE SYSTEM

4.1 Single Reaction
4.1.1 Ethylene oxide (C2H4O) is produced by reacting ethylene with oxygen. The feed
to the reactor contains 5 moles of ethylene (C2H4) 3 moles of oxygen and 2 moles
of ethylene oxide.
2C2H4 + O2 → 2C2H4O
i. Set up the material balances for this reaction which includes moles in,
moles out and the moles fraction for each component.
ii. Determine the amount of reaction occurred (ε):
a. If n C2H4 = 5 mol (the amount of ethylene coming out of the reactor is
5 moles).
b. If n C2H4 = 6 mol.
c. If n C2H4 = 0 mol.
iii. Determine the limiting reactant.
iv. If n C2H4 = 2 mol, determine the fractional conversion, ƒ.
(Final Exam Apr 2007)
Ans: (ii) (a) 0 mole (b) 0.5 moles (c) 2.5 moles (iv) 0.6

4.1.2 Nitric oxide (NO) is produced from the combustion process of ammonia as in
the following reaction:
4NH3 + 5O2 → 4NO + 6H2O

i. Determine the stoichiometric ratio of O2 to NO.

ii. When 100 kmol NH3/h and 40% excess O2 are fed to the reactor:
a. Draw and label the flow diagram of the system.
b. Determine the oxygen feed rate (kmol/h).
c. Calculate the molar composition of each component in the reactor
effluent when 98% conversion of the NH3 is achieved.
iii. If 50 mol of NH3 and 100 mol of O2 are fed to the reactor, determine:
i. The limiting and excess reactant.
ii. The percentage by which the other reactant is in excess.
iii. The extent of reaction equations for NH3 and O2.
(Final Exam Apr 2005/2007)
Ans: (ii) (b) 175 kmol O2/h (c) 0.6678 mole% NH3, 17.53 mole% O2, 32.72 mole% NO,
49.08 mole% H2O (iii) (b) 60%

4.1.3 In a production plant, propylene, ammonia and water are reacted to produce
acrylonitrile as shown in the following reaction:
C3H6 + NH3 + O2 → C3H3N + H2O
i. Draw and label the flowchart of the process.
ii. Balance the above stoichiometric equation.
iii. When 100 kmol NH3, 100 kmol C3H6 and 40% excess O2 are fed to the
reactor:

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 Material Balance For Reactive System Chapter 4

a. Determine the oxygen feed (kmol).

b. The extent of reaction equations for C3H6, NH3 and O2.
c. Calculate the molar composition of each component in the reactor
effluent when 80% conversion of the NH3 is achieved.
(Final Exam Oct 2005)
Ans: (iii) (a) 210 kmol O2 (c) 4.444 mole% NH3, 4.444 mole% C3H6, 20 mole% O2,
17.78 mole% C3H3N, 53.33 mole% H2O

4.1.4 A stream containing H2S and pure SO2 are fed to sulfur recovery reactor, where
the reaction below take place.
2H2S + SO2 → 3S + 2H2O
i. Determine the stoichiometric ratio of SO2 to S.
ii. Draw and label the flow diagram of the process.
iii. Determine the SO2 feed rate if 50% excess of the SO2 and 100 kmol/hr of
H2S will be used.
iv. Calculate the molar composition of each component in the reactor effluent
when 95% of the H2S is achieved.
(Final Exam Oct 2006)
Ans: (iii) 75 kmol/hr (iv1.8518 mole% H2S, 10.18 mole% SO2, 52.77 mole% S,
32.1852 mole% H2O

4.2 Multiple Reactions

4.2.1 Briefly explain the purpose of a purge stream in a chemical process.
(Final Exam Apr 2010)
4.2.2 A quality control inspector at Berjaya Soft Drink Company in 2006 had taken 500
samples per month to perform final inspection of two (2) different process lanes
which are lane A and lane B before the product can be released to the customers.
The yield percents of each process lane are shown in the Table 1.

Table 1 Yield Percent versus Month

Process Jan Feb Mar Apr May Jun July Aug Sept Oct Nov Dec
Lane A 80.0 82.0 85.0 83.0 83.4 85.0 85.7 89.0 89.7 88.0 88.7 89.0
Lane B 90.0 87.2 85.0 84.0 79.0 92.0 95.0 84.6 88.2 79.9 85.0 82.9

By using the data above:

i. Calculate the average percent yield of each process lane.

ii. For the following year, there will be a drop in volume of the quantity
requested by the customers. Evaluate both processes and propose which
process lane to be shutdown.
(Final Exam Oct 2012)
Ans: (ii) Lane A (85.7%), Lane B (86.7%)

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 Material Balance For Reactive System Chapter 4

4.2.3 Consider a continuous, steady state process in which the following reaction takes
place:
C6H12 + 6H2O → 6CO + 12H2
C6H12 + H2 → C6H14
In the process, 250 kmol/h C6H12 an 800 kmol/h H2O of the reactor are fed into
the reactor. The yield of H2 is 40.0% and the selectivity of H2 relative to C6H14 is
12.0.

i. Draw and label completely the flow diagram.

ii. Calculate the molar flow rates of all components in the reactor outlet.

Ans: (ii) 640 kmol H2/h, 53.33 kmol C6H14/h, 453.33 kmol H2O/h, 346.68 kmol CO/h, 138.89 kmol
C6H12/h.

4.2.4 Ethylene (C2H4) has been commercially used for production of ethanol (C2H5OH)
by hydration process:
C2H4 + H2O → C2H5OH
However, some of the product is converted to diethyl ether ((C2H5)2O) in the side
reaction:
2C2H5OH → (C2H5)2O + H2O
The feed to the reactor contains ethylene (C2H4), steam (H2O) and inert gas (G).
A sample of the reactor effluent gas is analyzed and found to contain 43.3 mole%
ethylene, 2.5 mole% ethanol, 0.14 mole% ether, 9.3 mole% inert gas and the
balance water. Based on 100 mol of effluent gas:

i. Draw and label a flowchart for this process.

ii. Calculate the molar composition of the reactor feed, the percentage
conversion of ethylene, the fractional yield of ethanol and the selectivity
of ethanol production relative to diethyl ether production.

Ans: (ii) 44.83 mole% C2H4, 46.11 mole% H2O, 9.05 mole% Inert, conversion (%) = 5.968%,
yield = 0.0543 and selectivity = 17.86 mol C2H5OH/mol (C2H5)2O

4.2.5 In the manufacture of methanol by the reaction of carbon monoxide and

hydrogen, some formaldehyde is also formed as a by-product.
CO + 2H2 → CH3OH
CO + H2 → HCHO
A mixture consisting of 20% CO and 80% H2 is allowed to react and the product
analyzed 2.92% CO, 19.71% methanol, 6.57% formaldehyde and 70.80%
hydrogen. If the basis is given 100 mol at feed stream, calculate the following:

i. Number of moles for every component at effluent stream with using

extent of reaction method.
ii. The percent conversion of limiting reactant.
iii. The percent excess of any reactant.
iv. Percent yield of methanol.

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 Material Balance For Reactive System Chapter 4

Ans: (i) 2.00 mol CO, 13.501 mol CH3OH, 4.500 mol HCHO, 48.497 mol H2 (ii) 90.0% (iii) 100%
(iv) 67.51%

4.2.6 In a urea synthesis process, ammonia and carbon dioxide are compressed at
certain temperature and pressure to form ammonium carbamate, NH4COONH2.
Dehydration of ammonium carbamate then produces urea, CO(NH2)2 and water
as below:
2NH3 + CO2 → NH4COONH2
NH4COONH2 → CO(NH2)2 + H2O
The feed to reactor contains ammonia, carbon dioxide and inert gas. A sample of
reactor effluent is then analyzed and found to contain 32.0 mole% ammonia,
7.0 mole% ammonium carbamate, 25.2 mole% urea, 1.5 mole% CO2,
9.1 mole% inert gas and the balance is water. By taking the effluent stream of
100 mol/hr as your basis,

i. Draw and label the flow diagram completely.

ii. Calculate the molar composition of the reactor feed.
iii. Calculate the percentage conversion of ammonia.
iv. Calculate the fractional yield and selectivity of urea.
(Final Exam Oct 2006, Apr 2008)
Ans: (ii) 69.25 mole% NH3, 24.21 mole% CO2 and 6.534 mole% Inert (iii) 66.8%

4.2.7 Ethylene glycol (HOCH2CH2OH) is used as a component in antifreeze. It is

produced by reacting ethylene oxide with water. A side reaction produces an
undesirable dimmer, DEG:
C2H4 + H2O → HOCH2CH2OH
HOCH2CH2OH + C2H4O → HOCH2CH2OCH2CH2OH
The reactor feed is 10 kmol/min ethylene oxide and 30 kmol/min water. The
fractional conversion of ethylene oxide is 0.92 and the selectivity is 0.85.

i. Draw and label completely the flow diagram.

ii. Calculate the number of moles for all components at reactor outlet.
iii. Determine the yield ethylene glycol.
(Final Exam Apr 2009)
Ans: (ii) 0.8 kmol/min C2H4O, 20.7438 kmol/min EG, 24.028 kmol/min H2O and 3.228 kmol/min
DEG (iii) 0.2744

4.2.8 Ethanol is produced commercially by the hydration of ethylene:

C2H4O + H2O → C2H5OH
Some of the product is converted to diethyl ether in the side reaction:
2C2H5OH → (C2H5)2O + H2O
The feed to the reactor contains ethylene, steam, and inert gas. A sample of the
reactor effluent gas is analyzed and found to contain (mole basis)
43.3% ethylene, 2.5% ethanol, 0.14% ether, 9.35% inert and the balance is water.

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 Material Balance For Reactive System Chapter 4

i. Sketch and label a flow diagram for the process.

ii. Calculate the molar composition of the reactor feed.
iii. Determine the fractional conversion of ethylene.
iv. Define yield and calculate the fractional yield of ethanol.
v. Define selectivity and determine the selectivity of ethanol relative to
diethyl ether.
(Final Exam Oct 2007/Sep 2011)
Ans: (ii) 44.87 mole% C2H4, 46.03 mole% H2O, 9.10 mole% I (iii) 0.061 (iv) 0.054
(v) 17.86 mol E/mol DE

4.2.9 In the anaerobic fermentation of grain, the yeast Saccharomyces cerevisiae digests
glucose (C6H12O6) from plant to form the products ethanol (C2H5OH) and
2-propenoic acid (C2H3CO2H) by the following reaction:
C6H12O6 → 2 C2H5OH + 2CO2
C6H12O6 → 2 C2H3CO2H + 2H2O
If the reactor feed is 3500 kg of 12 wt% glucose with water solution and during
the fermentation, about 120 kg of carbon dioxide is produced with 90 kg of
unreacted glucose.

i. Determine the molar composition for components at reactor feed.

ii. Draw and label completely the flow diagram.
iii. Calculate the number of moles (kmol) for the effluent components.
iv. Determine the yield of ethanol.
(Final Exam Oct 2009)
Ans: (i) 1.345 mole% C2H12O6, 9.8655 mole% H2O (iii) 2.727 kmol C2H5OH, 0.9393 kmol
C2H5CO2H, 172.049 kmol H2O (iv) 0.5834

4.2.10 Ethylene oxide is produced by partial oxidation of ethylene:

2C2H4 + O2 → 2C2H4O
Complete oxidation occurs as an undesired side reaction:
C2H4 + 3O2 → 2CO2 + 2H2O
The effluent composition for this reaction is 25 mole% O2, 40 mole% C2H4O,
17.5 mole% CO2 and 17.5 mole% H2O.

i. Draw and label completely the flow diagram.

ii. With using the atomic balance method, calculate the number of moles for
ethylene and oxygen feeds.
iii. Determine the yield and selectivity of ethylene oxide.
(Final Exam Oct 2008)
Ans: (ii) 48.75 mole C2H4, 71.25 mol O2 (iii) yiel = 0.8205, selectivity = 2.286 mol C2H4O/
mol CO2

4.2.11 100 mol/min of a solution of 70 mole% ethanol and 30 mole% water is fed to a
reactor operating at steady state, along with 80 mol/min of air (79 mole% N2,
21 mole% O2). Ethanol (C2H5OH) reacts with oxygen to make acetaldehyde
(CH3CHO). Acetaldehyde is further oxidized to acetic acid (CH3COOH).

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 Material Balance For Reactive System Chapter 4

i. Draw and label the flow diagram of the process.

ii. Write two (2) stoichiometric balanced chemical equations.
iii. Determine the limiting reactant.
iv. If there is 100% conversion of limiting reactant and the production rate of
acetaldehyde is 25 mol/min, calculate:
a. The composition of effluent stream.
b. The yield of acetaldehyde from ethanol.
c. The fractional conversion of the excess reactant.
(Final Exam Oct 2010)
Ans: (iv) (a) 21 mole% C2H5OH, 31 mole% H2O, 33 mole% N2, 13 mole% CH3CHO,
2 mole% CH3COOH (b) 0.74 (c) 42%

4.2.12 Methanol (CH3OH) is converted to formaldehyde (HCHO) according to the

following reactions:
2CH3OH + O2 → 2HCHO + 2H2O
CH3OH → HCHO + H2
A mixture containing 80 mole% methanol and 20 mole% oxygen is supplied as
fresh feed in a formaldehyde plant. The Single pass conversion of methanol is
50% and all of the oxygen is totally consumed. The exit stream from the reactor
contains methanol, hydrogen, water and formaldehyde. This stream then enters
a Separator in which all the formaldehyde and water are separated in the
product stream. The recycle stream which contains only hydrogen and methanol
enters a recovery unit in which 90% of hydrogen is removed. For a basis of
100 kmol/h methanol entering as a fresh feed and 90% recovery of hydrogen:

i. Redraw the flow diagram in Figure 1 and label it completely.

ii. Calculate the mass flow rate of formaldehyde produced.
iii. Calculate the mass flow rate of hydrogen produced.
iv. Determine the mass flow rate of methanol recycled.

Figure 1 Production of formaldehyde

(Final Exam Mar 2012)
Ans: (ii) 3000 kg HCHO/h (iii) 100 kg H2/h (iv) 3200 kg CH3OH/h

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 Material Balance For Reactive System Chapter 4

4.2.13 Ethylene oxide is produced commercially by the catalytic oxidation of ethylene:

2C2H4 + O2 → 2C2H4O
An undesired competing reaction is the combustion of ethylene:
C2H4 + 3O2 → 2CO2 + 2H2O
The feed to the reactor contains 3 moles of ethylene per mole of oxygen. The
single pass conversion of ethylene is 20% and for every 100 moles of ethylene
consumed in the reactor, 90 moles of ethylene oxide emerges in the reactor
product. A multiple unit process is used to separate the products: ethylene and
oxygen is recycled to the reactor, ethylene oxide is sold as product, and carbon
dioxide and water are discarded as waste. Figure 1 shows the production process
of ethylene oxide.

Figure 1 Ethylene oxide production process

By assuming a quantity of the reactor feed stream as a basis of calculation,

answer the following questions.

i. Calculate the molar flow rates of ethylene and oxygen in the fresh feed.
ii. Calculate the rate of production of ethylene oxide.
iii. Define and calculate the overall conversion of ethylene.
iv. State four (4) purposes of a recycle stream
(Final Exam Apr 2010)
Ans: (i) 15 mol C2H4/s, 11.25 mol O2/s (ii) 13.5 mol C2H4O (iii) 100%

4.3 Combustion
4.3.1 Five hundred mol/h of butane (C4H10) and 20,000 mol/h of air are fed into a
combustion reactor. Determine the percent excess air.
(Final Exam Oct 2010)
Ans: 29.28%

4.3.2 A gas contains 80 wt% propane, 15 wt% n-butane, and the balance is water.
Calculate the molar composition of this gas on both a wet and a dry basis, and
the ratio in unit of mol H2O/mol dry gas.
(Final Exam Oct 2010)
Ans: Wet basis − 77.2% propane, 11% n-butane, 11.8% H2O, Dry basis − 87.5% propane,
12.5% n-butane, 0.134 mol H2O/mol dry gas

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4.3.3 In a certain furnace, combustion process normally uses 50% excess air. Suggest
a reason why excess air is used in combustion and explain how a much higher
excess air (say 200%).
(Final Exam Sep 2011)
4.3.4 In the manufacture Methane gas (CH4) is burned in excess air (21% O2, 79% N2)
in a combustion chamber. Dry analysis of the flue gas yields 5.49 mole% CO2,
82.57 mole% N2, 10.97 mole% O2 and 0.97 mole% CH4.

i. Sketch and label a flow diagram for the process.

ii. Write a balanced chemical equation for the combustion of methane.
iii. Determine the percent conversion of methane.
iv. Calculate the percent excess O2.
v. Calculate the ratio of water to dry flue gas.
vi. Calculate the ratio at which methane and air is mixed.

Ans: (iii) 84.98% (iii) 69.89% (iv) 0.1098 mol H2O/mol Dry flue gas (v) 0.0618 mol CH4/mol Air

4.3.5 Methane gas (CH4) is fed with an amount excess of air in a combustion reactor.
In this reaction, 250 kmol/h of methane gas is fed and 65% of this gas feed is
converted to the product. In this reaction, the molar ratio of methane and
oxygen is 1:5.

i. Write the chemical reactions involved in the combustion process.

ii. Draw and label a flowchart of the process.
iii. Calculate the composition of wet flue gas.
iv. Explain why the excess air or excess oxygen is needed in burning the
fuel.
(Final Exam Oct 2008)
Ans: (iii) 1.411 mole% CH4, 14.91 mole% O2, 2.6 19 mole% CO2, 5.239 mole% H2O,
75.82 mole% N2

4.3.6 Methane gas (CH4) is burned in excess air (21% O2, 79% N2) in a combustion
chamber. Dry analysis of the flue gas yields 5.49 mole% CO2, 82.57 mole% N2,
10.97 mole% O2 and 0.97 mole% CH4.

i. Sketch and label a flow diagram for the process.

ii. Write a balanced chemical equation for the combustion of methane.
iii. Determine the percent conversion of methane.
iv. Calculate the percent excess O2.
v. Calculate the ratio of water to dry flue gas.
vi. Calculate the ratio at which methane and air is mixed.
(Final Exam Oct 2007)
Ans: (iii) 85% (iv) 70% (v) 0.11 mol H2O/ mol dry gas (vi) 0.06 mol CH4/ mol Air

4.3.7 Methane gas (CH4) is fed with an amount excess of air in a combustion reactor.
Orsat analysis of the flue gas yields the following molar composition:
8.44 mole% CO2, 9.10 mole% O2, 81.51 mole% N2 and 0.95 mole% CH4.

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 Material Balance For Reactive System Chapter 4

i. Write the chemical equation for the combustion process of methane gas.
ii. Draw and label the flow diagram completely.
iii. Calculate the composition of wet gas.
iv. Determine the percent of excess air.
(Final Exam Apr 2009)
Ans: (iii) 7.22 mole% CO2, 7.78 mole% O2, 69.74 mole% N2, 0.813 mole% CH4,
14.44 mole% H2O (iv) 15.37%

4.3.8 A waste gas mixture contains 30 mole% CH4, 25 mole% C2H6, 10 mole% water
vapor and 35 mole% CO2. The waste gas is burned in 100% excess air.
(Relative atomic mass: C = 12, H = 1, O = 16)

i. Write the balanced chemical equations for the above combustion process.
ii. Calculate the volumetric flow rate of entering air in ft3/h at 30°C and 2
bar (note: use Ideal gas law with reference to STP conditions).
iii. Determine the compositions of flue gas.
(Final Exam Apr 2008)
Ans: (ii) 626.06 ft3/h (iii) 7.58 mole% CO2, 9.72 mole% O2, 73.14 mole% N2, 9.56 mole% H2O

4.3.9 Methane gas (CH4) is fed with an amount excess of air in a combustion reactor.
An Orsat analysis of the flue gas yields the following molar composition:
8.44 mole% CO2, 9.10 mole% O2, 81.51 mole% N2 and 0.95 mole% CH4.

i. Write the chemical equation for the combustion process of methane gas.
ii. Draw and label the flow diagram completely
iii. Calculate the composition of the wet gas
iv. Determine the percent of excess air.
v. Carbon monoxide (CO) in the stack gas is a pollutant and undesired
product. Explain one method to reduce the concentration of CO in the
combustion process.
(Final Exam Apr 2009)
Ans: (iii) 7.22 mole% CO2, 7.78 mole% O2, 69.74 mole% N2, 0.813 mole% CH4, 14.44 mole%
H2O (iv) 15.37%

4.3.10 A gaseous fuel containing methane and ethane is burned with excess air. The
stack gas leaves the furnace contains 5.32 mole% CO2, 1.6 mole% CO,
7.32 mole% O2, 12.24 mole% H2O and the balance N2.
i. Write the chemical reactions involved in the combustion process.
ii. Draw and label a flowchart of the process.
iii. Calculate the composition of methane and ethane in the fuel gas and the
percentage excess air fed to the reactor.

Ans: (iii) 69.92 mole% CH4, 30.08 mole% C2H6

4.3.11 A gas mixture of 55 mole% propane, 40 mole% hydrogen and 5 mole% nitrogen
is burned with 55% excess air. Fractional conversions of 80% of the propane and
85% of the hydrogen are achieved; of the propane that reacts, 85% reacts to form
CO2 and the balance reacts to form CO.

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 Material Balance For Reactive System Chapter 4

i. Write the chemical reactions involve in the combustion process.

ii. Draw and label a flowchart of the process.
iii. Determine the molar flow rate of the supplied air.
iv. Calculate the molar flow rate of each component in the reactor effluent.
v. Explain effect of the nitrogen gas in the combustion process.
(Final Exam Apr 2006)
Ans: (iii) 2177.38 mol Air/h (iv) 11 mol C3H8/h, 6 mol H2/h, 112.2 mol CO2/h, 19.8 mol CO/h,
310 mol H2O/h , 1725.13 mol N2/h, 360.3 mol O2/h

4.3.12 A gas mixture of 65 mole% propane and 35 mole% hydrogen is burned with
40% excess air. Fractional conversions of 85% of the propane and 75% of the
hydrogen are achieved where 80% propane reacts to form CO2 and the balance
reacts to form CO.

i. Write the chemical reactions involved in the combustion process.

ii. Draw and label a flowchart of the process.
iii. Determine the molar flow rate of the supplied air.
iv. Calculate the molar flow rate of each component in the reactor effluent.
v. In a bid to reduce the CO gas produced, it is desirable to increase the
amount of excess air fed. Explain the effect of this increase of excess air to
the combustion process.
(Final Exam Apr 2008)
Ans: (iii) 2283.33 mol Air/h (iv) 9.75 mol C3H8/h, 132.6 mol CO2/h, 247.25 mol H2O/h,
33.15 mol CO/h, 206.7 mol O2/h, 8.75 mol H2/h, 1803.83 N2 mol/h

4.3.13 A waste gas contains 20 mol% CH4, 10 mol% H2, 5 mol% CO2 and the balance is
N2 is burned with 150% excess air in a combustion chamber. The conversion of
CH4 and H2 are 80% and 60% respectively. In this process, only 70% of the CH4
reacted to form CO2 while the balance forms CO.

i. Draw and label the flow diagram for the process

ii. Write two (2) chemical equations for the combustion of CH4 and one (1)
chemical equation for the combustion of H2.
iii. Taking a basis of 100 mol/s waste gas, calculate the flow rate of the inlet
air.
iv. Calculate the flow rates of constituents in the exit flue gas.
v. Determine the composition (in mol%) of dry flue gas.
(Final Exam Oct 2012)
Ans: (iii) 535.71 mol/s (iv) 4 mol/s CH4, 4 mol/s H2, 4.8 mol/s CO, 16.2 mol/s CO2,
38 mol/s H2O, 79. 9 mol/s O2, 488.2 mol/s N2 (v) 0.70 mol% CH4, 0.70 mol% H2, 0.28 mol% CO2,
74.23 mol% N2, 14.02 mol% O2, 10.07 mol% CO

4.3.14 Liquid methanol is fed to a space heater at a rate of 12 L/h and burned with
excess air. The product gas is analyzed and the dry basis mole percentages are
as follows. Given density of methanol is 0.792 g/cm3

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Table 1 Molar composition of a gas mixture

Compound mole%
Methanol, CH3OH 0.45%
Carbon dioxide, CO2 9.03%
Carbon monoxide, CO 1.81%

(Relative atomic mass : C = 12, H = 1, 0=16)

i. Write the chemical equation.

ii. Draw and label the flow diagram completely.
iii. Express DOF (Degree of Freedom) analysis for the overall system.
iv. Calculate the fractional conversion of methanol.
v. Calculate the percentage excess air fed.
vi. Calculate the mole fraction of water in the product gas.
(Final Exam Apr 2011)
Ans: (iv) 0.96 (v.) 29.1% (vi) 0.178 mol H2O/ mol

4.3.15 D and E are produced in the reaction of A, B, and C.

A + B + 3/2 C → D + 3 E

The reactor is fed with 126 kg A, 59.5 kg B and 120 kg C. The molecular weight of
A, B, and C are 42, 17, and 5, respectively.

a) Identify the limiting reactant and the excess reactant.

b) Calculate the percent excess of each of the excess of reactant.
c) If the conversion of limiting reactant is 30%, calculate the molar composition of
the effluent stream by using extent of reaction method.
(Final Exam Sept 2013)

4.3.16 Sodium carbonate ( ) may be produced by the following reaction,

Figure 2 shows the process flow for the above reaction. The ratio between the
amount of CaCO3 at S4 and Na2S at S2 entering the reactor is 1.6 : 1. Given that
the single conversion of across the reactor is 95% and the compositions of
streams S3, S4 and S9 are identical.

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 Material Balance For Reactive System Chapter 4

S1

13.33 mol% Na2S

86.67 mol% H2O
S6
MIXER 1 16.51 mol% Na2CO3
Figure 1 Flow diagram of production oxides of phosphorus
Na2S 83.49 mol% H2O
42 kmol/min S2 S11
.
S5
REACTOR SEPARATOR 1

S10
134 kmol/min S4 S7
5.88 mol% CaS
S9
MIXER 2 SEPARATOR 2 94.12 mol% H2O

S3 S8

7.16 mol% CaCO3 CaCO3

92.84 mol% H2O

Figure 2: Flow chart of sodium carbonate production

a) Redraw and label completely the flow diagram.

b) Express degree of freedom (DOF) at Reactor and Mixer
c) Evaluate the molar flow rate of stream S5.
d) Determine the molar flow rate of stream S6, S7, S9, S10 and S11.
(Final Exam Mac 2014)

4.3.17 The gaseous feed to a phosphorus oxidation reactor has the following
composition: phosphorus, P4= 8 mol %; carbon monoxide, CO = 89 mol% and
the balance, nitrogen, N2. This gas is burnt with air under conditions selectively
to oxidize phosphorus. Analysis of the flue gas shows CO2 = 0.9 mol%; CO =
22.5 mol%; N2 = 68 mol% and the balance, O2. Assume oxidation of phosphorus
is complete and that it exists in the flue gas partly as phosphorus trioxide, P4O6
and partly as phosphorus pentoxide, P4O10.

P4 + 3O2 P4O6

P4 + 5O2 P4O10

CO + O2 CO2

42 Faculty Of Chemical Engineering, UiTM (Terengganu) Kampus Bukit Besi

 Material Balance For Reactive System Chapter 4
Gas inlet Gas outlet to cooler

Combustion

Ai Flue gas
r
a) Redraw and label completely the flow diagram of the process.
b) Using atomic balance, calculate the percentage of CO entering the furnace
that oxidized to CO2.
c) Calculate the percentage of P4 that is oxidized to P4O10
(Final Exam Sep 2015)

43 Faculty Of Chemical Engineering, UiTM (Terengganu) Kampus Bukit Besi