ChE 31

INTRODUCTION TO
CHEMICAL ENGINEERING
2nd sem. 2013-2014
Prepared by: CGAlfafara

BALANCES ON MULTIPLE UNIT PROCESSES

BALANCES ON MULTIPLE-UNIT PROCESSES

Many industrial processes rarely involves just one process unit (several process
units, several process streams)
Feed 2
mixing point

Feed 1

Unit 1

Unit 2

Solution Strategy for Solving Balances on Multiple-Unit Processes

(a) Break up the whole system into sub-systems (draw system boundaries)
(b) Write mass balances on several sub-systems to obtain enough equations to
determine all unknown stream variables.

Mass Balances may be written for

(1) Whole system (overall mass balance)
(2) Sub-systems (on a process unit, or mixing point (point where several streams intersect)

BALANCES ON MULTIPLE-UNIT PROCESSES

A
Feed 2
B2

B1
C2
Feed 1

Unit 1

Unit 2

Product 4

C1

Product 1

Product 2

Product 3

System boundaries that can be made as basis for formulating mass balances

(1) Over all process: (A)

(2) Process Unit:
(B1), (B2)
(3) Mixing/Splitting Point:
(C1, C2)

BALANCES ON MULTIPLE-UNIT PROCESSES

Example: Two Unit Process
A labeled flowchart of a continuous steady-state two-unit process is shown below.
Each stream contains two components, A and B, in different proportions.
Three streams whose flow rates and/or compositions are not known are labeled 1,2
and 3.
Calculate the unknown flow rates and compositions of the unknown streams.
40.0 kg/h

30.0 kg/h

0.900 kgA/kg
0.100 kgB/kg

0.600 kgA/kg
0.400 kgB/kg

100.0 kg/h
0.500 kgA/kg
0.500 kgB/kg

30.0 kg/h
0.300 kgA/kg
0.700 kgB/kg

BALANCES ON MULTIPLE-UNIT PROCESSES

Example: Two Unit Process

40.0 kg/h

30.0 kg/h

0.900 kgA/kg
0.100 kgB/kg

0.600 kgA/kg
0.400 kgB/kg

100.0 kg/h
0.500 kgA/kg
0.500 kgB/kg

xA1 (kg A/kg)

(1-xA1) (kg B/kg

xA2 (kg A/kg)

(1-xA2) (kg B/kg

30.0 kg/h
0.300 kgA/kg
0.700 kgB/kg

Basis: 100 kg/h Feed

Continuous Process assumed steadystate No Reaction: input=output

OVERALL SYSTEM BOUNDARY

DF=2-2=0

xA3 (kg A/kg)

(1-xA3) (kg B/kg

BALANCES ON MULTIPLE-UNIT PROCESSES

Example: Two Unit Process

40.0 kg/h

30.0 kg/h

0.900 kgA/kg
0.100 kgB/kg

0.600 kgA/kg
0.400 kgB/kg

100.0 kg/h
0.500 kgA/kg
0.500 kgB/kg

xA1 (kg A/kg)

(1-xA1) (kg B/kg

xA2 (kg A/kg)

(1-xA2) (kg B/kg

30.0 kg/h
0.300 kgA/kg
0.700 kgB/kg

Basis: 100 kg/h Feed

Continuous Process assumed steadystate No Reaction: input=output

UNIT 1 SYSTEM BOUNDARY

DF=2-2=0

xA3 (kg A/kg)

(1-xA3) (kg B/kg

BALANCES ON MULTIPLE-UNIT PROCESSES

Example: Two Unit Process

40.0 kg/h

30.0 kg/h

0.900 kgA/kg
0.100 kgB/kg

0.600 kgA/kg
0.400 kgB/kg

100.0 kg/h
0.500 kgA/kg
0.500 kgB/kg

xA1 (kg A/kg)

(1-xA1) (kg B/kg

xA2 (kg A/kg)

(1-xA2) (kg B/kg

30.0 kg/h
Basis: 100 kg/h Feed

0.300 kgA/kg
0.700 kgB/kg

Continuous Process assumed steadystate No Reaction: input=output

MIXING POINT SYSTEM BOUNDARY

DF=2-2=0

xA3 (kg A/kg)

(1-xA3) (kg B/kg

BALANCES ON MULTIPLE-UNIT PROCESSES

NOTES
(1) Situation becomes more complicated with 3 or more processes
(2) With 3 or more units, balances can also be made around a
combination of process units
(3) Finding the right combinations can lead to better computational
efficiency

BALANCES ON MULTIPLE-UNIT PROCESSES

Extraction-Distillation Process
Basic terminology used for extraction
(1) Feed contains the solute (target for extraction) and diluent
(2) Solvent is the liquid used to extract the solute from the feed
(3) Extract is the exit stream rich in the solute
(4) Raffinate is the exit stream rich in the diluent
SOLVENT

FEED
solute
diluent

Extraction
stage

RAFFINATE
(diluent rich)

EXTRACT
(solute rich)

(1) Extraction stage usually consists of a mixer and settler

(2) Usually more than one extraction stages are used

BALANCES ON MULTIPLE-UNIT PROCESSES

Extraction-Distillation Process

FEED
solute
diluent

SOLVENT

SOLVENT

Extraction
stage 1

Extraction
stage 2

SOLVENT

Extraction
stage n
RAFF

EXTR 1

EXTR 2

Dist
Col

EXTR n

BALANCES ON MULTIPLE-UNIT PROCESSES

Example: Two- StageExtraction and Distillation Process
A mixture containing 50.0 wt % acetone (the solute) and 50.0 wt % water (the
diluent) is to be extracted by methylisobutylketone (MIBK) (the solvent), which
dissolves acetone but is nearly immiscible with water.
In a pilot plant study, for every 100 kg of acetone-water fed to the first extraction
stage, 100 kg of MIBK is fed to the first stage and 75 kg is fed to the second
stage. The extract from the first stage is found to contain 27.5% acetone. (All
percentages in the remainder of the problem statement are weight %). The
second stage raffinate has a mass of 43.1 kg and contains 5.3% aceetone,
1.6%MBK, and 93.1% water, and the second stage extract contains 9.0%
acetone, 88.0% MIBK, and 3.0% water. The overhead product from the
distillation column contains 2.0% MIBK, 1.0% water and the balance acetone.
Taking a basis of calculation of 100 kg acetone-water feed, calculate the masses
and compositions (component weight percentages) of the stage 1 raffinate and
extract, the stage 2 extract, the combined extract, and the distillation and
overhead products.

Part of the exit stream is mixed with fresh feed

an channeled into the reactor as blended feed
or mixed feed

RECYCLE PROCESSES
Fresh
Feed

Mixed
Feed

split
point
Composition of Final
Exit and Recycle
streams are the same

Recycle
Fresh
Feed

Mixed
Feed

Recycle

Composition of Final
Exit and Recycle
streams may not be
the same

Recycling is usually done when a component in a unit stream is not completely processed

Solution Strategy is the same as for Multiple Unit Process

: break into sub-process and then perform mass balance for each sub process

REYCLE PROCESS WITHOUT REACTION

Aside from recovering/reusing unconsumed reactants in a process, recycling is
also done under the followind conditions:
Recovery of
catalyst

Most of reactors use catalysis to increase the rate of reaction.

Catalysts are usually expensive, and the processes generally include
provisions for recovering them from the product stream and recycling
them to the reactor. They may be recovered with unconsumed
reactants or recovered separately in special facilities designed for this
purpose.

Dilution of
process stream

Example in filtration of slurry (suspension of solid in liquid). If the

solids concentration of the feed is to high, it may clog the filter. A
strategy is to recycle part of the filtrate back to fresh feed to dilute the
slurry.

Control of a
process variable

Example, lowering the heat generated in an exothermic reaction by

recycling to reduce reactant concentration.

Circulation of a
working fluid

In processes where a single material is used indefinitely

Example, circulation of refrigerant in household refrigerators

BYPASS PROCESSES
A fraction of the feed to a process is diverted around a unit and combined with the output stream
from the unit.

Bypass
Composition of both
fresh feed and
bypass streams are
the same

Fresh
Feed

split
point

mixing
point

Solution Strategy is the same as for Multiple Unit Process

: break into sub-process and then perform mass balance for each sub process

Sample Problem for Recycling: Air Conditioning Problem

Fresh air containing 4.00 mole% water vapor is to be cooled and dehumidified to a
water content of 1.70 mole% H2O.
A stream of fresh air is combined with recycle stream of previously dehumidified air
and passed through the cooler.
The blended stream entering the unit contains 2.30 mole% H2O. In the air
conditioner, some of the water in the feed stream is condensed and removed as
liquid.
A fraction of dehumidified air leaving the cooler is recycled and the remainder is
delivered to a room.

Taking 100 moles dehumidified air delivered to the room as basis of calculation,
calculate the moles of fresh feed, moles of water condensed, and moles of
dehumidified air recycled.

Sample Problem for Recycling: Air Conditioning Problem

Fresh air containing 4.00 mole% water vapor is to be cooled and dehumidified to a water
content of 1.70 mole% H2O. A stream of fresh air is combined with recycle stream of
previously dehumidified air and passed through the cooler. The blended stream entering the
unit contains 2.30 mole% H2O. In the air conditioner, some of the water in the feed stream is
condensed and removed as liquid. A fraction of dehumidified air leaving the cooler is recycled
and the remainder is delivered to a room. Taking 100 moles dehumidified air delivered to the
room as basis of calculation, calculate the moles of fresh feed, moles of water condensed,
and moles of dehumidified air recycled.
n5 (mole)
0.017 mol W /mol
0.983 mol DA /mol

n1 (mole)
0.04 mol W /mol
0.96 mol DA /mol

n2 (mole)
0.023 mol W /mol
0.977 mol DA /mol

n4 (mole)
0.017 mol W /mol
0.983 mol DA /mol

n3 (mole) (H2O)

100 moles
0.017 mol W /mol
0.983 mol DA /mol

Sample Problem for Recycling: Evaporative Crystallization Process

The flowchart of a steady-state process to recover crystalline potassium (K2CrO4) from an
aqueous solution of this salt as shown below:
H2O

4500 kg/h

EVAP

49.4% K2CrO4 sol

33.3 %K2CrO4
Filtrate
36.4% K2CrO4 sol

CRYS/FILT

Filter Cake
K2CrO4 crystals
(95% of total mass
of filter cake
36.4% K2CrO4 sol

Forty-five hundred kg per hour of a solution that is one third K2CrO4 by mass is joined by a
recycle stream containing 36.4% K2CrO4, and the combined stream is fed into an
evaporator. The concentrated stream leaving the evaporator contains 49.4% K2CrO4; this
stream is fed into a crystallizer in which it is cooled (causing crystals of K2CrO4 to come out
of solution) and then filtered. The filter cake consists of K2CrO4 cyrstals and a solution that
contains 36.4% K2CrO4 by mass; the crystals account for 95% of the total mass of the filter
cake. The solution that passes through the filter, also 36.4% K2CrO4, is the recycle stream.
Calculate the rate of evaporation, the rate of production of crystalline K2CrO4, the feed
rates that the evaporator and crystallizer must be designed to handle, and the recycle ratio
(mass of recycle/mass of fresh feed).

CLASS DISMISSED