Chemical Engineering Calculations
Material Balance without Reaction
Ten kilograms each of salts A and B are dissolved in 50 kg of
water. The solubility of A in water is 1 kg per kg water and that
of B is 0.5 kg per kg of water. The solution is heated to
evaporate water. When the concentration of the solution
reaches the saturation concentration of any salt, further
evaporation results in the crystallization of that salt. If 70% of
the water that is originally present in the solution is driven off
by evaporation, determine the following
The weight of the final solution – 32.5
The weight of the crystals formed – 2.5
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance without Reaction
What is the theoretical yield of crystals which may be obtained
by cooling a solution containing 1000 kg of sodium sulfate (mw
= 142 kg/kmol) in 5000 kg water to 283 K? The solubility of
sodium sulfate at 283 K is 9 kg anhydrous salt / 100 kg water
and the deposited crystals will consist of decahydrate. It may be
assumed that 2% of the water will be lost by evaporation during
cooling
1400
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance without Reaction
Oil is extracted from seeds by leaching with organic
solvents. Soybean seeds containing 20% oil, 65% inert
solids and 15% water are leached with hexane and after
extraction the solid residue is removed from the solution
of oil in hexane. The residue analyzed 1.0% oil, 88% inert
cake and 11% water. What percent of oil is recovered?
96%
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance without Reaction
One hundred pounds of solution containing 80 wt% Na2SO4
must be obtained by evaporating a dilute solution using a
double effect evaporator. If the evaporator from the 2nd effect
is 60% of that coming from the first effect and the concentrate
of the first effect contains 1 lb Na2SO4 per pound of water.
Calculate for the composition of the feed.
31% Na2SO4
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance without Reaction
For the preparation of potassium nitrate, 10000 kg/h of
a 20% KNO3 solution is mixed with a recycle stream and
sent to an evaporator. The rate of evaporation is 1.5
times the rate of introduction of recycle stream. The
concentrated solution leaving the evaporator contains
50% KNO3. This is admitted to the crystallizer which
yields crystals containing 5% water. At the crystallization
temperature the solubility is 50 kg/100 kg of water. The
major part of the mother liquor leaving the crystallizer
is returned to the evaporator as recycle. Calculate the
following:
The concentration of KNO3 in the stream entering the
evaporator – 25%
The flow rate of recycle stream in kg/h – 5143
The rate of production of crystals – 2007
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance without Reaction
For the preparation of potassium nitrate, 10000 kg/h of
a 20% KNO3 solution is mixed with a recycle stream and
sent to an evaporator. The rate of evaporation is 1.5
times the rate of introduction of recycle stream. The
concentrated solution leaving the evaporator contains
50% KNO3. This is admitted to the crystallizer which
yields crystals containing 5% water. At the crystallization
temperature the solubility is 50 kg/100 kg of water. The
major part of the mother liquor leaving the crystallizer
is returned to the evaporator as recycle. Calculate the
following:
The concentration of KNO3 in the stream entering the
evaporator – 25%
The flow rate of recycle stream in kg/h – 5143
The rate of production of crystals – 2007
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance without Reaction
A saturated solution of Na2CO3 is sent to a crystallizer where it
is cooled to 100C. The wet crop (Na2CO3 x10H2O + adhering
solution) is then sent to a drier producing anhydrous Na2CO3.
With 1000 kg of saturated solution at 300C and 5% of the
mother liquor adheres to the crop, calculate the following:
Weight of anhydrous Na2CO3 produced – 242
With the same conditions of the feed solution, at what
temperature must the crystallizer be operated to obtain 500 kg
of Na2CO3 x10H2O without accompanying adhering solution? -
21
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance without Reaction
An evaporation-crystallizer process is used to
obtain solid K2SO4 from an aqueous solution
of this salt. The fresh feed of the process
contains 19.6% wt K2SO4. The fresh feed
joins a recycle stream from the filtrate
product of the recycle and enters the
evaporator where 42% of the water fed is
evaporated. The evaporator has a maximum
capacity of 175 kg water evaporated per
second. The concentrated solution then
enters the crystallizer. The wet filter cake
consists of solid K2SO4 crystals and 40 wt%
K2SO4 solution, in a ratio of 10 kg crystals per
kg solution. The filtrate is recycled to join the
fresh feed. Calculate the maximum recycle to
fresh feed ratio.
1.80
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance without Reaction
An evaporation-crystallizer process is used to
obtain solid K2SO4 from an aqueous solution
of this salt. The fresh feed of the process
contains 19.6% wt K2SO4. The fresh feed
joins a recycle stream from the filtrate
product of the recycle and enters the
evaporator where 42% of the water fed is
evaporated. The evaporator has a maximum
capacity of 175 kg water evaporated per
second. The concentrated solution then
enters the crystallizer. The wet filter cake
consists of solid K2SO4 crystals and 40 wt%
K2SO4 solution, in a ratio of 10 kg crystals per
kg solution. The filtrate is recycled to join the
fresh feed. Calculate the maximum recycle to
fresh feed ratio.
1.80
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance without Reaction
Sulfur dioxide is absorbed in a weak liquor which enters the top
of the column at a rate of 75 m3/h with SO2 concentration of
0.05 wt% and leaves with SO2 concentration of 1 wt%. A gas
stream with 20% mol SO2 enters the column and 75% of the
SO2 in the gas stream is absorbed in the weak liquor. The
pressure in the column is 1.5 bar and the temperature is 310 K.
Assuming that the liquor has a specific gravity of 1.0, determine
the volume percent of SO2 in the gas leaving the column
5.88%
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance without Reaction
A liquid adhesive, which is used to make laminated boards,
consists of a polymer dissolved in a solvent. The amount of
polymer in the solution has to be carefully controlled for this
application. When the supplier of the adhesive receives an
order for 3000 kg of an adhesive solution containing 13 wt %
polymer, all it has on hand is (1) 500 kg of a 10 wt % solution,
(2) a
very large quantity of a 20 wt % solution, and (3) pure solvent.
Use all of the 10 wt % solution. Find the:
Amount of 20 wt% solution, kg – 1700v
Amount of pure solvent , kg – 800
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
In a process for the manufacture of chlorine by direct oxidation
of HCl with air over a catalyst to form Cl2 and H2O
(only), the exit product is composed of HCl (4.4%), CI2, (19.8%),
H2O (19.8%), O2 (4.0%), and N2 (52.0%).
The limiting reactant – HCl
Percent excess reactant – 26%
Degree of completion – 90%
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
In a process for the manufacture of chlorine by direct oxidation
of HCl with air over a catalyst to form Cl2 and H2O
(only), the exit product is composed of HCl (4.4%), CI2, (19.8%),
H2O (19.8%), O2 (4.0%), and N2 (52.0%).
The limiting reactant – HCl
Percent excess reactant – 26%
Degree of completion – 90%
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
Given the reaction of ethyl tetrabromide with zinc
dust produces C2H2 and ZnBr2. Based on the
C2H2Br4, on one pass through the reactor the
conversion is 80%, and the unreacted C2H2Br4 is
recycled. On the basis of 1000 kg/hr of C2H2Br4
fed to the reactor per hour, calculate
Rate of recycle – 250
Amount of Zn that has to be added per hour if Zn
is to be 20% in excess – 450
Mole ratio of ZnBr2 to C2H2 in the products – 2
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
TiCl4 can be formed by reacting titanium dioxide (TiO2) with
hydrochloric acid. TiO2 is available as an ore containing 78 %
TiO2 and 22 % inerts. The HCl is available as 45 wt% solution
(the balance is water). The per pass conversion of TiO2 is 75 %.
The HCl is fed into the reactor in 20 % excess based on the
reaction. Pure unreacted TiO2is recycled back to mix with the
TiO2 feed.
𝑇𝑖𝑂! + 4𝐻𝐶𝑙 → 𝑇𝑖𝐶𝑙" + 2𝐻! 𝑂
For 1 kg of TiCl4 produced, determine:
Kg of TiO2 ore fed – 0.54
Kg of 45 wt% HCl solution fed – 2.05
Ratio of recycle stream to fresh TiO2 ore (in kg) – 0.26
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
TiCl4 can be formed by reacting titanium dioxide (TiO2) with
hydrochloric acid. TiO2 is available as an ore containing 78 %
TiO2 and 22 % inerts. The HCl is available as 45 wt% solution
(the balance is water). The per pass conversion of TiO2 is 75 %.
The HCl is fed into the reactor in 20 % excess based on the
reaction. Pure unreacted TiO2is recycled back to mix with the
TiO2 feed.
𝑇𝑖𝑂! + 4𝐻𝐶𝑙 → 𝑇𝑖𝐶𝑙" + 2𝐻! 𝑂
For 1 kg of TiCl4 produced, determine:
Kg of TiO2 ore fed – 0.54
Kg of 45 wt% HCl solution fed – 2.05
Ratio of recycle stream to fresh TiO2 ore (in kg) – 0.26
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
Plants in Europe sometimes use the mineral
pyrites (the desired compound in the pyrites is
FeS2) as a source of SO2 for the production of
sulfite pulping liquor. Pyrite rock containing 48.0%
sulfur and 10% inerts is burned completely by
flash combustion. All of the iron forms Fe3O4 in
the cinder (the solid product), and a negligible
amount of SO3 occurs in either the cinder or the
product gas. The gas from such a furnace is
passed through milk of lime (CaO in water)
absorbers to produce bisulfite pulping liquor. The
exit gas from the absorber analyzes: SO2 0.7 %,
O2 2.9 % and N2 96.4 %.
Calculate the kg of air supplied to the burner per
kg of the pyrites burned
3.1
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
Plants in Europe sometimes use the mineral pyrites (the
desired compound in the pyrites is FeS2) as a source of
SO2 for the production of sulfite pulping liquor. Pyrite rock
containing 48.0% sulfur and 10% inerts is burned
completely by flash combustion. All of the iron forms
Fe3O4 in the cinder (the solid product), and a negligible
amount of SO3 occurs in either the cinder or the product
gas. The gas from such a furnace is passed through milk of
lime (CaO in water) absorbers to produce bisulfite pulping
liquor. The exit gas from the absorber analyzes: SO2 0.7 %,
O2 2.9 % and N2 96.4 %.
Calculate the kg of air supplied to the burner per kg of the
pyrites burned
3.1
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
Perchloric acid (HClO4) can be prepared as shown in the
diagram below from Ba(ClO4)2
and HClO4. Sulfuric acid is supplied in 20% excess to react with
Ba(ClO4)2. If 17,400 lb HClO4
leave the separator and the recycle is 6125 lb Ba(ClO4)2 over
the time period, calculate
Note: 20 % H2SO4 is based on the total Ba(ClO4)2 entering the
reactor.
𝐵𝑎 𝐶𝑙𝑂" ! + 𝐻! 𝑆𝑂" → 𝐵𝑎𝑆𝑂" + 2𝐻𝐶𝑙𝑂"
Calculate:
The overall conversion of Ba(ClO4)2 – 100%
The lb of HClO4 leaving the separator per lb of feed – 0.64
The lb of H2SO4 entering the reactor – 10730
The per pass conversion of Ba(ClO4)2 - 0.8
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
Perchloric acid (HClO4) can be prepared as shown in the
diagram below from Ba(ClO4)2
and HClO4. Sulfuric acid is supplied in 20% excess to react with
Ba(ClO4)2. If 17,400 lb HClO4
leave the separator and the recycle is 6125 lb Ba(ClO4)2 over
the time period, calculate
Note: 20 % H2SO4 is based on the total Ba(ClO4)2 entering the
reactor.
𝐵𝑎 𝐶𝑙𝑂" ! + 𝐻! 𝑆𝑂" → 𝐵𝑎𝑆𝑂" + 2𝐻𝐶𝑙𝑂"
Calculate:
The overall conversion of Ba(ClO4)2 – 100%
The lb of HClO4 leaving the separator per lb of feed – 0.64
The lb of H2SO4 entering the reactor – 10730
The per pass conversion of Ba(ClO4)2 - 0.8
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
Acetic acid is to be generated by the addition of 10
percent excess sulfuric acid to calcium
acetate. The reaction Ca(AC)2 + H2SO4 ...CaSO4 +
2HAc goes on with 90 percent completion. The
unused Ca(Ac)2 and the H2SO4 are separated from
the products of the reaction, and the excess Ca(Ac)2
is recycled. The acetic acid is separated from the
products.
Find the amount of recycle per hour based on 1000 lb
of feed per hour – 110
Find the pounds of acetic acid manufactured per hour
– 760
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
Acetic acid is to be generated by the addition of 10
percent excess sulfuric acid to calcium
acetate. The reaction Ca(AC)2 + H2SO4 ...CaSO4 +
2HAc goes on with 90 percent completion. The
unused Ca(Ac)2 and the H2SO4 are separated from
the products of the reaction, and the excess Ca(Ac)2
is recycled. The acetic acid is separated from the
products.
Find the amount of recycle per hour based on 1000 lb
of feed per hour – 110
Find the pounds of acetic acid manufactured per hour
– 760
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
Propane is dehydrogenated to from propylene in a catalytic
reactor
𝐶# 𝐻$ → 𝐶# 𝐻% + 𝐻!
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 product stream, is recycled to
the
reactor. Calculate:
The mol% propane in product composition – 2.6%
The ratio (moles recycled)/(moles fresh feed) – 9
The single-pass conversion. – 0.095
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
Propane is dehydrogenated to from propylene in a catalytic
reactor
𝐶# 𝐻$ → 𝐶# 𝐻% + 𝐻!
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 product stream, is recycled to
the
reactor. Calculate:
The mol% propane in product composition – 2.6%
The ratio (moles recycled)/(moles fresh feed) – 9
The single-pass conversion. – 0.095
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
The fresh feed to an ammonia production process
contains 24.75 mole % nitrogen, 74.25 mole%
hydrogen, and the balance inerts (I). The feed is
combined with a recycle stream containing the
same species, and the combined stream is fed to a
reactor in which a 25% single-pass conversion of
nitrogen is achieved. The products pass through a
condenser in which essentially all of the ammonia
is removed, and the remaining gases are recycled.
However, to prevent buildup of the inerts in the
system, a purge stream must be taken off.
The recycle stream contains 12.5 mole% inerts.
Calculate:
the overall conversion of nitrogen, - 92.9%
the ratio (moles purge gas/mole of gas leaving the
condenser), - 0.025
and the ratio (moles fresh feed fed to the reactor).
– 0.25
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
The fresh feed to an ammonia production process
contains 24.75 mole % nitrogen, 74.25 mole%
hydrogen, and the balance inerts (I). The feed is
combined with a recycle stream containing the
same species, and the combined stream is fed to a
reactor in which a 25% single-pass conversion of
nitrogen is achieved. The products pass through a
condenser in which essentially all of the ammonia
is removed, and the remaining gases are recycled.
However, to prevent buildup of the inerts in the
system, a purge stream must be taken off.
The recycle stream contains 12.5 mole% inerts.
Calculate:
the overall conversion of nitrogen, - 92.9%
the ratio (moles purge gas/mole of gas leaving the
condenser), - 0.025
and the ratio (moles fresh feed fed to the reactor).
– 0.25
UST October 2022 Boards Review
Chemical Engineering Calculations
Material Balance with Reaction
The fresh feed to an ammonia production process
contains 24.75 mole % nitrogen, 74.25 mole%
hydrogen, and the balance inerts (I). The feed is
combined with a recycle stream containing the
same species, and the combined stream is fed to a
reactor in which a 25% single-pass conversion of
nitrogen is achieved. The products pass through a
condenser in which essentially all of the ammonia
is removed, and the remaining gases are recycled.
However, to prevent buildup of the inerts in the
system, a purge stream must be taken off.
The recycle stream contains 12.5 mole% inerts.
Calculate:
the overall conversion of nitrogen, - 92.9%
the ratio (moles purge gas/mole of gas leaving the
condenser), - 0.025
and the ratio (moles fresh feed fed to the reactor).
– 0.25
UST October 2022 Boards Review
Chemical Engineering Calculations
Gaseous Fuels
A rotary drier burns a fuel with dry air at 40oF and 30.1 inHg.
The oil contains only carbon and hydrogen. Analysis of the flue
gas shows 13.1% CO2, 5.2% O2, 2.6% CO and 79.1% N2.
Calculate % excess air – 23%
Calculate wt% carbon in oil - 97%
UST October 2022 Boards Review
Chemical Engineering Calculations
Gaseous Fuels
A burner burns a fuel gas entering at 70oF and 1atm, employing
20% excess air with the same condition as the
fuel gas. Assuming complete combustion, give the orsat analysis
of the flue gas. Fuel gas composition (%vol) is as
follows: 1%O2, 3%CO2, 33%CO, 40%H2, 1%Benzene,
6%ethylene, 6%N2, 10%Paraffins (C12H44).
The number of moles of carbon dioxide in the flue gas per mole
of fuel gas – 1.74
The moles of theoretical oxygen per mole of fuel gas. – 2.91
UST October 2022 Boards Review
Chemical Engineering Calculations
Gaseous Fuels
A natural gas analyzes CH4, 80.0 percent and
N2, 20.0 percent. It is burned under a boiler and
most of the CO2 is scrubbed out of the flue gas
for the production of dry ice. The exit gas from
the scrubber analyzes CO2, 1.2 percent; O2, 4.9
percent; and N2, 93.9 percent. Calculate the
%CO2 absorbed – 87.6%
%excess air – 25%
UST October 2022 Boards Review
Chemical Engineering Calculations
Gaseous Fuels
A natural gas analyzes CH4, 80.0 percent and N2,
20.0 percent. It is burned under a boiler and most
of the CO2 is scrubbed out of the flue gas for the
production of dry ice. The exit gas from the
scrubber analyzes CO2, 1.2 percent; O2, 4.9
percent; and N2, 93.9 percent. Calculate the
%CO2 absorbed – 87.6%
%excess air – 25%
UST October 2022 Boards Review
Chemical Engineering Calculations
Gaseous Fuels
Ethane (C2H6) is burned with 50% excess air. The percentage
conversion of the ethane is 90%; of the ethane burned, 25%
reacts to form CO and the balance to form CO2. Calculate the
ORSAT composition of the O2 in the fuel gas and the – 9.7%
Ratio of water to dry fuel gas – 0.113
UST October 2022 Boards Review
Chemical Engineering Calculations
Gaseous Fuels
A natural gas of an unknown composition is burned with air. An
analysis of the product gas
yields the following results
0.13 mol H2O/ mol wet gas
ORSAT Analysis:
1.5% CO
6.0% CO2
8.2% O2
84.3% N2
Calculate the ratio of hydrogen to carbon in the gas – 4
UST October 2022 Boards Review
Chemical Engineering Calculations
Gaseous Fuels
A synthesis gas analyzing CO2, 4.5 percent; CO, 26 percent; H2,
13 percent; CH4, 0.5 percent; and N2, 56 percent, is burned in a
furnace with 10 percent excess air. Calculate the Orsat analysis
of the CO2 of the flue gas. – 17.8%
UST October 2022 Boards Review
Chemical Engineering Calculations
Solid Fuels
A furnace burns coal with the following analysis: M – 4.1%,
VCM – 24%, FC – 63.0%, N – 1.20%, S – 1.80%, Ash – 8.90%. The
refuse analyzed 4.8% VCM, 12.6% FC, 82.6% ash and a calorific
value of 32 MJ/kg.
Calculate the percentage of gross calorific value lost in the
refuse – 2.16%
If the residue was 7.5% VCM, 29.2% FC, and 63.3% Ash,
calculate the %VCM lost – 4.39%
Calculate the %CV lost – 5.81%
UST October 2022 Boards Review
Chemical Engineering Calculations
Solid Fuels
A furnace burns coal with the following analysis: M – 4.1%,
VCM – 24%, FC – 63.0%, N – 1.20%, S – 1.80%, Ash – 8.90%. The
refuse analyzed 4.8% VCM, 12.6% FC, 82.6% ash and a calorific
value of 32 MJ/kg.
Calculate the percentage of gross calorific value lost in the
refuse – 2.16%
If the residue was 7.5% VCM, 29.2% FC, and 63.3% Ash,
calculate the %VCM lost – 4.39%
Calculate the %CV lost – 5.81%
UST October 2022 Boards Review
Chemical Engineering Calculations
Solid Fuels
A furnace burns coal with the following analysis: M – 4.1%,
VCM – 24%, FC – 63.0%, N – 1.20%, S – 1.80%, Ash – 8.90%. The
refuse analyzed 4.8% VCM, 12.6% FC, 82.6% ash and a calorific
value of 32 MJ/kg.
Calculate the percentage of gross calorific value lost in the
refuse – 2.16%
If the residue was 7.5% VCM, 29.2% FC, and 63.3% Ash,
calculate the %VCM lost – 4.39%
Calculate the %CV lost – 5.81%
UST October 2022 Boards Review
Chemical Engineering Calculations
Solid Fuels
A furnace burns coal with the following analysis: M – 4.1%,
VCM – 24%, FC – 63.0%, N – 1.20%, S – 1.80%, Ash – 8.90%. The
refuse analyzed 4.8% VCM, 12.6% FC, 82.6% ash and a calorific
value of 32 MJ/kg.
Calculate the percentage of gross calorific value lost in the
refuse – 2.16%
If the residue was 7.5% VCM, 29.2% FC, and 63.3% Ash,
calculate the %VCM lost – 4.39%
Calculate the %CV lost – 5.81%
UST October 2022 Boards Review
Chemical Engineering Calculations
Questions
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UST October 2022 Boards Review
