Vaal University of Technology Faculty of Engineering and Technology

Department of Chemical and Metallurgical Engineering

Diploma in Chemical Engineering Materials and Energy Balances 2
EHMEB2A Tutorial 2: Recycle 18 April 2023
Problem 1 - *12.7
Examine fig 5.1. What is the quantity of the recycle stream in kg/hr? In stream C the
composition is 4% water and 96% KNO3.

Problem 2 – 12.8

Sea Water is to be desalinized by reverse osmosis using the scheme indicated in figure 1
below. Use the data given in the figure to determine:

a) The rate of waste brine removal (B)

b) The rate of desalinized water (called portable water) production (D)
c) The fraction of the brine leaving the reverse osmosis cell (which acts in essence as a
separator) that is recycled.
 1000 kg/hr Reverse
Sea Water Brine Water (B)
3.1% Salt 4.0% Salt Osmosis 5.25% Salt
Cell

D
Figure 1 Desalinised Water
500 ppm Salt

Problem 3 – 12.15 (6.3.15)

Hydrogen, important for numerous processes, can be produced by the shift reaction:
CO + H2O → CO2 + H2

In the reactor system shown in figure 1, the conditions of conversion have been adjusted so
that the H2 content of the effluent from the reactor is 3 mole%. P is 1000 moles/hr. Based
on the data in figure 1:

a) Calculate the moles/hr of CO and H2O in fresh feed?

b) Calculate the moles of recycle per mole of hydrogen produced?

CO, H2O R Recycle

FF RF RP
REACTOR SEPARATOR
3 mol% H2 P=100 moles/hr
CO 52%
%
H2O 48%
CO2 48
H2 48
CO 4
Figure 1

Problem 4 – 12.21 (6.3.20)

The process shown in Figure 2 below is the dehydrogenation of propane (C3H8) to propylene
(C3H6) according to the reaction
C3H8 → C3H6 + H2
The conversion of propane to propylene based on the total propane feed into the reactor at
F2 is 40%. The product flow rate F5 is 50 kg mol/hr.
a) Calculate all the six flow rates F1-F6 in kg mol/hr
b) What is the percent conversion of propane in the reactor based on the fresh
propane fed to the process (F1)

F4
ABSORBER H2
F1 F2 F3
&
Fresh BURNER F5 = 50 kg mol/hr
DISTILLATION
C3H8 C3H6
TOWER

80% C3H8 F6
20% C3H6 Recycle
Figure 2
Problem 5 – Past Exam Question
A top secret new process of producing hydrogen gas (H2) is shown in figure 2 below
The reaction: 2A + 5B → 3C + 6D

Is carried out in a reactor with 50% conversion of B. Most (not all) of the unreacted B is
recovered in a separator and recycled to the reactor. The fresh feed to the reactor consists of
A and B, with fresh A being 30% in excess of the stoichiometric amount required to react with
the fresh B. If the overall conversion of B in the process is 95%, calculate the product (P) and
recycle (R) flows required to produce 100 mol/h C.

Product, P
FF RF RP
REACTOR SEPARATOR A
Fresh
Feed B
A C
B D

B 100% R
Recycle
Figure 2
Problem 6 – Past Exam Question

Pure propane (C3H8) from El Paso is dehydrogenated catalytically in a continuous process to

obtain propylene (C3H6) according to the reaction below:

C 3H 8( g ) → C 3H 6(g) + H 2( g )
All of the hydrogen formed is separated from the rector exit gas with no loss of
hydrocarbon. The hydrocarbon mixture if then fractionated to give a product stream
containing 88 mol% propylene and 12 mol% propane. The other stream, which is 70 mol%
propane and 30mol% propylene, is recycled. The one-pass conversion in the reactor is 25%
and 1000kg of fresh propane is fed per hour.

(a) Find kg of product stream per hour

(b) The kmol recycle stream per hour

Problem 7 – 12.23/ 6.3.21 Past Exam Question (2nd opp 2020 1)

Sulphur dioxide may be converted to SO 3, which has many uses including the
production of H2SO4 and sulphonation of detergent. A gas stream having the
composition shown in the figure below is to be passed through a two stage converter.
The fractional conversion of SO2 to SO3 (on one pass through) in the first stage is 0.75
and in the second stage is 0.65. To boost the overall conversion to 0.95, some of the
exit gas from stage 2 is recycled back to the inlet of the stage 2. How much must be
recycled per 100 moles of inlet gas (stream F)?

Splitter SO3
SO2 10%
F CP1 CP2 P
1 2 SO2
O2 9%
O2
N2 81%
Figure 1 R N2
Problem 8 – Past Exam Question (T3 2020 1)
Production of ethylene oxide (CH2)2O can be accomplished by oxidation of ethane
C2H6 gas as shown by the reaction equation.

𝐶2 𝐻6 + 𝑂2 → (𝐶𝐻2 )2 𝑂 + 𝐻2 𝑂

C2H6: 100%
R

Reactor Splitter Decanter

FF RF RP DP Distillation
SP
C 2H6 C 2H6 Column
Air N2 W
P
O2
(CH2)2O: 100% H2O: 100% A
100% 100% O2
Figure 1 N2

The mol ratio of air to C2H6 in the reactor feed is 5:1 respectively. The conversion of
C2H6 on a single pass through the reactor is 85%. All the unreacted ethane is
separated by azeotropic distillation and recycled to combine with the fresh feed. If
1000 kmol/hr of pure (CH2)2O produced in P stream is separated in the splitter.

Using the 1000 kmol/hr in stream P as a basis, determine the following (round off all
your answers to 2 decimals):
1.1 Molar flow (kmol/hr) of C2H6 in fresh feed and molar flow of stream W? (5)
1.2 Molar flow of stream R? (5)
1.3 Composition (mole%) of O2, N2 and C2H6 in fresh feed? (9)
1.4 Composition (mole%) of stream A? (6)

Problem 9 – Past Exam Question (T2 2021 1)

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 single pass conversion of TiO2 is 75 %. The HCl is fed into the reactor in
20 % excess based on the reaction. Pure unreacted TiO2 is recycled back to mix with the TiO2
feed.
Reaction: TiO2 + 4 HCl -----> TiCl4 + 2H2O
For 1000 kg of TiCl4 produced, determine:

(a) The kg of TiO2 ore fed.

(b) The kg of 45 wt % HCl solution fed.
(c) The ratio of recycle stream to fresh TiO2 ore (in kg).
(MW: TiO2 79.9; HCl 36.47; TiCl4 189.7)

F1
F HCl 0.45 P (kg)
H2O 0.55
TiO2 0.78
Inerts 0.22 TiCl4 1.00
P1
REACTOR
G
Separator

R W (kg)
Pure TiO2 1.00
HCl?
H2O?
Inerts?

Problem 10 – Past Exam Question (T2 2021 1)

A distillation column separates 10,000 kg/hr of a mixture containing equal mass of benzene
and toluene. The product D recovered from the condenser at the top of the column contains
95% benzene, and the bottom W from the column contains 96% toluene. The vapor V entering
the condenser from the top of the column is 8000 kg/hr. A portion of the product from the
condenser is returned to the column as reflux R, and the rest is withdrawn as the final product
D. Assume that V, R, and D are identical in composition since V is condensed completely. Find
the ratio of the amount refluxed R to the product withdrawn D.

V= 8000 kg/hr
DISTILLATION COLUMN

condenser
F= 10 000 kg/hr
R
D
95% Benzene

W
96% Toluene
Problem 11 – Past Exam Question

Hydrogen is used to reduce 1 ton/hr Fe2O3 to metallic iron (Fe) according to the
reaction
𝐹𝑒2 𝑂3 + 3𝐻2 → 2𝐹𝑒 + 3𝐻2 𝑂
The water is condensed and the unreacted hydrogen is recycled (see figure 3 below).
Because the hydrogen in the fresh feed contains 1% CO2 impurity, some of the
unreacted hydrogen must be purged. Calculate the flow rate of all streams and the
composition of the purge stream required to limit the CO2 in the reactor feed to 3.5%
if the ratio of recycle to fresh feed is 5:1 on a molar basis.

Recycle

Reactor
Fresh Condenser
Feed Purge
Feed

Fe2O3 H2O
Fe
Figure 3

Problem 12 – Past Exam Question (T3 2020 1)

Methanol maybe produced by the reaction of CO2 and H2

𝐶𝑂2 + 3𝐻2 → 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂

The fresh feed to the process contains CO2 and H2 in stoichiometric proportions and
0.55 mol% N2. The reactor effluent passes to a condenser which removes essentially
all of the CH3OH and H2O formed, none of the reactants or N2. The latter substances
are recycled back to the reactor. To avoid build-up of N2 in the system; a purge stream
is withdrawn from the recycle. The feed to the reactor contains 23.50 mol% CO2,
73.50% H2 and 3.00% N2 and the single pass conversion of H2 is 62%. Molecular
weights for CO2 is 44.01, H2 is 2.02 and N2 is 28.01.
 R
Recycle CO2
H2
Reactor N2
FF RF Condenser
RP CP Purge P
CO2 mol% CO2 CO2
H2 CO2 23.5 CO2
H2 H2
N2 0.55 mol% H2 73.5 W H2
N2 N2
N2 3.0 CH3OH CH3OH N2
Figure 2 H2O H2O

Using a flow of 1267 kg/hr in stream RF as a basis, calculate the following (round off
all your answers to 2 decimals):

2.1 Calculate the molar flow rates (kmoles/hr) RP, W and CP? (18)
2.2 Calculate the composition (mole%) of CP, P and R? (4)
2.3 Calculate the molar flow rates (kmoles/hr) FF, R and P? (9)
2.4 The overall conversion of H2? (2)

Problem 13 – Past Exam Question (T5 2021 1)

Methanol is synthesized from carbon monoxide and hydrogen in a catalytic reactor.

The fresh feed (FF) to the process contains 32.00 mole% CO, 64.00% H2, and 4.00%
N2. This stream is mixed with a recycle stream (R) in a ratio of 5 mol recycle/1 mol
fresh feed to produce the feed to the reactor (RF), which contains 13 mole% N2. A low
single pass conversion is attained in the reactor. The reactor effluent (RP) goes to a
condenser from which two streams emerge: a liquid product stream (M) containing
essentially all the methanol formed in the reactor, and a gas stream (CP) containing
all CO, H2 and N2 leaving the reactor. The gas stream is split into two fractions: one is
removed from the process as a purge stream (P), and the other is the recycle stream
(R) that combines with the fresh feed to the reactor.

𝐶𝑂 + 2𝐻2 → 𝐶𝐻3 𝑂𝐻

CO 32%
H2 64%
N2 4% RF Reactor RP Condenser M
FF CO
H2 CH3OH 100%
N2 13%
CP
CO x%
H2 y%
N2 z%
Recycle, R Purge, P

Figure 1
If the fresh feed (FF) is 100 kmol/hr, calculate:

1.1 The kmol/hr of the recycle stream (R) and the reactor feed stream (RF)? (6)

1.2 The composition, z, of N2 in the reactor feed stream, RF (mole%)? (2)

1.3 The flow rate (kmol/hr) of the purge stream, P? (3)

1.4 The flow rate (kmol/hr) of the methanol product (M) and the composition of CO and
H2 in the recycle stream (x & y)? (9)

1.5 The flow rate (kmol/hr) of stream CP and RP? (4)

1.6 The single pass conversion (%) and the overall pass conversion (%) in terms of
H2? (6)

1.7 Briefly explain in your own words the reasons for including (i) the recycle stream
and (ii) the purge stream in the process design? (2)

Problem 14 – 12.25 Past Exam Question (T3 2021 1)

As part of the preliminary design process, you are required to perform a mass balance
of a distillery a process for methanol synthesis as shown in Figure 1.1. The pertinent
chemical reactions involved are:

𝐶𝐻4 + 2𝐻2 𝑂 → 𝐶𝑂2 + 4𝐻2 (Main reformer reaction) (i)

𝐶𝐻4 + 𝐻2 𝑂 → 𝐶𝑂 + 3𝐻2 (Reformer side reaction) (ii)

2𝐶𝑂 + 𝑂2 → 2𝐶𝑂2 (CO Converter reaction) (iii)

𝐶𝑂2 + 3𝐻2 → 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 (Methanol synthesis reaction) (iv)

Ten percent excess steam, based on reaction (i), is fed to the reformer and conversion of
methane is 100%, with a 90% yield of CO2. Conversion in the methanol reactor is 55% on one
pass through the reactor. A stoichiometric quantity of oxygen is fed to the CO converter and
CO is completely converted to CO2. Additional makeup CO2 is then introduced to establish a
3-to-1 ratio of H2 to CO2 in the feed stream to the methanol reactor.

The methanol reactor effluent is cooled to condense all the methanol and water, with the
non-condensable gases recycled to the methanol reactor feed. The H2/CO2 ratio in the recycle
stream is also 3-to-1. Because the methane feed contains 1% nitrogen as an impurity, a
portion of the recycle stream must be purged as shown in Figure 1.1 to prevent the
accumulation of nitrogen in the system. The purge stream analyses 5% nitrogen.

On the basis of 100mol of methane feed (including the N2), As part of the preliminary design
process, you are required to perform the following calculations:
a) How many moles of H2 are lost in the purge? [6]
b) How many moles of makeup CO2 are required? [8]
c) The recycle to purge ratio in mol/mol [8]
d) How much methanol solution (in kg) and its composition (weight percent) is
produced? [8]
e) If a litre of methanol solution costs R5.42 how much is the total cost of the product
leaving stream 11? [5]
f) What is the significance of the recycle stream in this process? [3]

8 13

RECYCLE PURGE
12

11
Condenser
r Methanol
Solution
CO2
Makeup 6 7 10
Methanol
9 Reactor

Oxygen
CO Converter
4

Reformer 2 Methane
Feed

Stream
1

Figure 1.1
Problem 15 – Past Exam Question

Problem 16 – Past Exam Question

Considerable interest exists in the conversion of coal into more convenient liquid products for
subsequent production of chemicals. Two of the main gases that can be generated under suitable
conditions from insitu (in the ground) coal combustion in the presence of steam (as occurs naturally
in the presence of groundwater) are H2 and CO. After cleanup, these two gases can be combined to
yield methanol according to the following equation:

CO + 2H2 CH3OH

E
CH3OH
100%
S
E
P
A
% F R
67.3 H2 REACTOR A
32.5 CO T
0.2 CH4 O
R

Recycle
Purge P
x H2
split
y CO
z CH4
Some CH4 enters the process, but does not participate in the reaction. A purge stream is used to
maintain the CH4 concentration in the exit from the separator at no more than 3.2 mol % and prevent
hydrogen build up as well. The once-through conversion of the CO in the reactor is 18 %. Compute the
moles of recycle, CH3OH and purge per mole of feed and also compute the purge gas composition.

Problem 17 – Past Exam Question

Problem 18 – 12.16 / 6.3.10 Past Exam Question

Acetic acid (HAc) is to be generated by the addition of 10 percent excess sulfuric
acid to calcium acetate (Ca (Ac)2). The reaction Ca (Ac)2 + H2SO4→CaSO4 + 2HAc
goes to 90 percent completion based on a single pass through the reactor. The
unused Ca (Ac)2 is separated from the products of the reaction and recycled. The
HAc is separated from the remaining products.
Find the amount of recycle per hour based on 1000 kg of Ca (Ac) 2 fresh feed per hour,
and also calculate the kg of HAc manufactured per hour. See Figure 4.1 that illustrates
the process. (Ac = CH3CO2-)

H2SO4 HAc
44444

H2SO4 + CaSO4
Reactor Separator

Ca (Ac)2

Figure 4.1
Problem 18 – 12.16 / 6.3.10 Past Exam Question
Methanol maybe produced by the reaction of CO2 and H2

𝐶𝑂2 + 3𝐻2 → 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂

The fresh feed to the process contains CO2 and H2 in stoichiometric proportions and
0.5 mol% Inerts(I). The reactor effluent passes to a condenser which removes
essentially all of the CH3OH and H2O formed, none of the reactants or inerts. The latter
substances are recycled back to the reactor. To avoid build-up of the inerts in the
system; a purge stream is withdrawn from the recycle. The feed to the reactor contains
23.5 mol% CO2, 74.5% H2 and 2% inerts and the single pass conversion of H2 is 60%.
R
Recycle CO2
H2
RF = 100 Reactor I
FF moles/hr Condenser
RP CP Purge P
CO2 mol% CO2 CO2
H2 CO2 23.5 CO2
H2 H2
I 0.5 mol% H2 74.5 W H2
I I
I 2.0 CH3OH I
Figure 1 H2O

Calculate the molar flow rates (moles/hr) RP, W and CP? (13), Calculate the
composition (mole%) of CP, P and R? (4), Calculate the molar flow rates (moles/hr)
FF, R and P? (9), The overall conversion of H2? (2)

Problem 19 – Previous Project (2012 1)

You are part of the technical team working at U87, Iso-Octane Plant.

A process to make iso-octane from iso-butane and butylene follows the production scheme below:

Decanter
Still Final
Product
Reactor
Reactor Product
Recycle

acid Recycle
iso-butane Recycle

Fresh Feed

The reaction, which takes place in a strong sulfuric acid (catalyst), is:

C4H10 + C4H8 → C8H18

The following is known:
a)The fresh feed is 40 000 lbm , with the following molar composition:

Composition
iso-butane 25 %
butylene 25 %
n-butane 50 %
(HINT: It would be easier to solve the problem in consistent units of mass or moles to avoid
confusion)

b) The fresh feed and iso-butane recycle are combined so that the combined feed contains 5.0 moles
of iso-butane/mole butylene

c) There is enough product recycle to give the reactor feed of 200 moles of iso-butane/mole of
butylene (HINT: Besides acid, what species composes most of this stream?)

d) The reaction goes to completion in the reactor, where there is 2 lbm of sulfuric acid/lbm of
hydrocarbons. (HINT: Sulfuric acid is inert)

e) No iso-butane appears in the final product stream.

Your Technical Manager, Nathi Khoza, request that you determine the number of lb-moles of
butylene and iso-butane in every stream and the complete composition of the final product stream.
He also wants to know what is the mole fraction of acid in the reactor feed? (Remember, on recycle
problems, that sometimes it is best to start with the overall picture.)

***END***