TK-315 Chemical Process Industry 2

(3 sks)

Dicky Dermawan

Production of Sulfuric Acid

Methanol from Syngas

Objectives
Developing a capacity to do effective and original thinking in
analysis & problem solving in industrial chemistry problems.

Active work is essential on case-type problems in which are

presented a little of the confusion of the industrial world, its
superabundance of data or lack of data, and its need for
judgment and invention.

Emphasized in problem solving: problem solving is the heart of

this class, text material is mainly supplementary as introductory
to the process principles: no new concept is presented.

Using previously gained knowledge: chemical engineering basic

principles of material & energy balance, physical chemistry,
thermodynamics, and a passing familiarity with chemical plant
equipment.

References

GV Reklaitis, Introduction to Material &

Energy Balances, John Wiley & Sons,
1983

Meissner,H.P, Process and System

inIndustrial Chemistry, Prentice Hall
Inc, 1971

Score & Grading

20 4 all work & quiz

40 4 midterm exam
40 4 final term examination
A 4 74.5 ++
B 4 59.5 ++
C 4 49.5 ++
D 4 39.5 ++

Quantitative: Material (&Energy)

Balances
Single Unit 2 Multiple Unit:
with/without Special Config, i.e. Recycle and/or ByPass
with/without Equlibrium Constrain
Non-reacting Systems 2 Reacting Systems,
both Single Reaction & Multiple Reactions
both Homogeneous & Heterogeneous Systems

Qualitative: Chemical Process

Description

General knowledge on common terminology in

chemical processes: WGS, SMR, Pyrolysis, Deacon
Process, Bayer Process, SynGas,..

Dealing with Quantitative

Problems
Sebaiknya
Jangan

Bekerja dari bagian

yang mudah,
sekalipun tidak
langsung menjawab
pertanyaan
Mengerjakan soal
Pahami benar
tanpa tahu apa
spesifikasi yang
pertanyaannya
dimuat dalam soal
Mengarang soal:
sebagai bagian dari
mengada-ada
sarana untuk
spesifikasi yang tidak
Be
menyelesaikan soal.
adaaware
di soalof tie component(s)
Sometimes multiple units are merely repetition of
several single-same units

Material Balances
in Nonreacting
Systems
Single Unit

Aluminum Production via Bayer Process

A crucial step in the production of aluminum from bauxite ore
is the separation of alumina from the remaining mineral
impurities in the ore. In the Bayer process, this is
accomplished by treating bauxite with aqueous NaOH to
produce NaAIO2. Since NaAIO2 is water soluble while the
residual mineral constituents of bauxite are not, a separation
can be achieved by allowing the minerals to settle out and
decanting the aqueous solution of NaAIO2 and unreacted
NaOH. In order to further recover any NaAl02 entrained in the
settled mineral solids, this "mud" is repeatedly washed with
In this
a feed
slurry
consisting
water and allowed to settle,
andstage,
the wash
water
is decanted.
of 10%
solids,
11% NaOH, 16%
Figure 2.5 shows one stage
of this
washing-settling
process.
NaAI02, and the rest water is washed
with a wash water stream containing
2% NaOH to yield a decanted solidsfree solution containing 95% water
and a settled mud containing 20%
solids. How much NaAI02 is recovered

Purification of Titanium dioxide

Titanium dioxide, TiO2 is a white hiding pigment manufactured
in large quantities and used heavily in the paint and paper
industries. In a new pigment plant that is to produce 4000 lb/h
dry TiO2 product, an intermediate stream consisting of Ti02
precipitate suspended in an aqueous salt solution, is to be
purified of salt so that the final product contains, on a waterThe
removal
is 100
to be
free salt
basis,
at most
parts per million (1 ppm = mass
accomplished
the
fraction of 10-6by
) ofwashing
salt.
precipitate with water. If the
raw pigment stream contains
40% TiO2, 20% salt, and the
rest water (all mass %) and if
the washed pigment is, upon
settling, projected to consist
of about 50% (mass) TiO2
solids, what will the
composition of the waste
wash water stream be?

Distillation of Hydrocarbon
A feed stock available at the rate of
1000 mol/h and consisting of (all in
mol %)
20% Propane (C3)
30% Isobutane (i-C4)
20% Isopentane (i-Cs)
30% Normal pentane (Cs)
is to be separated into two fractions
by distillation. The distillate is to
contain all of the propane fed to the
unit and 80% of the isopentane fed
to the unit and is to consist of 40%
isobutane. The bottoms stream is to
contain all the normal pentane fed to
the unit.
Calculate the complete distillate and

Production of Absolute Alcohol

The conventional method for separating ethyl alcohol from
an alcohol/water mixture is by distillation. However, this
procedure can at best only produce a product 95% by
volume alcohol because alcohol and water form a constant
boiling mixture called an azeotrope, of that composition.
Simple distillation cannot eliminate the azeotrope.
Instead, if a pure alcohol product is desired, benzene is
added to the feed solution. The benzene itself forms an
azeotrope with water but one which has a lower boiling
point than the alcohol and thus the alcohol can be
Suppose it is desired to produce
purified.
1000 Ib/h pure ethyl alcohol in this
manner by distilling a feed mixture
containing 60% water and 40%
alcohol (in mass %). If the distillate
composition (in mass %) is 75%
benzene and 24% water, with the
rest alcohol, how much benzene

Extraction of Benzoic Acid

Benzoic acid can be extracted from a dilute water solution by
contacting the solution with benzene in a single-stage
extraction unit. The mixture will separate into two streams:
one consisting of benzoic acid and benzene and another
stream consisting of all three constituents as shown in the
schematic of Figure. Benzene is slightly soluble in water; thus,
stream 4 will contain 0.07 kg benzene/kg water. Benzoic acid
will distribute between streams 3 and 4 as follows:
The feed solution, stream
1, contains 2 x 10-2 kg
acid/kg water and is fed at
the rate of 104 kg/h:
Suppose benzoic acid
extracted into stream 3 is
worth $1/kg and that fresh
benzene (stream 2) costs
3/kg. Construct a graph
of net profit vs. benzene

Multiple Unit

Aromatics Separation Train

Consider a separation train consisting of two distillation
columns which are designed to separate a three component
mixture of benzene, toluene, and xylene into three streams,
each rich in one of the species. The system diagram listing
the species present in each stream isGiven
givenainfeed
Figure.
rate of
1000 mol/h of a
mixture consisting of
20% benzene, 30%
toluene, and the rest
xylene (all mole %), a
bottoms product of
2.5% benzene and 35%
toluene is obtained in
the first unit and an
overhead product of
8% benzene and 72%
Determine how much material will betoluene
processed
by second
each
in the
unit and how this material will be divided among the outlet

Aromatics Separation Train (2)

The feed to a two-column fractionating system is 30,000
Ibm/h of a mixture containing 50% benzene (B), 30%
toluene (T), and 20% xylene (X). The feed is introduced into
column I and results in an overhead consisting of 95%
benzene, 3% toluene, and 2% xylene. The bottoms from
column I are fed to the second column, resulting in an
overhead from column II containing 3% benzene, 95%
Assume and
that 2%
52%
of
toluene,
xylene
(see Figure P2.19).
the feed appears as
overhead in the first
column and that 75%
of the benzene fed-to
the second column
appears as overhead,
calculate the
composition and flow
of the bottoms
stream from the

Aromatics Separation Train (3)

The feed to a unit consisting of two columns contains 30%
benzene (B), 55% toluene (T), and 15% xylene (X). The
overhead stream from the first column is analyzed and
contains 94.4% B, 4.54% T, and 1.06% X. The bottoms from
the first column is fed to the second column. In this second
column, it is planned that 92% of the original T charged to
the unit shall be recovered in the overhead stream and that
the T shall constitute 94.6% of the stream. It is further
planned that 92.6% of the X charged to the unit shall be
recovered in the bottoms from this column and that the X
If these conditions are
shall constitute 77.6% of that stream (see Figure P2.20).
met, calculate:
a) Analysis of each
stream leaving the
unit.
b) Percentage
recovery of
benzene in the

Purification of Titanium dioxide (2)

A slurry consisting of Ti02 precipitate in a salt water solution is
to be washed in three stages as shown in the flowsheet of
Figure P2.21.
If the feed slurry consists of 1000 lbm/h of 20% Ti02, 30% salt,
a)
of the
salt fed
to eachthe
stage
leaves
the to
waste
and80%
the rest
water,
calculate
wash
waterinrate
each
solution.
stage.
that:
b) TheAssume
stages are
operated so that
the slurry leaving
contains one third
solids.
c) In each stage, the
salt concentration
in its waste
solution is the
same as the salt
concentration of
the solution

Multiple Effect Evaporator

Evaporators are typically used to concentrate solutions by
boiling off some of the solvent. To economize on the energy
input required, evaporation is often carried out in stages with
each stage providing some of the evaporation duty. In the
multistage evaporation shown in Figure P2.22, a 50% by
weight sugar solution is concentrated to 65% by evaporating
an equal amount of water in each of the four stages.
With a total input of 50,000 Ibm/h, determine the
concentrations of the intermediate streams.

Multiple Stage Process: Alcohol Washing

A mixture of alcohol and ketone containing 40 wt % alcohol
is washed with successive water washes to remove the
alcohol. The wash water used contains 4 wt % alcohol. The
water and ketone are mutually insoluble. The distribution of
alcohol (A) between the ketone (K) and the water streams
(W) is given by:
(See Figure P2.23A)
a) If 150 lb of stream 2 is
used per 200 lb feed
mixture, calculate the
composition of stream
4 after one wash.
b) If the washing is
repeated with 150 lb
wash at each stage,
how many wash
stages are required to

Special Configuration:
Recycle & By-pass

Recycle: Condenser Reflux

Staged distillation columns are devices which separate
volatile materials by boiling off the more volatile
components. In order for a clean separation to take place,
these devices require that at least part of the vapor boiled off
be condensed and returned to the column. This is necessary
to ensure that both liquid and vapor phases coexist
throughout the column. Consider the recycle system
consisting of a distillation column and its condenser. Suppose
the column
to separate
a three-component mixture
The
column is
is used
designed
to
consisting
of 7%stream
acetone, 61.9% acetic acid, and 31.1%
yield a bottoms
acetic anhydride.
containing
no acetone and
a distillate containing 10%
acetone and 88% acetic
acid. If the column is
operated so that 60% of the
overhead is returned as
reflux, calculate all flows
assuming all compositions

DMF Solvent Recovery

A purification system with recycle is used to recover
the solvent DMF from a waste gas containing 55%
DMF in air. The product is to have only 10% DMF (see
Figure P2.24).
Calculate the recycle fraction assuming that the
purification unit can remove two thirds of the DMF in
the combined feed to the unit.

By-pass: Concentration of Orange

Juice
Fresh orange juice typically consists of about 12% (mass %)
dissolved solids, largely sugars, in water. In order to reduce
the cost of shipping, the juice is often concentrated prior to
shipping and then reconstituted by adding water at the
destination.
Concentration must be carried out in specially designed,
short residence-time evaporators operated at below
atmospheric pressures in order to reduce the loss of volatile
and thermally sensitive flavor and aroma components
present in trace amounts.
Since some loss of these components is nonetheless
unavoidable, a widely accepted approach is to somewhat
overconcentrate the juice and then add a small amount of

Concentration of Orange Juice

(Cont)
Suppose that 10% of the feed to such a process is used
as cutback and that the evaporator is operated to
produce an outlet concentrate containing 80% dissolved
solids. If the process feed rate is 10,000 lb/h fresh juice,
calculate the rate at which water must be evaporated
and the composition of the final product.

Gas Purification System

A widely employed method of gas purification is to
selectively absorb the undesirable constituents of the
gas into a specifically selected liquid medium. The
liquid medium is subsequently regenerated by
chemical or heat treatment to release the absorbed
material.

Removal of Sulfur Compound

In a particular installation, the purification system for the
removal of sulfur compounds, designed to operate at a feed
rate of up to 820 mol/h, is temporarily subjected to a feed
rate of 1000 mol/h. Since the absorption system simply can
accommodate only 82% of this flow, it is proposed that the
overload be bypassed and that the exit H2S concentration of
the absorption system be reduced far enough so that the
mixed exit stream contains only 1% H2S and 0.3% COS on a
mole basis (see Figure P2.25). Calculate all flows in the
system. The feed stream consists of (mole basis) 15% C02,
5% H2S, and 1.41% COS, with the remainder being CH4.

Removal of Sulfur Compound (2)

Suppose the operation of the absorption system of the
previous is modified so that all of the COS and one mole of
C02 per mole of H2S are absorbed as shown in the schematic
in Figure P2.26. The feed stream consists of (mole basis) 15%
C02, 5% H2S, and 1.41% COS, with the remainder being CH4.
Again, 18% of the feed bypasses the absorption system.
Calculate all flows in the system.

Vegetable Oil Extraction

Oilseed protein sources

include soybean,
cottonseed, peanut,
The analysis of
sunflower, copra, rapeseed,
cottonseed is 4%
sesame,
safflower,
castor,
Commonly, the separation of the oil
hull, 10% linter,
and flax.
from
the protein meal is performed by
37% meal, and
solvent
extraction.
During the
extraction step, about 2 lbm solvent,
49% hexane,
oil.
must be used per 1 lbm clean seeds processed (see Figure
P2.29). For each ton of raw seeds to be processed,
determine the amount of oil and oil-free meal produced

Instant Coffee Process

Instant coffee is produced via the

flowsheet in Figure P2.27. Roasted,
ground coffee is charged with hot
water to a large percolator in which
water-soluble material is extracted.
The extract is spray dried to produce
the product, and the wet grounds are
partially dewatered prior to disposal
as land fill or by incineration. For
simplicity, the coffee feed is
assumed to consist of solubles,
insoluble, and no water. The
standard charge consists of 1.2 lb
water per lb coffee. As a reasonable
approximation, it may be assumed
that the solubles-to-water ratio in
the two streams leaving the
percolator is the same. Similarly for

Instant Coffee Process Modification

In the plant flowsheet considered in previous problem,
recovery of solubles as product is quite low. In an effort to
improve the recovery, suppose the waste solution from the
press is recycled back to the percolators. However, to reduce
the possible release of bitter-tasting material during
pressing, the dewatering rate is decreased so that a slurry of
40% insolubles is generated, as shown in the flowsheet in
Figure P2.28. To handle the higher water content slurry, the
Calculate
the recovery
drier operation
is also adjusted to produce a 62.5%
ratio resulting
from
this
insolubles
coffee
grounds.
modification. Assume
that the feed coffee
composition is 0% water
and 32.7% insolubles
and allow the feed
water-to-coffee ratio to
be variable. The
solubles-to-water ratios

Thickener in Kraft Paper Mill

As shown in the flow diagram, Figure P2.31, a countercurrent
thickener consisting of three stages is used in a Kraft paper
mill to wash a "white mud" consisting of 35% solids (CaC03)
and 17% NaOH in water.
Two wash streams are used, the first (stream 5) contains 4%
suspended solids, 6% NaOH, and the rest H20; the second
(stream 8) contains no solids, 2% NaOH, and the rest H20.
The clear liquids from stage I and stage II contain 0.5%
suspended solids; the clear liquid from stage III contains
0.4% solids. The flow of wash liquid to stage II (stream 5) is
1.5 times the flow of the feed sludge (stream 1), and the
washed sludge from stage II contains one third solids. The
washed sludge from the third stage (stream 9) contains
32.5% solids and 2.5% NaOH, and the flow rates of streams
7 and 9 are equal.
All compositions are given on a mass basis.

Thic
ken
er
in
Kraf
t
Pap
er
Mill
(co
nt)