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CHE112P Lecture Recycle - Bypass

The document discusses recycling, purging, and bypassing in chemical processes. It provides definitions and examples of: - Recycling processes that return material back to an upstream process for further processing. Reasons for recycling include recovery of catalysts or controlling process variables. - Product separation units like distillation that separate or purify desired products. - Purging streams that remove accumulating inerts or unwanted materials from recycle streams. - Multiple system boundaries for performing material balances around processes and recycle/purge streams. - Bypass streams that divert some feed around a process unit before being mixed downstream.

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153 views22 pages

CHE112P Lecture Recycle - Bypass

The document discusses recycling, purging, and bypassing in chemical processes. It provides definitions and examples of: - Recycling processes that return material back to an upstream process for further processing. Reasons for recycling include recovery of catalysts or controlling process variables. - Product separation units like distillation that separate or purify desired products. - Purging streams that remove accumulating inerts or unwanted materials from recycle streams. - Multiple system boundaries for performing material balances around processes and recycle/purge streams. - Bypass streams that divert some feed around a process unit before being mixed downstream.

Uploaded by

Yze
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Recycle and Product Separation

Purge
By-pass
RECYCLE AND PRODUCT SEPARATION
• Recycling involves returning material (or
energy) that leaves a process back to the process
for further processing
▫ Recycle stream is a term denoting a process
stream that returns material from downstream of
a process unit back the process unit ( or to a unit
upstream of the unit)
▫ Recycling processes are operating in the steady
state.
RECYCLE AND PRODUCT SEPARATION
▫ No build up or depletion of material takes
place inside the process or in the recycle stream.

▫ Reasons for using Recycle in a chemical process:


 Recovery of catalyst
 Dilution of a process stream
 Control of a process variable
 Circulation of a working fluid
RECYCLE AND PRODUCT SEPARATION
▫ Product Separation is any unit operation used
to separate, recover or purify the desired product.
 Distillation Process
 Condensation Process (Cooler)
 Extraction Process
 Filtration Process
RECYCLE DIAGRAM
• F – the fresh feed
• M – the mixed feed
• O – the output stream from the reactor
• P – the final product
• R – the recycle stream
RECYCLE DIAGRAM

F M O P
Converter Separator

R
SYSTEM BOUNDARIES FOR THE
MATERIAL BALANCES
• About the entire process including the recycle
stream
▫ These balances contain no information about the
recycle stream.
• About the junction point at which the fresh feed is
combined with the recycle stream.
• About the process only (reactor).
▫ These balances contain no information about the
recycle stream.
• About the separator
• In addition, balances can be made about
combination of subsystems.
SYSTEM BOUNDARIES FOR THE
MATERIAL BALANCES

F P
Reactor Separator
SYSTEM BOUNDARIES FOR THE
MATERIAL BALANCES

F M

Reactor Separator

Mixing point – the


% composition of the
entering and exit
streams are different
SYSTEM BOUNDARIES FOR THE
MATERIAL BALANCES

M O
Reactor Separator
SYSTEM BOUNDARIES FOR THE
MATERIAL BALANCES

O P
Converter Separator

R
SYSTEM BOUNDARIES FOR THE
MATERIAL BALANCES

Reactor Separator
REACTANT CONVERSION
• Single-pass conversion
ninput_ to _ reactor  noutput_ from_ reactor
f pass 
ninput_ to _ reactor
REACTANT CONVERSION

• Overall conversion

ninput_ to _ system  noutput_ from_ system


f OA 
ninput_ to _ system
PURGE
• A stream bled off to remove an accumulation of
inerts and unwanted material that might
otherwise build up in the recycle stream

• Additional streams
▫ S – exit from separator
▫ G – purge stream
PURGE DIAGRAM
RECYCLE AND PURGE
Prob 1./p.364
A catalytic dehydrogenation process shown in the figure
produces 1,3 butadiene (C4H6) from pure normal butane
(C4H10). The product stream contains 75 mol/hr of H2
and 13 mol/hr of C4H10. The recycle stream is 30% (mol)
C4H10 and 70% C4H6, and the flow is 24 mol/hr.

(a) What is the feed rate, F, and the product flow rate of
C4H6 leaving the process?
(b) What is the single-pass conversion of butane in the
process?
F=?
Pure C4H10

C4H10  C4H6 Separator


+ 2H2

Product
nH2 = 75 mol/h
nC4H10 = 13 mol/h
Recycle = 24 mol/h nC4H6 = ?
X C4H10 = 0.30
X C4H6 = 0.70
Ex 12.6/p. 369
Considerable interest exist 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 coal combustion in the
presence of steam are H2 and CO. After cleanup, these two
gases can be combined to yield methanol according to the
following equation:
CO + 2H2  CH3OH
Figure illustrates a steady-state process for the production of
methanol. All compositions are in mole fraction or percent.
The stream flows are in moles.

Note in the figure that 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 buildup as
well. The once-through conversion of CO in the reactor is 18%.

Compute the moles of recycle, CH3OH, purge per mole of


feed, and also compute the purge gas composition.
Feed
Product
67.3% H2
100 % CH3OH
32.5% CO
0.2 % CH4 M
P
F
once-through conversion of CO in the 3.2 % CH4
reactor is 18%. H2
R G CO

Compute per mole of feed


the moles of recycle. R
Product CH3OH
purge, G
compute the purge gas composition
By-pass DIAGRAM

F M O P
Converter Mixer

B
The feed stream to a Claus process (for the sulfur recovery
in petroleum refinery) consist of 20.0 % H2S and 80.0 %
CO2. One-third of the stream is sent to a furnace where
H2S is burned completely with the stoichiometric amount
of air fed at 1 atm and 25 oC. The reaction
H2S (g) + 1½ O2 (g) SO2 (g) + H2O (g)
The product gases from the reaction are then mixed
with the remaining two-thirds of the feed stream and
sent to a catalytic reactor in which the following
reaction goes to completion:
2H2S (g) + SO2 (g) 2 H2O (g) + 3 S (s)
The gases leave the reactor flowing at a rate of 380.0
mol/min. Calculate the feed rate of air in kmol / hr

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