Chapter 11

Example 11.2: Multiple Units without Reaction

Acetone is used in the manufacture of many chemicals and also as a
solvent. In its latter role, many restrictions are placed on the release
of acetone vapor to the environment. You are asked to design an
acetone recovery system having the flowsheet illustrated in Figure. All
of the concentrations shown in Figure of both the gases and liquids
are specified in weight percent in this special case to make the
calculations simpler. Calculate A, F, W, B, and D in kilograms per hour.
Assume that G = 1400 kg/hr.

2
 A, kg D, kg
Air = 0.995
Water, 100 % Condenser 3
Water = 0.005 Distillate
W, kg 1.0
Acetone = 0.99
Water = 0.01
1.0

Absorber Distillation B, kg
Column Column
Acetone = 0.04
Water = 0.96
1 2 1.0

G = 1400 kg/hr Acetone = 0.19

Entering Gas Water = 0.81
Air = 0.95 1.0
F, kg
Acetone = 0.03
Water = 0.02
1.0 3
Calculate A, F, W, B and D G+W=A+F (1)
Basis: 1 hr of operation Air Balance
Stream G 1330 + 0 = 0.995 A + 0 (2)
Acetone Balance
Air = 0.95  1400 = 1330 kg
42 + 0 = 0 + 0.19 F (3)
Acetone = 0.03  1400 = 42 kg A = 1336.7 kg
H 2 O = 1400 - (1330 + 42) = 28 kg F = 221.05 kg
W = 157.75 kg
System 1 Absorber Column (1)
Accumulation = Input - Output + Generation + Consumption
For Steady State Conditions
Input = Output

4
System 2 Distillation Column (2) + Condenser (3)
For Steady State Conditions
Input = Output
F=D+B (4)
Acetone Balance
0.19 F = 0.99 D + 0.04 B (5)
D = 34.89 kg
F=D+B
B=F-D
B = 221.05 - 34.897 = 186.15 kg 5
Example 11.3: Multiple Units with Reactions
In the face of higher fuel costs and the uncertainty of the
supply of a particular fuel, many companies operate two
furnaces, one fired with natural gas and the other with fuel
oil. In the RAMAD Corp., each furnace has its own supply of
oxygen; the oil furnace uses as a source of oxygen a stream
that has the following composition: O2 20%, N2 76%, and
CO2 4%. The stack gases from both furnaces exit using a
common stack.

6
• During one blizzard, all transportation to the RAMAD Corp. was cut off, and
officials were worried about the dwindling reserves of fuel oil because the natural-
gas supply was being used at its maximum rate possible. The reserve of fuel oil
was only 560 bbl. How many hours could the company operate before shutting
down if no additional fuel oil was attainable? How many pound moles per hour of
natural gas were being consumed? The minimum heating load for the company
when translated into the stack gas output was 6205 lb mol/hr of dry stack gas.
Analysis of the fuels and stack gas at this time is shown in Table. Also, calculate the
percent increase in toxic emissions of aesenic and mercury per hour caused by the
combustion of fuel oil rather than natural gas. The molecular weight of the fuel oil
was 7.91 lb/lb mol, and its density was 7.578 lb/gal.

7
 Natural Gas Fuel Oil ( API Gravity =24.0) Stack Gas
Mol % (Orsat Analysis)
CH4 96% C 50 N2 84.93%
C2H2 2% H2 47 O2 4.13%
CO2 2% S 3 CO2 10.84%
SO2 0.10%

Emission Factor

Arsenic Mercury

Natural gas 2.30 x 10-4 lb/106 ft3 1.34 x 10-4 lb/106 ft3

Oil 3.96 x 10-4Ib/103 gal 5.92 x 10-4Ib/103 gal

 Stack Gas Water
P = 6205 lb mol/hr W = 100% H2O
N2 = 84.93%
O2 = 4.13%
SO2= 0.10%
CO2=10.84% Air
100% O2 = 0.20
N2 = 0.76
CO2 = 0.04
1.0
A A*
Gas Oil
Air = mol% Furnace Furnace
O2 = 21%
N2 = 79%
100% Nat. Gas Fuel Oil
CH4 = 0.96 mol fr C = 0.5 mol fr
G C2H2 = 0.02 mol fr H2 = 0.47 mol fr
Fuel Oil Mol Wt = 7.91lb / lb mol
Density = 7.578 lb/gal
CO2 = 0.02 mol fr S = 0.03 mol fr
1.0 1.0
9
F
Sol:
CH 4  2O2  CO2  2 H 2O
5
C2 H 2  O2  2CO2  H 2O
2
C  O2  CO2
1
H 2  O2  H 2O
2
S  O2  SO2
Basis : 1 hr of operation
10
Stream P
P = 6205 lb moles
N 2 = 0.8493  6205 = 5270 lb moles
O 2 = 0.0413  6205 = 256.30 lb moles
SO 2 = 0.001  6205 = 6.21 lb moles
CO 2 = 0.1084  6205 = 672.40 lb moles
Element Balance
N = 2  5270 = 10540 lb moles
O = 2  256.30 + 2  6.21 + 2  672.40 = 1869.74 lb moles
S = 6.21 lb moles
C = 672.40 lb moles 11
Stream W Stream A
H 2 O = W lb moles O 2 = 0.21 A lb moles
Element Balance N 2 = 0.79 A lb moles
H = 2 W lb moles Element Balance
O = W lb moles O = 2  0.21 A = 0.42 A lb moles
Stream A* N = 2  0.79 A = 1.58 A lb moles
O 2 = 0.20 A* lb moles
N 2 = 0.76 A* lb moles
CO 2 = 0.04 A* lb moles
Element Balance
O = 2  0.20 A* + 2  0.04 A* = 0.48 A* lb moles
N = 2  0.76 A* = 1.52 A* lb moles
C = 0.04 A* lb moles 12
Stream F Stream G
C = 0.50 F lb moles CH 4 = 0.96 G lb moles
C2 H 2 = 0.02 G lb moles
H 2 = 0.47 F lb moles
CO 2 = 0.02 G lb moles
S = 0.03 F lb moles Element Balance
Element Balance C = 0.96 G + 2  0.02 G + 0.02 = 1.02 G lb moles
C = 0.50 F lb moles H = 4  0.96 G + 2  0.02 G = 3.88 G lb moles
O = 2  0.02 G lb moles
S = 0.03 F lb moles
H = 2  0.47 F = 0.94 F
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Overall Element Balance
A+G+F+A*=P+W
H 0 + 3.88 G + 0.94 F + 0 = 0 + 2 W (1)
O 0.42 A + 0.04 G + 0 + 0.48 A* = 1869.74 + W (2)
N 1.58 A + 0 + 0 + 1.52 A* = 10540 + 0 (3)
S 0 + 0 + 0.03 F + 0 = 6.21 (4)
C 0 + 1.02 G + 0.50 F + 0.04 A* = 672.40 + 0 (5)

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From Equation (4)
0.03 F = 6.21
F = 207 lb moles
Put in Eq (1)
3.88 G + 0.94 (207) = 2 W
W = 1.94 G + 97.29 (6)
From Eq (3)
1.58 A + 1.52 A* = 10540
10540 - 1.52 A*
A=  6670.8  0.96 A * (7)
1.58 15
Put W and A from Eq (6) and (7) in Eq (2)
0.42 (6670.8 - 0.96 A*) + 0.04 G + 0.48 A* = 1869.74 + (1.94 G + 97.29)
A* = 24.73 G - 10901.05
From Eq (5)
1.02 G + 0.50 (207) + 0.04 (24.73 G - 10901.5) = 672.40
G = 500 lb moles (Answer of Part b)
Part a
207 lb moles 7.91 lb gal 1 bbl
hr lb moles 7.578 lb 42 gal
= 5.14 bbl / hr
For 560 bbl
𝟓𝟔𝟎
𝒕= = 108.9 hrs
𝟓.𝟏𝟒
16
The arsenic and the mercury produced are: The increase in levels of
Oil arsenic and mercury are:
(5.14 bbl/hr)(42 gal/bbl) = 216 gal/hr
Arsenic 
 8.55  4.11 105
(100)  108%
5
216 gal 3.96 10 lb 4 4.11  10
5
Arsenic  3
 8.55  10 lb 12.78  2.40  105
10 gal Mercury  5
(100)  433%
4
2.40 10
216 gal 5.92 10 lb 5
Murcury  3
 12.78  10 lb
10 gal
Natural Gas
(488 lb mol/hr)(359 ft 3 /lb mol) = 1.79 x 105 ft 3 /hr
1.79 105 ft 3 2.30 104 lb 5
Arsenic  6 3
 4.11  10 lb
10 ft
1.79 105 ft 3 1.34 104 lb 5
Mercury  6 3
 2.40  10 lb
10 ft
EXAMPLE 11.4: Analysis of a Sugar Recovery
Process Involving Multiple Serial Units:
Figure E 11.4 shows the process and the known data.
You are asked to calculate the compositions of every
flowstream, and the fraction of the sugar in the cane
that is recovered.

18
19
Basis M, 1000 lb/hr of sugar Pulp Balance
Crystalizer as System E (0.14) = G (0.95) + H (0)
K=L+M (1) From Eq (3) G = E - H
Sugar Balance: (0.4) K = 0 + 1000 (1) E (0.14) = (0.95) E - (0.95) (6666.67)
K = 2500 lb/hr E = 7819 lb/hr
From Eq (1) Putting in Eq (3)
L = 1500 lb/hr G = 1152.3 lb/hr
(a) Evaporator as System Using Sugar Balance
H=J+K (2) (0.13)E = (0.15) H + G (x GS )
Sugar Balance: (0.15) H = 0 + 2500 (0.40) (0.13)7819  (0.15)6666.67 + (x GS )1152.3
H = 6666.67 lb/hr (x GS )  0.0143
From Eq (2)
(xWG ) = 0.05 - 0.0143 = 0.0357
J = 4166.76 lb/hr
(b) Screen as System
E=G+H (3)
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(c) Mill as System
F=E+D (4)
Pulp Balance: (0.59) F = (0.14) 7819 + (0.80) D
(e) Mill as System
F = 24574 lb/hr
1000
D = 16755 lb/hr  100  25%
(0.16)(24600)
(d) Sugar Balance around Mill The process is not efficient because
Sugar Balance: (0.16) F = x SD D  (0.13) E only 25% of sugar is received as
x SD D = 2915 lb/hr final product.
Sugar Lost in Bagasse
2915
= 100  74%
(0.16)(24600)

21
EXAMPLE 11.5 Production of a Hormone in
Connected Reactors
Figure shows two different reactor configurations to produce a
hormone.
The relation that gives the growth (generation in Equation (10.1» of the
hormone in each vessel in the steady state is the Monod equation
max Cs

K s  Cs

where µ = the specific growth rate, l/hr

µmax. ;: maximum specific growth rate (the state at which the concentration of
nutrient becomes the limiting factor in the growth of cells). l/hr
Cs = nutrient concentration in the vessel, g nutrient/L substrate
Ks = Monad constant, g nutrient/L substrate
The substrate is the liquid containing water, nutrients. and cells.
A coefficient that relates the g of dry cells formed/g nutrient consumed is
usually given the symbol Yx/s, and is called the biomass yield coefficient.
Two related processes for the growth of a hormone have been
proposed. Option I is to use a single well mixed vessel having a volume
of 100 L. Option 2 is to use two well mixed vessels each of volume 50 L
connected in series so that the output of vessel becomes the input to
vessel 2.
Which option win give the highest concentration (g cells/L of
substrate)?
Data: The substrate flow rate into the vessel for Option 1, or into vessel
1 Option 2, is 15 L/hr. and contains no cells, but contains a nutrient
with a concentration of 10 g/L. Yx/s is equal to 0.2 g cells/g nutrient
consumed. :Ks = 2 g/L. and µmax = O.4/hr. The consumption nutrient is
of nutrient µxout/ Yx/s
 Two material balances are involved
1) Cell Balance (x gcells/L)
Sol: 2) Nutrient Balance Cs
Assumptions
1) Steady state Process
2) Well mixed vessel
Option 1
F
Cells: 0  x out   x out  0  0 (a)
V
F in F out  x out
Nutrients : Cs  Cs  0  0 (b)
V V Yx / s
F/V=dilution rate
F  F
From equation (a):     x out  0 hence  (c)
V  V
F  in out x out 
From equation (b):  cs  cs  0
V yx / s 
hence x out  Yx / s (csin  csout ) (d)
F 15
is
V 100
15L 0.4 csout g / L

1hr 100 L 1hr 2 g csout

L L
csout  1.2 g nutrient / L substrate
 10 g nutrient 1.2 g nutrient 
  
x out

0.2 g cell  L substrate L substrate 
 1.76 g cells / L substrate
1 g nutrient consumed
Option 2 The solution of Equations (e), (f),
For Vessel 1:
plus the Monad equation
15 L 0.4csout
 ,1
form a set of non linear equations
hr 50 L 2  csout
,1
and the solution shows
,1  6 g nutrient / L
csout
From equation (d) s ,2  1.35 g nutrient/L
cout
x1out  0.2(10  6)  0.8 g cells/L substrate
2  1.73 g cells/L substrate
x out
For Vessel 2: Equation (a) and (b) becomes
The values remain the same
F out F out
x1  x2   x2out  0  0 (e)
V V
F in F out  x2out
Cs ,1  Cs ,2  0  0 (f)
V V Yx / s