CHE201ch12

Recycle, Bypass, Purge, & the
Industrial Application Material Balances

What is a recycle system?
A recycle system is a system that includes one or
more recycle streams.
Recycle
Feed
Process 1
ChE 201: Introduction to Chemical Engineering
products
Process 2
products
Dr Saad Al-Shahrani

some examples of the application of material recycling in the process
industries
Increased reactant conversion.
Circulation of a working fluid.
Continuous catalyst regeneration.
Dr Saad Al-Shahrani

Recycle without Chemical Reaction
Recycle of material occurs in a variety of processes that do
not
involve
chemical
reaction,
including
distillation, crystallization, and heating and refrigeration

systems.
Dr Saad Al-Shahrani
EXAMPLE: The following figure is a schematic of a process for the production of flake
NaOH, which is used in households to clear plugged drains in the plumbing (e.g.,
Drano).
The fresh feed to the process is 10,000 lb/hr of a 40% aqueous NaOH solution.
The fresh feed is combined with the recycled filtrate from the crystallizer, and fed
to the evaporator where water is removed to produce a 50% NaOH
solution, which in turn is fed to the crystallizer. The crystallizer produces a filter
cake that is 95% NaOH crystals and 5% solution that itself consists of 45%
NaOH. The filtrate contains 45% NaOH.
a.You are asked to determine the flow rate of water removed by the evaporator,
and the recycle rate for this process.
b.Assume that the same production rate of NaOH flakes occurs, but the filtrate is
not recycled. What would be the total feed rate of 40% NaOH have to be then?
AssuChmE 2e01t:hInatrotdtuhcteionptorCohdemuiccatl Esnogilnueetriiongn from the evaporator still

Solution
Steps 1,2,3, and 4
Open,
steady-state process. The
contains the
figure information needed to solve the

problem.
Step 5
Basis: 10,000 lb fresh feed (equivalent to 1 hour)
Dr Saad Al-Shahrani

Steps 6 and 7
The unknowns are W, G, P, and R.
Two overall component balances can determine the values of W and P
Two component balances on a crystallizer can determine the values of
G and R.
Steps 8 and 9
Overall NaOH balance
(0.4)(10,000) = [0.95 + (0.45) (O.O5)]P
P=4113 lb
Overall H2O balance
Dr Saad Al-Shahrani

(or use the overall total balance 10,000 = 4113 + W)
The total amount of NaOH exiting with P is
Tow component balances on a crystallizer.

NaOH balance on the crystallizer
H20 balance on the crystallizer
Dr Saad Al-Shahrani

(or use the total balance G = R + 4113)
Dr Saad Al-Shahrani

b. Now, suppose recycle from the crystallizer does not occur, but the
production and composition of P remains the same. Then the output of
the crystallizer is just P.
Step 5
The basis is now P = 4113 Ib (the same as 1 hour)
Dr Saad Al-Shahrani

Steps 6 and 7
The unknowns are now F, W, G, and H. You can make two component
balances on the evaporator and two on the crystallizer plus two overall
balances. Only four are independent
Steps 8 and 9
NaOH balance on the crystallizer
H20 balance on the crystallizer
Dr Saad Al-Shahrani

An overall NaOH balance gives the new F
Overall NaOH balance
Note that without recycle, the feed rate must be 5.37 times larger than
with recycle to produce the same amount of product,
Dr Saad Al-Shahrani

3.
Recycle with Chemical Reaction
The
most
common
involving chemical
application
reaction
is
the
of
recycle
recycle
of
for
systems
reactants,
an
application that is used to increase the overall conversion in a reactor

the
extent
of reaction is the same regardless of whether an
overall material balance is used or a material balance for the reactor is

used.
Dr Saad Al-Shahrani

You will encounter two types of conversion when reactions occur:
1. Overall fraction conversion:
mass (moles) of reactant in the fresh feed - mass (moles) of reactant in the output of the overall process
mass (moles) of reactant in the fresh feed
2. Single - pass fraction conversion:
When the fresh feed consists of more than one reactant,

the conversion can be expressed for a single component, usually
the limiting reactant, or the most important (expensive) reactant.
Dr Saad Al-Shahrani

Overall conversion of species A = fOA=
Single-pass conversion = fSP =
-
nA fresh feed
-
nA reactor feed
Where reactor feed = fresh feed + recycle

The relationship between overall and single-pass conversion:
Dr Saad Al-Shahrani

EXAMPLE: Cyclohexane (C6H12) can be made by the reaction of benzene
(Bz) (C6H6) with hydrogen according to the following reaction:
For the process shown in the following Figure, determine the ratio of the recycle
stream to the fresh feed stream if the overall conversion of benzene is 95%, and
the single-pass conversion is 20%. Assume that 20% excess hydrogen is used in
the fresh feed, and that the composition of the recycle stream is 22.74 mol
% benzene and 78.26mol % hydrogen.
Dr Saad Al-Shahrani

Solution
Step 1,2,3 and 4
The process is open and steady state.
Step 5
Basis: 100 mol of fresh benzene feed,
Dr Saad Al-Shahrani

The Figure contains all of the information available about the flow streams
except the amount of H2, which is in 20% excess (for complete reaction,
remember)
= 100(3)(1 + 0.20) = 360 mol
nFH 2
The total fresh feed = 100 +360 = 460 mol.
From reaction equation benzene (z = - 1)
-
fOA=
fresh feed
nA
= 95 reacting moles.
Dr Saad Al-Shahrani

Steps 6 and 7
The unknowns are R, nP Bz, nP , nFC
H2
6H12
You can write three species balances for each of the three systems,
the mixing point, the reactor, and the separator plus overall balances
(not all of which are independent, of course).
Steps 8 and 9
Dr Saad Al-Shahrani

The amount of the Bz feed to the reactor = 100+ 0.2274R
also
95
For benzene
fSP =
reactor feed
nA
The ratio of recycle to fresh

feed is:
Dr Saad Al-Shahrani

4.
Bypass and Purge
A bypass stream is a stream that skips one or more stages of the

process and goes directly to another downstream
Bypass B
Feed
Divider
Process
Mixer
Product
Dr Saad Al-Shahrani

A purge stream is a stream bled off from the process to remove an
accumulation of inerts or unwanted material that might otherwise build
up in the recycle stream
Recycle R
Feed
Divider
Process
Divider
Mixer
Purge
Product
Dr Saad Al-Shahrani
EXAMPLE : In the feedstock preparation section of a plant manufacturing

natural
gasoline,
gasoline. Assume
isopentane
for
is
purposes
removed
of
from
simplification
butane-free
that
the
process and components are as shown in the following Figure.
What fraction of the butane-free gasoline is passed through

the isopentane tower? Detailed steps will not be listed in the
analysis and solution of this problem. The process is in the steady
state and no reaction occurs.
Dr Saad Al-Shahrani

Solution
Basis: 100 kg feed
a. Overall balances (each stream is designated by the letter F, S, or P with
the units being kg)
Total material balance:
In
Out
100
=S+P
Component balance for n-C5 (tie component)

In =
Out l00(0.80)
= S(0) + P(0.90)
Dr Saad Al-Shahrani

b. Balance around isopentane tower:

Total material balance:
In
x
=
Out
= 11.1+y
Component balance for n-C5 (a tie component):

x(0.80) = y
x = 55.5
Dr Saad Al-Shahrani

C. Balance around mixing point 2:
Total material:
In
Out (100 - x) + y =
88.9
Component (iso-C5):
In =
Out (100 - x)
(0.20) + 0 = 88.9(0.10)
Dr Saad Al-Shahrani

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Recycle, Bypass, Purge, & the

Industrial Application Material Balances

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

Increased reactant conversion.

Circulation of a working fluid.

Continuous catalyst regeneration.

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

distillation, crystallization, and heating and refrigeration

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

steady-state process. The

figure information needed to solve the

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

Tow component balances on a crystallizer.

H20 balance on the crystallizer

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

Recycle, Bypass, Purge, & the

H20 balance on the crystallizer

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

Recycle with Chemical Reaction

application that is used to increase the overall conversion in a reactor

of reaction is the same regardless of whether an

overall material balance is used or a material balance for the reactor is

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

2. Single - pass fraction conversion:

When the fresh feed consists of more than one reactant,

Recycle, Bypass, Purge, & the

Single-pass conversion = fSP =

Where reactor feed = fresh feed + recycle

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

Recycle, Bypass, Purge, & the

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

The ratio of recycle to fresh

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

Bypass and Purge

A bypass stream is a stream that skips one or more stages of the

ChE 201: Introduction to Chemical Engineering

Recycle, Bypass, Purge, & the

ChE 201: Introduction to Chemical Engineering

EXAMPLE : In the feedstock preparation section of a plant manufacturing