Saint Louis University

SCHOOL OF ENGINEERING AND ARCHITECTURE

Department of Chemical Engineering

MODULE 3: MATERIAL BALANCES WITHOUT CHEMICAL REACTION BUT

WITH RECYCLE, BYPASS AND PURGE

Topic Learning Outcomes: At the end of this module, each student should be able to:
TLO4: Analyze and solve material balance problems involving special processes
(recycling, bypass, purge) without chemical reaction.

PROCESS FLOW ARRANGEMENT

A whole chemical plant is composed of several unit operations and unit process
equipment. In actual industrial processes where conditions are far from ideal, the optimum
operation can best be obtained from proper flowchart arrangement. For instance, 100%
completion of reaction is seldom attained and there is a need to recover the unreacted
raw material and feed it again. Sometimes, when a reaction becomes uncontrollable,
there is a need to redirect flow and bypass a reactor. Whether it is for control or for
economy, proper arrangement is vital in any industrial set-up.

Three basic flow arrangements are used. RECYCLE, BYPASS, and PURGE.
Combination of these three is widely used in most processes.

RECYCLE

Recycling operations refer to the process in which part of the product is returned
and mixed with the feed entering a process equipment. The figure below shows a process
that makes use of recycle stream.

There are several reasons for using recycle in a chemical process besides recovering and
reusing consumed reactants, and this includes the following:

i. Recovery of catalyst. Many reactors use catalyst to increase the rate of the reaction.
Catalysts are usually expensive, and the processes generally include provisions for

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ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

recovering them from the product stream and recycling them to the reactor. They
must be recovered with the unconsumed reactants or recovered separately in special
facilities designed with this purpose.
ii. Dilution of a process stream. Suppose a slurry (a suspension of solids in a liquid) is fed to
a filter. If the concentration of solids in the slurry is too high, the slurry is difficult to
handle and the filter will not operate properly. Rather than diluting the feed with fresh
liquid, a portion of the filtrate can be recycled to dilute the feed to the desired solids
concentration.
iii. Control of a process variable. Suppose a reaction releases an extremely large amount
of heat, making the reactor difficult and expensive to control. The rate of heat
generation can be reduced by lowering the reactant concentration, which can in turn
be accomplished by recycling a portion of the reactor effluent to the inlet. In addition
to acting as a diluent for the reactants, the recycled material also serves as a
capacitance for the hear released: the greater the mass of the reaction mixture, the
lower the temperature to which that mass will be raised by a fixed amount of heat.
iv. Circulation of a working fluid. The most common example of this application is the
refrigeration cycle used in household refrigerators and air conditioners. In these
devices, a single material is reused indefinitely, with only small makeup quantities being
added to the system to replenish working fluid that may be lost through leaks.

Sample Problems:

1. The manufacture of such products as penicillin, tetracycline, vitamins and other

pharmaceuticals, as well as photographic chemicals, dyes and other fine organic
compounds, usually requires separating the suspended solids from their mother liquor
by centrifuging, and then drying the wet cake. A closed loop system for centrifuge
unloading, drying, converging and solvent recovery is comprised of equipment
especially designed for handling materials requiring sterile and contamination-free
conditions.
Given the experimental measurements on the pilot plant equipment outlined below,
what is the lb/hr of the recycle stream R?

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 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

REQUIRED: lb/hr of recycle stream, R

SOLUTION: Basis: 1 hour SSO

Overall TMB:

Vitamins balance:

At the filter:

TMB:

Vit. Balance: *R

2. Data are presented in the diagram for an evaporator. What is the recycle stream in
lb/hr?

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ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

REQUIRED: Recycle stream, R in lb/hr

SOLUTION: Basis: 1 hour SSO

Overall TMB:

KNO3 balance:

At the crystallizer:

TMB:

KNO3 balance:

3. To save energy, stack gas from a furnace is used to dry rice. The flow sheet and
unknown data are shown in figure below. What is the amount of recycle gas (in lbmole)
per 100 lb of P if the concentration of water in the gas stream entering the dryer is 5.20%.
Find also the value of S and W.

REQUIRED: Recycle gas, R in lbmole, S and W

SOLUTION: Basis: P= 100 lb

H2O removed
𝐻 𝑂 𝑟𝑒𝑚𝑜𝑣𝑒𝑑 𝑥𝑃 𝑃 ( ) ( )
𝑥𝐹 𝑥𝑃
DRYER 𝐻 𝑂 𝑟𝑒𝑚𝑜𝑣𝑒𝑑 𝑙𝑏
F P=100 lb

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ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

For gas streams:

𝑙𝑏𝑚𝑜𝑙
TMB: 𝑆 𝑙𝑏 𝐻 𝑂 𝑊 𝑆
S W 𝑙𝑏

4.73% H2O DRYER

9.31% H2O H2O balance: 𝑆 𝑊
𝑺 𝟐𝟗 𝟑𝟑𝟓𝟑 𝒍𝒃𝒎𝒐𝒍𝒆 𝑾 𝟑𝟎 𝟖𝟏𝟔𝟏 𝒍𝒃𝒎𝒐𝒍𝒆
26.6667 lb H2O

R
9.31% H2O TMB: 𝑆 𝑅 𝑋 𝑅

S X H2O balance: 𝑅 𝑋
4.73% H2O 5.2 % H2O 𝑋 𝑙𝑏𝑚𝑜𝑙𝑒 𝑹 𝟑 𝟑𝟓𝟒𝟔 𝒍𝒃𝒎𝒐𝒍𝒆

ACTIVITY 1:
1. Fresh air containing 4.00 mole % water vapor is to be cooled and dehumidified to a water
content of 1.70 mole% H2O. A stream of fresh air is combined with a recycle stream of
previously dehumidified air and passed through the cooler. The blended stream entering
the unit contains 2.30 mole% H2O. In the air conditioner, some of the water in the feed
stream is condensed and removed as liquid. A fraction of the humidified air delivered to
the cooler is recycled and the remainder is delivered to a room. Taking 100 mole of
dehumidified air delivered to the room as a basis of calculation; calculate the moles of
fresh feed, moles of water condensed, and moles of dehumidified air recycled.

BYPASS

Closely related to recycle is the bypassing of a fluid stream. A main stream is split
into two with one stream set to the process equipment and the other one mixed with the
outlet stream from the process equipment. This is shown below.

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ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

The divider is actually a control valve. Bypassing of a stream is useful in attaining

operations. Either the arithmetic or algebraic method is suitable. Mass balance can be
taken around the four portions:

1. around the whole system

2. around the process between the bypass top
3. around the point of splitting
4. around the point of mixing

Sample Problems:

1. In the feed-stock preparation section of a plant manufacturing natural gasoline, iso-

pentane is removed from butane-free gasoline. Assume for purposes of simplification
that the process and components are shown in the diagram. What amount of the
butane-free gasoline is passed through the iso-pentane tower?

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ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

REQUIRED: Amount of the butane-free gasoline passed through the iso-pentane tower,X

SOLUTION:

Overall TMB:

i-C5H12 balance:

At iso-pentane tower:
TMB:

n- C5H12 balance:

ACTIVITY 2:

1. In a process of concentrating 1000 kg/hr of freshly extracted juice (orange) containing

12.5% solids, the juice is strained yielding 800 kg/hr of strained juice and 200 kg of pulpy
juice. The strained juice is concentrated in an evaporator to give an evaporated juice
of 58% solids. The pulpy juice is bypassed around the evaporator and mixed with the
evaporated juice in a mixer to improve the flavor. This final concentrated juice is 42%
solids. Calculate a) the solids concentration in the strained juice b.) the kg/hr of final
concentrated juice and c) the concentration of solids in the pulpy juice bypassed.

PURGE (to take out impurities)

Purge is a flow arrangement which is used in some recycling operations. If in a
process using a recycle, a separator is provided in removing only the desired product
from the gross product, then there will be a gradual accumulation of inert and
impurities in the recycle stream. The inert and impurities which are entering with the
feed should be provided with an outlet stream. This is done by bleeding out a portion of
the recycle line. The arrangement is shown below.

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ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

If the desired product does not contain any inert material or impurity, by a
component balance around the whole system (outside the recycle loop) the inert or
impurities in the feed is equal to the inert in the purge stream.

Sample Problems:

1. It is desired to produce 1000 kg/hr of Na2SO4. 10 H2O crystals from a feed aqueous solution
containing 5.6% w Na2SO4. The original solution is first evaporated in an evaporator to a 35
wt % solution and then cooled to 293K in a crystallizer, where the hydrated crystals and
the mother liquor are removed. One out of 10 kg of mother liquor is discarded to waste to
get rid of impurities and the remaining mother liquor is recycled to the evaporator. The
solubility of Na2SO4 at 293K is 9.91% wt. Calculate the feed rate in kg/hr; H2O evaporated
in kg/hr and the mother liquor recycled in kg/hr.

REQUIRED: Feed rate F, H2O evaporated W and mother liquor recycled R

SOLUTION:

Around the crystallizer:

TMB:

Na2SO4 balance: ( )

Around the evaporator:

TMB:

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ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

Na2SO4 balance: ( )

2. A distillation column separates 10,000 lb/hr of a 50% benzene, 50% toluene mixture. The
product recovered from the condenser at the top of the column contains 95% benzene
and the bottoms from the column contain 96% toluene. The stream entering the
condenser from the top of the column is 8000 lb/hr. A portion of the product is returned to
the column as reflux and the rest is withdrawn for use elsewhere. Assume the compositions
of the streams at the top of the column; the product withdrawn and the reflux are
identical. Find the ratio of the amount refluxed to the product withdrawn.

GIVEN:
8,000 lb/hr
CONDENSER Product, P
95% C6H6 95% C6H6
5% C7h8
D Reflux, R
10,000 lb/hr
C
50% C6H6 95% C6H6
50% C7H8
Bottoms, B
96% C7H8, 4% C6H6

REQUIRED: Ratio of reflux to product, R/P

SOLUTION: Basis: 1 hour SSO

Overall TMB:

C6H6 balance:

At the distillation column:

TMB:

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ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

OR: At the condenser:

TMB:

Therefore:

3. In a pilot process, a sticky material containing 25% water is to be dried. To facilitate the
operation, a part of the dried product containing 5% water is recycled and mixed with
the feed. If the material entering the drier contains 12% water, calculate (a) the kg water
removed per 2000 kg fresh feed and, (b) the recycle-to-feed ratio. (If feed is not
specified, assume it to be fresh feed)

GIVEN: W

12% H2O
Feed, F P
DRYER
2,000 kg 5% H2O
25% H2O

Recycle, R
5% H2O

SOLUTION:

a) kg water removed
( ) ( )

b) the recycle-to-feed ratio

TMB:

2000 kg X H2O balance: 𝑅 𝑋

TMB: 𝑅 𝑋
R 𝑹 𝟑𝟕𝟏𝟒 𝟐𝟖𝟓𝟕 𝒌𝒈 𝑋 𝑘𝑔

Therefore:

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ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

ACTIVITY 3:

1. In a process producing KCIO3 salt, 1000 kg/hr of a feed solution containing 20% by wt.
KCIO3 (and traces of impurities) is feed to the evaporator which evaporates some water
at 422K to produce 50% by wt. KCIO3 solution. This solution is then feed to a crystallizer at
32 C where crystals containing 96% by wt. KCIO3 are removed. The saturated solution
from the crystallizer is recycled by the evaporator. Calculate the (a) amount of crystals
produced and (b) amount of solution recycled.

Solubility @ 32 C= 12 kg KCIO3 / 100 kg H2O

4. In a wood drier, the hot air must contain at least 2% by wt. water to prevent the wood
from drying too rapidly and splitting or warping. The original fresh air feed contains 1% by
wt. water. Wood is dried from 20% to 5% by wt. water. The wet air leaving the dried
contains 4% by wt. water. Calculate the amount of wet air that must be returned to the
drier if 1000 kg/hr of wet wood is dried.

5. A solid material containing 15% w is moisture is dried so that it contains 7% w H 2O by

blowing fresh air mixed with recycle air over the solid in the drier. The inlet fresh air has a
humidity of 0.01 kg H2O/kg dry air. The air from the drier that is recycled has a humidity
0.1kg H2O/ kg dry air and the mixed air to the drier of 0.03 kg H2O/ kg dry air. For a feed of
100 kg solid /hr fed to the drier, calculate (a) kg/hr of dry air in the fresh air (b) kg/hr of dry
air in the recycle air c) kg/hr of dried product.

6. It is desired to lower the n-hexane content of a nitrogen- n-hexane mixture at 45 C (the

partial pressure of n-hexane =310 mmHg) and a total pressure of 757 mmHg to a mixture
containing 15% mole n-hexane. This could be achieved by passing a portion of the gas
mixture through a chiller which condenses out some of the n-hexane and leaves the gas
saturated at 10 C (the partial pressure of n-hexane =64 mmHg) and a total pressure of
750 mmHg. The bypassed gas mixes with the gas from the chiller to form 15% mole n-
hexane. Three hundred cubic meters per minute of the original gas mixture is to be
treated.
Solve a) kmoles/min of the final mixture containing 15% mole n – hexane

b) kmoles/min of the n-hexane condenses in the chiller

c) kmoles/min of the gas that bypasses the chiller.

7. Figure 2 is a diagram of the shirt-cleaning process used by Lala Laundry Services, Inc.
The shirts are soaked in an agitated tub containing Whizzo, the Wonder Detergent, and
are then wrung out and sent to a rinse stage. The dirty Whizzo is sent to a filter in which

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ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

most of the dirt is removed, and the cleaned detergent is recycled back to join a
stream of pure Whizzo, with the combined stream serving as the feed to washtub.

Required:
a) How much pure Whizzo (A) must be supplied per 100 lbm of dirty shirts?
b) Find the amount of B, C, D, E and R,
c) What is the composition of the recycled stream?

Data:

1. Each 100 lbm of dirty shirts contains 2 lbm of dirt

2. The washing removes 95% of the dirt in the dirty shirts
3. For each 100 lbm of dirty shirts, 25 lbm of Whizzo leaves with the clean shirts, of which is
22 lbm is wrung back into the tub
4. The detergent that enters the tub contains 97% Whizzo, and that which enters the filter
contains 87%. The wet dirt that leaves the filter contains 8% Whizzo.

8. A stream containing 5.15% wt% chromium, Cr, is contained in the wastewater from a
metal finishing plant. The wastewater stream is fed to a treatment unit that removes
95% of the chromium in the feed and recycles it to the plant. The residual liquid stream
leaving the treatment unit is sent to a waste lagoon. The treatment unit has a capacity
of 4500 kg wastewater/hr. If wastewater leaves the finishing plant at a rate higher than
the capacity of the treatment unit, the excess (anything above 4500 kg/hr) bypasses
the unit and combines with the residual liquid leaving the unit, and the combined
stream goes to the waste lagoon. If the wastewater leaves the finishing plant at rate of
6000 kg/hr, calculate the flow rate of liquid to the waste lagoon and the mass fraction
of Cr in this liquid.

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ENGR. MYLENE M. OCASION
 Saint Louis University
SCHOOL OF ENGINEERING AND ARCHITECTURE
Department of Chemical Engineering

9. If machine parts are degreased by means of kerosene as shown in the diagram, how
much kerosene make-up is needed per day? How much kerosene has to enter the
degreasing vat per day? There are about 3 lb of grease per 100 lb of machine parts,
and 60 tons of machine parts are processed each day. Five thousand pounds of
kerosene (the 10% solution) are carried away by the machine parts each day but drip
off and are caught and put back in the degreasing vat. Two hundred pounds of the
10% solution are lost each day from the vat by evaporation, spillage, or by being
carried away.

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ENGR. MYLENE M. OCASION