m2= 800

1 H20
0 FeCl3

m1=

m3= 2355

3155 kg/hr

x1 FeCl3
1-x1 H20

kg/hr

Evaporator

0.45 FeCl3
0.6 H20

c
Basis
The final product is assumed to have 40% concentration of Ferric Chloride
The upper stream only produce water
Assumption
The evaporation process produce 800kg/hr of water
m1 = m2 + m3
m1=
3155 kg/hr
m1x1 = m2x2 + m3x3
x1 = 0.335895
Concentration FeCl2 0.335895
Concentration H20 0.664105

m2=
785
0.4 FeCl3
0.6 H20

kg/hr
m1=

2355

0.4 FeCl3
0.6 H20

Recycle

m3=

Basis
The flow rate at final product is 1570 kg/hr
1/3 of the product produced from evaporator is recycled back to the reactor
Total production = 13000 ton per year
Shutdown days = 20 days
Operating days = 345 days
Mass flow rate per hr = 1570 kg/hr
m2=
m3=

785 kg/hr
2355 kg/hr

e reactor

kg/hr

1570 kg/hr
0.4 FeCl3
0.6 H20

m3= 4.750395 kg/hr

1 H2
11200
m1= 200
1 Fe

kmol/hr
kg

Reactor

m2= 1411
kg/hr
0.245768 HCl
kg
0.754232 H20
kg
Assumption
Assume that the inlet for iron metal is 3000 kg/hr
Assume that the inlet for hydrochloric acid is 1000kg/hr
The hydrochloric acid contain 24% weight
mw hcl
mw h20
mw fe
mw Cl2
mol hcl
molh20
total

36.5 mw fecl2
18 mw fecl3
56
70.9 mw N2
9.500789 0.138447
59.1234 0.861553
68.62419
1

Balance for HCl

nin = nout -2E
E= -4.750395 kmol/hr
Balance for FeCl2
nin = nout + E
nFeCl2=
4.750395 kmol/hr

nH2=

Balance for H2
nin = nout + E
4.750395 kmol/hr

Balance for H20

m1xh20 = m4xh20
nh20
59.1234 kmol/hr

nfe=

Balance for Fe
nin = nout -E
195.2496 kmol/hr

balance solution
FeCl2
H20

126
162.2
28

m4= 259.1234
0.018333 FeCl2
0.228167 H20
0.7535 Fe

fecl2
h20

598.5497 0.359971
1064.221 0.640029
1662.771

kmol/hr

1= 259.1234 kmol/hr
0.359971 0.018333 FeCl2
0.228167 H20
0.7535 Fe
1

0.2465

mol
mol

0.987241
0.012759

Cyclone

2=
x2 0.006238
y2 8.06E-005
z2 0.999898
1.006217

1.2181415825
0.0157428122
1.2338843947

Assumption
63.87379 Assume that all the Fe Metal is recycled back to the stream 1
0.074372
0.925628
Fecl2 balance
Fe balance
1
m1x1=m2x2+m3x3
m1z1=m2z2+m3z3
x2= 0.006238 kg/hr
z2= 0.999898
m1 =m2+ m3
m2= 195.2695 kg/hr
H20 balance
m1y1=m2y2+m3y3
y2= 8.06E-005

mass
molar
598.5497
1064.221
10933.98

fecl2
H2O
fe

fecl2
H2O
fe

195.2496
nfecl2
nh20
total

598.029
1063.938
1661.967

1
2
3
12596.75 14341.055544787 1661.967
259.1234 195.2694810802 63.85392
mass fraction
0.047516
0.0107025483
0.359832 153.4858
0.084484
0.2268725478
0.640168 3253.592
0.868
0.7624249039
0
10933.98
1
1
mole fraction
0.018333
0.0062382589
0.07433
0.228167
0.000080621
0.92567
0.7535
0.9998982135
0
1
1.0062170933
1

m2=

3= 63.85392 kmol/hr
0.07433 FeCl2
4.746262
0.92567 H20
59.10766
0 Fe
0
m1= 63.85392 kg/hr
1
0
0.07433 FeCl2
195.2695 kmol/hr
0.92567 H20
FeCl2
195.2496 kg/hr
H20
0.019876
Fe
assume conversion
0.9
0.1

m4=

fecl2 out
fecl2 out
0.474626 0.007433 mol/mol
Fecl2 balance
nin = nout -E
E= -4.271636 kg/hr

e balance
=m2z2+m3z3

kg/hr
kg/hr
kg/hr

Chlorinator

H20 balance
m1y1=m3y3
m3y3 = 59.10766 kg/hr
y3= 0.92567 mol/mol

0.359832
0.640168

FeCl3 balance
nin = nout + E
nfecl3 = 4.271636 kg/hr
nfecl3 = 0.066897 mol/mol
mol/mol kg/hr
kg/kg
0.007433 59.8029 0.03292 fecl2
0.92567 1063.938 0.585675 h20
0.066897 692.8593 0.381404 fecl3
1
1816.6
1

inlet stream of raw material

mole flowrate
mole/molemass flowkg/kg
ferrous chloride
4.746262 0.07433 598.029 0.359832
water
59.10766 0.92567 1063.938 0.640168
TOTAL
63.85392
1 1661.967
inlet stream of gas
chlorine

6.000023

0.85933 425.4016 0.939278

inert
TOTAL

0.982187
6.98221

0.14067 27.50125 0.060722

1 452.9028
1

outlet stream of the gas

chlorine
3.864205 0.797336 273.9721 0.908777
inert
0.982187 0.202664 27.50125 0.091223
TOTAL
4.846392
1 301.4734
1
outlet stream of the product
ferous chloride
0.474626 0.007433 59.8029 0.03292
water
59.10766 0.92567 1063.938 0.585675
ferric chloride
4.271636 0.066897 692.8593 0.381404
TOTAL
63.85392
1
1816.6
1

mw
mw
mw
mw

hcl
h20
fe
Cl2

36.5 mw fecl2
18 mw fecl3
56
70.9 mw N2

126
162.2
28

nator

6.98221 kmol/hr
0.85933 Cl2
0.14067 inert
1

0.9821875

m3= 63.853918 kg/hr

0.007433 Fecl2
0.92567 h20
0.066897 fecl3
1
4.846392 kg/hr
0.797336 Cl2
0.202664 inert

cl2 balance
nin = nout - 1/2E
ncl2= 3.864205 kg/hr
inert balance
nin = nout -1E
nin= 0.982187 kg/hr

m1

63.85392 kmol/hr

Evaporato

0.007433 Fecl2
0.92567 h20
0.066897 fecl3
1

Fecl2
0.474626

Fecl3
4.271636

fecl2
h20
fecl3

mw
output
h20
45.40766
total
50.15392

mw hcl
mw h20
mw fe

16
17
mass flow
1816.6
1570
molar flow 63.85392 50.15392
mass fraction
59.8029 FeCl2
0.03292 0.038091
1063.938 H2O
0.585675 0.520597
692.8593 FeCl3
0.381404 0.441312
1
1
mole fraction
FeCl2
0.007433 0.009463
H2O
0.92567 0.905366
FeCl3
0.066897 0.085171
1
1

m3

Evaporator

50.15392 kmol/hr

0.009463 Fecl2
0.905366 h20
0.085171 fecl3
m2

13.7 kmol/hr
1 h20

mol
kg/hr
kg/kg
0.009463 59.8029 0.038091
0.905366 817.3378 0.520597
0.085171 692.8593 0.441312
1570
31.30364 kg/kmol
1570 kg/hr
36.5 mw fecl2
18 mw fecl3
56

18
767.2
13.7

action
0
1
0
1

ction
0
1
0
1

0
767.2
0

126
162.2

1000 kg/hr

Reactor