Chemical Engineering

Calculations Lec 1
Recycle, Bypass and Purge
Calculations
 Recycle
• RECYCLE SYSTEM CAN BE FOUND IN EVERYDAY LIFE;
– USED NEWSPAPER IS COLLECTED FROM HOUSEHOLDS,
PROCESSED TO REMOVE THE INK AND USED TO PRINT NEW
NEWSPAPER;
– RECYCLING OF GLASS, ALUMINUM CAPS, PLASTICS, COPPER
AND IRON ARE COMMON;
– RECYCLE SYSTEMS ALSO OCCUR IN NATURE – CONSIDER “THE
WATER CYCLE”;
 RECYCLE
• BECAUSE OF THE RELATIVELY HIGH COST OF INDUSTRIAL
FEEDSTOCKS, WHEN CHEMICALS REACTIONS ARE INVOLVED
IN A PROCESS, RECYCLE OF UNUSED REACTANTS TO THE
REACTOR CAN OFFER ECONOMIC SAVINGS FOR HIGH
VOLUME PROCESSESING SYSTEMS;
• HEAT RECOVERY WITHIN A PROCESSING UNITS (ENERGY
RECYCLE) REDUCES THE OVERALL ENERGY CONSUMPTIONS
OF THE PROCESS;
 Recycle
• Reasons for Recycle
– Recovering and reusing unconsumed reactants
– Recovery of catalyst (catalyst : expensive)
– Dilution of process stream
– Control of process variables
– Circulation of working fluid
A+B→C

A+B A
B
C
Recycle unused reactants (A,B)
 Recycle without Reaction
• Recycle of material occurs in a variety of
processes that do not involve chemical
reaction including:
– Distillation
– Crystallization
– Heating and Refrigeration Systems;
 Bypass
• A fraction of the feed is diverted around
the process unit and combined with the
output stream.
• Controlling properties and compositions of
product stream
 Product separation and recycle
• Normally, reactions are not complete
– Separation and recycle
– Improved yield, conversion ,…

Reactants Product Products

Reactor Separation
Unit
Recycle

• Overall conversion
• Single-pass conversion
 Recycle, By pass and Purging
(1)

RECYCLE, R

FRESH NET
FEED PRODUCT
MIXERTOTAL OR PROCESS SEPARATOR
GROSS GROSS
FEED PRODUCT
(2) (3) (4)
MATERIAL BALANCES FOR DIFFERENT SYSTEMS.
OMB (1) : FRESH FEED = NET PRODUCT
MIXING PT (2): FRESH FEED+RECYCLE=TOTAL OR GROSS FEED
PROCESSING PT (3): TOTAL OR GROSS FEED=GROSS PRODUCT
SEPARATOR (4) : GROSS PRODUCT=RECYCLE + NET PRODUCT
Recycle with No
Reaction
Sample Problem No. 1: Find the kg of Recycle/kg Feed if
the amount of waste (w) is 60 kg of A.

R (100% A)

G G
Product (P)
A 5 wt %
B 95 wt%
Feed (F) 40 wt % A 40 wt % A
A 20 wt %
B 80 wt%

W = 60 kg
(100% wt A)
 Sample Problem 2: Find the Kg R/100 kg Fresh Feed

60 kg Water

40 % KCl
60% Water
Product (P)
(F)
20% KCl EVAPORATOR 60 % KCl
GF GP 40 % Water
80% Water

Fresh Feed
Recycle, R

60% KCl
40% Water
Himmelbleau, 5th: 2.69/p.225: What is the quantity of the
recycle stream in kg/hr
 Board Work Exercise from Felder

• Problem 4.31
• Problem 4.33
• Problem 4.35
 Recycle with
Chemical Reaction
Recycle and Purging Calculations
 Relationship of SP & OA
𝑠𝑖𝑛𝑔𝑙𝑒 𝑝𝑎𝑠𝑠 𝑛 𝑓𝑟𝑒𝑠ℎ 𝑓𝑒𝑒𝑑
• =
𝑜𝑣𝑒𝑟𝑎𝑙𝑙 𝑛 𝑓𝑟𝑒𝑠ℎ 𝑓𝑒𝑒𝑑+𝑛 𝑟𝑒𝑐𝑦𝑐𝑙𝑒
Sample Problem 1: A catalytic dehydrogenation process
shown in the Figure , produces 1,3 butadiene (C4H6) from
normal butane (C4H10). The product stream contains 75
moles/hr H2 and 13 mol/hr of C4H10 as well as C4H6. The
recycle steam is 30% (mol) C4H10 and 70% (mol) 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?

Pure
C4H10→C4H6+2H2 Separator
C4H10 nH2=75 moles/hr
F=? moles/hr nC4H10=13 moles/hr
nC4H6= ?

Recycle = 24 mol/hr
xC4H10=0.30
xC4H6=0.70
Sample Problem No. 2
 350 mol/min Product
REACTOR COOLER CH3OH
CO 10.6 wt% H2
H2 64.0 wt% CO
25.4 wt% CH3OH

CO + 2H2→CH3OH

Recycle
CO - x
H2 - y
CH3OH (0.40 mol %)
 Purging

◼ Getting rid of undesired materials in

recycle stream.

Reactants Product Products

Reactor Separation
Unit
Recycle
Purging
 Group Activity

Felder- 4.56, 4.58, 4.59

Use Solution Paper Provided