Last Class: Classifying Process Types

Last class
1. Classifying process types

Batch vs. Semi-batch vs. Continuous
Steady-State vs. Unsteady-state or Transient
2. Applying the general balance equation

Integral balances between 2 instants in time
Differential balances for processes with a rate
3. Material balance calculations

Organizing process data in flowcharts
Scaling and basis of calculation
Balancing a process
Quiz results
184 responses out of 197
Q1: Hydrogen technologies continue to be investigated for uses to mitigate human

impacts. Most hydrogen is currently produced by steam reforming hydrocarbons
such as natural gas. In a simplified example of this process, methane, CH4, and
water, H2O, are fed into a tubular reactor and produce Carbon monoxide, CO, and
Hydrogen, H2. The reactants are fed in at the front of the reactor and the products
are removed at the other end. If the reactor is initially filled with air, how would you
classify this process during an initial period?
25
20
15
10
5
0
B/SS
B/US
SB/SS
SB/US
C/SS
C/US

[discuss] Is this process steady or unsteady state?

[discuss] Is this process steady or unsteady state?

[discuss] Is this process batch, semi-batch or continuous?
Solving Material Balances

Feed 2
Feed 1
Unit 1
Product 1
Unit 2
Product 2
Product 3
Feed 3
Learning objectives
By the end of this class you will be able to:
Analyze the degrees of freedom (DOF) of processes to understand
whether they are under specified, adequately specified or over specified Ch 4.3 d
Apply a general procedure to organize process flow calculations - Ch 4.3e
Content will be Chapter 4.3 and 4.4
Degree of freedom analysis

Method to determine if a system is solvable before trying to solve it.
Step 1 draw and fully label our process flowchart
[Individually] An extractor is used to separate olive oil from olive solids. One
kilogram per second of olives entering the process contains 10% oil by mass and
this is completely separated from the solids. Solve the system for all flows.
= ?
Olives
= 1/
= 0.1
= 0.9
Extractor
= ?

Step 2: Count unknown variables
Note variables must be independent, e.g. with 2 species, only 1 composition is
needed to specify a stream
= ?
Olives
= 1/
= 0.1
= 0.9
Extractor
nunknowns = 2
= ?

Step 3: Count independent equations
Includes
Material Balances with 1 for each molecular species (in text nms)
Process specifications given (e.g. 40% of the flow of stream 1 goes to stream 2)
Physical properties and laws (e.g. knowing mass flow from volumetric flow given a specific
gravity)
Physical constraints (e.g. mole fractions adding up to 1)
Stoichiometric relations (considered later in this course in Ch 4.7)
Energy Balances for each unit (considered later in this course in Ch 7-9)
10

Step 3: Count independent equations
Includes
Material Balances with 1 for each molecular species (in text nms)
= ?
Olives
= 1/
= 0.1
= 0.9
Extractor
nunknowns = 2
nindep eqns = 2 (number of species)
= ?
11

Step 4: Subtract independent equations from unknown variables to get
degrees of freedom
=
= ?
Olives
= 1/
= 0.1
= 0.9
Extractor
= ?
nunknowns = 2
nindep eqns = 2 (number of species)
ndf = nunknowns - nindep eqns = 0
12

degrees of freedom
=
3 possibilities
= 0, number of unknowns is equal to the number of independent equations. The
problem can, in principle, be solved. (adequately specified)
13

degrees of freedom
=
3 possibilities
> 0, more unknowns than equations. We need an additional ndf values to be
specified before being able to solve. (underspecified)
14

degrees of freedom
=
3 possibilities
> 0, more unknowns than equations. We need an additional ndf values to be
specified before being able to solve. (underspecified)
< 0, more equations than unknowns, may have redundant or possibly
inconsistent relations. Get multiple solutions if we try to solve. (overspecified)
15
Practice on Degree of freedom analysis

[Individually] In plastics manufacturing polymer pellets may be mixed and heated using a
screw feeder and then fed into a mold to be cast into a shape. These pellets may be made
of a number of constituents including polymers and plasticizers, which are small molecules
that make plastics more flexible. Polymer pellets can be made in a pelletizer. If a pellet is
composed of polyvinyl chloride (A) and 2 phthalate esters (B and C), weights 1 gram, and
contains 1 % phthalates by weight, what are the individual feed rates of A, B and C into the
pelletizer? Do a degree of freedom analysis before solving.
1. Flowchart
2. # unknowns
3. # independent exns
4. =
16
[Individually] In plastics manufacturing polymer pellets may be mixed and heated using a
screw feeder and then fed into a mold to be cast into a shape. These pellets may be made
of a number of constituents including polymers and plasticizers, which are small molecules
that make plastics more flexible. Polymer pellets can be made in a pelletizer. If a pellet is
composed of polyvinyl chloride (A) and 2 phthalate esters (B and C), weights 1 gram, and
contains 1 % phthalates by weight, what are the individual feed rates of A, B and C into the
pelletizer? Do a degree of freedom analysis before solving.
= ?
= ?
= ?
Pelletizer
(mixer)
1 = 1
= 0.99
= ?
= 1
1. Flowchart
2. # unknowns = 4
3. # independent exns = 3
4. = = 4-3 = 1
Problem underspecified, need more information
17
Phthalates
18
Quiz 1 Question 3
A distillation column is used to separate ethylene (C2H4) from ethane
(C2H6). The diagram for a pilot plan to study the process efficiency is show
below. If the inlet stream is scaled to a flow of 300 kmol/s, what is the flow of
the ethane leaving in stream 2 in kmol/s?
19
One interpretation
Flow in stream 1 :
4 /
30.07/
6 /
Ethene:
28.05/
Total: 0.347
Ethane:
0.214
= 0.133
=
Convert basis flow of ethane:

=
So = 115 /
300 /
2 = 115
0.25 = 28.7 /
0.133 /
0.347 /
of ethane flows in stream 2 so
20
One interpretation
Flow in stream 1 :
4 /
Ethane:
30.07/
6 /
Ethene:
28.05/
Total: 0.347
=
=
0.133
0.214
Convert basis flow of ethane:

So = 115 /
300 /
2 = 115
0.25 = 28.7 /
0.133 /
0.347 /
of ethane flows in stream 2 so
Note that converting from mass to molar basis or vice versa, is much harder
than converting between different masses or molar flows (as we dont need to
change compositions.
21
Another interpretation
Flow of ethane is now 300 kmol/s

of ethane flows in stream 2 so 2 = 300
0.25 = 75 /
22
General procedure for single-unit material balance

calculations
1. List and update assumptions as you go through the problem
2. Choose a basis of calculation (flow rate)
Generally use the one in the problem if given
If multiple are given, assume they are consistent and use them collectively
If no basis is given, you can choose an arbitrary basis (e.g. 100 kg/s)
3. Draw flowchart and label known and unknown quantities

Flow rates are completely labelled if you can express the mass or mass flow rate (or
mole or molar flow rate) of each component in each stream using algebraic symbols
Incorporate known relationships in labelling (e.g. If stream 2 has a flow rate of two
times that of stream 1, label stream 2 as 2*1)
Label volumetric quantities only if they are given, these should be converted to mass
or molar quantities.
23
General procedure for single-unit material balance

calculations
4. Express what the problem statement asks you to determine in terms of
labelled variables
5. Convert all quantities to either a molar or mass basis (choose 1)
6. Do the degree-of-freedom analysis
7. If the equations are to be solved manually, write them in an efficient order
8. Check your solution by substituting calculated variables into any balance
equations that were not used
9. Solve additional equations for quantities requested in the problem
statement
10. Convert the basis if required in the problem statement
24
Nylon production
[individually] Nylon, a common polymer used in many clothing products, is made from
caprolactam. The polymerization reaction of caprolactam is not completely efficient and the
reactor outlet contains 10% caprolactam and 90% nylon. This caprolactam is then recovered
using pure water since it is soluble in water, unlike the polymer nylon. All the caprolactam is
recovered in the water stream, which enters at twice the mass of the outlet stream of the reactor.
However the final polymer stream still contains 1% by mass of water. What is the weight fraction
of the caprolactam in the water stream?(Start with steps 1-3 and we will take it up again once
you have a flowchart)
Picture by: Nuklear at English Wikipedia [CC BY-SA 3.0 (http://creativecommons.org/licenses/by-sa/3.0)

or GFDL (http://www.gnu.org/copyleft/fdl.html)], via Wikimedia Commons
25
[individually] Nylon, a common polymer used in many clothing products, is made from
caprolactam. The polymerization reaction of caprolactam is not completely efficient and the
reactor outlet contains 10% caprolactam and 90% nylon. This caprolactam is then
recovered using pure water since it is soluble in water, unlike the polymer nylon. All the
caprolactam is recovered in the water stream, which enters at twice the mass of the outlet
stream of the reactor. However the final polymer stream still contains 1% by mass of water.
What is the weight fraction of the caprolactam in the water stream?
1.
2.
3.
List and update assumptions as you go through the problem - none

Choose a basis of calculation (flow rate) 100 kg reactor outlet
Draw flowchart and label known and unknown quantities
W water
N Nylon
C - caprolactam
1 = 100
1 = 0.1
1 = 0.9
3 = ?
3 = ?
= (1 3 )
Recovery unit
2 = 2 1 = 200
4 = ?
4 = 0.01
4 = 0.99
Continue to until completing a DOF analysis

26
[individually] Nylon, a common polymer used in many clothing products, is made from caprolactam.
The polymerization reaction of caprolactam is not completely efficient and the reactor outlet contains
10% caprolactam and 90% nylon. This caprolactam is then recovered using pure water since it is
soluble in water, unlike the polymer nylon. All the caprolactam is recovered in the water stream, which
enters at twice the mass of the outlet stream of the reactor. However the final polymer stream still
contains 1% by mass of water. What is the weight fraction of the caprolactam in the water stream?
1.
2.
3.
List and update assumptions as you go through the problem - none

Choose a basis of calculation (flow rate) 100 kg reactor outlet
Draw flowchart and label known and unknown quantities
W water
N Nylon
C - caprolactam
4.
5.
6.
1 = 100
1 = 0.1
1 = 0.9
3 = ?
3 = ?
= (1 3 )
Recovery unit
2 = 2 1 = 200
4 = ?
4 = 0.01
4 = 0.99
Express what the problem statement asks you to determine in terms of labelled variables wc3
Convert all quantities to either a molar or mass basis (choose 1) already in mass basis
Do the degree-of-freedom analysis - = = 3 - 3 = 0
Continue to solve the question completely

27
4.
Express what the problem statement asks you to determine in terms of labelled variables wc3
5.
Convert all quantities to either a molar or mass basis (choose 1) already in mass basis
6.
Do the degree-of-freedom analysis - = = 3 - 3 = 0
7.
If the equations are to be solved manually, write them in an efficient order
Balance on nylon (N): =
.
.
= .
Overall balance: = + = + . = .
Balance on caprolactam (C): =
8.
9.
.
.
= .
Check your solution by substituting calculated variables into any balance equations that were not used

. .
.
Balance on water (W): =
Compositions on stream 3: = + = . + . (solved independently)
= .
Solve additional equations for quantities requested in the problem statement - none
10. Convert the basis if required in the problem statement - none
28
Balances on Multiple-unit Processes

Need to identify and analyze systems in our process where we can use
material (or energy) balances
System any portion of a process that can be enclosed in a hypothetical
box
29

box
Feed 2
Feed 1
Unit 1
Product 1
Unit 2
Product 2
Product 3
Feed 3
30

box
Feed 2
Feed 1
Unit 1
Product 1
Unit 2
Product 2
Product 3
Feed 3
31

box
Feed 2
Feed 1
Unit 1
Product 1
Unit 2
Product 2
Product 3
Feed 3
32

box
Feed 2
Feed 1
Unit 1
Product 1
Unit 2
Product 2
Product 3
Feed 3
33

box
Feed 2
Feed 1
Unit 1
Product 1
Unit 2
Product 2
Product 3
Feed 3
34

Feed 2
Feed 1
Unit 1
Product 1
Unit 2
Product 2
Product 3
Feed 3
We can analyze any system we choose. But, it is a good idea to do a

degree-of-freedom analysis to see which systems are solvable.
With 3 or more units, this can be complicated as there are subsystems
composed of multiple individual units.
35
[Individually] Rayon is a fiber made from purified cellulose found in wood pulp. Sheets of
pure cellulose are first treated with a 50% by weight sodium hydroxide solution in water in a
vessel. This intermediate, in 1 mixed stream consisting of 10% cellulose by mass, is then
transferred to a drier to remove 90% of the water by mass. Following this the sheets are
shredded into crumbs and aged in metal containers. After ageing the crumbs are mixed with
a solution of 25% by mass of carbon disulphide in water as a final treatment step. The
carbon disulphide and sodium hydroxide are then completely removed with the water to
produce the final product. Completely solve the system for the production of 1 kg of final
product.
C cellulose
W water
N NaOH
S CS2
To start, create a flowsheet and label the process units and streams, and what species are
in each stream. I will use the convention above for labelling species. We will then check to
make sure were on the same page.
36
Rayon is a fiber made from purified cellulose found in wood pulp. Sheets of pure cellulose are first
treated with a 50% by weight sodium hydroxide solution in water in a vessel. This intermediate, in 1
mixed stream consisting of 10% cellulose by mass, is then transferred to a drier to remove 90% of the
water by mass. Following this the sheets are shredded into crumbs and aged in metal containers.
After ageing the crumbs are mixed with a solution of 25% by mass of carbon disulphide in water as a
final treatment step. The carbon disulphide and sodium hydroxide are then completely removed with
the water to produce the final product. Completely solve the system for the production of 1 kg of final
product.
4. Water
7. NaOH,
CS2 Sol.
1. Cellulose
Vessel
2. NaOH Sol.
3. Intermediate
Dryer/
Shredder/
Aging
5. Crumbs
Final
Treatment
8. Final Product
6. CS2 Sol.
37
Rayon is a fiber made from purified cellulose found in wood pulp. Sheets of pure cellulose are first
treated with a 50% by weight sodium hydroxide solution in water in a vessel. This intermediate, in 1
mixed stream consisting of 10% cellulose by mass, is then transferred to a drier to remove 90% of the
water by mass. Following this the sheets are shredded into crumbs and aged in metal containers.
After ageing the crumbs are mixed with a solution of 25% by mass of carbon disulphide in water as a
final treatment step. The carbon disulphide and sodium hydroxide are then completely removed with
the water to produce the final product. Completely solve the system for the production of 1 kg of final
product.
C cellulose
7. NaOH,
7. N, S, W
W water
4. Water
CS2 Sol.
N NaOH
4. W
S CS2
1. Cellulose
1. C
Vessel
2. NaOH Sol.
2. W, N
3. Intermediate
3. C, W, N
Dryer/
Shredder/
Aging
5. Crumbs
5. C, W, N
Final
Treatment
8. Final Product
8. C
6. CS2 Sol.
6. S, W
38
Rayon is a fiber made from purified cellulose found in wood pulp. Sheets of pure cellulose are first treated
with a 50% by weight sodium hydroxide solution in water in a vessel. This intermediate, in 1 mixed stream
consisting of 10% cellulose by mass, is then transferred to a drier to remove 90% of the water by mass.
Following this the sheets are shredded into crumbs and aged in metal containers. After ageing the crumbs
are mixed with a solution of 25% by mass of carbon disulphide in water as a final treatment step. The
carbon disulphide and sodium hydroxide are then completely removed with the water to produce the final
product. Completely solve the system for the production of 1 kg of final product.
1. Cellulose
1 = ?
(1 = 1)
2. NaOH Sol.
2 = ?
2 = 0.5
(2 = 0.5)
C cellulose
4. Water
W water
4 = ? = 0.9 3 3
N NaOH
(4 = 1)
S CS2
Vessel
3. Intermediate
3 = ?
3 = 0.1
3 = ?
(3 = ? )
Dryer/
Shredder/
Aging
7 = ?
7. NaOH, = ?
7
CS2 Sol.
7 = ?
(7 = ? )
5. Crumbs
5 = ?
5 = ?
5 = ?
(5 = ? )
Final
Treatment
Terms in brackets represent those I can know from mass fraction totals
8. Final Product
8 = 1
(8 = 1)
6. CS2 Sol.
6 = ?
6 = 0.25
(6 = 0.75)
39
C cellulose
W water
N NaOH
S CS2
1. Cellulose
1 = ?
(1 = 1)
2. NaOH Sol.
2 = ?
Vessel
2 = 0.5
(2 = 0.5)
4. Water
4 = ? = 0.9 3 3
(4 = 1)
3. Intermediate
3 = ?
3 = 0.1
3 = ?
(3 = ? )
Dryer/
Shredder/
Aging
7 = ?
7. NaOH, = ?
7
CS2 Sol.
7 = ?
(7 = ? )
5. Crumbs
5 = ?
5 = ?
5 = ?
(5 = ? )
Final
Treatment
8. Final Product
8 = 1
(8 = 1)
6. CS2 Sol.
6 = ?
6 = 0.25
(6 = 0.75)
Now complete the DOF analysis for the overall system and each individual unit
(we wont do analysis on the 2 unit subsystems)
40
1. Cellulose
1 = ?
(1 = 1)
2. NaOH Sol.
2 = ?
2 = 0.5
(2 = 0.5)
C cellulose
W water
N NaOH
S CS2
Vessel
7 = ?
7. NaOH, = ?
7
CS2 Sol.
7 = ?
(7 = ? )
4. Water
4 = ? = 0.9 3 3
(4 = 1)
3. Intermediate
3 = ?
3 = 0.1
3 = ?
(3 = ? )
Dryer/
Shredder/
Aging
5. Crumbs
5 = ?
5 = ?
5 = ?
(5 = ? )
Final
Treatment
Overall : = . = 7 4 = 3
Vessel : = . = 4 3 = 1
Dryer : = . = 6 3 1 = 2
Final : = . = 7 4 = 3
8. Final Product
8 = 1
(8 = 1)
6. CS2 Sol.
6 = ?
6 = 0.25
(6 = 0.75)
Can this be solved? In its current formno
41
1. Cellulose
1 = 1
(1 = 1)
2. NaOH Sol.
2 = ?
2 = 0.5
(2 = 0.5)
C cellulose
W water
N NaOH
S CS2
Vessel
7 = ?
7. NaOH, = ?
7
CS2 Sol.
7 = ?
(7 = ? )
4. Water
4 = ? = 0.9 3 3
(4 = 1)
3. Intermediate
3 = ?
3 = 0.1
3 = ?
(3 = ? )
Dryer/
Shredder/
Aging
5. Crumbs
5 = ?
5 = ?
5 = ?
(5 = ? )
Final
Treatment
But we can alter the basis from m8 to m1 (or m2)

This is a solution method with multi-unit processes
8. Final Product
8 = ?
(8 = 1)
6. CS2 Sol.
6 = ?
6 = 0.25
(6 = 0.75)
Overall : = . = 7 4 = 3
Vessel : = . = 3 3 = 0
Dryer : = . = 6 3 1 = 2
Final : = . = 8 4 = 4
42
Summary
Analyzed whether we can solve a process before we start solving
equations using DOF.
Applied a general solution strategy for material balance problems
Explored the analysis of multiple unit processes
43

Last Class: Classifying Process Types

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Last class

1. Classifying process types

2. Applying the general balance equation

3. Material balance calculations

Q1: Hydrogen technologies continue to be investigated for uses to mitigate human

Q1: Hydrogen technologies continue to be investigated for uses to mitigate human

[discuss] Is this process steady or unsteady state?

Q1: Hydrogen technologies continue to be investigated for uses to mitigate human

[discuss] Is this process steady or unsteady state?

Solving Material Balances

Degree of freedom analysis

Degree of freedom analysis

Degree of freedom analysis

Degree of freedom analysis

Degree of freedom analysis

Degree of freedom analysis

Degree of freedom analysis

Degree of freedom analysis

Practice on Degree of freedom analysis

Convert basis flow of ethane:

of ethane flows in stream 2 so

Convert basis flow of ethane:

of ethane flows in stream 2 so

Flow of ethane is now 300 kmol/s

General procedure for single-unit material balance

3. Draw flowchart and label known and unknown quantities

General procedure for single-unit material balance

Picture by: Nuklear at English Wikipedia [CC BY-SA 3.0 (http://creativecommons.org/licenses/by-sa/3.0)

List and update assumptions as you go through the problem - none

Continue to until completing a DOF analysis

List and update assumptions as you go through the problem - none

Continue to solve the question completely

Do the degree-of-freedom analysis - = = 3 - 3 = 0

If the equations are to be solved manually, write them in an efficient order

Balance on nylon (N): =

Balance on water (W): =

Compositions on stream 3: = + = . + . (solved independently)

10. Convert the basis if required in the problem statement - none

Balances on Multiple-unit Processes

Balances on Multiple-unit Processes

Balances on Multiple-unit Processes

Balances on Multiple-unit Processes

Balances on Multiple-unit Processes

Balances on Multiple-unit Processes

Balances on Multiple-unit Processes

We can analyze any system we choose. But, it is a good idea to do a

Can this be solved? In its current formno

But we can alter the basis from m8 to m1 (or m2)

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