CHEMICAL PROCESS CALCULATIONS

QUESTION BANK

1. Define the partial pressure of a component in a gas mixture. (Nov 2017)

Partial pressure of a component is the product of its mole fraction and the total pressure of the gas
mixture.
Pi = xiP

2. The volumetric flow rate of a liquid of specific gravity 0.8 is 120 ft3/min. Find the mass flow
rate in kg/s. (Nov 2017)
Data: Specific gravity = 0.8.
Density of liquid = specific gravity (Density of water) = 0.8 (1000) = 800 Kg/m3
3
 ft 3   m   1  min 
3
 1  m3
Volumetric flow rate = 120   =120         0.057
 min   3.28   ft   60  sec  s
 m3   Kg 
Mass flow rate = (Volumetric flow rate) (Density) = 0.057 800 3   45.6
Kg
 s  m  s
3. Estimate the molecular weight of air (Nov 2017, Nov 2014)
Average molecular:
=  (Molecular weight of the compound) (Mole fraction of the compound)
Assuming air is a binary mixture of nitrogen and oxygen, with the mole fraction of 0.79 and 0.21
respectively,
Average molecular weight of air
= (Mole Wt of N2)(Mole fraction of N2) + (Mole Wt of N2)(Mole fraction of N2)
= (28)(0.79) + (32)(0.21) = 28.84 gr/gr mole

4. Define Weight fraction, Volume fraction and Mole fraction. (May 2017, 2013)
Weight fraction of a component in a mixture is the ratio of its weight to the total weight of the
sample.
Individual weight of the component in the sample
Weight fraction of a component = [-----------------------------------------------------------------]
Total weight of the sample
Volume fraction of a component in a mixture is the ratio of its volume to the total volume of the
sample.
Individual Volume of the component in the sample
Volume fraction of a component = [-----------------------------------------------------------------]
Total Volume of the sample

Mole fraction of a component in a mixture is the ratio of its mole to the total mole of the sample.
Individual moles of the component in the sample
Mole fraction of a component = [-----------------------------------------------------------------]
Total moles of the sample

5. State Dalton’s and Amagat’s law (May 2017, May 2013)

Dalton’s Law: If Pi is the partial pressure exerted by a single component in a mixture with the mole
fraction yi then total pressure. PT = ΣPi and Pi = PT yi
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 Amagat’s Law: If Vi is the volume of pure component i present in the mixture, total volume of the
gas V is given by, V = ΣVi

6. What are the basic and derived units? (May 2016)

The SI is founded on seven SI base units for seven base quantities assumed to be mutually
independent. They are meter (Length), Kilogram (Mass), Second (Time), ampere (Electric current),
Kelvin (Temperature), mole (Amount of substance) and Candela (Luminous intensity). These are
basic units.
Other quantities, called derived quantities, are defined in terms of the seven base quantities via a
system of quantity equations. Ex: m/S (Velocity), Kg/m3 (Density).

7. How many Kgs of Charcoal is required to reduce 2 Kg of Arsenic trioxide where the products
are CO and As. (May 2016)

Arsenic trioxide As2O3 + 3C 2As +3 CO

1 Kg mole of Arsenic trioxide required 3 Kg atom of carbon.
75 +75 + 16 + 16 + 16 = 198 Kgs of Arsenic trioxide requires 36 Kgs of Carbon.
2 Kg of arsenic trioxide requires = (36/198) x 2 = 0.364 Kgs = 363.64 gm of charcoal is required.

8. Find the molar mass of KMnO4. (May 2015)

Molar mass is the mass of the chemical per mole of the compound, g per mol or Kg per Kg mol.
Moles = Mass/Molecular weight. Molecular weight of KMnO4 = 39 + 55 + 4 (16) = 158
1 = Mass/158
Hence molar mass = 158 g/mol.

9. Find the density of an oil having specific gravity of 0.79 in oAPI and oBe. (Nov 2014)
141.5 141.5
API refers American Petroleum Institute: oAPI=  131.5 =  131.5  47.6
288.8K 0.79
sp.gr
288.8K
140 140
o
Be refers Baume scale: oBe= 130   130  47.22
288.8K 0.79
sp.gr
288.8K
10. Write the unit of solubility. (May 2014)
Units of solubility are gr of solute per gr of solvent or kilograms of solute per kilograms of solvent.

11. The nitrogen content of an urea sample is 22% by weight. Calculate the purity of the sample.
(May 2010)
The molecular weight of urea (NH2CONH2) is 60. 60 g of urea contains 28 g of nitrogen.
Given sample contains 22 g in 100 g.
28/60 = 0.467 corresponds to 100% purity
22/100 = 0.22 corresponds to (100/0.467) x 0.22 = 47.1% Purity.

12. Calculate the density of air at 2.5 atm and 45oC. (May 2010)
Molar volume of air V = RT/P = (8.314x10 )(273.15 + 45)/2.5 (1.01325 x 10 ) = 10.44 m3/Kg mole.
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Air is assumed to be made up of Nitrogen (0.78 Mole fraction) and Oxygen (0.22 Mole fraction)
Average Molecular weight of air = 28(0.79) + 32(0.21) = 28.84 Kg/Kg mole.

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 Density of the gas = Molecular weight / Molal volume = 28.84/10.44 = 2.76 Kg/m3.

13. Define mole fraction and explain how it is related to partial pressure. (May 2010)
Mole fraction of a component is a mixture is the ratio of its moles to the total number of moles of the
mixture. Partial pressure on any component in a mixture can be determined by multiplying its mole
fraction with the total pressure of the mixture.
Mole fraction = Partial pressure/Total pressure.

14. Do the following conversions (Nov 2010)

(i). 7000 A to nm  1 A = 0.1 nm. Hence 7000 A = 700 nm.
o o o

(ii) 4000 cm to Ao a cm = 1 x 10Ao Hence 4000 cm = 4000 x 108 Ao

(iii). 0.94 g/cc in to specific volume. Specific volume cc/gm Inverse of density. Ans: 1.064 cc/g.
(iv) 4.5 g water to mole of water. Mole of water = (Wt of water)/(Mol. Wt of water) = 4.5/18 = 0.25
g/g mol.

15. Calculate the molarity of the solution when 34.2 gram C12H22O11 is dissolved in one litre of
water. (Nov 2010)
Molecular weight of sucrose C12H22O11 = (12*12 +1*22+16*11) = 342
34.2 gm  34.2/342 = 0.1 moles.
Molarity = moles of solute/Litres of solvent = 0.1/1 = 0.1 M

16. A wet paper contains 12% water on a wet basis. Calculate the % of water on a dry basis.
Given 100 Kg of wet sample contains 12 Kg of water.
On dry basis: (100-12) = 88 Kgs of dry sample contains 12 Kg of water
 12 
Hence % of water on dry basis =  100  13.64%
 88 
17. Calculate the volume of 50 Kgs of O2 at a pressure of 730 mm Hg and 40oC. (May 2012)
Basis: 50 Kg of CO2
760 mmHg 1 atm
 1 
730 mm Hg  730  0.96
 760 
nCO2=Kg mol of Co2=50/44=1.14 Kg Mol
V = nRT/P=1.14*0.082058 (273+40)/0.96 = 30.5 m3

18. Show that for a mixture of ideal gas mixtures pressure% = mole% = Volume%. (May 2012)
As per ideal gas law for a component in a mixture at constant volume: PaV = naRT (1)
Where Pa is the partial pressure of Component a and na is number of moles of Component a.
Ideal gas law as applicable to the whole mixture PV = nRT (2)
Where P is the total pressure and n is total number of moles. V and T are volume and temperature
applicable to both component and total mixture.
Taking the ratio of (1) /(2)
𝑃𝑎 𝑉 𝑛𝑎 𝑅𝑇 𝑃𝑎 𝑛𝑎 𝑃𝑎
= ; = ; 𝑀𝑢𝑙𝑡𝑖𝑝𝑙𝑦𝑖𝑛𝑔 𝑏𝑜𝑡ℎ 𝑠𝑖𝑑𝑒𝑠 𝑏𝑦 100, 𝑥100
𝑃𝑉 𝑛𝑅𝑇 𝑃 𝑛 𝑃
𝑛𝑎
= 𝑥100; 𝐻𝑒𝑛𝑐𝑒 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒% = 𝑀𝑜𝑙𝑒%
𝑛

As per ideal gas law for a component in a mixture at constant pressure: PVa = naRT (3)
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 Where Va is the partial volume of Component a and na is number of moles of Component a.
Ideal gas law as applicable to the whole mixture PV = nRT (4)
Where V is the total pressure and n is total number of moles. P and T are pressure and temperature
applicable to both component and total mixture.
Taking the ratio of (3) /(4)
𝑃𝑉𝑎 𝑛𝑎 𝑅𝑇 𝑉𝑎 𝑛𝑎 𝑉𝑎
= ; = ; 𝑀𝑢𝑙𝑡𝑖𝑝𝑙𝑦𝑖𝑛𝑔 𝑏𝑜𝑡ℎ 𝑠𝑖𝑑𝑒𝑠 𝑏𝑦 100, 𝑥100
𝑃𝑉 𝑛𝑅𝑇 𝑉 𝑛 𝑉
𝑛𝑎
= 𝑥100; 𝐻𝑒𝑛𝑐𝑒 𝑣𝑜𝑙𝑢𝑚𝑒% = 𝑀𝑜𝑙𝑒%
𝑛

Hence Pressure % = Mole% = Volume%

19. Define partial pressure and vapor pressure. (May 2011)

The partial pressure of a component in a gaseous mixture is defined as the pressure that the
component exerts when it occupies the same volume as that of the mixture at the same temperature
of the mixture.
The vapor pressure of liquid is defined absolute pressure at which the liquid and its vapor are in
equilibrium at a given temperature.

20. What is the weight of 1 litre of methane at NTP? (May 2010)

At NTP, P = 101.325 kPa; T = 273.15 K n= PV/RT
= (101.325 x 103) (1 x 10-3) /8.314 x 103 (273.15)
= 0.446 x 10-3 Kg moles

Mass of chlorine = (Kg moles) x (molecular weight) = (0.446 x 10-3)(35.5) = 1.58 x 10-3 Kgs.

21. State Dalton’s and Amagat - Leduc’s law (May 2013)

Dalton’s Law: If Pi is the partial pressure exerted by a single component in a mixture with the mole
fraction yi then total pressure
PT = ∑Pi and Pi = PT yi
Av. Molecular Weight = ∑ Mi Yi
Where Mi = Molecular weight of i th component. and Yi = Mole fraction of the i th component.
Amagat-Ludec’s Law: If Vi is the volume of pure component i present in the mixture, total volume
of the gas V is given by,
V = ∑Vi

22. A solution of NaCl in water contains 230 g of NaCl per litre of solution. The density of the
solution is 1.148 g/cc. Find the molality. (April 2010)
Molality is defined as the moles of solute dissolved in one Kg of the solvent.
Density of the solution = 1.148 g/cc; 1 cc  1.148 g; 1000 cc  1 litre  1148 g.
1.148 Kg of solute contains 230 g of NaCl  230/58.5 = 3.93 moles.
Molality moles of solute /Mass of solvent in Kgs = 3.93/(1.148-0.230) = 4.28 M

23. Find the value of gas constant R in ft3 atm/lbmol oR (May 2012)
Normal Temperature = 273.15K; 1K 1.8 oR; 273.15 K = 491.67 oR.
Normal pressure = 1 atm

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  m 3  ft 3  3.28   Kgmol  1 
3

Volume 22.4136  22.4136  3       358.89 ft3/lb mol

 Kgmol  m  1   lbmol  2.205 
R = PV/T = (1 x 358.89)/491.67 = 0.730 ft3 atm/lb mol oR

1. Indicate Recycle, by pass and purging operation in a chemical manufacturing scheme. (Nov
2017)
Recycle: Unconverted sucrose is separated and recycled back to the reactor.

Bypass: In the desalination unit some amount of the feed is bypassed and mixed with the product in
order to regulate the product specification.

Purging: In the manufacture of ammonia a portion of the recycle stream is bled off to reduce the
concentration of argon and other impurities.

2. Define selectivity and yield. (Nov 2017)

The yield of a reaction is the ratio of the desired product formed to the total amount that could have
been made with full conversion and no side reactions occurred.
The selectivity of a reaction is the ratio of the desired product formed to the undesired product
formed.

3. A certain soap contains 50% by weight of moisture on wet basis when it is raw. The moisture
is reduced to 20% before it is pressed into cakes. How many 150 gm cakes can be obtained
form 1 tonne of raw soap. (May 2017)
Soap content in the raw soap = 100 – 50 = 50%
Soap content in the product = 100 – 20 = 80%
By soap balance: Fxf = Pxp ; 1000(0.5) = P (0.8) Hence P = 625 Kg
Number of 150 gm cakes obtained from one tonne of raw soap = 625 x 103/150 = 4166.67

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4. What is Baume gravity scale? (May 2017)
The Baume scale was created by French chemist Antoine Baume for use in marking hydrometers,
which measure the density of liquids. For water and liquids heavier than water, zero degrees Baume
corresponds to a specific density of 1.000 (the density of water at 4 degrees Celsius). For liquids
lighter than water, zero degrees Baume corresponds to the density of a 10% sodium chloride
solution.

5. Define the terms excess and limiting reactants. (Noc 2017 May 2016, May 2015)
Limiting reactant: The component that present in less quantity than its Stoichiometric proportion
with respect to other reacting components is known as limiting reactant.
Excess reactant: The component that is present in excess quantity than its Stoichiometric proportion
with respect to other reacting components is known as excess reactant.

Ex: CH4 + H2O  CO + 3H2

In the reforming reaction of Methane with steam, usually steam that is fed to the reformer is in
excess of the Stoichiometric requirement.

6. What do you mean by purge and by pass?

Purging is the operation in which inert component is (bleed off) taken off from the recycle stream. If
the recycled stream contains the inert material it leads to accumulation of such material, which is not
desirable. The accumulation of inert material may cause decrease in conversion, decrease in yield by
causing the side reactions.

Bypass stream is a stream that skips one or more stages of the process and goes directly to another
downstream stage.

7. How will you differentiate between recycle and bypass? (May 2015)

A recycle stream is one where a portion of the outlet of a process unit is combined with fresh feed
and sent into the same unit again. In a reactive process, there is generally some unreacted feed
material found in the product. In order to reduce cost and increase efficiency, the unreacted material
is often separated and reused in a recycle loop.

Bypass stream is a stream that skips one or more stages of the process and goes directly to another
downstream stage.

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8. In an evaporator a dilute solution of 5% NaOH is concentrated to 50% NaOH. Calculate the
evaporation of water per Kg of feed (NOV 2014)
Assuming a feed of 100 Kgs;
By component Balance: F xf = Pxp; 100 (0.05) = P (0.5); Hence P = 10 Kgs.
By Material balance: F = V + P ; 100 = V + P; Hence P = 90 Kgs.

Evaporation of water per Kg of feed = 90/100 = 0.9 Kg.

9. Classify the material balance problems. (May 2014)

Material balance problems can be classified are classified in two categories:
1. The material balance problems of processes involving no chemical reactions
2. The material balance problems of processes involving chemical reactions.
Further each category is divided into: (i). Steady state operations and (ii). Unsteady state operations.

10. Why recycle is performed in industrial processes? (May 2014)

Recycling operations has the following objectives: (i) To utilize the valuable reactants to their
maximum and avoid wastage (ii) to utilize the heat being lost in the outgoing steam (iii) to improve
the performance of the equipment (iv) to control the operating variables in a reaction and (v) to
improve the selectivity of a product.

11. An evaporator is fed with 10,000 Kgs/hr of a solution containing 1% solute which is
concentrated to 1.5% by wt of solute. Determine the amount of weight of vapor. (May 2012)
By component balance : FXf = PXp  10,000(0.01) = P (0.015) ; P = 6666.67 Kgs/hr.
V= F- P = 10,000 – 666.67 = 3333.33 Kg/hr.

12. Define limiting reactant and degree of completion. (May 2012)

Limiting reactant is one that is available in less quantity than other reactants, as per the
stoichiometric proportions. Degree of completion, the extent to which a reaction progresses.

13. Define purge stream with a simple schematic. (May 2012)

When a process uses a recycle loop, there can often be a buildup of some undesired material within
the system. By using a purge, a fraction of the recycle loop material is removed. This purge fraction
is generally only a few percent of the recycle flow rate. It is done to bring down the concentration of
unwanted substance in a gas mixture by addition of inert gas such as nitrogen or argon in tank and
then venting the mixture to atmosphere.

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14. CO combines with Cl2 in the presence of a catalyst to form phosgene as per the reaction CO(g)
+ Cl2  COCl2(g). After reaction the products contained 12 moles of COCl2, 3 moles of Cl2 and
8 moles of CO. Assuming that the original reactant mixture is free of phosgene, find out the
percentage excess of the excess reactant used. (May 2012)
As per the Stoichiometry, 1 mole of CO reacts with 1 mole of Cl2 to give 1 mole of COCl2.
Hence reaction mixture composition: 20 moles of CO and 15 moles of Cl2.
Excess reactant is CO, and the limiting reactant is Cl2.
% Excess = (18-15/15) x 100 = 20%.

15. Wood containing 40% moisture is dried to 5% moisture. What mass of water in kilograms is
evaporated per kilogram of dry wood? (May 2012)
Water Vapor
Basis: 100 Kg of moist wood.

100 Kg Feed Product 5%

40 % Water
By Overall Material balance: F = V+P; 100 = V + P;
By component balance for water 0.4 (100) = V + 0.05P; Solving these two V = Water evaporated =
36.85 Kg. Mass of water in kilograms evaporated per kilogram of dry wood = 36.85/60 = 0.614.

16. Explain bubble point and dew point with a diagram. (May 2012)

17. Define Reflux ratio and recycle ratio. (May 2012)

Reflux ratio: The ratio of the amount of condensate being refluxed to the amount being withdrawn as
product. Generally, the higher the reflux ratio, the greater is the degree of separation of the
components in a distillation system.
Recycle ratio: In a reactive process, there is generally some unreacted feed material found in the
product. In order to reduce cost and increase efficiency, the unreacted material is often separated and
reused in a recycle loop. Recycle ratio is the ratio of quantity of recycle feed to the quantity of fresh
feed.

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18. 400 Kg of anhydrous salt is separated when 1000 Kg of a salt solution containing 50% salt is
cooled. What is the solubility of the salt at the lower temperature expressed as Kg salt/Kg
water.
Salt balance: Total salt in the feed = 1000(0.5) = 500 Kg
Salt separated = 400. Amount of salt left over in the mother liquor = 100 Kg.
Amount of water in the mother liquor = 500 Kg.
Hence solubility at the lower temperature = 100/500 = 0.2 Kg slat/Kg of water.

19. Define Reactant ratio.

The number of moles of an excess reactant per mole of limiting reactant in the reactor feed.

20. An aqueous solution of soda ash contains 20% Na2CO3 by weight. Express the concentration as
weight % Na2O.
Basis: 100 Kg of Na2CO3 solution.
Soda Ash content=20%=20 kg
H2O Content= 80%=80 Kg
Na2CO3  Na2O + CO2
106 Kg 62 44
20 Kg 20*62/106 20*44/106
=11.6298 =8.302
Na2O content =20*62/106 =11.698 kg
Composition of Na2O =11.698*100/100=11.698%(wt%)

21. Define unsteady state energy balance. (May 2017)

Unsteady state energy balance is the one which includes energy generated, energy consumed, energy
accumulated and energy lost from the system in addition to energy in and out.
Input + Generation - Output – Consumption = Accumulation + Losses

22. Is all continuous process are steady? If not when they will be and how? (May 2017)
No continuous process is stead all the time. Essentially they show unsteady state behaviour during
the starting and stopping of the process. After some time when all the parameters of the system
attains the set level, it shows steady state behaviour.

23. Give the general differential equation for unsteady state material balance.

24. Name any three general processes which are unsteady state by nature.
(i). All the batch processes are unsteady in nature. (ii). All semi continuous or regenerative processes
are unsteady. (iii). Continuous operations or steady state processes during the periods of start up,
shutdown are unsteady in nature.
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25. A country had a population of 10 million people in 1900 AD. Over the period from 1900 to
2000 AD, 4 million people immigrated into the country, 2 million people emigrated from the
country, 5 million people were born in the country and 3 million people died in the country.
Determine the number of people in 2000 AD.
The balance equation:
ACC of people = IN of people – OUT of people + GEN of people – CON of people
in system to system from system in system in system
Accumulation = Final no. of people in system – Initial no.of people in system = unknown = X
Input of people to system = immigration = 4 million people
Output of people from system = emigration = 2 million people
Generation of people in system = born = 5 million people
Consumption of people in system = died = 3 million people
Substitute values into the general balance equation
X = 4 – 2 + 5 – 3 = 4 million people
Final number of people in 2000 AD: Initial no. of people in 1900 + X = 10 + 4 = 14 million people

26. An automobile driven by an internal combustion engine burns 10 kmol of gasoline consisting of
100% octane (C8H18) as per the following reaction.
2C8H18 + 25O2 16 CO2 + 18H2O What is the amount of carbon dioxide discharged to the
atmosphere from 10 kmol octane?
ACC of CO2 = IN of CO2 – OUT of CO2 + GEN of CO2 – CON of CO2
in system to system from system in system in system
Accumulation of CO2 in system = 0 kmol (all CO2 is discharged)
Input of CO2 to system = 0 kmol (zero CO2 enters engine)
Output of CO2 from system = unknown = X kmol
Generation of CO2 in system = (16/2)(consumption of C8H18 in system)= (16/2)(10 kmol)
= 80 kmol (from stoichiometry)
Consumption of CO2 in system = 0 kmol (CO2 is a product, not a reactant)
Substitute values for each term into the general balance equation.
0 = 0 – X + 80 – 0
Solve the balance equation for the unknown “X”. X = 80 kmol CO2 discharged to atmosphere
≡ (80 kmol)(((1)(12.01) + (2)(16.00)) kg/kmol) = 3521 kg CO2

27. A jet engine burns kerosene fuel (C14H30) at the steady rate of 1584 kg/h. The fuel undergoes
complete combustion to CO2 and H2O. Calculate the flow of water vapour in the engine
exhaust stream.
2C14H30 + 43O2 28CO2 + 30H2O Let X = flow of water in engine exhaust. [kmol/h]
Rate ACC = Rate IN – Rate OUT + Rate GEN – Rate CON
Rate ACC = 0 (steady-state) Rate IN = 0 Rate OUT = X
Rate GEN = (15 kmol H2O/kmol C14H30)(1584 kg C14H30/h)/(198 kg C14H30/kmol C14H30)
= 120 kmol/h H2O
Rate CON = 0; 0 = 0 – X + 120 – 0 X = 120 kmol H2
O /h = (120 kmol/h)(18 kg/kmol) = 2160 kg/h H2O

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