Course Code & Name BEP2043 Mass Balance

Semester May – Aug 2023

Group Members (G1) Arriana Paulina Peter 1002162633
Sarmena Nair A/P Mahendra 1002266664
Ng Yoke Ling 1002162856
Tasmea Sultana 1002265865
Instructor/ Lecturer Asst. Prof. Ts. Dr. Chung Ying Tao
Submission Date 6th Aug 2023

Instruction:

This question paper consists of 3 pages inclusive cover page and marking rubric. Answer all
questions and present it in PDF format.

1. The report should be presented in the form of technical report.

2. A cover page of report is needed and must include the following information (i.e., Course
Code & Name, Student Name & ID, Year & Semester, etc.)

3. A short introduction (i.e., selection of unit operations) and conclusion is needed for this
project.

4. Present all calculations and results in the form of technical report with basic formatting and
specifications with consistency throughout the entire report.

5. The evaluation is based on the criteria stated in marking rubric and the accuracy of
calculations, analysis, conclusion, and the overall presentation of the report.
6. Submission is to be done via CN portal before 6th Aug 2023, 11.59pm.

Warning:

No marks will be awarded if the solutions are found copied or plagiarized from other sources.
Late submission will not be entertained and marked as zero.

CLO Marks Scores

3 45
4 55
Total marks 100
Percentage 30%
Question

Methanol is a common raw material in the manufacture of formaldehyde, acetic acid and a
few other important chemicals. As a chemical engineer, you are required to design a process
producing 80 kg/h methanol at an optimal conversion rate of 80 % in a reaction between
carbon monoxide and hydrogen. As such, a fresh feed stream with 34.5 mole % carbon
monoxide, 62.5 mole % hydrogen and nitrogen gas are fed into a reactor. The products from
the reactor are then undergoing separation process to obtain pure methanol as the final
product.

The methanol can be produced based on the two scenarios of process design below:

Scenario A

The products from the reactor are then separated with 100% efficiency to obtain pure
methanol. No recycle stream is involved.

Scenario B

A recycle stream to recover the raw material is considered in the process design. After the
separation process, a portion of the vapour is recycled back into the feed stream. A purge
stream with purge to recycle ratio of 1:7 is required in this design.

a) Based on the process design in the 2 scenarios, determine the flow rates and
compositions for all components in every stream for Scenario A & Scenario B.
b) Compare the findings obtained with a conclusion on the two process designs.
c) Evaluate the best scenario for the production process and determine the required feed
if the process is to be upscaled to 180 kmole methanol/h.

END OF QUESTION PAPER

 a) Flow diagram:

Scenario A

Conversion rate = 80%

Unconverted = 100% - 80%

= 20% (0.2)

Extend of reaction:

CO(g) + 2H2(g) → CH3OH(g）

ξ = ń4 =（80kg/h）/（32kg/kmol）

= 2.5kmol/h

nCO - ξ = 0.2nCO

(1-0.2) nCO = 2.5

nCO = 3.125kmol/h CO

nH2 - 2 ξ = 0.2 nH2

(1-0.2) nH2 = 2(2.5)

nH2 = 6.25kmol/h H2
(CO : H2)feed = 0.345 : 0.625

= 1 : 1.8116

(CO : H2)stoich = 1: 2

❖ H2 is a limiting reactant.

ń1 = （6.25kmol/h）/（0.625）

= 10kmol/h

For CO:

Consumed: 3.125 x 0.8 = 2.5kmol/h

Unconsumed: (0.345 x 10) - 2.5 = 0.95kmol/h

For H2:

Consumed: 6.25 x 0.8 = 5.0kmol/h

Unconsumed: (0.625 x 10) - 5.0 = 1.25kmol/h

For N2:

Inert: 0.03 x 10 = 0.3kmol/h

ń2 = CH3OH + CO + H2 + N2

= 2.5kmol/h + 0.95kmol/h + 1.25kmol/h + 0.3kmol/h

= 5kmol/h

Finding x, y, z:

0.95 = 5y

y = 0.19kmol CO

1.25 = 5z
z = 0.25kmol H2

5x = 2.5（1）

x = 0.5kmol CH3OH

Finding ń3, a, b

5kmol/h = ń3 +2.5kmol/h

ń3 = 2.5kmol/h

5(0.19) = 2.5a

a = 0.38kmol CO

5(0.25) = 2.5b

b = 0.5kmol H2

Scenario B
 100% pure
0.345kmol CO CH3OH
0.625kmol H2

0.030kmol N2

Conversion rate = 80%

Unconverted = 100% - 80%

= 20% (0.2)

Extend of reaction:

CO(g) + 2H2(g) → CH3OH(g）

ξ = ń5 =（80kg/h）/（32kg/kmol）

= 2.5kmol/h

[n1]

nCO - ξ = 0.2nCO

(1-0.2) nCO = 2.5

nCO = 3.125kmol/h CO

[n2]

nH2 - 2 ξ = 0.2 nH2

(1-0.2) nH2 = 2(2.5)

nH2 = 6.25kmol/h H2

(CO : H2)feed = 3.125: 6.25

= 1: 2; H2 is the limiting reactant

ń1 = （6.25kmol/h）/（0.625）

= 10kmol/h

For CO:

Consumed: 3.125 x 0.8 = 2.5kmol/h

Unconsumed: (0.345 x 10) - 2.5 = 0.95kmol/h

For H2:

Consumed: 6.25 x 0.8 = 5.0kmol/h

Unconsumed: (0.625 x 10) - 5.0 = 1.25kmol/h

For N2: [n3]

Inert: 0.03 x 10 = 0.3kmol/h

ń2 = CH3OH + CO + H2 + N2

= 2.5kmol/h + 0.95kmol/h + 1.25kmol/h + 0.3kmol/h = 5kmol/h

n4= ń5

=2.5kmol/h
As purge separator separates the incoming stream to recycle stream and purge stream, the
ratio of ń3 and ń4= 1:7

ń3 1 1 7
=7; ń4 = 8 ń3
ń4 8

ń4=2.5/8

=0.3125kmol/h

ń3=7(0.3125)

=2.1875kmol/h

0.345 kmol CO

0.625 kmol H2

0.030kmol N2
b) COMPARISON

SCENARIO 1 SCENARIO 2
Recycle stream is not involved Recycle stream is involved
Multiple unit process Purging process
More straight forward and compact Complex

c) Upscaling to 180 kmole methanol/h

scenario 1

Scaling factor = (180kmol/h) / (2.5kmol/h) = 72

Feed stream, n:

(CO): 0.345 x 10 x 72 = 248.4kmol

(H2): 0.625 x 10 x 72 = 450.0kmol

(N2): 0.030 x 10 x 72 = 21.6kmol

scenario 2

180𝑘𝑚𝑜𝑙/ℎ
scaling factor= =72
2.5𝑘𝑚𝑜𝑙/ℎ

feed stream, n:

CO: 0.345x10x72= 248.4kmol

H2 : 0.625x10x72 = 450.0kmol

N2 : 0.030 x10x72= 21.6kmol

In conclusion, scenario B is the most suitable for the production process.