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Lecture # 9
Chemical Process Calculations

By
Samir R. Kale, Chemical Engg Faculty, BITS, Pilani
BITS Pilani samirr@pilani.bits-pilani.ac.in
Pilani|Dubai|Goa|Hyderabad Mobile No- 09030279063
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Recycle operations
• The recycling operation with chemical reactions is common in industrial
processes.

• This is mainly performed to utilize the valuable reactants to their maximum so

that the loss of the reactants minimized.

• Recycling is returning back a portion of the steam leaving a process unit to the
entrance of the process unit for further processing.
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Recycling operations, commonly encountered in unit operations and unit processes are
performed for:

– Maximum utilization of the valuable reactants.

– Improvement of the performance of the operation.

– Utilization of the heat being lost in the exit stream

– Better operating conditions of system.

– Improvement of the selectivity of a product.Maintaining process rate at a high

value.
– Enrichment of a product.
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• In distillation operations, a part of the distillate is fed back to column to enrich the
product, so that almost pure product can be obtained.

• In drying operations, a major portion of the hot air leaving the dryer is recirculated to
conserve heat-to utilize the heat being lost in the exit air.

• In absorption towers, better wetting of tower packings is done by recycling part of the exit
solvent stream.

• In chemical reactions, exit catalyst or spent catalyst is returned to the reactor for reuse
after being regenerated.

• For achieving complete conversion, keeping the yield of byproduct to minimum and
effecting reactions at a high rate.
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• A Recycle stream is a process stream that returns material leaving a process unit back to
the entrance of the same unit

• Recycle operations are carried out under steady-rate conditions.

• In these operations these is no build-up or material takes place inside the process or in
the recycle stream.
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• About the entire process including the recycle stream –where in the fresh feed is equated with the
net product.

• About the junction point 1 at which the fresh feed combines with the recycle stream.

• About the junction the gross product is divided into recycle and net product.

• Involving only process feed and gross product streams.

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Purging operation
• In this operation, a fraction of the recycle stream is continuously bled-
of order to limit the concentration of inerts to a desired level in the
mixed stream.

• In the synthesis of ammonia, some of the gas stream must be purged to

prevent build of argon and methane.
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• The recycling of air/recirculation of air in the drying of solids is shown diagrammatic.

• In a recycling operation: combined feed=Fresh feed +Recycle feed

• The combined feed is a mixture of the fresh feed and the recycle feed/recycle stock
• Gross product= Recycle feed + Net Product
• The gross product is a mixture of the net product and the recycle feed.
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• Recycle ratio: It is the ratio of the quantity of recycle feed to the quantity of fresh feed.

• Combined feed ratio: It is the ratio of quantity of mixed feed to the quantity of fresh feed.
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• Purge Ratio: It is the of ratio of the quantity of purge stream to the quantity of recycle feed.
• In manufacture of ammonia, built up of CH4 in recycle loop a certain tolerance limit is avoided by
purging.
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Bypassing operation

• In these operations, a fraction of the feed stream to a

process unit is diverted around and combined with
the output.
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Samir R. Kale, Chem Engg Faculty, BITS,

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Work Integrated Learning Program (WILP)

Samir R. Kale, Chem Engg Faculty, BITS,

Pilani (c)
Work Integrated Learning Program (WILP)

Samir R. Kale, Chem Engg Faculty, BITS,

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Pilani (c)
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Samir R. Kale, Chem Engg Faculty, BITS,

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Samir R. Kale, Chem Engg Faculty, BITS,

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Samir R. Kale, Chem Engg Faculty, BITS,

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Samir R. Kale, Chem Engg Faculty, BITS,

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Gases, Vapors, Liquids and Solids

By Property we mean a measurable characteristic of a Substance such as

• Temperature
• Pressure
• Volume

Or a characteristic that can be calculated such as Internal Energy etc.

Why do we require it

Design of Equipment's and unit operations

:

At any given temperature a pure compound can exit as gas , liquid or solid at
certain T and Pressure

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Thus, a compound may consist of one or more phases. A phase is defined as a

completely homogenous and uniform state of matter.

Liquid water would be a phase and ice would be another phase.

Two immiscible liquids in the same container such as mercury and water would
represent two different phases because the liquids, although each are homogenous
Are having different properties

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Ideal Gas Law

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1. The projection to the left onto the p - T plane shows straight lines for constant values of V.
Why? Equation (13.1a) for constant specific volume is p == (constant) T, the equation of a
straight line. A

2. The projection to the right onto the p - V plane shows curves for values of constant T.,., What
kinds of curves are they? For constant T, Equation (3.1a) becomes pV = constant, namely a
hyperbola.

3. The projection downward onto the T - ... V plane again shows straight lines .
Why? for constant p is V = (constant) T. Equation (3.1) can be applied to a pure component or
to a mixture.

What are the conditions for a gas to behave as predicted by the ideal gas law?
The major ones are
1. The molecules of an ideal gas do not occupy any space; they are infinitesimally
small.
2. No attractive forces exist between the molecules so that the molecules move
completely independently of each other.
3. The gas molecules move in random, straight-line motion" and the collisions between
the molecules. and between the molecules and the walls of the container

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The density of a gas is defined as the mass per unit volume and can be
expressed in kilograms per cubic meter, pounds per cubic foot, grams per liter, or
other units. Inasmuch at;; the mass contained in a unit volume varies with the
Temperature and pressure, as we have previously mentioned, you should always
be careful to specify these two conditions in calculating density. If not otherwise
specified, the densities are presumed to be at S.C.

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Dalton's Law summation of each of the partial pressures of the components in a system equals
the total pressure. The other related law (of partial pressures) is that the total pressure times the
mole fraction of a component in a system is the partial pressure of the component.

Density of gas Mass per unit volume expressed in kglm3, Ib/ft3, gIL, or equivalent
units.

Ideal gas constant constant in the ideal gas law (and other equations) denoted by the symbol R.
Ideal gas law Equation relating p. V. n, and T that applies to many gases at low
density (high temperature and/or low pressure).

Partial pressure The pressure that would be exerted by a single component in a mixture if it
existed alone in the same volume as occupied by the mixture and at the temperature of the
mixture.

Specific gravity Ratio of the density of a gas at a temperature and pressure to the
density of a reference gas at some temperature and pressure.

Standard conditions (S.C.) Arbitrarily specified standard states of temperature

and pressure established by custom.

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