CH33: CHEMICAL PROCESS CALCULATIONS

NUMERICAL PROBLEMS
Conversions
1. Convert to
a 3 weeks to milliseconds
b 554 m4/d-kg to cm4/min-g
c 38.1 ft/sec to mi/h
d 760 mi/h to m/s
e 5.37x103 kJ/min to hp
f 921 kg/m3 to lbm/ft3
g 23 lbm-ft/min2 to kg-m/s2 0.088
2. Consider the equation: 𝐷 = 3 𝑡 – 4, where D is in ft and t in minutes. What are the
units of 3 and 4? Convert the equation into SI system.
20000
3. Consider the equation: 𝑘 = 1.2 × 105 𝑒𝑥𝑝 (− ) where k is in mol/cm3-sec and T in
1.987 𝑇
Kelvin. What are the units of constants in the equation? Convert the equation into
SI system.
4. 20 m3/min of a gas mixture analyzes Methane 10%, propane 30% and rest Nitrogen.
Find the average molecular weight, mass flow rate in kg/s and its composition in
weight percent.
5. How do you express the concentration of sugar solutions and petroleum fractions?
Give the equations used for the same.
6. The average molecular weight of a fuel gas sample is found by an engineer as 30.8
by taking the molecular weight of N2 as 28. Another engineer found the average
molecular weight as 18.74 by taking the molecular weight of N2 as 14. If CO2 and
O2 are the remaining gases in the mixture, then calculate the composition of the
mixture.

7. Atmospheric air contains 79% of N2 and 21% of O2. Calculate

a) Average molecular weight of air.
b) The composition in weight percent.
c) Density of air at 25o C and a total pressure of 685 mm Hg.
8. Estimate the number of foot-balls that can be filled in your room.
9. You are trying to decide which of two bikes to buy. The first one costs INR 45000
and gives a mileage of 45 km/lit. The second one costs INR 75000 but gives a
mileage of 70 km/lit. Estimate how much distance you should have to drive for the
lower fuel consumption of the second bike in to compensate the higher cost of this
bike.
10. A waste treatment pond is 50 m long, 15 m wide and 2 m depth. The density of the
weight is 85.3 lbm/ft3. Calculate the weight of the pond contents in lbf.
11. A solution of NaCl in water contains 230 g of NaCl per liter at 20 OC. The specific
gravity of the solution at this temperature is 1.148. Find the composition in
weight%, mole%, atomic %, molarity and weight ratio of NaCl to water. [ Answer:
Molarity = 3.93M, Weight ratio = 0.252]
12. A benzene solution of Anthracene (M.W. = 178) contains 10% by weight of the
solution. Find the composition in terms of molality and mole fractions. [Answer:
Molal 0.624 k-mole /kg, xbenzene = 0.954]

13. Calculate weight of NaCl that should be placed in a 1-liter volumetric flask to prepare
a solution of 1.8 molal concentrations. Density of the solution is 1.06 g/cc.
14. A compound (M.W. = 103] analyses C: 81.5%, H: 4.9%, N: 13.6%. Find its
empirical formula. [Answer: C7H5N]
15. The average molecular weight of a fuel gas sample is found by an engineer as 30.8
by taking the molecular weight of N2 as 28. Another engineer found the average
molecular weight as 18.74 by taking the molecular weight of N2 as 14. If CO2 and
O2 are the remaining gases in the mixture, then calculate the composition of the
mixture. [Answer: 81%, 11% and 8%]
16. 2.5 m3/min of a gas mixture flows through an equipment and analyses: Methane
10%, Ethane 30% and rest Nitrogen. Find the average molecular weight, mass flow
rate in kg/s and its composition in weight percent. [Answer: 11.8/mole, 1.84 kg/min]

17. The heat transfer equation is given by:

16.6𝐶𝑃 𝐺 0.8
ℎ=
𝐷0.2
Convert CP, heat capacity, Btu/lb0F to kCal/kg 0C
D, Diameter of pipe, inch to m
G, Mass velocity, lb/ft2 s tokg/m2 s
h, heat transfer co efficient, Btu/hr ft 2 0F to kCal/m2hrR
𝐵𝑡𝑢
18. Stainless steel has a thermal conductivity k of 16.2 (ℎ𝑟)(𝑓𝑡)(℉)
. Convert this value of
𝑔−𝑐𝑎𝑙
into (𝑆𝑒𝑐)(𝐶𝑚)(℃)

19. 500 lbm of N2 is to be charged into a small cylinder at 25 0C and a pressure such that
its density becomes 11.5 kg/m3, estimate the required cylinder volume without using
a calculator. Show your calculations.
20. Find the volume of 25 kg of Chlorine and 100 kg of Hydrogen at standard conditions.
[Answer: 7.9 and 1120.7 m3]
21. It is desired to compress 30 lb of CO2 to a volume of 20 ft3 at 30 OC. Find the
pressure of gas stored. [Answer: 30 atm]
22. Calculate the maximum temperature to which 10 kg of nitrogen gas enclosed in a
2.2 m3 chamber may be heated without exceeding a pressure of 7 atm.

23. Calculate the density at 29” in Hg pressure and 30 OC of mixture containing 21%
oxygen and rest nitrogen. [Answer: kg/m3]
24. A 35 m3 of a mixture contains Hydrogen, Nitrogen and Carbon dioxide at 250 OF.
The partial pressures of the gasses are 0.26, 0.32 and 1.31 atm respectively.
Assuming the mixture behaves ideally calculate the following:
a) K-mole of hydrogen present
b) Mole fractions of hydrogen and nitrogen
c) Pressure fraction of carbon dioxide
d) Partial volumes of nitrogen and hydrogen
e) Volume fraction of CO2
f) Weight of CO2
g) Average molecular weight
h) Composition of the mixture by weight
i) Density of the mixture at STP and also at given conditions
25. A gas contains 81.8% of carbon and 18.2% hydrogen by weight. If 369 ml of the
gas at 22 OC and 748 mm Hg weighs 0.66 g, the find the formula of the gas.
26. Prove Dalton’s law and Amagot’s law.
27. Convert 340 mm Hg pressure to inch of water and kilo Pascal
28. The thermal conductivity of aluminium is 1.75 W/m.K 117 Find the value of thermal
conductivity in Btu/hr.ft.°F.
29. Atmospheric air contains 79% N2 and 21% O2. Calculate
a) Average molecular weight.
b) Find the composition in mass%.
c) Calculate the density of air at 30 oC and total pressure of 705 mm Hg.
30. Find the equivalent of 35 psi in inches of mercury
31. The thermal conductivity of aluminium is 117 Btu/ hr ft °F. Find the value of thermal
conductivity in w/m.°C
32. The value of heat transfer coefficient is given as 396 Btu/hrft 2°F. What is its value in
kcal/m2hr°C
33. Find the Btu equivalent of kWh
34. Explain the Psychometric Chart.
35. The mass velocity of a fluid is 5 kg/m2s. Convert this to lb/ft2min
36. A solution of NaCl in H2O contains 250g of NaCl for 1lt at 20oC. The specific gravity
of solution is 1.25. find composition in Wt%, mol%, Normality, Molarity and Molality.
37. The heat transfer coefficient is given by the correlation
 𝐶𝑃 𝐺 0.8 16.6𝐶𝑃 𝐺 0.8
ℎ= =
𝐷0.2 𝐷0.2
where
Cp - the heat capacity, Btu/ lb.°F,
D - internal diameter of pipe, inch,
G - mass velocity, lb/ft2.s,
h - heat transfer coefficient, Btu/hr.ft2.°F
′ 𝐶𝑃′ 𝐺 ′0.8
If the equation is written in the new unit system as ℎ′ = ;
𝐷 ′0.2
Where Cp’ is the heat capacity, kcal/kg.°C
D’- internal diameter of pipe, cm
G’ -mass velocity, kg/m2 s
h’ -heat transfer coefficient, kcal/hr.m2.°C. find the value of the constant
38. The conductance of a fluid flow system is computed from the relation

𝑇
𝐶 = 89.2 𝐴 √
𝑀

ft3/s where A is the area of opening, ft2 T- the temperature, R, M is the molecular
weight. Convert the empirical equation in to SI units
39. The heat capacity equation for nitrogen as a function of temperature is as follows
Cp = 6.339 + 10.14 × 10−3 TK − 3.415 × 10−6 TK2
where Cp is the heat capacity, cal/g-mole K and TK is the temperature in Kelvin. It is
desired to transform the equation in to a new form where CP’ is the heat capacity in
Btu/lb.°F and temperature tF is in Fahrenheit scale. Find the equation suitable for
new system of units.
40. The heat capacity equation for carbon dioxide is as follows
Cp = 6.339 + 10.14 × 10−3 TK − 3.415 × 10−6 TK2
where Cp is the heat capacity, cal/g-mole.K and TK is the temperature in degree
Kelvin. It is desired to transform the equation in to a new form where CP’ is the heat
capacity in Btu/lb.°F and temperature tF is in Fahrenheit scale. Write the new
equation.
41. The vapour pressure of water P in units of mm Hg is given as a function of
temperature T, °C by the following equation
logP = 7.96681-1668.21/ T+228. Convert this equation to get vapour pressure in
bar as a function of temperature, K
42. An empirical equation for calculating the heat transfer coefficient is given by the
empirical relation
0.023𝐺 0.8 𝑘 0.67𝐶𝑝0.33
ℎ=
𝐷0.2 𝜇0.47
Where h, G, k, Cp , D,  are measured as
h - heat transfer coefficient, Btu/(hr.ft 2.F)
G - mass velocity of the liquid, lb/(hr.ft 2)
k - thermal conductivity of the liquid, Btu/(hr.ft.F)
Cp - heat capacity of the liquid, Btu/(lb.F)
 - Viscosity of the liquid, lb/(ft.hr)
D - diameter of the pipe, ft
Convert this empirical equation to SI system.
43. The density of a fluid is given by the empirical equation where is density (lbm/ft 3)
and p is pressure (lbf/in2).
−7
𝜌 = 70.5𝑒 8.27×10 𝑃
a) What are the units of 70.5 and 8.27×10-7?
b) Calculate the density in g/cm3 for a pressure of 9×106 N/m2
c) Derive a formula for (g/cm3) as a function of P (N/m2).
44. In the manufacture of HNO3, initially NH3 and air are mixed at 7 atmg and 650 °C.
The composition of gas mixture in volume% is as follows N2-70.5%, O2-18.8%, H2O-
1.2%, NH3-9.5%. Find the average molecular weight, density and specific gravity of
gas mixture using ideal gas law.
45. A gas mixture is found to contain the following composition by weight. Ethylene 30
% Benzene 25% oxygen 1.5%, methane 15.5% ethane 25% and the remaining
nitrogen. Find the composition in mole%, average molecular weight and density of
the gas mixture.
46. Lime stone contains 65% CaCO3 and the rest is MgCO3. Calculate
a) Quantities of CaCO3 and MgCO3 in 2 tons of limestone.
b) Find the composition of limestone in terms of mole fraction/percent.
c) What is the average molecular weight of limestone?
d) Find the density of limestone (𝜌𝐶𝑎𝐶𝑂3 = 2720 𝑘𝑔/𝑚3; 𝜌𝑀𝑔𝐶𝑂3 = 2910 𝑘𝑔/𝑚3 ).
47. 2.5 kmol/min of a gas mixture flows through an equipment and analysis: methane
10%, ethane 30% and rest nitrogen. Find the average molecular weight, mass flow
rate in kg/s and its composition in weight percent.

48. An aqueous solution of NaCl is prepared by dissolving 45 kgs of NaCl in 100 kgs of
H2O. Find weight percentage and mole percentage.
49. Calculate the volume occupied by 30 g of Cl 2 at a pressure of 743 mmHg and 30 OC.
50. A gas mixture contains CH4-80%, C2H6-10% and C2H4-10%. What is the average
molecular weight of the mixture? Also find the weight fraction of CH 4 in the mixture?
51. A solution of NaCl in water contains 230 g of NaCl per liter. The specific gravity of
the solution at the prevailing temperature is 1.148. Find the composition in mole%,
molarity and weight ratio of NaCl to water.

52. The relationship between the pressure (P) and volume (V) of the air in a cylinder
during the upstroke of a piston in an air compressor can be expressed PV K = C. where
K and C are constants during a compression test the following data taken. Determine
the values of K and C that best fit the data.
P (mm of Hg) 760 1140 1520 2280 3040 3880
V (cm3) 48.3 37.4 31.3 24.1 20.0 17.4
53. The Arrhenius equation which relates rate of reaction with temperature is as follows:
𝑘 = 𝐴𝑒 −(𝐸 ⁄𝑅𝑇)
Where k = specific reaction rate, sec-1
A = frequency factor, sec-1
e = base of natural logarithms
E = energy of activation, g-cal per g – mole
R = gas constant, g-cal/ (g-mole) (K)
T = absolute temperature, K
A certain chemical reaction, the following data were obtained.
Temperature (o C) 100 110 120 130 140 150
-1
Reaction rate (sec ) 1.055 1.070 9.25 6.94 4.58 3.19
Calculate the constants A and E, using the semi-log graph paper.
54. An aqueous solution of K2CO3 by dissolving 43 kgs of K2CO3 in 100 kgs of H2O at
293k. Find the normality, Molarity and Molality of solution. Density of solution is
1.3kg/lt.

55. Calculate weight of KCl that should be placed in a 1L volumetric flask to prepare a
solution of 1.8 molal concentration. Density of the solution is 1.06 g/cc.
56. Find how many ppm of chlorine are present in a solution containing 2.5% NaCl in
water. Assume the solution to be dilute.
57. A useful dimensionless number called Reynolds number is Dvρ/μ, where D is
diameter, v is the velocity, ρ is the fluid density and μ is viscosity of fluid. Calculate
the Reynolds’s number if D = 2.0 inches, v = 1.0 miles/hr, ρ =1lb/ft3 and μ =
0.14x10-4 lbm/ft-s.
58. It is desired to expand 100 g of CO2 to a volume of 20 m3. Calculate the pressure in
N/m2 that is required at a temperature of 30 OC. Assuming the applicability of ideal
gas law.
59. The relative humidity of a Vapour gas mixture at 40 oC is 65% and 1 atm total
pressure. Calculate composition of vapour gas mixture molal humidity absolute
humidity.

60. Explain briefly about Cox’s chart.

61. Explain briefly how vapor-liquid equilibria can be determined for a miscible binary
liquid solution.
62. Define the following:
a) Relative saturation
b) Molal saturation
c) Absolute saturation
d) Dew point
63. Air is saturated with H2O vapor 93 oC and 1 atm pressure. It is cooled and
compressed. The final condition are 27 oC and 5 atm. Calculate the ratio of initial to
final volume, neglect volume of water condensed.
64. On a sunny day the dry bulb temperature is 35 o C. The partial pressure of water
vapour in the atmospheric air is 26 mm Hg the barometer reads 750 mm Hg.
Calculate absolute, molal, percentage and relative humidities of the air on that day.
65. Air at a temperature of 20OC and 1 bar has a relative humidity of 80%. Calculate:
a) Molal humidity
b) Molal humidity, if the temperature is reduced to 10OC and the pressure is
increased to 2.5 bar condensing some amount of water.
c) Weight of water condensed in part (b) for 100 m3 of original wet air.
d) Final volume of wet air in part (c).
66. A chimney gas has the composition by volume CO2-9.5%, CO-0.2 % O2-9.6% and
N2-80.7%. Using the ideal gas law calculate
a) composition of gas by weight %.
b) volume occupied by 100 kg of gas at 25 °C and atm. pressure.
c) Specific gravity of the gas mixture.
d) density of the gas mixture in kg/m3.
67. State and explain Daltons law and Amagats law.
68. Prove for an ideal gas mixture volume % = mole %= partial pressure %

69. A product gas from a reaction has the composition by weight Cl 2-67%, Br2-28%, O2-
5%. Using ideal gas law, calculate
a) the composition of gas by mole.
b) density of gas mixture in gm/lit at 25 °C.
c) specific gravity of mixture and d. average molecular weight.
70. It is proposed to recover acetone which is used as a solvent in an extraction process
by evaporating in to a stream of nitrogen. The nitrogen enters the evaporator at a
temperature of 30 ⁰C and containing acetone such that its due point is 10 ⁰C. It
leaves at a temperature of 25 ⁰C with a dew point of 20 ⁰C. The barometric pressure
is constant at 750 mm hg.
a) Calculate the vapor concentration of the gases entering and leaving the
evaporator expressed in moles of vapor per mole of vapor free gas.
b) Calculate the moles of acetone evaporated per mole of vapor free gas passing
through the evaporator.
c) Calculate the acetone evaporated per 100 m3 of gases entering the evaporator.
d) Calculate the gases leaving evaporator per 100 m 3 of gases entering the
evaporator. Vapour pressure of acetone = 116 mm Hg at 10 ⁰C and 185 mm
Hg at 20 ⁰C.
71. Air at a temperature of 20 ⁰C and a pressure of 750 mm Hg has a relative humidity
of 80%.
a) Calculate the molal humidity of air.
b) Calculate the molal humidity of this air if the temperature is reduced to 10 ⁰C
and pressure increased to 1800 mm Hg condensing some water.
c) Calculate the weight of water condensed from 100 m3 of original wet air in
cooling and compressing to the conditions of b.
d) Calculate the final volume of wet air for 100 m 3 of original air.
Data: Vapour pressure of water=17.5 mm Hg at 20 ⁰C and 9.2 mm at 10 ⁰C
72. A mixture of methyl acetate vapour and air has a relative saturation of 65% at a
total pressure of 750 mm Hg and 30 OC. Calculate absolute, molal, and percent
saturations. Vapour pressure of methyl acetate at 30 OC is 140 mm Hg.
63. 30 m3 of a mixture of H2, N2 and CO2 at 120o C, the partial Pressure of the three
gases are 0.26, 0.32 and 1.31atm in the order named. Assuming the gas behaver
ideally, find
a) What is the partial volume of H 2?
b) What is weight of H2?
c) What is the average molecular weight of mixture?
73. Wood containing 100% of its own weight of water is dried by means of hot air. The
dew point of entering air is 15OC and of the exit air is 25OC. If 1500 kg of entering
air are forced through the drier per hour, how many kg of water are removed per
hour from leather? Barometer reads 760 mm Hg and vapor pressure of water at 150C
= 12.8 and 250C = 23.8 mm Hg

74. The vapour pressure of an organic liquid (M.W. 78) is calculated from the equation:
2788
𝑙𝑛(𝑃 𝑆𝑎𝑡 ) = 15.9008 −
(𝑇 − 52.36)
Where, PSat is in mm Hg, T in K.
Determine the heat of vaporization of the liquid at its normal boiling point.
75. Pure component vapour pressures of benzene and heptane at 80 OC are 1060 and
426 mm Hg respectively. Assuming Raoult’s law is valid calculate the composition
of vapour and liquid in equilibrium at 760 mm Hg total pressure.
76. The following table gives the vapour pressure data of hexane (A) and heptane (B)
system. Assuming the solution behaves ideally calculate the equilibrium data at a
total pressure of 760 mm Hg. Using the values draw T – x, y diagram. Derive the
equation(s) used.
Temp, OC 69 70 75 80 85 90 95 99.2
A, mm Hg 760 780 915 1060 1225 1405 1577 1765
B, mm Hg 295 302 348 426 498 588 675 760
77. The dry bulb temperature and the wet bulb temperature of an air sample are found
to be 30ᵒC and 20ᵒC respectively. Using humidity chart calculate i) Absolute humidity
ii) absolute molal humidity iii) % relative saturation iv) percentage saturation v)
humid heat vi) Humid volume.
78. The dry bulb temperature and dew point of an air sample are 30C and 18 C
respectively. The air is cooled to 10C. Calculate the amount of water condensed from
200 m3 of original air.
79. Calculate the enthalpy of air with 30ᵒC DBT and 20ᵒC WBT.

80. The dry bulb temperature and the wet bulb temperature of an air sample are found
to be 30 OC and 20 OC respectively. Using humidity chart calculate i) Absolute
humidity ii) absolute molal humidity iii) % relative saturation iv) percentage
saturation.
81. Air is saturate with water at a temperature of 140⁰ F and a pressure of 29.68 mm
Hg. Calculate
a) To what temperature must the air be cooled to separate 68% water from it
keeping the total pressure constant.
b) To what pressure must the air be compressed to separate same amount of
water.
82. Calculate the maximum temperature to which gas enclosed in 2.5m3 chamber
without exceeding a pressure of 8 atm.
83. Suppose the N2 gas was replaced by 10 kgs of air. Calculate partial pressure and
partial volume of O2 and N2 in the mixture.
84. State and explain Ideal gas law and Vanadar walls laws that can explain the
behaviour of ideal gases? Discuss briefly.
85. For ideal gases prove that volume%=mole%=partial pressure%.
86. A mixture of NH3 and air at a pressure of 730 mm Hg under temperature 30 o C
contains 5.1% NH3 by volume. The gas is passed at rate of 100 m 3/ min through an
absorption tower where only NH3 is removed. The gases leave the tower at pressure
of 725 mm Hg and temperature of 20oC and contains 0.05% NH3 by volume using
ideal gas law calculate,
a) rate of flow of gases leaving the tower in m3/min.
b) rate of NH3 absorbed in tower/min.

A mixture of gas analysing 20% methane, 50% Ethane and rest hydrogen by volume
flows through a pipe line of internal dia meter of at the rate of 600 m3/hr at a
temperature of 25oC and a pressure of 5 atmospheres compute
i). Concentration of each copmpnent as kmol/m3.
ii). Density of gas mixture in kg/m3
iii). Mass flow rate in kg/hr
iv). Partial pressure of each component
Mixed Acid Mixed Acid Problems
87. For carrying out nitration reaction, it is desired to have a mixed acid containing 39%
HNO3, 42% H2SO4 and 19% H2O by weight. Nitric acid of 68.3% by weight is readily
available. Calculate a. the required strength of H 2SO4 to obtain the above acid and
b. the weight ratio of nitric acid to sulphuric acid to be mixed.
88. It is required to make 1000 kg of mixed acid containing 60% H 2SO4,32% HNO3 and
8% water by blending a) the spent acid containing 11.3% HNO3, 44.4 % H2SO4and
44.3% H2O b) aqueous 90% HNO3 and c) 20% oleum (80%H2SO4 and 20% SO3). All
percentages are by weight. Calculate the quantities of each of the three acids
required for blending.
89. The waste acid from a nitrating process contains 21% HNO3, 55%H2SO4 and 24%
H2O by weight. This acid is to be concentrated to contain 28% HNO3 and 62%H2SO4
by addition of con. HNO3 containing 10%H2O and concentrated sulphuric acid.
Calculate the waste acid and concentrated acids.
90. It is required to prepare a concentrated acid containing 28% HNO3 and 62%H2SO4
by addition of con. HNO3 containing 10%H2O and concentrated sulphuric acid. A
waste acid mix containing 21% HNO3, 55%H2SO4 and 24% H2O by weight is also
available. Calculate the waste acid and concentrated acids.
91. It is required to make 1000 kg of mixed acid containing 60% H 2SO4, 30% HNO3 and
10% water by blending i) 25% oleum (75% H2SO4 and 25% SO3) ii) aqueous 90%
HNO3 and iii) the spent acid containing 12% HNO3, 45%H2SO4 and 43% H2O. All
percentages are by weight. Calculate the quantities of each of the three acids
required for blending.
92. The spent acid from a nitrating process contains 36% HNO3, 33% H2SO4 and 31%
H2O. This acid is to be strengthened by the addition of concentrated sulphuric acid
containing 95% H2SO4 and concentrated nitric acid containing 78% HNO3. The final
strength of mixed acid should be 43% HNO3 and 40% H2SO4. Calculate the weights
of spent acid, concentrated H2SO4 and concentrated HNO3 solutions to be mixed to
produce 1500 kg of desired acid.
93. A paint mixture containing 25% pigment and the balance water sells for INR180/kg,
and a mixture containing 12% pigment sells for INR100/kg. If a paint retailer
produces a blend containing 17% pigment, for how much (INR/kg) should it be sold
to yield a 10% profit?
94. Discuss and analyze the solution of mixing acids problem used in a nitrating process
Distillation Problems
95. A solution composed of 50% ethanol, 10% methanol and 40% water is fed at the
rate of 100 kg/hr in to a separator that produces one stream at the rate of 60 kg/hr
with composition of 80% ethanol, 15% methanol and 5% water and the second
stream at unknown composition. Calculate the composition of three compounds in
the unknown stream and its flow in kg/hr.
96. Benzene and toluene are to be separated by distillation. The feed contains 43% by
weight benzene. After distillation the overhead product contains 98% benzene by
weight. The bottom product contains 8% of the total benzene fed to the distillation
column. Find the overhead product rate in kg/hr. and toluene composition in bottom
product if the feed rate is 2000 kg/hr.

97. A feed mixture containing 40% benzene, 30% toluene and 30% xylene by weight is
being separated in to three products using two distillation columns. The overhead
product from the first column contains 99.5% benzene and 0.5% toluene. The
bottom product from this column is fed to the second column to separate in to
overhead product containing 97% toluene, 2% toluene and 1% xylene and bottom
product containing 95% xylene and 5% toluene. Calculate the percent recovery of
each feed component in its own product stream. Also determine the composition of
the stream fed to the second column.
98. A mixture of benzene (72 mol%) and the rest toluene is fed to a distillation column,
where it separates into a top product containing 99.5 mol% and bottoms containing
97 mol% toluene. A reflux ratio of 1.8 is used. Calculate the yield of benzene and
toluene.
99. A distillation column separates a feed mixture containing 32% benzene. 48% toluene
and rest is xylene on mole basis into an overhead fraction containing 94% benzene.
5% toluene and rest is xylene and a bottom product of 2% benzene. The reflux ration
is 2.4 on the basis of 1000 kmole of feed per hr. calculate
a) Mass of top product.
b) Recovery of benzene in top product and xylene in the bottom product.
100. P Xylene, styrene, toluene, and benzene are to be separated with the array of
distillation Columns as shown. Calculate the molar flow rates of D1, D2, B1, and B2
and also D and B
Xylene: 0.15 (0.7) = 0.07D1 + 0.18 B1 + 0.15 D2 + 0.24 B2
Styrene: 0.25 (0.7) = 0.04D1 + 0.24 B1 + 0.10 D2 + 0.65 B2
Toluene: 0.40 (0.7) = 0.54D1 + 0.42 B1 + 0.54 D2 + 0.10 B2
Benzene: 0.20 (0.7) = 0.35D1 + 0.16 B1 + 0.21 D2 + 0.01 B2
Solving, D1 = 26.25 k mol, D2 = 8.75 k mol, B1 = 17.5 k mol, B2 = 17.5 kmol
Extraction Problems
101. Ethylene tetrachloride C2Cl4, water H2O and isopropyl alcohol C3H7OH separate in
to two phases in composition ranges. The equilibrium data are given below
C2Cl4 rich layer: C2Cl4-94%, C3H7OH-5.2%, H2O-0.8%
H2O rich layer: C2Cl4-0.9%, C3H7OH -28.1%, H2O-71%
To a 100 kg mixture containing 30% C3H7OH and 70% H2O, 50kg of C2Cl4 is added,
thoroughly mixed and allowed to settle. Calculate the amount of phases formed.
102. A mixture of water and phenol constitutes a mutually soluble two phase system. At
30 °C the phenol rich layer contains 70 weight % phenol and water rich layer
contains 91 weight % water. A mixture is made up of 50 kg phenol and 50 kg water
at 30 °C. Calculate the weight of phenol rich layer and water rich layer after the
system attains equilibrium.
103. Oil from seeds containing 25% oil, 18.0% moisture and rest lignin is extracted with
a solvent. The dried flakes after extraction is found to contain 4.1% oil, 2.5%
moisture and rest lignin. Find the %recovery of oil by the solvent from feed.
104. An aqueous solution of pyridine containing 27 wt% pyridine and 73 % by weight
water is to be extracted with chlorobenzene. The feed and the solvent are mixed
well and allowed to stand for phase separation. The extract phase contains 11%
pyridine, 88.1% chlorobenzene and 0.9% water by weight. The raffinate phase
contains 5% pyridine and 95 % water by weight. Calculate a. the quantities of the
two layers and b. the weight ratio of solvent to feed based on 100 kg of feed.
105. A 100 kg mixture of 27.8% acetone A, 72.2% chloroform B, by weight is to be
extracted with a mixed solvent at 25C. This mixed solvent of unknown composition
is known to contain water S1 and acetic acid S2. The mixture of the original mixture
and mixed solvent is shaken well, allowed to attain equilibrium and separated in to
two layers. The composition of two layers is given below.
Layer A B S1 S2
Upper layer 7.5 3.5 57.4 31.6
Lower layer 20.3 67.3 2.8 9.6
Calculate
a) the quantity of two layers
b) weight ratio of mixed solvent to original mixture
c) Composition of mixed solvent
Solubility and Crystallization
106. A solution of sodium chloride in water is saturated at a temperature of 15 °C.
Calculate the weight of sodium chloride that can be dissolved by 100 kg of this
solution if it is heated to a temperature of 65 °C. Data: Solubility of NaCl at 15
°C=358 kg per 1000 kg water, 65 °C=372.65 kg per 1000 water.
107. A solution of calcium chloride in water contains 62 kg CaCl 2 per 100 kg water.
Calculate the weight of this solution required to dissolve 250 kg of CaCl 2.6H2O at
a temperature of 25 °C. Solubility of CaCl2 at 25 °C=7.38 kg moles CaCl2 per 1000
kg water.
108. A solution of Na2CO3 in water is saturated at a temperature of 10 °C.Calculate the
weight of Na2CO3.10H2O crystals which can be dissolved in 100kg of this solution
at 30 °C. Solubility of Na2CO3 at 10 °C = 10gm per 100gm water, at 30°C=20 gm
per 100 gm water.
109. A solution of NaNO3 in water at 40 °C contains 49% NaNO3. a. Calculate the %
saturation of this solution. Calculate the weight of NaNO 3 that may be crystallized
from 1000 kg of this solution by reducing the temperature to 10°C.Calcultae the %
yield of this process. Solubility of NaNO3 at 40 °C=51.4% by weight, at 10
°C=44.5% by weight.

110. A solution of K2Cr2O7 in water contains 13% K2Cr2O7 by weight. From 1000 kg of
this solution are evaporated 640 kg of water. The remaining solution is cooled to
20 °C. Calculate the amount and the percentage yield of K2Cr2O7 crystals produced.
Solubility of K2Cr2O7 at 20°C=114.66 gm per 1000 gm Water.
111. A solution of FeCl3 in water contains 64.1% FeCl3 by weight. Calculate the yield of
FeCl3.6H2O crystal obtained from 1000 kg of this solution if it were cooled to 27 °C.
The Solubility of FeCl 3 at 27°C = 68.3% by weight.
112. The solubility of Barium nitrate at 100 °C is 34 gm per 100gm water and at 0 °C is
5 gm per 100 gm. water. You start with 100 kg of Ba(NO3)2 and make a saturated
solution in water at 100 °C. How much water is required? If the solution is cooled
to 0 °C, how much of Ba(NO3)2 is precipitated out of solution?
113. One thousand kg of a salt solution containing 30% salt are heated to evaporate a
part of water and then cooled to 20 °C to crystallize the salt. If 60% of dissolved
salt in the original solution is to be crystallized out calculate the weight of water to
be evaporated and the weight of mother liquor left after crystallization. The
solubility of the salt at 20 °C is 36 gm. per 100 gm. of water.
114. 1000 kg of 25% by weight solution of sodium nitrate is concentrated to saturation
by evaporation. The solution is cooled to 20°C. The crystals of sodium nitrate are
removed by filtration. The wet crystals carry 10% by weight mother liquor. This is
dried. The solubility of sodium nitrate is 1.76 kg per kg of water at 100°C and 0.88
kg per kg water at 20 °C. Calculate the amount of water to be evaporated to get a
saturated solution at 100 °C and the total weight of sodium nitrate obtained.

115. 150 Kg saturated solution of AgNO3 at 100 °C is cooled to 20 °C. The crystals are
filtered out. The wet filter cake containing 80% solid crystals and 20% saturated
solution by mass is sent to drier. Calculate the amount of water that must be
removed to get a moisture free product. Also calculate the weight of dry AgNO 3
obtained. Solubility of AgNO3 at 100 °C is 952 gm per 1000 gm of water and at 20
°C is 222 gm per 1000 gm of water.
116. Solubility of silver nitrate (AgNO3) at 100o C is 1.8 kg per 1 kg of water. Calculate
amount of solution that can be prepared using 100kg of silver nitrate.
117. A tank holds 10000 kg of saturated solution of NaHCO 3 at 60 °C. It is required to
crystallize 500 kg NaHCO3 from this solution. To what temperature must the
solution be cooled?
Solubility data:
Temperature, °C 60 50 40 30 20 10
Solubility of NaHCO3 (gm) per
16.4 14.45 12.7 11.1 9.6 8.15
100 gm of H2O

118. 1000 kg of sodium carbonate solution containing 25% Na 2CO3 is subjected to

evaporative cooling, during which 15% of the water present in the solution is
evaporated. Na2CO3.10 H2O crystallize out. How much crystals are produced?
Solubility of Na2CO3. 10 H2O is 21.5 gm per 100 gm H2O.
119. A mixture of CuSO4.5H2O and FeSO4.7H2O weighs 100 g. It is heated in an oven at
110 OC to separate the water of hydration. The weight of the mixture after the
removal of water is 59.78 g. Calculate weight percentage of each component in the
original mixture.
120. A solution of sodium sulfate in water is saturated at a temperature of 40 OC.
Calculate the weight of crystals (Na2SO4.10H2O), formed and percent yield obtained
by cooling 100 kg of this solution to a temperature of 5 OC. Data: The solubility
of salt at 40OC and 5OC are 32.6 and 5.75% Na2SO4 respectively.
121. A tank holds 10000kg of a saturated solution of a Na2 CO3 at 300 C. To what
temperature must the solution be cooled in order to crystallize 3000 kg of Na2
CO3.10 H2O crystals without accompanying water? Solubility data is given below:

Temperature 0C 0 10 20 30

Solubility, gNa2CO3/100gH2O 7 12.5 21.5 38.8

Evaporation-Tie Substance Balance

122. A spent lye sample obtained from a soap making unit contains 9.6% glycerol and
10.3% salt. It is concentrated at a rate of 5000 kg/hr. in an evaporator until the
solution contains 80% glycerol and 6% salt. Calculate the amount of salt
crystallized in the salt box of the evaporator. What is the quantity of water
evaporated?
123. A spent lye sample obtained from a soap making unit contains 9.6% glycerol and
10.3% salt. It is concentrated at a rate of 5000 kg/hr. in an evaporator unit the
solution contains 80% glycerol & 6% salt, 4.5% glycerol is lost by entertainment.
Some salt crystallizers. Find the amount of salt crystallized out in the salt box of
the evaporator.

124. A spent lye sample obtained from a soap making unit is found to contain 9.6%
glycerol and 10.3% salt (NaCl). It is concentrated at a rate of 4000 kg/hr in a
double effect evaporator system until the final solution contains 80% glycerol and
6% salt. Assume that 5% glycerol is lost in entrainment. Calculate the evaporation
taken place in the system and the amount of salt crystallized in the salt box of the
evaporator.

125. The municipal sewage sludge contains 70% water and 30% solids. It is passed
through a drier and the resultant product containing 25% water is sent for
composting. How much water is evaporated/ton of solids handled by the drier?
126. 5 tons/hr of 12% aqueous solution of NaNO3 is concentrated in a triple effect
forward feed evaporator to final concentration of 40%. Assuming equal evaporation
of water in all the three stages, find the concentration of solution leaving each stage
and the rate of water evaporated.
127. A solid contains 15% moisture, it is dried to contain 5% moisture under the sun.
calculate the amount of water evaporated and the final fried product obtained for
1.5 tons of feed. If the amount of water evaporated in the drier is 1 kg/sec then
calculate the capacity of the drier in terms of tones of bone dry solid and per day.

Inert Substance Balance

128. Soybean seeds are extracted with hexane in batch extractors. The flaked seeds
contain 18.6% oil, 69.0% solids and 12.4% moisture. At end of the operation, de-
oiled cake (DOC) is separated from the hexane-oil mixture. DOC analysis yields
0.8% oil, 87.7% solids and 11.5% moisture. Find the percentage recovery of oil.
129. Write general material balance equation. Explain the strategy of solving material
balance equations written for a continuous dryer.
Material Balance with Reaction (General Reactions)
With example explain the Limiting reactant, Excess reactant, Degree of completion,
Yield and Selectivity.
130. Write the step by step procedure for solving the material balance problems.
132. Phenol is produced by the reaction of chlorobenzene with sodium hydroxide
according to the reaction
C6H5Cl + NaOH  C6H5OH + NaCl
In a particular batch operation 1320 kg of chlorobenzene is mixed with 1200 kg of
sodium hydroxide solids to produce 1000 kg of phenol. Determine
a) percentage excess of reactants used
b) yield of phenol obtained
c) amount of salt produced.
133. In the process of manufacturing HCl from common salt and sulphuric acid, the two
reactants are heated in a retort; HCl gas coming out of retort is absorbed in water
to produce 31.5% HCl by weight. Some HCl is lost during absorption. To produce 1
ton of 31.5% HCl, the retort is charged with 550 kg NaCl and 480 kg of 98% H 2SO4.
The reaction goes to completion. Calculate
a) % loss of HCl during absorption
b) quantity and composition of residue left in the retort assuming 50% of water
distils over.
134. A quantity of Barytes containing only pure barium sulphate and infusible matter is
fused with an excess of pure anhydrous soda ash. The analysis of the fusion mass
is as follows. BaSO4-11.3%, Na2SO4-27.7%, Na2CO3-20.35% remaining barium
carbonate and infusible matter. Calculate a) the % composition of the original
Barytes b) % conversion of BaSO4 to carbonate c) Complete analysis of fusion mass
d) Na2CO3 used in excess.

135. Formaldehyde is produced by dehydrogenation of methanol according to the

reaction:
CH3OH ↔ HCHO + H2
Single pass conversion is 67%. The product leaving the reactor is fed to separation
unit where formaldehyde is separated from methanol and hydrogen. The separated
methanol is recycled to the reactor. If the production rate of HCHO is 1000 kg/hr,
Calculate
a) Combined feed ratio
b) Flow rate of methanol in fresh feed.
136. HNO3 is prepared by the oxidation of NH 3.
4𝑁𝐻3 + 5𝑂2 → 4𝑁𝑂 + 6𝐻2 𝑂
2𝑁𝑂 + 𝑂2 → 2𝑁𝑂2
3𝑁𝑂2 + 𝐻2 𝑂 → 2𝐻𝑁𝑂3 + 𝑁𝑂
If only 95% of the amount reacts according to first reaction & combined efficiency
of second & third reaction is 98%. Calculate the amount of NH 3 needed for the
production of 1 tonne of 65% by weight HNO3, also calculate the quantity of water
to be supplied.
137. Identify the limiting reactant, excess reactant and percentage excess for the
reactions:
C + O2  CO2
where C and O2 are present in the mole ratio of 4:3
Ammonia synthesis gas containing N2 & H2 in the mole ratio of 1:4
138. What will be the composition of the gases obtained by burning pure FeS2 with 60%
excess air? Assume that the reaction proceeds according to the following reaction
4FeS2 + 11O2  2Fe2O3 +8SO2
139. In the Decan process for the manufacture of chlorine, a dry mixture of HCl gas and
air is passed over a catalyst, which promotes oxidation of acid. Air is used 30% in
excess of that theoretically required. Calculate a. the weight of air supplied per kg
of acid b. assuming 60% of acid is oxidized in the process, calculate the composition
of the gases leaving by weight from the chamber.
140. In the lablanc deacon process for the manufacturing chlorine, a dry mixture of HCl
and air passed over a catalyst which promotes oxidation od acid. Air is used 25%
in excess of that theoretically requires. Calculate
a) the weight of air supplied per kg of acid.
b) assuming 60% of the acid is oxidized in the process.
c) the composition of gases leaving by weight from the chamber.
141. 10 kg of PbS and 3 kgs of O2 react to yield 6 kgs of Pb and 1 kg of PbO2 according
to the reaction
PbS + O2  Pb+ SO2
PbS+2O2  PbO2+SO2
Calculate
a) the amount of PbS that does not react
b) % excess O2 based on the amount of PbS that actually reacts
c) amounts of SO2 formed
d) % conversion of PbS to Pb.
142. 100 kg of lime stone containing 60% CaCO3, 33.5% MgCO3 and rest inserts is
treated with 12% by weight aqueous sulphuric acid to obtain pure CO 2 gas. An
excess of 15% over the minimum acid required is used to ascertain complete
reaction. Determine
a) the quantity of aqueous acid actually used.
b) quantity of CO2 formed.
c) quantity of residue formed and
d) composition of residue produced.
143. A lime stone analysis calcium carbonate 94.5%, magnesium carbonate 4.25% and
insoluble matter 1.25%.
a) How many kgs of calcium oxide could be obtained from 5 tons of lime stone?
b) How many kgs of CO2 are given per kg of lime stone?
144. Zinc sulphide ore containing 74 % ZnS and 26 % inert is roasted in a burner.
Assume complete combustion of the ore to SO2 with dry air at 27 o C and 750 mm
Hg. The burner is supplied with 55 % excess air. The gases are passed through
V2O5 catalyst bed where 98 % of SO2 gets converted to SO3. The gases from the
converter are passed through an absorption tower where all SO3 is absorbed in the
form of H2SO4 of 90 % strength acid by spraying pure water at the top of the
absorption tower. Calculate
a) the analysis of the burner gases
b) the analysis of the converter gases
c) the volumetric flow rate of air entering the burner in m3 when 1000 kg ore is
burnt per hour.
Atomic weights Zn-65.39, S-32, O-16
Material Balance with Reactions (Combustion Reaction)
145. A furnace is to be designed to burn coke at the rate of 500 kg/hr. The composition
of the coke used in the furnace is C-89%, ash–11%. The efficiency of the grate is
such that only 90% of the carbon charged is burnt 25% excess air is supplied. Of
the carbon burnt only 95% is oxidized to dioxide and 5% goes to carbon monoxide.
Calculate the composition of flue gases from the furnace. Calculate the volumetric
flow of the gases at a temperature of 25 °C and 750 mm Hg pressure for the
purpose of designing the stack.
146. Write briefly on the following:
a) Proximate analysis
b) Ultimate analysis
c) Orsat analysis
147. A furnace uses coke containing 80% carbon, 0.5% hydrogen and rest ash. The
furnace operates with 50% excess air. The ash contains 4% unburned carbon of
the carbon burnt 5% goes to monoxide. Calculate the composition of the flue gases.
What is the quantity of ash produced per 100 kg of coke burned?
148. A producer gas made from coke has the following composition CO-28%, CO2- 3.5%,
O2-0.5 % and the rest N2. The gas is burnt with such a quantity of air that the O2
from air is 25% in excess of that required for combustion. The combustion is 95%
complete. Calculate the composition of the flue gases by volume and by weight for
100 kg of gas burnt. What is the density of the flue gas?
149. A petroleum refinery burns a gas mixture containing C5H12-7.5%, C4H10-10%, C3H8-
15%, C2H6-9%, CH4-55%, N2-3.5% at the rate of 200 m3 measured at 4 bars and
25 °C. The air rate is adjusted to have 20% excess air. The flue gases contain CO 2
and CO in the ratio 20:1. Calculate the volume of air used at 1.5 bars and 30 °C
and composition of flue gases.
150. A petroleum refinery burns a gas mixture containing C5H12 – 7%, C4H10 – 10%,
C3H8 – 16%, C2H6 – 9%, CH4 – 55% and N2 – 3% at 4.5 bars and 30°C. The air
rate is adjusted such that 15% excess air is used and under the conditions. The
ratio of moles of CO2 to CO is 20:1 in the flue gas. Calculate
a) The volumetric flow rate of air (in m3/h at 30°C and 1 bar pressure) per 100
m3/h of entering fuel gas
b) Composition of flue gas on dry basis
151. A coal has the ultimate composition C-67.34%, H2-4.67%, O2-8.47%, N2-1.25%,
S-4.77% and the rest ash. Find the theoretical air fuel ratio. If 20% excess air is
used find the composition of the flue gases leaving.
152. A furnace is to be designed to burn coke at the rate of 500 kg/hr. The composition
of the coke used in the furnace is C-89%, ash –11%. The efficiency of the grate is
such that only 90% of the carbon charged is burnt and 25% excess air is supplied
of the carbon burnt only 95% is oxidized to dioxide and 5% goes to carbon
monoxide. Calculate the composition of flue gases from the furnace. Calculate the
volumetric flow of the gases at a temperature of 250 °C and 750 mm Hg pressure
for the purpose of designing the stack.
153. A furnace uses coke containing 80% carbon, 0.5 % hydrogen and rest ash. The
furnace operates with 50% excess air. The ash contains 4% unburned carbon of
the carbon burnt 5% goes to monoxide. Calculate the composition of the flue gases.
a) Composition of flue gases.
b) The ash produced per kg of coke burnt.
c) Kg of carbon per kg of coke burnt.
d) What is the quantity of ash produced per 100 kg of coke burned?
154. A producer gas made from coke has the following composition CO-28%, CO2-3.5%,
O2-0.5 % and the rest N2. The gas is burnt with such a quantity of air that the O2
from air is 25% in excess of that required for combustion. The combustion is 95%
complete. Calculate the composition of the flue gases by volume and by weight for
100 kg of gas burnt. What is the density of the flue gas?
155. A synthesis gas analyses 40% CO, 20% H 2 and rest N2. It is burned with 50 %
excess air. What is the composition of flue gases? What is the average molecular
weight of flue?

Material Balance with Reaction (Combustion-Orsat

Problems)
156. The gas obtained from the furnace fired with a hydrocarbon fuel analyses 10.2%
CO2, 7.9% O2 and 81.9% N2 on dry basis. Calculate a. the % excess air b. carbon
to hydrogen ratio c. kg of air supplied per kg of fuel burned.
157. A sample of coal is found to contain 65% carbon, 12.7% ash by weight and the
remaining H2 and water vapor. The refuse obtained after burning the fuel is found
to have 8.6% carbon. Assume negligible oxygen is present in the coal. Flue gas
analysis showed CO2-10.6%, O2-8.7% and N2-80.7% by volume. Calculate a.
actual weight of flue gas produced by burning coal b. actual weight of dry air used
for burning the coal c. amount of combustible H2 present in s fuel d. % excess air.
158. A solid fuel with composition by weight of C-78%, H2-6%, O2-9.8%, N2-1.2%, ash-
5% and is burnt in air. The products of combustion give an orsat analysis CO2-
12.5%, CO-0.09%, O2-5.6% and rest N2. The refuse removed from ash pit contains
30% carbon by weight. Find the actual air fuel ratio and % excess air.
159. Wood having the analysis C-46%, O2—23%, ash-5% and rest being moisture and
H2 is burnt in a furnace. The orsat analysis of flue gas obtained is CO 2-14.9%, CO-
1.65%, O2-3.45% and N2-80%. Calculate a. complete analysis of wood used b. fuel
to air ratio by weight c. % excess air used d. complete composition of stack gases.
160. The analysis of the flue gas from a combustion reaction is as follows. CO2 -10.8%,
CO-4%, O2-9.2% and N2-76% by volume. The producer gas burnt had the
composition CO2-9.2%, C2H4-0.4%, CO-20.9%, H2-19.6%, CH4-1.9% and N2-48%
on volume basis. Compute a. m3 of air used in combustion of 1 m3 of producer gas
b. % excess air.

161. A furnace is fired with a fuel oil. The orsat analysis of the flue gases indicated 10.6%
CO2, 2.6% O2 and rest N2 by volume. Find C-H ratio of the fuel assuming that fuel
oil does not contain nitrogen.
162. A coal containing C-67.9% H2-4.4% S-0.8% N2-13.21% O2- 7.9%, ash 4.5%, H2O-
1.29% is burnt in a furnace. The flue gas has CO2-14.5%, O2-4.7% and rest N2.
Calculate a. theoretical volume of air per 100 kg coal. b. % excess air.
163. A combustion chamber is fed with butane and excess Air. The combustion of butane
is complete. The composition of combustion gases by volume is given below.CO2-
9.39%, H2O –11.73%, O2-4.5% and N2-74.38%. Find the % excess air used and
mole ratio of air to butane used
164. The orsat analysis of flue gases is CO2-12.7% O2-7.1%, N2-80.2%. Determine the
% excess air used in the combustion. The N2 present in the flue gas is contributed
by air only.
165. A coal containing C-67.9% H2-4.4% S-0.8% N2-13.21% O2-7.9%, ash-4.5%, H2O-
1.29% is burnt in a furnace. The combustion dry gas has CO2-14.5%, O2-4.7% and
rest N2. Calculate a. theoretical volume of air per 100 kg coal. b.% excess air.
166. The gas obtained from the furnace fired with a hydrocarbon fuel analyses CO2-
10.2%, O2-7.9% and N2-81.9% on dry basis. Calculate a. the % excess air b.
carbon to hydrogen ratio c. kg of air supplied per kg of fuel burned.
167. A sample of coal is found to contain 65% carbon, 12.7% ash by weight and the
remaining H2 and water vapor. The refuse obtained after burning the fuel is found
to have 8.6% carbon. Assume negligible oxygen is present in the coal. Flue gas
analysis showed CO2-10.6%, O2-8.7% and N2-80.7% by volume. Calculate a.
actual weight of flue gas produced by burning coal b. actual weight of dry air used
for burning the coal c. amount of combustible H2 present in s fuel d. % excess air.
168. The orsat analysis of flue gases produced by the combustion of a hydrocarbon in
excess air is CO2-10%, CO-2%, O2-5% and N2-83%. Calculate the % excess air
used in combustion. What are the mole and weight ratio of hydrogen to carbon?
169. A coal having the following analysis 90% carbon, 10% ash is burned with excess
air. The residue removed contains 90% ash and un burnt carbon. The analysis of
the flue gases gave the following result CO2-13%, CO-0.9%, O2- 6% and N2-80.1%.
Determine the excess air used. Volume of flue gases produced per 100 kg of fuel
at 300 ◦C and 780 mm Hg.

Special Problems
170. A natural gas that analyses CH4-80% and N2-20% is burnt and the CO2 scrubbed
out of the resulting products for use in the manufacture of dry ice. The exit gases
from the scrubber analyses O2-6%, N2-94%. Calculate air to gas ratio, % excess
air.
171. One method of producing chlorobenzene is to react benzene, HCl and air and the
following reaction takes place
C6H6 + HCl +1/2O2  C6H5Cl + H2O
After the waste gases from such a process have been scrubbed to remove any
unreacted HCl and benzene and the entire product its composition is N2-88.8%, O2-
11.2%. Determine the number of moles of chlorobenzene produced per mole of air
fed to the reaction.
Bypass and Recycling
172. Fresh orange juice contains 12% solids and balance water. It is concentrated to
contain 42% solids. In the present process the evaporator is by passed with a
fraction of fresh juice. The juice that enters the evaporator is concentrated to 58%
solids and is mixed with bypassed fresh juice to achieve the final desired
concentration. Calculate the amount of concentrated juice produced per 1000 kg of
fresh juice fed to the process and the fraction of the feed that is by passed. Also
calculate the quantity of water evaporated.
173. Fresh orange juice containing 10% of solids and rest water. In order to make a
concentrated juice containing 40% solids part of juice is bypassed through an
evaporator where it is concentrated to contain 80% solids and then mixed with the
bypassed stream. Calculate the fraction of stream bypassed through the
evaporator and the kg of water evaporated per kg of fresh juice.
174. Fresh orange juice containing 45% pulp is prepared from an orange juice containing
15% pulp by evaporated water from a part of juice and making it to 80% pulp and
mixing it with remaining juice. Calculate the amount of water evaporated of final
product of making 1 ton of final juice. Calculate the fraction of juice that bypassed
through the evaporator.
175. It is required to concentrate an aqueous solution to 45%. A fresh feed containing
10% solids is available. In the present process the evaporator is by passed with a
fraction of solution. The solution that entered the evaporator is concentrated to
60% and is mixed with bypassed solution to get the final desired solution. Calculate
the amount of desired product produced per 1000 kg of fresh feed solution fed to
the process and the fraction of the feed that is by passed. Also calculate the quantity
of water evaporated.
176. In a process for concentrating 1000 kg of freshly extracted orange juice containing
15% solids, the juice is strained, yielding 750 kg of strained juice and 250 kg of
pulpy juice. The strained juice is concentrated in a vacuum evaporator to give an
evaporated juice of 60% solids. The 250 kg of pulpy juice is bypassed around the
evaporator and mixed with the evaporated juice in a mixer to improve the flavor.
The final concentrated juice contains 40% solids. Calculate the following. The mass
of the final concentrated juice. The concentration of solids in the strained juice. The
concentration of the solids in the pulpy juice.
177. A process stream contains 4% weight salt and rest water. This is prepared by
passing a part of water stream through a saturator containing the salt. The solution
leaving the saturator contains 20% salt is mixed with the pure water bypassed to
get the process stream. What fraction of pure water available is to be bypassed
through the saturator?
178. Air at 35 °C saturated with water vapor is to be dehumidified. Part of the air is sent
through a unit where it is cooled and some water condensed. The air leaves the
unit saturated at 18 ⁰C. It is then remixed with the air which by passed the unit.
The final air contains 0.01 kg water vapor per kg of dry air. The vapor pressure of
water at 35 ⁰C is 8400 N/m2 and at 18 ⁰C is 1400 N/m2. Calculate
a) the ratio of kg of dry air by passed to kg of dry air sent through the
dehumidifier.
b) Volume of final air on the basis of 1000 m3 of original wet air.
179. The maximum allowable limit of impurities in the effluent from a processing unit is
100 ppm whereas the discharge from the plant contains 500 ppm impurities. To
reduce the level of impurities to the allowable limit, a fraction of the effluent is sent
through a treatment plant which brings down the impurities to 10 ppm and mixing
the treated effluent with the fraction of effluent that is bypassed. Determine the
fraction of the effluent that is bypassed.
180. Desalination of brackish water is achieved by evaporation. A fraction of the feed
water is sent through an evaporator and the other is bypassed. The fraction
bypassed and the pure water leaving the evaporator are mixed together to give the
desalinated water of the desired quality. If the feed water has 400 ppm of salt, and
the salt content in the water used for irrigation is to be limited to a maximum of 50
ppm, what fraction of the feed water is to be sent through the evaporator?
181. Stock containing 1.5 kg water per kg of dry material is to be dried to 0.1kg per kg
of dry material. For each kg of dry material 60 kg of dry air passes through the
dryer. The air leaves at a humidity of 0.05. The fresh air is supplied at a humidity
of 0.015. Calculate the fraction of air recirculated
182. A wet organic pigment containing 35% by weight of CCl4 is to be dried to 5% by
weight wet basis. The drier is to operate adiabatically with fresh and recycled air
entering the drier with 0.43 kg CCl 4 per kg dry air. The air leaves the drier at 0.945
kg CCl4 per kg dry air. The capacity of the drier is 200 kg bone dry solid per hour.
Calculate the ratio of recycle to fresh air.
183. Explain the use of bypass, recycle and purging with an example for each.
184. Methanol is produced by the hydrogenation of CO2. The reactor is fed with a
mixture of CO2 and H2 which contains 2 mol% of inerts. The purge stream contains
4.8 mol% inerts. The fresh feed is supplied at a rate of 480 k mol/h. What is the
flow rate of purge stream?

Recycling with Reaction

185. Consider a chemical reaction A + B  C being carried out in a unit shown in figure
below. The single pass conversion A is 25%. Assume the reactants are present in
stoichiometric proportions in fresh feed. What the amount is of recycled per 100
moles of fresh feed?
186. The reaction A  2B + C takes place in a catalytic reactor as shown in figure. The
reactor effluent is sent to a separator. The overall conversion of A is 95 %. The
product stream from the separator consists of B, C and 0.5% of A entering the
separator, while the recycle stream consists of reminder of the unreacted A and 1
% of B entering the separator. Calculate
a) single pass conversion of A in reactor.
b) mole ratio of recycle to feed.
187. The process schematic of a propane dehydrogenation plant is shown below. It is
desired to setup a simplified version of the material balance for this plant. Assume
the reaction is the dehydrogenation of propane to propylene, no side reactions. The
yield of propylene per pass is 30%. Assume that the amount of carbon formed on
the catalyst is negligible. The product flow rate Stream S2 is 50 k mole per hr.
Calculate the flow rates of all the other streams. Notice that all streams except
stream S2 are pure.
188. Methanol is produced by the reaction of CO with H 2 as CO+ 2H2  CH3OH
Only 15% of the carbon monoxide entering the reactor is converted to methanol.
The methanol formed is condensed and recovered completely. The unreacted CO
and H2 are recycled back to the reactor. The fresh feed will contain H 2 and CO in
the mole ratio 2:1. For 3200 kg/ hr. of methanol produced, calculate k mole/ hr. of
fresh feed, k mole/hr. of recycle gas.
189. In the operation of a synthetic ammonia plant, 1:3 nitrogen hydrogen mixtures are
fed to the converter resulting in 25% ammonia. The ammonia formed is separated
by condensation and the unconverted gases are recycled to the reactor. The initial
nitrogen-hydrogen mixture contains 0.2 parts of argon to 1000 parts of N2-H2
mixture. The toleration limit of argon entering the reactor is assumed to be 5 parts
to 100 parts of N2-H2 by volume. Estimate the fraction of recycle that must be
continually purged.
190. Propane (C3H8) is dehydrogenated to form propylene (C3H6) in a catalytic reactor.
The process is designed for a 95% overall conversion of propane. The reaction
products are separated into two streams; one containing H 2, Propylene and 0.555%
of the propane that leaves the reactor which is taken off as product; the second
stream which contains the balance of the un-reacted C3H8 and 5% of the propylene
in the product stream is recycled to the reactor. Calculate the composition of the
product; recycle ratio and the single pass conversion.
191. The conversion of ethanol on a single pass through the reactor is 25%. The
unreacted ethanol is completely separated from the reaction products and recycled.
a) what is the ratio of recycle stream to the fresh feed stream?
b) what is the composition of the outlet stream from the reactor in mass percent
and mole percent?
Thermochemistry- Energy Balance
192. Explain the effect of pressure on heat of reaction.
193. Calculate the amount of heat produced if 2400 mol/s of CO 2 is produced in the
following reaction: 2𝐶4 𝐻10(𝑔) + 13𝑂2 (𝑔) → 8𝐶𝑂2 + 10𝐻2 𝑂(𝑙)
Data:∆𝐻𝑓,𝐶
0
4 𝐻10
0
(𝑔) = −124.7; ∆𝐻𝑓,𝐶𝑂2
0
(𝑔) = −393.5; ∆𝐻𝑓,𝐻2𝑂
(𝑙) = −241.83 ; 𝑖𝑛 𝑘𝐽/𝑚𝑜𝑙

194. Calculate the heat required to raise the temperature of 42 Kg of CO from 27° to
727°C. Cp for CO is given by ession:𝐶𝑝 = 6.35 + 1.811𝑥10–3 𝑇– 0.267𝑥10–6 𝑇2, where 𝐶𝑝
is in Kcal/k mol-K.
195. Define Standard Heats of Formation, Combustion and Reaction.
196. Calculate the standard heat of reaction of CO + H2O  CO2 + H2, using the heats
of formation for CO, H2O and CO2 as 110.6, 242 and 394 respectively, in KJ/mol.
197. Calculate the heat of reaction at 1073 K. Methanol is synthesized according to the
following reaction
CO + 2H2  CH3OH.
The standard heat of formation at 298 K of CO is -110.6 kJ /mole and of CH3OH is
-238.64 kJ/mole. The specific heats (J/mole K) are
CH3OH: 18.4+100.5 x 10-3T- 28.7 x 10-6T2
CO: 28.1+4.6 x 10-3T-2.8 x 10-6T2
H2: 27.1+3.5 x 10-3T+6.9 x 10-6 T2.
Calculate the standard heat of reaction ΔH298 of the reaction
198. FeS2+11/2 O2  Fe2O3 +4SO2

The standard heats of formation of the compounds are Compound ΔH298, cal
Thermodynamic data
Compound ΔHf, kcal/gmole
FeS2 -42,520
Fe2O3 -1,96,500
SO2 -70,960
Calculate the heat of reaction at 25⁰C for the following reaction
199. Na2CO3 + Fe2O3  Na2OFe2O3 + CO2
Thermodynamic data
Compound ΔHf, kcal/gmole
Na2CO3 -269.8
Fe2O3 -195.2
Na2OFe2O3 -337.3
CO2 -24.05
Calculate the standard heat of reaction Δ H298 of the following reaction
200. C2H5OH + CH3COOH C2H5OOCH3+ H2O
The heats of combustion of the compounds are
Thermodynamic data
Compound ΔHc, cal
C2H5OH -326,700
CH3COOH -208,340
C2H5OOCH3 -538,760
Calculate the heat of reaction of the following reaction
201. CO2 +H2  CO +H2O
The formation reactions are
Compound ΔHf at 298K, kcal
CO2: C+O2  CO2 -94.051
CO: C+1/2 O2  CO -26.416
H2O: H2+1/2O2  H2O -57.798
H2: Since H2 is an element its heat of formation is zero

202. Calculate the heat of formation of CHCl 3. Following equations are available

Chemical Reaction ΔHf at 298K, kJ

CHCl3 +½O2+ H2O  CO2 + 3HCl -509.93

H2+½O2  H2O -296.00

C +O2  CO2 -393.78

½H2 + ½Cl2  HCl -167.50

203. Calculate the heat of reaction at 873K and 1.013 bar for the following reaction
CO2+4H2  CH4+2H2O
The heats of formation of the compounds are
Compound ΔHf at 298K, KJ/g-mole
CO2 - 393.65
H2O -241.90
CH4 -74.89

Specific heat data Joule/ gm mole K

Compound Specific heat, Cp
CO2 Cp = 26.54+42.25x10-3T-14.29x10-6 T2
H2 Cp = 26.89+4.35x10-3T-0.3265x10-6 T2
H2O Cp = 29.18+14.50x10-3T-2.02x10-6 T2
CH4 Cp = 13.41+77.06x10-3T-18.76x10-6 T2

204. Calculate the theoretical flame temperature when CO is burned with 100 % excess
air when both reactants are at 373 K. The standard heat of combustion at 298 K is
-282.99kJ / g-mole CO. The heat capacities (J/g-mole K) are CO-29.2, O2-33.1, N2-
33.59 CO2-53.59.
205. Pure methane is burnt with theoretical amount of air in a reactor. Assuming the
combustion to be complete and adiabatic, determine the exit temperature of flue
gas produced. Both methane and air enter the reactor at standard state. HR =-
8.028x105 kJ/kg mole of CH4.
Mean heat capacities (kJ/k-mole.K) of gases are
CO2 - 51.88, H2O-40.45, O2-34.01, N2-32.21

206. 4.Methane is burnt with 20 % excess air. Both methane and air enter at 298 K.
Determine the theoretical flame temperature. The following data is available.
Standard heat of combustion of methane is -802.6 kJ
Heat capacity in J /g-mole.K varies with temperature given by
Specific heat data Joule/ gm mole K
Compound Specific heat, Cp
CO2 Cp =45.37+08.688x10-3T
H2O Cp =28.85+12.055x10-3T
O2 Cp =30.25+04.206x10-3T
N2 Cp =27.27+04.940x10-3T

207. Calculate the theoretical flame temperature of a gas containing 20% CO and 80 %
N2 when completely burnt with 50% excess air, both air and gas entering the burner
at 25 C. Data: Heat of reactions is 2.765 x105 kJ/k-mole
Cp= a+bT+cT2, kJ/kg mole K
a bx103 cx106
CO2 6.34 10.14 3.15
O2 6.12 0.17 1.00
N2 6.46 1.39 0.04

208. Determine the adiabatic reaction temperature for the combustion of 1kgmole of
methane using 15 k-mole of air. The reactants may be assumed to be at 95⁰C.
Heat of formation data, kJ/k-mole.
The heats of formation of the compounds are
Compound ΔHf at 298K, KJ/g-mole
CO2 - 393.65
H2O -241.90
CH4 -74.89

209. Dry methane is burnt with dry air both being initially at 25 ⁰C, the flame
temperature is 1570K. If complete combustion is assumed how much excess air is
being used?
Data: standard heat of reaction = -801556 J/g-mole.
Mean specific heat of gases between 25 ⁰C and 1570K J/mole.K
CO2-51.79, H2O-40.19, O2-32.40 and N2-32.15
210. Calculate the theoretical flame temperature for a gas containing 25% CO and 75%
N2 when burnt with 100 % excess air when both the reactants are at 298 K. The
standard heat of formation is -393.51 kJ mole for CO2 and -110.6 kJ/ mole for CO.
The mean molar specific heat in J/mole K is

T,K CO2 O2 N2
800 45.43 31.59 30.31
1000 47.56 32.37 30.64
1200 49.35 33.02 31.22
1400 50.82 33.60 31.77
1600 51.99 34.05 32.25
1800 53.18 34.40 32.65
211. State Kopp’s rule. Using this rule calculate specific heat capacity of Ca(OH) 2 and
Na2SiO3.
212. Explain briefly, the method of finding theoretical flame temperature.
213. Define calorific value of a fuel. Distinguish between GCV and NCV.
214. 15000 m3 of a gas contains SO2-10%, O2-12% and N2-78% at standard conditions.
How much heat must be added to raise the temperature of the gas mixture from
30° to 425°C? The molar heat capacity (Cal/kmol-°C) is given by the equation 𝐶𝑃 =
𝑎 + 𝑏 𝑇 and the constants of the equation are:
Component a b x 103
SO2 10.00 11.00
O2 6.96 7.32
N2 6.80 7.72
215. Calculate the theoretical flame temperature for the combustion of methane using
stoichiometric quantity of air.
𝐶𝐻4 + 2𝑂2 → 𝐶𝑂2 + 2𝐻2 𝑂
Heat of Formation and Average CP Data:
Average CP Hf
Component
kcal/kmol kJ/mol
CH4 7.6 -74.89
O2 16.6 -
N2 15.8 -
H2O 15 -241.90
CO2 13 -393.65
216. Calculate the heat of reaction at 500°C for the reaction CO2 + 4H2  2H2O + CH4,
using the data given below: Standard Heat of reaction at 25°C is – 39433 K Cal/K
mol and Enthalpy data is:

Enthalpy in K Cal/K mol

Temp in °C
C CO2 H2O CH4
25 218 172 200 210
500 5340 3499 4254 5730
217. Calculate the theoretical flame temperature of gas containing 20% CO and 80% N2
when burnt with 150% excess air and gas being at 25 oC.

Average CP ∆Hf
Component
J/(g-mole)(K) KJ/(g-mole)
CO2 50.16 -393.137
CO - -10.402
N2 31.56 -
O2 33.02 -

218. Calculate the standard heat of reaction ∆𝐻25 of the following.

CH3Cl (g) + KOH (s) ↔ CH3 OH (l) + KCl (s)
Data:
0 0
(s) = −101,780 cal; ∆Hf,KCl (s) = −104,175 cal;
∆Hf,KOH
0 0
∆Hc,CH3Cl (g) = −182,810; ∆Hc,CH3OH (l) = −173,650; cal
Note:∆𝐻𝑓 = −∆𝐻𝑐′ − 94,051.8𝑎 − 34,158.7𝑏 + 3670𝑐 − 5864.3𝑑 − 44,502𝑒 − 15,213.3𝑔 −
148,852.6𝑖
219. The heat capacity of air is given by CP = a + b T + CT 2 . where a = 6.386, b = 1.762 ×
10−3 and c = −0.266 × 10−6 . Find the mean molal heat capacity in the range from 25 to
250o C. What is the quantity of heat required for 10kmol of air to be heated from 25
to 250 oC.
220. Calculate the theoretical flame temperature of a gas containing 20% CO, and 80%
N2 when burnt with 100% excess air, both air and gas initially being at 25 o C.
Data: ∆𝐻298= -67636 cal/mol.
cal
Cp of CO2 = 6.339 + 10.14 × 10−3 T − 3.415 × 10−6 T 2
g − mole. K
cal
Cp of O2 = 6.117 + 3.167 × 10−3 T − 1.005 × 10−6 T2
g − mole. K
cal
Cp of N2 = 6.457 + 1.389 × 10−3 T − 0.065 × 10−6 T 2
g − mole. K
221. Dry methane is burned with dry air, both are at a temperature of 300K initially, and
the flame temperature is 1570 K. If complete combustion is assumed, how much
excess air is used?
Data: ∆𝐻298 = −0.8028 × 106 J/mol.
Component CO2 (g) 𝑁2 (g) H2 O (l) Air
Cp
51.79 32.15 40.19 32.40
(J/(mole)(K)
222. Calculate the standard heat of reaction ∆𝐻25 of the following.
CaC2 (s) + H2 O (l) ↔ Ca(𝑂𝐻)2 (s) + C2 𝐻2 (g)
Data:
Hf ∆𝐻𝑐′
Component
(cal) (cal)
CaC2 (s) -15,000 -
Ca(𝑂𝐻)2 -235,800 -
C2 𝐻2 (g) - -310,615
H2 O (l) -68,317.4 -
Note:∆𝐻𝑓 = −∆𝐻𝑐′ − 94,051.8𝑎 − 34,158.7𝑏 + 3670𝑐 − 5864.3𝑑 − 44,502𝑒 −
15,213.3𝑔 − 148,852.6𝑖