ANJALAI AMMAL MAHALINGAM ENGINEERING COLLEGE DEPARTMENT OF CHEMICAL ENGINEERING CH 2254 CHEMICAL PROCESS CALCULATIONS / QUESTION BANK / APRIL

IL 2013
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 1. 2. TWO MARK QUESTIONS Differentiate units and dimensions. Oil has specific gravity of 0.79. Find the density in API and Be. Derive from ideal gas law, Volume % = Mole % = Pressure %. What is the weight of 2 l of methane at standard condition? Find the composition of air in weight percentage. Find the value of R in two different units. Define partial pressure and vapor pressure. State Daltons and Amagats law. Write down the van der Waals equation and explain its terms. What are excess and limiting reactants? Define a tie and inert material. Define conversion and yield. Define the terms purge and recycle. What do you mean by unsteady state material balance. Name some liquid and gaseous fuel. What do you mean by adiabatic flame and adiabatic reaction temperature? Define internal energy. Define Kopps rule. Distinguish exothermic and endothermic reactions Define sensible heat and latent heat. Define Net Calorific Value (NCV) and Gross Calorific value (GCV). Define heat capacity and give is importance. What do you mean by mean specific heat? Define heat of mixing and solution. Define Standard heat of reaction Define Dry Bulb Temperature (DBT). What do you mean by Wet Bulb Temperature (WBT)? Define dew point. Define Adiabatic Saturation Temperature (AST). Define absolute humidity and molal humidity. Define relative humidity. FOUR or SIX MARK QUESTIONS Prove that for univalent compounds molarity is equal to normality. Write down the steps to do material balance. Explain Orsat Analysis of flue gases Write a note on proximate analysis. Write a note on ultimate analysis. Explain Durings line and Cox Chart. Explain Enthalpy Concentration Chart. Write a note on Psychrometric (humidity) chart. Explain the effect of pressure on heat of reaction. Explain the terms CV and CP. How will you calculate heat of reaction, using data? FOUR to SIX MARK QUESTIONS In a double effect evaporator plant, the second effect is maintained under vacuum of 475 torr (mmHg). Find the absolute pressure in kPa, bar, psi A sample of caustic soda flakes contains 74.6% Na2O (by mass). Find the purity of the flakes.

CH 2254 - Chemical Process Calculations/Question Bank 2013/Compiled by R.Arul Kamalakumar

Page 1

3. An aqueous solution contains 19% NH3, 65.6% NH4NO3 and 6% urea by mass. Calculate the available nitrogen content. 4. A solution contains 25 kg of NaCl in 100 kg of water at 65C. The density of the solution is 1.2 kg/L. Find molarity, molality, normality and concentration. 5. Convert, (a) 294 g/L H2SO4 to normality (b) 5N H3PO4 to g/L (3) 3 M K2SO4 to g/L (4)54.75 g/L of HCl to molarity 6. A gas mixture has the following composition by volume. Ethylene 30.6% ; Benzene 24.5% ; Oxygen 1.3% ; Methane 15.5%; Ethane 25.0% ; Nitrogen 3.15. Find (a) Composition by mass, (b) the average molar Mass of the gas mixture and (c) the density of the gas mixture in kg/m3 at NTP. 7. A weight of 1.1 kg CO2 occupies a volume of 0.033 m3 at 300 K. Using van der Waals equation calculate the pressure. Data: For CO2 gas a= 3.60 (m3)2 KPa/(kmol)2 and b= 4.3 x 10-2 m3/kmol. 8. The analysis of magnesite is as follows: MgCO3= 81%; SiO2=14% and H2O=5%. Find the mole composition. 9. A single effect evaporator having a capacity to process one ton of crystal NaOH per day, concentrates caustic soda liquor from 4% to 25%. If the plant is to process a liquor of concentration 5% to 50% and water evaporating capacity is same for both the cases, find the capacity of the plant. 10. Soybean seeds are extracted with n-hexane in batch extractors. The flaked seeds contain 18.8% oil, 69% solids and 12.2% moisture. At the end of the extraction process, the de-oiled cake (DOC) is separated from the nhexane-oil mixture. DOC analysis yields 0.8% oil, 11.5% moistures and rest is solids. Find the percentage recovery of oil. All percentages are in mass. 11. Waste acid from a nitrating process containing 25% HNO3, 55% H2SO4 and 20 % H2O by weight. This is to be concentrated to get fortified acid containing 27% HNO3, 60% H2SO4 and 13 % H2O. This is done by adding concentrated H2SO4 of strength 93% and HNO3 of strength 90% to the waste acid. If 1500 kg of the acid to prepared, calculate the quantities of each acid to be mixed. 12. A tank of weak H2SO4 contains 12.43% acid. If 200 kg of 77.7% H2SO4 are added to the tank and final acid is 18.63%, how many kg of weak acid have been made up? 13. Identify the limiting reactant, excess reactant, percentage excess and degree of completion for the following reactions. C + O2 CO2, Where C and O2 are present in the mole ratio of 4:3. 14. Monochloroacetic acid is manufactured in a reactor at 373 K inn the presence of catalyst. To prevent the formation of dichloroacetic acid excess acetic acid is used. In one day operation 5000 kg/d Monochloroacetic acid is produced requiring 4536 kg/d of chlorine gas. 263 kg/d dichloroacetic acid is also separated in the crystallizer to get almost pure Monochloroacetic acid product. (1) Write the stoichiometric reaction and find the % conversion, % yield of Monochloroacetic acid and selectivity. 15. A crystallizer is charged with 7500 kg of aq. solution at 104.4C, 29.6% weight of which is anhydrous sodium sulfate. The solution is cooled. During the cooling operation 5% of the water originally present is lost. As a result wet crystals of crystallizes out. The mother liquor is found o contain 18.3% by weight of anhydrous salt. Calculate the yield of crystals and the quantity of mother liquor. 16. Lime stone mixed with coke is being burnt in a kiln. An average analysis of the limestone is = 84.5% and rest is inerts. The coke contains 76% carbon, 21% ash and 3% moisture. The calcination of The carbon in the coke is completely burnt to . The coke is fed into the kiln at a rate of 1 kg of coke per 5 kg of limestone. Assume the moisture present is completely vaporized. Calculate the weight percentage of CaO in the products leaving the kiln. 17. CO combines with in presence of suitable catalyst to form phosgene as per the reaction, . After reaction the products contained 12 moles of phosgene, 3 moles of chlorine and 8 moles of carbon monoxide. Calculate (1) The percent excess reactant used and (2) the percent conversion of the limiting reactant. 18. Propane is burnt with excess air to ensure complete combustion. If 55 kg of and 15 kg of CO are obtained when propane is completely burnt with 500 kg air. Determine, (1) The mass of propane burnt (2) The percent excess air (3) The composition of the flue gas. CH 2254 - Chemical Process Calculations/Question Bank 2013/Compiled by R.Arul Kamalakumar

Page 2

19. For a reaction Fresh Feed A

, the process flow diagram is shown in figure. (1) (2) Reactor Separator Recycle (3) Purge

The fresh feed A contains 0.5% inerts by volume. 60% conversion of A per pass is obtained. The concentration of inerts going to the reactor at point 1 must be held at 2% by volume. Assume all streams are ideal gases and at steady state. Calculate, (1) How many moles need to be recycled per mole of total feed to the reactor at point 1, (2) how many moles need to be purged and (3) What is overall conversion. 20. A fuel oil containing 72% carbon by weight the remaining is combustible hydrogen and moisture is burnt with excess air. The flue gas analyzed 9% CO and 3% and the remaining is . Determine the following: (1) Percentage excess air, (2) C:H ratio (3) ratio of carbon to total hydrogen on wt basis (4) The percentage of hydrogen to moisture (5) The mass of moisture present in the flue gas to per kg of oil burnt. 21. A gas produced in the Deacon process enters the absorption tower at 740 mm Hg and 24C. The partial pressure of is 59 mm Hg and remainder being inert gas. The gas leaves at 27C and 743 mm Hg, with having a partial pressure of 0.5 mm Hg. Calculate, (1) Volume of gas leaving per 100 lit entering (2) weight of absorbed. 22. 5000 kg of KCl are present in a saturated solution at 80C. The solution is cooled to 20C in an open tank. The solubility of KCl at 80C and 20C are 55 and 35 parts per 100 parts of water. Assume 30% of water by weight is lost, calculate the quantity of crystals obtained and calculate the yield of crystals neglecting the loss of water by evaporation. KCl crystallizes without any water hydration. 23. Calculate the total pressure and the composition of the vapor in contact with a solution at 100C containing 35% (Benzene), 40% (Toluene) and 25% (Xylene). At 100C the vapor pressure are 1340, 360 and 210 mm Hg. respectively (all composition in Wt%) 24. One mole of of undergoes complete combustion with stoichiometric amount of air. Both reactants and products are in gas phase. Calculate the mole fraction of water vapor produced. 25. A distillation column has a capacity of processing 200 kmols/hr of feed containing dilute (10% mole) and rest is water. The overhead and bottom product contains 89% and 0.3% (mole) of . The bottom product is wasted. Calculate quantity of alcohol wasted per day. 26. A wet solid is dried in a drier using air. The fresh wet solid containing 70% water is mixed with recycled dried solid To reduce the water content to 50% before being admitted to the drier where it is brought into contact with air initially containing 0.25% water and leaves with 5% by weight. The solids leaving the drier, contains 20% water by weight. A portion of this solid is recycled. For 1000 kg/hr of wet solid as fresh feed determine: (1) The amount of solid recycled, (2) The circulation rate of dry air. 27. A coal containing 87% carbon and 7% hydrogen by weight is burnt with 40% excess air. Calculate: (1) kg of air supplied per kg of coal burnt (2) Composition of flue gas on weight basis assuming complete combustion. 28. is manufactured by treating Dolomite with 94% . The ore containing and the rest silica. The reaction is as follows:

Find: (1) produced (2) acid required per ton of ore (3) Composition by weight. (All composition by weight) 29. Methanol is produced by the reaction of CO with H2 as Only 15% of CO entering the reactor is converted to methanol and recovered. The un-reacted CO and H2 are recycled back o the reactor. CH 2254 - Chemical Process Calculations/Question Bank 2013/Compiled by R.Arul Kamalakumar Page 3

The feed will contain H2 and CO in the mole ratio of 2:1. For 3200 kg/hr of methanol produced calculate: (1) The amount of fresh feed in kmol/h (2) The amount of recycle gas in kmol/hr. 30. Refinery oil contains 88% C, 12% H2. Its GCV at 25 C is 45000 kJ/kg oil. Calculate its lower heating value. If the latent heat of water vapor is 2442.5 kJ/kg. 31. A flue gas has the following composition by volume. CO2 = 10.2%, O2 = 8.3%, N2 = 81.5%. Calculate: (1) The percentage excess air used (2) Composition of the fuel oil and (3) m3 of air supplied per kg of fuel. 32. A chimney gas has the following composition by mole%. 11.4 % CO2, 4.4% O2 and 84.4% N2. Assuming complete combustion Calculate the percent excess air used and C:H ratio of the fuel. 33. A coal has the following ultimate analysis by mass. C = 50.22%, H2 = 2.79%, S = 0.37%, N2 = 2.05%, Ash = 19.53%, O2 = 18.04% and moisture = 7% and combusted with 100% excess air. Calculate: Theoretical O2 required per kg of fuel (2) Theoretical dry air required per kg of fuel (3) The wet and dry basis analysis of the flue gas per 100 kg of coal is combusted completely with 100% excess air. 34. A catalytic reactor is used to produce HCHO from CH3OH. A single pass conversion of 70% is achieved in the reactor. The methanol is separated and recycled. Calculate the quantity of CH3OH feed rate in kmol/hr to have a product (HCHO) at a rate of 500 kg hr. 35. A solution contacting 55% benzene (C6H6), 28% toluene (C6H5CH3) and 17% xylene (C6H4(CH3)2 by weight is in contact with its vapor at 373 K. Calculate the total pressure and molar composition of the liquid and vapor. Data: Vapor pressure at 373 K, for, Benzene=178.6 KPa, Toluene=74.6 KPa, Xylene=28 KPa 36. A mixture of acetone vapor and nitrogen contains 14.8% acetone by volume. Vapor pressure of acetone at 293 K is 24.638 kPa. Calculate the following at 293 k and at a pressure of 99.33 kPa. a. Partial pressure of acetone b. Moles of acetone pr mole of nitrogen c. Relative saturation of mixture at 293 K d. Percentage saturation of the mixture at 293 k. 37. Calculate the theoretical flame temperature of a gas containing 22% CO and remaining N2 when burnt with 100% excess air. Both air and gas are at 25C initially. The standard heat of combustion of CO(g) is 67.64 Kcal/gmol at 1 atm and 25C. The mean molal heat capacities in cal/gmolK in temperature range involved are, CO2 = 11.82, O2 = 7.9 and N2 = 7.5. 38. Calculate the adiabatic flame temperature (theoretical flame temperature) for CO when burned with 100 percent excess air when both the reactants are at 273 K. The heat capacities (J/mol K) may be assumed constants as follows: CO = 29.23; O2 = 34.83; CO2=53.59; N2=33.03. The standard heat of combustion at 298 K is -282.99 kJ/mol 39. Calculate the formation of gaseous ethyl alcohol at 298C using the data, Ff of CO2= -393.51 and of H2O= 285.83 KJ/mol. Heat of combustion of gaseous ethanol at 298C = -1410.09 KJ/mol 40. Heat capacity of SO2= 43.458 + 10.634 X 10-3T 5.945 X 105/T2. Calculate the heat required to raise the temperature of 1 Kgmol of SO2 from 300 K to 1000 K. 41. Calculate the standard heat of reaction of the reaction: CH3OH (l) + 0.5 O2 HCHO (g) + H2O (l) Hf in KJ/mol at 298 K of CH3OH (l) = -239.2, HCHO (g) = -108.6, H2O (l) = -285.83 **********************************************************************************************

CH 2254 - Chemical Process Calculations/Question Bank 2013/Compiled by R.Arul Kamalakumar

Page 4

SAMPLE QUESTION PAPER ANSWER ALL QUESTIONS PART A (10 X 2 = 20) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Find the composition of air by weight percent, if the volume percent is as follows: N2=79%, O2=21%. Define equivalent weight. Differentiate density and specific gravity. State Amagats law. Define the term conversion and yield. Define bypass operation. Define vapor pressure. Define adiabatic flame temperature. State Hesss law. Define sensible heat and latent heat. PART B (5 X16 = 80) 11. a. 20 grams of caustic soda are dissolved to prepare 500 ml of solution. Find the molarity, molality and normality. (8) b. An aqueous solution contains 19% NH3, 65.6% NH4NO3 and 6% urea by mass. Calculate the available nitrogen content. (8) (OR) 12. a. A liquid mixture contains three components A (Mol Wt=72), B (Mol Wt=58) and C (Mol Wt=56), in which the A and B are in mole ratio of 1.5:1. And the weight percent of B is 25%.Calculate the analysis in mole percent and also the average molecular weight of the mixture. (8) b. Cracked gas from oil refinery has the following composition by Volume: CH4 = 45% ; C2H6 = 10% ; C2H4 = 25% ; C3H8 = 12% ; C4H10 = 8%. Calculate. 1. The average molar mass of the gas mixture. 2. The composition by mass 3. The specific gravity of the gas mixture if the density of air is 28.97

(3+3+2)

13. a. The waste acid from a nitrating process contains 23% HNO3; 57% H2SO4 and 20% H2O. This acid is to be concentrated to 27% HNO3, 60% H2SO4 by addition of 93% H2SO4 and 90 % HNO3.Calculate the quantities of the acids to be blended to get the desired mixture. (8) b. A catalytic reactor is used to produce formaldehyde from methanol by the reaction CH3OH HCHO + H2. The conversion rate is 70%. Calculate the required feed rate of methanol in Kmol and Kg per hour to Produce 500 kg/hr of formaldehyde produced and kg of methanol recycled assuming no losses. (4+4) (OR) 14. a. A continuous distillation column treats 200 kmol/hr of a feed containing 10% (mol) of ethyl alcohol and the rest water. The overhead (top) containing 89% (mol) of alcohol and bottom product has 0.3% (mol) alcohol. The top product is sent for further processing and the bottom product is wasted. Calculate the quantity of alcohol in kg wasted per day. (8) b. A plant makes liquid CO2, by treating dolomite with commercial sulfuric acid. The dolomite analysis yields CaCO3= 68%, MgCO3= 30% and SiO2= 2%. The acid used is 94% H2SO4 and 6% H2O. The reactions are, CaCo3 + H2SO4 CO2 + CaSO4 + H2O MgCo3 + H2SO4 CO2 + MgSO4 + H2O Calculate: 1. CO2 produced in kg per ton of dolomite treated. 2. Kg of commercial acid required pr ton of dolomite. (4+4) 15. a. Refinery oil contains 88% C, 12% H. Its GCV at 25 C is 45000 kJ / kg of oil. Calculate its lower CH 2254 - Chemical Process Calculations/Question Bank 2013/Compiled by R.Arul Kamalakumar Page 5

heating value. if the latent heat of water vapor is 2442.5 kJ/kg. Calculate the latent heat of water vapor at 25C in this problem. (3+3) b. A natural gas has the following composition on mole basis: CH4 = 84%, C2H6 = 13%, N2 = 3% Calculate: 1. The heat to be added to heat 2 kmol of gas mixture from 38C to 260C 2. The heat required to heat 200 kg of natural gas from 38C to 260C Data: Component CH4 C2H6 N2 Cpm (38-25C) 8.610 12.784 6.958 Cpm (260-25C) 9.979 16.121 7.012

(10)

(OR) 16. a. A stream flowing at a rate of 250 gmole / min contains 25% by mole of nitrogen and rest is hydrogen, is to be heated from 25C to 200C. Calculate the heat that must b transferred using Cp data. (8) Data: for Cp = a + bT + cT2 Component a b X 103 C X106 H2 6.946 -0.196 0.4757 N2 6.457 1.389 -0.069 b. For the equation, C2H4 (g) + 3 O2 (g) 2 CO2 (g) + 2 H2O (g), Calculate the heat of formation of ethylene gas. Data: f of CO2 = 394 kJ/mol ; f of H2O = 242 kJ/mol ; c of CH4 = 1323 kJ/mol (4) c. Calculate the formation of gaseous ethyl alcohol at 298C using the data, Ff of CO2= -393.51 and of H2O= -285.83 KJ/mol. Heat of combustion of gaseous ethanol at 298C = -1410.09 KJ/mol (4) 17. a. A solution contacting 55% benzene (C6H6), 28% toluene (C6H5CH3) and 17% Xylene (C6H4(CH3)2 by weight is in contact with its vapor at 373 K. Calculate the total pressure and molar composition of the liquid and vapor. (3+3) Data: Vapor pressure at 373 K, for, Benzene=178.6 KPa, Toluene=74.6 KPa, Xylene=28 KPa b. A crystallizer is charged with 7500 kg of aqueous solution of sodium sulphate at 373 K containing 30% by weight of salt. The solution is cooled to 293 K. 5% of the original water is lost due to evaporation. Na2SO410H2O (Gluber salt) crystallizes out. The solubility is 19.4 kg of Na2SO4 in 100 kg water at 293 K. Calculate: 1. The quantity of water lost by evaporation (3+4+3) 2. The quantity of crystals formed 3. The quantity of mother liquor leaving (OR) 18. a. The dry bulb and wet bulb temperatures on a particular day was recorded as 35C and 26C respectively. Using the psychrometric chart, find (6) 1. The absolute humidity 2. Percent relative humidity 3. Dew point b. A mixture of acetone vapor and nitrogen contains 14.8% acetone by volume. Vapor pressure of acetone at 293 K is 24.638 kPa. Calculate the following at 293 k and at a pressure of 99.33 kPa. (10) 1. Partial pressure of acetone 2. Moles of acetone pr mole of nitrogen 3. Relative saturation of mixture at 293 K 4. Percentage saturation of the mixture at 293 k. 19. a. A furnace is fired with fuel oil. The Orsat analysis of the flue gas indicated 10.6% CO2,6% O2 and rest is N2 by volume. Find C : H ratio in fuel oil assuming that fuel oil does not contain nitrogen. (6) b. 100 kg of coal containing 75% C, 4.4% H2,8.5% O2, 1.2% S, 1.4% N2 and 9.5% ash on mass basis is burnt with 20% excess air to ensure complete combustion. Assuming complete combustion and all the CH 2254 - Chemical Process Calculations/Question Bank 2013/Compiled by R.Arul Kamalakumar Page 6

sulfur is converted to SO2. Calculate: (3+3+4) 1. Theoretical quantity of air required 2. Actual quantity of air supplied 3. Analysis of the flue gas on dry basis. (OR) 20. a. The analysis of flue gas from a boiler house chimney gives: 10% CO2, 3.8%O2 and 86% N2 by volume on dry basis. Assuming that complete combustion has taken place, 1. Percent excess air 2. C:H ratio (8) b. Calculate the adiabatic flame temperature (theoretical flame temperature) for CO when burned with 100 percent excess air when both the reactants are at 273 K. The heat capacities (J/mol K) may be assumed constants as follows: (8) CO = 29.23 ; O2 = 34.83; CO2=53.59; N2=33.03. The standard heat of combustion at 298 K is -282.99 kJ/mol

CH 2254 - Chemical Process Calculations/Question Bank 2013/Compiled by R.Arul Kamalakumar

Page 7