ChL 410 Chemlcal Lnglneerlng CalculaLlons 2 Second SemesLer 2011 2012

1

ChL 410
CnLMICAL LNGINLLkING CALCULA1ICNS II
INDUS1kIAL S1CICnICML1k
1extbook and keferences
lndusLrlal SLolchlomeLry
8y Lewls 8adasch Lewls
SLolchlomeLry for Chemlcal Lnglneers
8y Wllllam and !ohnson
lnLroducLory ConcepLs ln Chemlcal Lnglneerlng
8y Wllfredo l !ose
LlemenLary Chemlcal Lnglneerlng
8y eLers
8aslc rlnclples and CalculaLlons ln Chemlcal Lnglneerlng
8y Plmmelblau
SLolchlomeLry of luel CombusLlon and 8elaLed rocess lndusLry
8y Lvelyn LaurlLo

Course Cut||ne

l luels and CombusLlon
Case l CalculaLlons 8ased on luel Analysls
Case ll CalculaLlons 8ased on llue Cas Analysls
Case lll CalculaLlons 8ased on Lhe arLlal Analysls of Lhe llue Cas

ll CombusLlon of Solld luels
klnds of Coal Analysls
Coal CombusLlon wlLh no CombusLlbles ln Lhe 8efuse
Coal CombusLlon wlLh CombusLlbles ln Lhe 8efuse
Lnergy (PeaL) 8alances

lll CxldaLlon of Sulfur and lLs Compounds
8urnlng of 8aw Sulfur
8oasLlng of lron yrlLes
roducLlon of Sulfurlc Acld and Cleum

ChL 410 Chemlcal Lnglneerlng CalculaLlons 2 Second SemesLer 2011 2012

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ULLS AND CCM8US1ICN
1he appllcaLlon of sLolchlomeLrlc prlnclples Lo problems lnvolvlng fuels and combusLlon ls lmporLanL ln
modern lndusLrlal work luel combusLlon consLlLuLes an lmporLanL sLep ln almosL any chemlcal process lndusLry
where heaL generaLlon ls deslred
Combust|on
O Commonly employed lndusLrlal process for heaL generaLlon lL ls Lhe chemlcal reacLlon of a free reactant
(oxygen C
2
|n a|r) and a commonly avallable chemlcal called fue| lL ls accompanled by Lhe evoluLlon of llghL and
heaL Lhus lL ls generally used ln Lhe generaLlon of heaL Lo supply energy Lo Lhe process lndusLrles
ue|
O 1hey are burned Lo generaLe Lhermal energy for lndusLrlal purposes
C|asses of ue|s
1he sLlochlomeLrlc LreaLmenLs of problems lnvolvlng dlfferenL classes of fuels are slmllar ConsequenLly ln
Lhe sLudy of Lhe meLhods for manlpulaLlon of Lhe daLa supplled Lhe acLual form of Lhe fuel ls noL of greaL
lmporLance
A Gaseous ue|s
O lndusLrlal fuels LhaL usually conLaln CC llghL or low molecular welghL hydrocarbons and someLlmes
nlLrogen and oxygen
O Lxamples
1 naLural Cas combusLlble gas LhaL occurs ln porous rocks of Lhe earLh's crusL


MeLhane (CP
4
)
LLhane (C
2
P
6
)
ropane (C
3
P
8
)
8uLane (C
4
P
10
)
CC P
2
n
2

2 Llquefled naLural Cas (LnC) naLural gas ln llquefled form
3 Llquefled eLroleum Cas (LC) can be llquefled under moderaLe pressure aL normal LemperaLure
buL are gaseous under normal aLmospherlc pressure
4 8eformed Cas applled Lo lower Lhermal value gases obLalned by Lhe pyrolysls and sLeam
decomposlLlon of hlgh Lhermal value gases
3 Cll Cases made from Lhermal decomposlLlon of olls
6 roducer Cas generaLed by blasLlng a deep hoL bed of coal or coke conLlnuously wlLh a mlxLure or
alr and sLeam
7 8lue waLer gas a blasL of alr ls forced Lhrough a fuel bed and sLeam ls passed Lhrough formlng blue
waLer gas
8 CarbureLed WaLer Cas waLer gas enrlched wlLh oll
9 8lasL furnace gas a byproducL of Lhe manufacLure of plg lron ln blasL surfaces

8 L|qu|d ue|s
O llghL and heavy olls obLalned ln Lhe reflnlng of peLroleum oll
ChL 410 Chemlcal Lnglneerlng CalculaLlons 2 Second SemesLer 2011 2012

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O Lxamples
1 non eLroleum Llquld luels
a 1ar Sands sLrlp mlned and exLracLed wlLh hoL waLer Lo recover heavy oll
a Cll Shale non porous rocks conLalnlng organlc kerogen exLracLed by pyrolysls afLer mlnlng
2 LlghL Clls sulLable for use wlLh lnLernal combusLlon englnes and [eL englnes
a Alcohols obLalned by synLhesls or fermenLaLlon process ( meLhyl or eLhyl)
b Alcogas mlxLures of meLhyl or eLhyl alcohol and gasollne
c 8enzole obLalned by dlsLlllaLlon of coal Lar or by exLracLlon from coal gas
d Casollne
e araffln
f kerosene

C So||d ue|s
O Lxamples Coal Wood Charcoal
CCMLL1L AND INCCMLL1L CCM8US1ICN
Comp|ete Combust|on
O All combusLlble maLerlals are completely qoslfleJ all carbon C ln Lhe fuel ls burned Lo carbon dloxlde CC
2

and hydrogen P
2
Lo waLer P
2
C
O 8eacLlons
C + C
2
CC
2
+ heaL
P
2
+ Z C
2
P
2
C + heaL
1he compleLe combusLlon of any hydrocarbon ls represenLed by

C
m
P
n
+ (m + n/4 ) C
2
m CC
2
+ (n/2) P
2
C
Incomp|ete Combust|on
O lndlcaLed by Lhe presence of CC and unburned P
2
ln Lhe producL and unburned combusLlbles ln Lhe refuse
(ln solld fuels only) lL represenLs a heaL loss
O 8eacLlon
C + Z C2 CC + heaL
|ue Gas
O Lerm used for Lhe gaseous producLs of combusLlon
1nLCkL1ICAL AND LkCLSS CkGLN
1heoret|ca| Cxygen alr C
2
requlred for compleLe combusLlon
Methods of Determ|n|ng 1heoret|ca| Cxygen
,etboJ l 1he balance equaLlon for compleLe combusLlon ls wrlLLen and Lhe LheoreLlcal C
2
ls Lhe sum of all oxygen
consumed for compleLe combusLlon of Lhe fuel
ChL 410 Chemlcal Lnglneerlng CalculaLlons 2 Second SemesLer 2011 2012

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1heoreLlcal C
2
LoLal oxygen requlred (MeLhod l) C
2
free ln Lhe fuel
,etboJ ll 1he componenLs of Lhe fuel are broken down lnLo lLs correspondlng aLoms of carbon sulfur and moles
of oxygen Cne C aLom needs 1 mole of C
2
one S aLom needs 1 mole of C
2
one P aLom needs x mole
of C
2

1heoreLlcal C
2
LoLal oxygen requlred (MeLhod ll) C
2
free ln Lhe fuel
Lxamp|e ueLermlne Lhe amounL of C
2
LheoreLlcally requlred for Lhe combusLlon of 100 kmols of a blasL furnace
gas analyzlng 23 CC 10 CC
2
3 P
2
10 CP
4
43 n
2
and 3 C
2

Lxcess C
2
ls Lhe amounL of alrC
2
supplled above LhaL of LheoreLlcally requlred for compleLe
combusLlon/oxldaLlon of Lhe combusLlbles ln Lhe fuel
1here are several alLernaLe ways Lo deLermlne Lhe percenL excess alr as lndlcaLed below
excess alr excess C
2


cxccss 0
2
thcoctcuI 0
2
(100)

cxccss 0
2
totuI 0
2
suppIcd - cxccss 0
2
(100)

totuI 0
2
suppIcd - thcoctcuI 0
2
thcoctcuI 0
2
(100)
Slnce LoLal (alr) C
2
supplled LheoreLlcal C
2
+ excess C
2

or comp|ete combust|on excess C
2
C
2
free ln Lhe flue gas
or |ncomp|ete combust|on excess C
2
C
2
free ln Lhe flue gas C
2
needed Lo burn unburned combusLlbles
CASLS 1C 8L CCNSIDLkLD
1 CalculaLlons based on compleLe analysls of Lhe fuel

2 CalculaLlons based on sLack/flue gas analysls
lmporLanL quanLlLles LhaL can be calculaLed
a C
2
supplled lf Lhe fuel ls n
2
free Lhe n
2
ln Lhe flue gas ls Lherefore comlng from alr and can
be used Lo deLermlne Lhe C
2
supplled
b Lxcess C
2
/lree C
2
C
2
needed Lo burn Lhe unburned combusLlbles
c P
2
C formed lf C
2
from alr ls more Lhan Lhe C
2
ln Lhe flue gas assume LhaL Lhe C
2
unaccounLed
for was used Lo burn P
2
Lo P
2
C
d P/C aLomlc raLlo C ln Lhe flue gas C ln Lhe fuel ( for gaseous and llquld fuels only)
e neL hydrogen ls Lhe hydrogen ln Lhe fuel whlch needs alr C
2
for burnlng

3 CalculaLlons based on parLlal analysls of Lhe flue or sLack gas
ury alr conLalns 79 volume n
2
and 21 volume C
2

CrsaL Analysls dry basls ( P
2
C ls excluded ln Lhe analysls)
ChL 410 Chemlcal Lnglneerlng CalculaLlons 2 Second SemesLer 2011 2012

3

AnAL?SlS Cl 1PL lLuL CAS
CC
2
dry flue gas or
CompleLe llue gas or CC SC3 free CrsaL* analysls
SLack Cas Analysls C
2
dry flue gas
n
2
analysls
SC
2

SC
3

P
2
C

* CrsaL Lechnlque deLermlnes Lhe amounLs of componenLs of combusLlon gases by measurlng Lhe decrease ln
volume of a gas sample as lL ls passed over selecLlve llquld absorbenLs ln serles
Lhe composlLlon obLalned ls on a dry basls
lu8nACL S18LAMS
C
2
21 CC
2

n
2
79 CC
(P
2
C) n
2

alr n
2
ln Lhe flue gas C
2
free
P
2

P
2
C
botoeJ / qoslfleJ SC
2

SC
3








(from solld fuel only)
osb

Cas Llquld Solld C
C C C P
P P P C
C C C n
n
2
n usually negllglble S usually negllglble
S ash
Ash
P
2
C

ULL
LUL GAS(LS)

UkNACL

AIk
kLUSL
ChL 410 Chemlcal Lnglneerlng CalculaLlons 2 Second SemesLer 2011 2012

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CASL I CALCULA1ICNS 8ASLD CN ULL ANALSIS

8C8LLMS
1 CCM8uS1lCn Cl u8L CA88Cn
100 kg of pure C ls burned lor each of Lhe followlng cases calculaLe Lhe composlLlon of Lhe combusLlon
gases
a 1heoreLlcal amounL of C2 ls used compleLe combusLlon
b 1heoreLlcal amounL of alr ls used compleLe combusLlon
c 23 excess alr ls used compleLe combusLlon
d 23 excess alr ls used 90 of Lhe C burns Lo CC
2
10 Lo CC
e 30 excess alr ls used 80 of C burns Lo CC2 13 burns Lo CC 3 as unburnL C
f 23 excess alr ls used molar raLlo of CC
2
Lo CC ln Lhe flue gas ls 101

2 CCM8uS1lCn Cl P?u8CCLn
lf molsL hydrogen conLalnlng 4 waLer by volume ls burnL compleLely ln a furnace wlLh 40 excess alr
calculaLe Lhe CrsaL analysls of Lhe flue gas from Lhls furnace llnd Lhe compleLe analysls of Lhe flue gas

3 CCM8uS1lCn Cl u8L P?u8CCA88CnS
1he followlng pure compounds are burned wlLh 40 excess alr llnd Lhe composlLlon of Lhe flue gas lf
combusLlon ls compleLe
a C
2
P
6
b C
6
P
6
c C
2
P
4


AddlLlonal roblem CalculaLe Lhe compleLe analysls of Lhese pure gases lf 90 of Lhe carbon burns Lo CC
2

and Lhe resL Lo CC

4 CCM8uS1lCn Cl MlxLu luLLS
A flue gas conLalnlng 60 CP
4
and 40 C
2
P
6
ls burned wlLh dry alr LlghLy percenL of Lhe carbon goes Lo
CC
2
Lhe resL Lo CC lorLy percenL excess alr ls used llnd Lhe CrsaL analysls of Lhe flue gas

AddlLlonal roblem CalculaLe Lhe CrsaL analysls of Lhe flue gas ln roblem no 4 lf molar raLlo of CC
2
Lo
CC ln Lhe flue gas ls 32 and P
2
Lo CC ls 14

3 CC88LC1lCn Cl n
2
ln 1PL luLL
A blasL furnace gas analyzlng 23 CC 10 CC2 3 CP4 4 P2 and 36 n2 aL 23C and 98 ka and
saLuraLed wlLh waLer vapor ls burned wlLh 20 excess alr Alr ls supplled aL 30C 760 mmPg and also
saLuraLed wlLh waLer vapor 93 of Lhe LoLal C ln Lhe fuel ls converLed Lo CC2 Lhe resL Lo CC Molar raLlo
of P2 Lo CC ls 14 ln Lhe sLack gas whlch leaves aL 200C and 760 mmPg CalculaLe Lhe (a) CrsaL analysls of
Lhe sLack gas (b) alrfuel raLlo by volume and (c) moles of sLack gas/mole of fuel

6 CC88LC1lCn lC8 C
2
ln 1PL luLL
Cool gas aL 13C 760 mmPg and saLuraLed wlLh waLer vapor ls burned ln a furnace Alr wlLh 60 8P ls
supplled aL Lhe raLe of 37 m
3
/m
3
of coal gas and enLers aL Lhe same LemperaLure and pressure as Lhe coal
gas 1he coal gas analyzes 14 CC
2
27 C
2
P
2
070 C
2
38 CC 332 P
2
296 CP
4
and 66 n
2
1he
molar raLlo of CC
2
Lo CC ln Lhe sLack gas ls 101 All Lhe P
2
ln Lhe fuel ls burned Lo waLer 1he sLack gas
leaves aL 400C and 100 ka

CalculaLe Lhe a excess alr
b CrsaL analysls of Lhe sLack gas
c m
3
of sLack gas / m
3
of coal gas
d dew polnL of Lhe sLack gas
ChL 410 Chemlcal Lnglneerlng CalculaLlons 2 Second SemesLer 2011 2012

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CASL II CALCULA1ICNS 8ASLD CN LUL GAS ANALSIS

noLes

1 lf Lhe n
2
ln Lhe fuel ls negllglble Lhe n
2
ln Lhe flue gas may be assumed Lo be all comlng from alr
2 Lxcess C2 may be compuLed as
Lxcess C
2
C
2
free mole CC/2 + moles P
2
/2 ln flue gas
3 An C
2
balance wlll deLermlne Lhe C
2
unaccounLed for (C
2
dlsappearance) 1hls C
2
was used Lo burn P
2
Lo waLer and was noL accounLed slnce waLer ls noL lncluded ln Lhe CrsaL analysls
4 When loses of combusLlble maLLer such as sooL are small all Lhe carbon ln Lhe fuel are accounLed for
ln Lhe sLack gas or flue gas (le carbon ln Lhe fuel ls equal Lo Lhe carbon ln Lhe flue gas)
3 1he neL hydrogen ls Lhe hydrogen ln Lhe fuel LhaL uses C
2
from alr for combusLlon 1he neL hydrogen
ls equal Lo Lhe LoLal hydrogen ln Lhe fuel lf no C
2
ls presenL ln Lhe fuel
6 ALomlc raLlo or welghL raLlo of P Lo C C ln flue gas C ln Lhe fuel (for gaseous and llquld fuels only!)

roblems

1 1he combusLlon gases from a cerLaln furnace uslng nlLrogenfree fuel are analyzed carefully by Lhe CrsaL
Lechnlque and are found Lo conLaln

Case A 16 CC
2
3 C
2
and 79 n
2

Case 8 12 CC 73 C
2
and 803 n
2

Case C 113 CC
2
12 CC 77 C
2
and 798 n
2

Case u 11 CC
2
1 CC 1 P
2
73 C
2
and 793 n
2


WhaL concluslon can be drawn from Lhe flgures glven for each case? llnd Lhe excess alr

2 A pure saLuraLed hydrocarbon gas aL 70l ls burnL ln a furnace glvlng a flue gas conLalnlng 108 CC2
38 C2 and Lhe resL nlLrogen and lnerLs 1he flue gas leaves aL 600l and 760 mmPg

a CalculaLe Lhe aLomlc raLlo P/C and from Lhls Lhe formula of Lhe fuel
b lf Lhe furnace burns 200 lb of fuel per hour calculaLe Lhe volume of combusLlon gases ln fL
3
/mln

3 CrsaL analysls of Lhe sLack gas from Lhe combusLlon of a gaseous mlxLure of aceLylene and meLhane
shows 982 CC
2
137 CC 069 P
2
343 C
2
and 8269 n
2
ueLerlne Lhe

a excess alr
b Mole composlLlon of Lhe gaseous fuel
c m
3
of weL alr supplled aL 26C 736 Lorrs and 70 8P per kg of fuel

4 1he analysls of a flue gas from a fuel gas conLalnlng no nlLrogen ls 462 CC
2
308 CC 891 C
2
and
8339 n
2


CalculaLe Lhe followlng

a Mols dry alr supplled per mole of dry flue gas
b ercenL excess alr lf combusLlon ls compleLe
c neL P
2
burned per mole of dry flue gas
d Analysls of Lhe flue gas whlch ls a mlxLure of CP
4
and C
2
P
6


ChL 410 Chemlcal Lnglneerlng CalculaLlons 2 Second SemesLer 2011 2012

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CASL III CALCULA1ICNS 8ASLD CN 1nL Ak1IAL ANALSIS C 1nL LUL GAS

1 1he burnlng of pure buLane wlLh excess alr glves a sLack gas whlch analyzes 113 CC2 on a dry basls
Assumlng compleLe combusLlon calculaLe

a 1he percenL oxygen
b 1he compleLe orsaL analysls of Lhe sLack gas

2 A gaseous fuel aL 22C 763 mmPg and saLuraLed wlLh waLer vapor ls burned wlLh excess alr Alr wlLh 60
8P ls supplled aL Lhe same LemperaLure and pressure as Lhe fuel 1he composlLlon of Lhe fuel shows 96
CC2 040 C2P4 209 CC 136 P2 19 CP4 and 316 n2 1he sLack gas leaves aL 400C and 733
mmPg and conLalns 1316 CC2 and 184 CC on a dry basls CalculaLe

a ercenL excess alr
b CompleLe analysls of Lhe sLack gas
c uew polnL of Lhe sLack gas

3 roducer gas analyzlng 23 CC 132 P
2
040 CP
4
34 CC
2
080 C
2
and 33 n
2
ls burned ln excess
alr aL 23C 743 mmPg and 70 8P arLlal orsaL analysls of Lhe sLack gas shows 1613 CC2 179 CC
and 072 P
2


CalculaLe

a 1he percenL excess alr
b CompleLe orsaL analysls of Lhe sLack gas
c arLlal pressure of P
2
C ln Lhe sLack gas lf Lhe sLack gas leaves aL 1 aLm
d uew polnL of Lhe sLack gas