Q37.

It is desired to prepare 50% sulphuric acid for which a dilute waste acid of 25% is
fortified with a purchased acid of 98%. How much of purchased acid should be
employed for 100 kg of waste acid?

Ans:
Input = Output
Overall Balance
X+Y=Z
100 + Y = Z ------ (1)
H2SO4 acid balance :
100x0.25 + 0.98Y = 0.5 Z --- (2)
Solving (1) and (2)
Z = 152 kg Y = 52 kg

Q 38 Two effluent streams are mixed. One stream contains 6% solids whereas the
other none. In what ratio must the 2 streams be mixed to get a stream containing 0.45
% solids?
Basis: 100 kg of outlet stream

Z =100 kg
Overall material balance:
X+Y=Z
X + Y =100---- (1)
Solid Balance :
0.06 x X + 0 = 100 x 0.0045
X = 7.5
Substituting in (1)
Y =92.5 kg

X/ Y = 7.5/92.5 =0.0811
Q 39 A waste acid from a nitration process contains 21 % HNO3, 55 % H2SO4, and 24
% water. The acid is to be concentrated to contain 28 % HNO3, 62 % H2SO4 by wt. by
the addition of conc. H2SO4 and HNO3 having concentrations 93 % and 90% by wt.
respectively. Calculate the weight of the waste acid and conc. acid required to obtain a
product of 1000kg.
Ans :
Basis: 1000 kg of the product
Overall material balance
X + Y +Z = 1000 ---------- (1)
Sulfuric acid balance:
0.55 X + 0.93 Y + 0 x Z = 1000 x 0.62 ----- (2)
Nitric Acid balance
0.21 X + Y x 0 + Z x 0.9 = 1000 x 0.28 ----(3)

Solving, X = 126.8 kg, Y = 591.68 kg, Z = 281.53 kg

Q40. A gas mixture flowing through a pipe line contains 4% oxygen by volume and
rest an inert gas. The flow rate is 500 m3/ min. It is desired to increase the oxygen
content of the gas so that the leaving gas contains 8% of oxygen by volume.
Calculate:
i. the rate of addition of oxygen,
ii. If the change in composition is caused by pure air, find the rate of addition of pure
air,
iii. Find the volume of gas mixture leaving under condition (ii)
iv. What is the composition of outgoing gas mixture under condition (ii)
v. What is the composition in wt% of gas leaving under condition (ii)
If the M.Wt. of inert gas is 40?
vi. What is the average molecular wt. of the leaving gas mixture?

Ans:
Basis: Input flow rate = 500 m3/min
Overall material balance:
500 + X =Y

Oxygen Balance
0.04 x 500 + 0.21 X = 0.08 Y

Solving (1) and (2)

X = 153.85 m3/min
Y = 653.85 m3/min

i. 21 % of X = (21/100) x 153.85 = 32.8 m3/min

ii. 153.85 m3/min
iii. Y = 653.85 m3/min
iv.
m3/min Mole fraction
O2 653 x 0.08 52.3/ 653.85 =
= 52.3 0.08
N2 153.5 x 121.26/ 653.85 =
0.79 = 0.185
121.26
Inert 500 x 0.96 480/ 653.85 =
=480 0.734
 Σ= 653.85
m3/min

v. Basis 1 kg mole
vi.
Mole Mwt. Wt Wt%
fraction
O2 0.08 32 2.55 6.9
N2 0.185 28 5.18 13.96
Inert 0.734 40 29.36 79.13
Σ= 37.1 100
vii. Average molecular weight = Mav= (37.1/1) = 37.1
Q40. A solution of NaCl in water is saturated at a temperature of 15 oC. Calculate the
weight of NaCl that can be dissolved by 45.36 kg of this solution if it is heated to a
temperature of 65oC.
Data given:
Solution of NaCl at 15oC = 2.776 kg mole/453.6 kg water
Solution of NaCl at 65oC = 2.889 kg mole/453.6 kg water

Ans:
Basis: 45.36 kg of feed solution.

XF = 162.396/ 162.396+453.6 = 0.26363 (kg solute/ kg of solution)

XM = 169.0065/ (453.6 + 169.0065) = 0.27144

F+C =M
45.36 + C = M ------ (1)

FXF + CXC = MXM

45.36 x 0.26363 + C x 1 = M x 0.27144 --- (2)

Solving (1) and (2)

C = 0.4868 kg M = 45.822 kg
 DISTILLATION

Distillation is a process by which a liquid mixture is separated into fractions with higher
concentrations of certain components by exploiting differences in relative volatility.
Overall balance
F = D +W ---- (1)

Component balance (more volatile substance)

FXF = D XD + WXW ---- (2)

Q42. 1000 kg/h of a 40 mole % solution of EDC in phenol is fed to a distillation column.
The distillate stream consists of 95 mole % EDC and bottom stream contains 10 mole
% EDC. What is the flow rate of each product stream?
Ans:
Basis : 1000 kg/h of Feed
Ethylene Dichloride (C2H4Cl2) MWt. = 97
Phenol (C6H5OH) MWt. =94
Avg molecular wt. = 0.4x97 + 0.6x 94 = 95.2

No. of kg moles = 1000/95.2 = 10.5 kg moles/h.

F = D+ W
10.5 = D+W ------------ (1)

FXF = D XD + WXW
10.5 x0.4 = Dx0.95 + Wx0.1 ----- (2)

Solving (1) and (2)

D = 3.706 kg mole/h
W= 6.79 kgmole/h
Q43. A solution of methyl alcohol containing 8.6% by wt of alcohol is fed at the rate of
1000 kg/h to a column. The distillate contains 95.4% by wt of alcohol. The waste
solution from the still contains 0.1% by wt of alcohol. Calculate:
i. Mass flow rate of top and bottom product?
ii. % loss of alcohol?

Ans:
Basis: 1000 kg/h of feed.
i. F = D+ W
1000 = D+W ------------ (1)

FXF = D XD + WXW
1000 x0.086 = Dx0.954 + Wx0.001 ----- (2)
D= 89.19 kg/h W = 910.808 kg/h
ii. % loss = MA in residue/ MA in feed =
= (910.8 x 0.001)/ (1000 x 0.086)x 100
= 1.059 %
Q44. In a distillation train, a liquid HC containing 20 % ethane, 40% propane and 40%
butane (on mole basis) is to be fractionated into essentially pure components as shown
in figure below. On the basis of F = 100 moles what is P in moles and the composition
of stream A?
Ans:
Basis: 100 moles of Feed.
F= E+P+B
100 = E+P+B

C2 balance:
100 x 0.2 = 0.95 E + 0 P + 0 B
E = 21.052 moles

C3 balance:
100 x 0.4 = 0.04 E + 0.99 P + 0.084 B
100 x 0.4 = 0.04 x 21.052 + 0.99 P + 0.084 B ------ 1

C4 balance:
100 x 0.4 = 0.01 E + 0.01 P + 0.916 B
100 x 0.4 = 0.01 x 21.052 + 0.01 P + 0.916 B -- 2

Solving 1 and 2
P= 35.9 moles, B =43.05 moles
To calculate A
F=E+A
100= 21.052 + A
A = 78.948 moles

C-3 balance over column 1:

F XFc3 = E XEc3 + A XAc3
100x 0.40 = 21.052 x 0.04 + 78.95 XAc3
XAc3 = 0.4959

C-4 balance over column 1:

F XFc4 = E XEc4 + A XAc4
100 x 0.4 = 21.052 x 0.01 + 78.95 x XAc4
XAc4 = 0.504
Q45. A feed mixture containing 40 % Benzene , 30 % Toluene and 30% Xylene is being
separated into 3 product streams. All compositions are expressed as wt %. And are
shown in Figure given below.

Calculate:
i. The % recovery of each feed component in its own product stream
ii. The composition of the intermediate stream.
Ans:
Basis : 100 kg
Component Balance
F = B+T+X
100 x 0.4 = 0.995 B + 0.02 T + 0 X
100 x 0.3 = 0.5 B + 0.97 T + 0.05 X
100 x 0.3 = 0 B + 0.01 T + 0.95 X

B= 39.62 kg, T= 29.11 kg, X= 31.27 kg

39.62 𝑥 0.995
% B= 𝑥 100 = 98.55%
40
29.11 𝑥 0.97
% T= 𝑥 100 = 94.12%
30
31.27 𝑥 0.95
% X= 𝑥 100 = 99.02%
30

Intermediate composition:
F = B +I
100 = 39.62 + I
I = 60.38 kg

Benzene balance over column 1

FXFB = B XBB + I XIB
100x 0.4 = 39.62 x 0.995 + 60.38 XIB
XIB = 0.0096

Toluene balance over column 1

FXFT = B XBT + I XIT
100 x 0.3 = 29.11 x 0.005 + 60.38 x XIT
XIT = 0.4934

Xylene balance over column 1

FXFX = B XBX + I XIX
100 x 0.3 = 0 B + 60.38 XIX
XIX = 0.497
 EXTRACTION AND LEACHING

Acetic acid (solute) + water (diluent) system

(Feed)

 Difficult to separate by distillation.

 Can be easily separated by using a
solvent Ethyl acetate.
 When Ethyl acetate is mixed with feed,
it will dissolve most of the AcAcid and
form the extract phase.
 Water will only retain a little of Ac acid
and form the raffinate phase.
Single stage contactor.
Multi stage cross-current contactor
 Multistage counter-current contactor

Q46. Soyabeen seeds are extracted with hexane in a single stage batch extractor. The
fresh feed contains 18.6% oil, 69% solids and 12.4% moisture. At the end of the
process the cake is separated from the hexane oil mixture. The reject cake analyses as
follows: 0.8% oil, 87.7% solids and 11.5% moisture. Find the percent recovery of oil.

Ans:
Basis; 100 kg of feed
Solids enter through F and leave through s only. So we take solid balance.
0.69 x 100 = 0.877 S
S = 78.67 kg
Oil extracted
100 x 0.186 – 0.008 x 78.67 = 17.97 kg
% oil extracted = (17.97/ 18.6) x 100
=96.6%
Q47. Hemlock bark contains 6% moisture, 10.8% tannin and 8.2% soluble non-tannin.
The balance is insoluble lignin. After extraction the waste bark on dry basis contains
0.95% tannin and 0.22% soluble non tannin. If raw tannin brings Rs. 100 per kg, how
much money is lost per 1000 kg of original bark because of imperfect extraction of
tannin? Also find % recovery of tannin?

Basis: 1000 kg of Hemlock bark

Lignin Balance:
1000 x 0.75 = S x 0.9883
S = 758.87 kg

Tannin lost due to imperfect leaching

= 0.0095 x 758.87 = 7.209 kg
Value of 7.209 kg = 100 x 7.209 = Rs 720.9

Tannin recovered = (0.108 x 1000 - 0.0095 x 758.87)/ (0.108 x 1000) X 100

= 93.325 %

Q 48 A liquid mixture containing 47.5% Acetic Acid and 52.5% water is being separated
by extraction in counter current unit. The solvent is isopropyl ether which is fed at the
rate of 1.3 kg/kg of feed. The extract composition is 82% of acid by weight. The raffinate
is found to contain 14% acid. Calculate the percentage of acid unextracted?

Basis: 100 kg of feed

F+S = E+R
100 +130 = E +R
230 = E + R ----- (1)
Solute balance
100x47.5 + 0 = 0.14 R + 0.82 E ----- (2)
Solving (1) and (2)
R = 207.5 kg
E = 22.5 kg

% ge acid unextracted = (0.14 x 207.5)/ (100 x 0.475) x 100 = 61.157 %

Q49. 20 wt % solution of acrylamide (A) in Benzene(B) is contacted with water (W). For
purpose of extracting acrylamide which is more soluble in water than in Benzene. The
solution is mixed with pure water in a tank and pumped to a settler where the water
and Benzene layers are separated. The water and Benzene are completely immiscible
and have the following composition.

Water Layer (mass frn) Benzene Layer (mass frn)

Acrylamide (0.6) Acrylamide (0.01)
Water (0.4) Benzene (0.99)

What is the ratio of water used to Benzene?

Ans: Basis : 100 kg of feed

Benzene balance
100 x 0.8 = R x 0.99
R = 80.81 kg
Acrylamide balance
100 x 0.2 = E x 0.6 + 80.81 x 0.01
E = 31.96 kg

Overall balance
F+S = E+R
100 + S = 31.986 + 80.81
S = 12.80 kg

Ratio of water to Benzene = 12.8/ 80 = 0.16

HUMIDITY
Humidity is defined as mass of water vapour present or carried by a unit mass of
vapour free gas.
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑣𝑎𝑝𝑜𝑢𝑟
1. Absolute humidity = 𝑌 ′ =
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑣𝑎𝑝𝑜𝑢𝑟 𝑓𝑟𝑒𝑒 𝑔𝑎𝑠

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑣𝑎𝑝𝑜𝑢𝑟
Molal Humidity = 𝑌 =
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑣𝑎𝑝𝑜𝑢𝑟 𝑓𝑟𝑒𝑒 𝑔𝑎𝑠
𝑝̅𝐴
𝑌=
𝑃𝑇 − 𝑝̅𝐴

′
𝑝̅𝑎 18
𝑌 = ×
𝑃𝑇 − 𝑝̅𝐴 29

2. Saturation Humidity
Saturated vapour gas mixture completely saturated with vapours is called
saturated gas at the gas temperature.
In a saturated mixture, the partial pressure of vapours is equal to vapour
pressure at the gas temperature.

𝑝̅𝐴 = 𝑃𝐴

Saturated absolute humidity

PA 18
YS  
PT  PA 29
Saturated Molal Humidity
PA
YS 
PT  PA
Vapour pressure or
equilibrium vapor
pressure is defined as
the pressure exerted by
a vapor in
thermodynamic
equilibrium with its
condensed phases
(solid or liquid) at a
given temperature in a
closed system.
3. % Humidity or % saturation
̅𝐴
𝑝 18
̅ 𝐴 29
𝑃𝑇 − 𝑝
= 𝑃𝐴 18 x 100
𝑃𝑇 − 𝑃𝐴 29

𝑝̅𝐴 𝑃𝑇 − 𝑃𝐴
%𝐻 = [ ] × 100
𝑃𝐴 𝑃𝑇 − 𝑝̅𝐴

4. % Relative humidity
𝑝̅𝐴
% 𝑅𝐻 = × 100
𝑃𝐴
5. Dew Point Temperature
The dew point is the temperature to which a vapour gas mixture must be cooled
to become saturated with vapor. When cooled further, the airborne water vapor
will condense to form liquid (dew).

e.g. When air cools to its dew point through contact with a surface that is colder
than the air, water will condense on the surface.
 Alternately, Dew point is the temperature at which the first drop of dew is
produced when a vapour gas mixture is cooled at constant humidity.
6. Humid heat
The humid heat is the heat required to raise the temperature of unit mass of gas
and its accompanying vapour by 1 oC at constant pressure.

𝐶𝑠 = 𝑄𝐺 + 𝑄𝑉

𝐶𝑠 = (𝑚𝐶𝑃 ∆T)𝑔𝑎𝑠 + (𝑚𝐶𝑃 ∆T)𝑣𝑎𝑝𝑜𝑢𝑟

𝐶𝑠 = 1𝐶𝐵 x1 + 𝑌 ′ 𝐶𝐴 1

𝐶𝑠 = 𝐶𝐵 + 𝑌 ′ 𝐶𝐴

7. Humid Volume (VH)

 It is the volume of the unit mass of gas and its accompanying vapour at prevailing
temperature and pressure.

𝑛 𝑅𝑇
𝑉𝐻 =
𝑃
1 𝑌′
𝑉𝐻 = ( + ) × 𝑅𝑇 (P=1 atm)
𝑀𝐵 𝑀𝐴

8. Adiabatic Saturation temperature (AST or Ts)

It is the steady state equilibrium temperature attained by an unsaturated vapor-
gas mixture when it is brought into intimate contact with the liquid in an insulated
equipment for sufficiently long time.
9. Dry bulb temperature
The dry-bulb temperature (DBT) or TG is the temperature of air measured by a
thermometer freely exposed to the air
The wet-bulb temperature (WBT) or TW is the temperature read by a thermometer
covered in water-soaked cloth (wet-bulb thermometer) over which air is passed.
At 100% relative humidity, the wet-bulb temperature is equal to the air
temperature (dry-bulb temperature); at lower humidity the wet-bulb temperature
is lower than dry-bulb temperature because of evaporative cooling.
(For Air-water vapour system AST = WBT)
 Q50. An air water vapor system at 1 atm. has a dry bulb temperature of 40oC and 70 %
humidity. Determine
i. The absolute humidity
ii. The molal humidity
iii. Dew point temperature
iv. The wet bulb temperature
v. The humid heat
vi. Humid Volume
vii. The relative saturation
i. Y’ = 0.034 kg water/ kg of dry air

0.034
18
ii. Y = 1 = 0.0548 (kg mole of water/ kg mole of air)
29
iii. Td = 34 oC
Adiabatic saturation temperature = wet bulb temperature for air water vapour
system.
WBT = 35oC
Humid Heat = 1.06 kJ/ kg oC
VH = 0.88 + (0.96- 0.88) x 0.7
= 0.936 m3/(kg of dry air)

𝑌 ′ = 0.034
𝑝̅𝑎 18
= ×
1 − 𝑝̅𝐴 29

𝑝̅𝑎 = 0.052 atm

𝑌 ′𝑆 = 0.050
𝑃𝐴 18
= ×
1 − 𝑃𝐴 29

𝑃𝐴 = 0.074 𝑎𝑡𝑚

RH % = 0.052/0.074 x 100
= 71.56 %
51. Air has a dry bulb temperature and wet bulb temperature of 53oC and 30oC
respectively. Using humidity chart find the absolute humidity, molal humidity, dew
point % saturation and humid volume.
Y’ = 0.017 kg of H2O/ Kg of dry air

Y = (0.017/18)/ (1/29) = 0.0274 kgmole water/ kgmole of air

Dew point = 22oC (Go along the path A-B-C-D-E)
Y’ = 0.017 kg of water/ kg dry air (found earlier)
Ys’ = 0.101 kg of water/ kg dry air

% humidity = (0.017/ 0.101) x 100 = 16.83 %

Humid Volume = 0.92 + 0.1683 (1.07-0.92)
= 0.945 m3/ kg of dry air
52 On a particular day in Manipal the weather conditions are reported as 35oC dry
bulb and 80% relative humidity at a barometric pressure of 752 mm Hg. Calculate:
i. Absolute humidity
ii. Saturation humidity
iii. % Humidity
iv. Humid heat
v. Humid volume
Cp vapour = 2.006 kJ/kg K
Vapour pressure at 35oC = 31 mm Hg

i. Absolute humidity
′
𝑝̅𝑎 18
𝑌 = ×
752 − 𝑝̅𝐴 29

𝑝̅𝐴 = 0.8 𝑥 31 = 24.8 𝑚𝑚

′
24.8 18
𝑌 = ×
752 − 24.8 29
 = 0.0212 kg of water/ kg dry air

31 18
ii. 𝑌𝑠 ′ = ×
752−31 29

= 0.02669 kg of water/ kg dry air

𝑝̅ 𝐴 𝑃𝑇 − 𝑃𝐴
iii. %𝐻 = [ ] × 100
𝑃𝐴 𝑃𝑇 − 𝑝̅ 𝐴

752 − 31
%𝐻 = 0.8 [ ] × 100
752 − 24.8

= 79.3%

iv. 𝐶𝑠 = 𝐶𝐵 + 𝑌 ′ 𝐶𝐴
= 1.001 + 0.0212 x 2.006
= 1.0435 kJ/ kg dry air

1 𝑌′ 𝑅𝑇
v. 𝑉𝐻 = ( + ) ×
𝑀𝐵 𝑀𝐴 𝑃

1 0.0212 0.082 𝑥 308

=( + ) × 752
29 18
760
= 0.9113 m3/kg dry air