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Lecture Sl. No. 08

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Massive Open Online Course under NPTEL

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The Ministry of Human Resource Development (MHRD), Govt. of India

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Basic Principles and Calculations

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in Chemical Engineering

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Module-3: Fundamentals of Material

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Balance

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with Recycle & Bypass
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Prof. S. K. Majumder
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Chemical Engineering Department,

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Indian Institute of Technology Guwahati

Guwahati-781039, India. Phone: +913612582265 (O)
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Email: skmaju@iitg.ac.in ; skmaju@gmail.com

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Welcome IIT Guwahati https://www.iitg.ac.in/chemeng/skm/home

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Previous Lecture Present Lecture

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 Flowchart Material balances on non-

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 Labeling a Proces Flowsheet reactive processes:

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 General Material Balance With recycle

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Equation

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With bypass
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 Basis for Calculation
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 Typical single unit material
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balance problems
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Process Unit
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Process Unit and System (Recap)
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Process flowsheet or Flowchart (Recap)

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 It is a sequence of process units connected by process streams. It shows the

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flow of materials and energy through the process units.

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 A flowsheet is a convenient way of organizing process information for

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subsequent calculations.

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 To obtain maximum benefit from the flowsheet in material balance
calculations, you must:

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 Write the values and units of all known stream variables at the
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locations of the streams on the sheet.
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 Assign algebraic symbols to unknown stream variables and write
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these variable names and their associated units on the sheet

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Process Unit
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Stream
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Flowchart (Single unit)-Recap

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Process Flowchart Benzene Production

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(Multi-unit)-Recap

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Gas Recycle (RG) Purge (P)

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Makeup

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M 100% H2 H2,

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CH4 only

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Separator
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Feed Gross B
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Mixer Reactor
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Feed, Benzene (100%)

100% Tolune G
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Liquid Recycle (RL) Diphenyl (100%)

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100% Tolune
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Some cases: Recycle, Bypass

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Recycle: Unused material being cycled back to the feed stream

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Unused reactants

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Feed Reactor 1 Reactor 2 Product

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Bypass: A stream that skips one or more stages of another process
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and goes directly to another stage further downstream

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Feed Reactor 1 Product

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Divider
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Special case: Purge

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Purge: A stream bled off from the process to remove an accumulation

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of inerts or unwanted materials that might otherwise buildup in the

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recycle stream

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Separator
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Reactor
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Special Case: Makeup

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 A makeup stream is required to replace losses to leaks, carryover,

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etc., within the recycle loop. Proper sizing and location of makeup

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and purge streams can prevent many problems within process

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Product

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Mixer
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Separator
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Reactor
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Makeup
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Process with makeup stream.

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General Material Balance Equation

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(Recap)

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Positive contributions to the system: Input & Generation

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Negative contributions to the system: Output & Consumption

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Simplified Equation

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 No chemical reaction within process unit(s) – then mass cannot be

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generated or consumed; mass conservation simplifies to:

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 ACCUMULATION = INPUT – OUTPUT

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 At steady state, there is no accumulation, so further simplifies to:

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 INPUT = OUTPUT
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 For a given system, a material balance can be written in terms of

the following conserved quantities:
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 Total mass or moles., Mass or moles of a chemical compound.,

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Mass or mole of an atomic species.

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Example: Separation of Benzene and

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Toluene in Distillation Column with Recycle

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 A continuous operation distillation column operating at 1 atmosphere is to

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be designed as shown in Figure to separate 13620 kg/hr of a solution of

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benzene and toluene containing 0.4 mass fraction benzene, into the

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overhead product containing 0.97 mass fraction benzene and bottom
product containing 0.98 mass fraction toluene.

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 (a) Write the overall material balance equation.
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 (b) Write the overall benzene balance equation.
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 (c) Estimate, D (distillate) and B (bottoms product)

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 (d) What will be the reflux per kg of distillate product (R) is to be used if the
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overhead vapor is 11713 kg.

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Solution

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Overall Material balance:

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F=D+B

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Or 13620 = B + D

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Overall benzene balance:

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Fxb,F = Bxb,B + D xb,D Recycle

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Or, 13620*0.4 = B*0.02+D*0.97

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Solving, we get,
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D = 5448 kg, B = 8172 kg

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Balance around condenser

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V = L+D
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11713 = D*R+D
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R = 11713/D -1 = 1.15
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Example: Steady state process of

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evaporation and mixing with bypass

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Calculate the bypass fraction M3 kg H2O

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Mixing point

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Bypass

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Basis: 100 kg m4 kg m5 kg
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0.12 kg S/kg 0.12 kg S/kg 0.58 kg S/kg 0.42 kg S/kg
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0.88 kg H2O/kg 0.88 kg H2O/kg 0.42 kg H2O/kg 0.58 kg H2O/kg

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S stands for Solid

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m2 kg
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0.12 kg S/kg
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0.88 kg H2O/kg
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Solution

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Example: Purge

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 Problem: A Fresh feed containing 55 wt% A and 45 wt% B flowing at

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100 kg/h enters a separator that removes a portion of pure

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component A only as a bottom product. The top product stream of

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the separator contains 10 wt% of component A and the balance is

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B. A small part of the separator product stream is recycled and

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joined in the fresh feed stream. The other portion is purged. The
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separator is designed to remove exactly two-thirds of component A
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fed to it (not the fresh feed). The recycle loop is used to achieve this
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goal. Compute all unknown stream flow rates and compositions.

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Solution

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System: Overall process

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Purge

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Total mass balance:

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Component balance (A):

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Substituting m6 from overall balance equation,

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Solving for m4,

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System: Separator.

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Total mass balance:

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Component balance (A):

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Since, Separator removed 2/3 of A fed to it in the bottom stream:
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Now the component balance and the relation,

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Implies
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System: Splitter
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Overall mass balance:

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equation around the separator,

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Substituting m3 = 250 kg/h into overall mass balance

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Further reading......

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Text Books:

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 R. M. Felder, Ronald W. Rousseau, Lisa G. Bullard, Elementary

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Principles of Chemical Processes, 4th Ed., John Wiley & Sons,

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Asia, 2017.

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 D. M. Himmelblau, J. B. Riggs, Basic Principles and Calculations in

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Chemical Engineering, 7/8th Ed., Prentice Hall of India, 2012.
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Reference Books:
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 N. Chopey, Handbook of Chemical Engineering Calculations,

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4th Ed., Mc-Graw Hill, 2012.

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 Olaf, K.M. Watson and R. A. R. Hougen, Chemical Process

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Principles, Part 1: Material and Energy Balances, 2nd Ed., John

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Wiley & Sons, 2004.

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Thank You

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processes

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Material balances on reactive
Next Lecture:
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