UNIVERSITY OF CALIFORNIA Department of Chemical Engineering and Materials Science ECH 51 Material Balances Mid-term exam: February 12,

2007
(Closed book and notes; no questions asked or answered)

Given for Exam:

Total Mass Balance r V + r Hv - w L n A = 0 t HtL Ht L Species Mass Balance r V + r A Hv A - w L n A = rA V, A = 1, 2, , N t HtL A HtL HtL (1)

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To obtain partial credit on any problem you must do the following: (i) indicate the control volume selected for your analysis, (ii) show your working equations, (iii) state any key assumptions. All the following problems are well posed. The degree of freedom analysis indicates DOF=0.

Problem 1 (10 points)

The flowchart of a steady-state process to recover crystalline potassium chromate ( K2 CrO4 ) from an aqueous solution of this salt is shown in Fig 1. The feed stream (#1) is 4500 kg/hr of a solution that is one third K2 Cr04 by mass. It is mixed with a recycle stream #6 and then fed to an evaporator unit. The concentrated stream (#4) leaving the evaporator contains 49.4% K2 CrO4 by mass. The vapor stream #3 leaving the evaporator is pure water. The liquid stream #4 leaving the evaporator contains 49.4% by mass K2 CrO4 . It is fed into a crystallizer/filter where it is cooled (causing crystals of K2 CrO4 to come out of solution) and then filtered. Stream #5 leaving the crystallizer/filter unit is a filter cake suspension consisting of the filter cake (pure K2 CrO4 crystals) and some residual solution that contains 36.4% K2 CrO4 by mass. =m The mass flow rate of the filter cake suspension is m 5 crys + mres where mcrys is the mass flow rate of filter cake and m res is the mass flow rate of the residual solution in the filter cake suspension. The flow rate mcrys accounts for 90% of the total mass of stream #5. The solution that passes through the filter ( stream #6) is recycled back to the evaporator; it contains 36.4% by mass K2 CrO4 .

ECH51FirstExam_07Soln.nb

Figure 1 Calculate the rate of evaporation, the rate of production of crystalline K2 CrO4 , the feed rates to the evaporator and crystallizer, and the recycle ratio (mass flow rate of recycle)/(mass flow rate of fresh feed)

Solution
Let C denote K2 Cr O4 . We begin by taking a control volume that cuts streams #1, #3 and #5 K2 CrO4 : The overall balance is Overall : = m m3 + m 1 5 (4) Hw L = m m5 HwC L5 = mcrys + mres Hwc Lres 1 C 1 (3)

Now we are told that stream #5 can be represented as m5 = m crys + mres and that the mass flow rate of m crys is 90% of the total flow rate m5 .Thus we have mcrys = 0.9 Hm crys + mres L mcrys = 9 m res (5)

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Thus m5 = m crys + mres = 10 m res Substituting this result into the chromate balance gives H4500L H0.333L = mres H9 + Hwc Lres L = m res H9.364 L we get Solving for m H4500L H0.333L mres = = 160.028 kg h 9.364 Then it follows that
res

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mcrys = 9 m res = H9L H160.028 L = 1440.25 kg h : From the overall balance we can m
3

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-m = 4500 - H1440.25 + 160.028 L = 2899.72 kg h m3 = m 1 5

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ECH51FirstExam_07Soln.nb

Consider next a control volume that cuts streams #4, #5 and #6. The overall balance and chromate balance gives Overall : K2 CrO4 : = m m5 + m 4 6 m4 HwC L4 = mcrys + mres Hwc Lres + m 6 Hw C L 6 (12)

Substituting in the known values we get = 1600.28 + m Overall : m 4 6 K2 CrO4 : m4 0.494 = 9 m res + m res 0.364 + m6 0.364 allows us to write the chromate balance as Eliminating m H1600.28 + m6 L 0.494 = H160.028 L H9.364 L + m6 0.364 Solving for m gives
6 4

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m6 H0.494 - 0.364L = H160.028L H9.364L - H0.494 L H1600.28L 707.964 m6 = J N = 5445.88 kg h 0.130 becomes Thus m 4 m4 = 1600.28 + m6 = 1600.28 + 5445.88 = 7046.16 kg h The feed rate to the evaporator is m2 = 5445.88 + 4500 = 9945.88 kg h

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The recycle ratio is 5445.88 R = = 1.2102 = 1.21972 4500 The production rate of Chromate crystals is mcrys = 1440.25 kg h

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Problem 2 (10 points)

(i) Suppose you have a stream with two species A and B. The mole fraction of species A in the stream is xA , Derive a formula for the mass fraction wA of species A in terms of the mole fractions x A and xB and the molecular weights of species A and B. (ii) Consider the following process for recovering NH3 from a gas stream composed of N2 and NH3 (see Figure 2). Flowing upward through the process is the gas stream (#1), which contains NH3 and N2 but no solvent S. The mass flow rate of stream #1 is 1000 kg/hr and the mole fraction of NH3 in stream #1 is xA = 0.1. The solvent stream (#3) entering the process has a mass flow rate of 1000 kg/hr and contains pure solvent S. The gas stream leaving the process (#2) contains N2 and NH3 , The liquid stream leaving the process (#4) contains NH3 and solvent S. The mass fraction of NH3 in the gas stream #2 is related to the mass fraction of NH3 in the liquid stream #4 by the following empirical relationship: HwNH 3 L2 = 2 HwNH3 L4 (20)

ECH51FirstExam_07Soln.nb

Calculate the compositions of streams A and B. The atomic mass of nitrogen is 14 and the atomic mass of hydrogen is 1.

Figure 2

Solution
(i) The mole fraction of species A is related to the molar concentration CA and the molar density of the mixture by xA = CA C (21)

The mass density of species A is related to the molar density, which in turn is related to the mole fraction by rA = MWA CA = MWA C xA where MWA is the molecular mass of species A. The density r of the mixture is given by r = rA + rB = MWA C xA + MWB C xB Now the mass fraction of specie A in the mixture is given by rA MWA C xA MWA C xA MWA xA wA = = = = r r MWA C xA + MWB C xB MWA xA + MWB xB (24) (23) (22)

(ii) We consider a control volume V that encompasses the process unit and cuts streams #1, #2, #3, #4. In this process we have 3 species. The steady state species balances in terms of mass units are NH3 : N2 : S : Hw L = m m2 HwNH 3 L2 + m4 HwNH3 L4 1 NH 3 1 m1 HwN2 L1 = m2 HwN2 L2 m3 HwS L3 = m4 HwS L4

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We are told that the mole fractions of NH3 and N2 in stream #1 are HxNH 3 L1 = 0.1, HxN2 L1 = 0.9 (26)

Converting these quantities to mass units gives

H17L H0.1L HwNH 3 L1 = = 0.063197 H17L H0.1L + H28L H0.9L

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Thus

ECH51FirstExam_07Soln.nb

HwN2 L1 = 1 - HwNH 3 L1 = 0.936803 We are also told that m1 = 1000 kg h, m3 = 1000 kg h, HwNH3 L2 = 2 HwNH 3 L4 Hw L + 63.2 = 2 m m4 HwNH 3 L4 2 NH 3 4 936.8 = m2 HwN2 L2 81 - Hw L < 1000 = m 4 NH3 4

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Substituting these quantities into the species balances gives NH3 : N2 : S :

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From the overall balance we also know that +m 2000 = m 2 4 we get the following two equation in two unknowns Eliminating m2 in terms of m 4 NH3 : S : Solving for wNH3 we get L Hw L + 63.2 = 2 H2000 - m m4 HwNH3 L4 4 NH 3 4 1000 = m 4 81 - HwNH3 L4 < (31)

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Solving for HwNH3 L4 we get

5000 HwNH3 L4 2 - 3829 HwNH 3 L4 + 79 = 0 HwNH 3 L4 = 0.02122, HwNH3 L4 = 0.74458 = 3915.12 kg h m4 = 1021.68 kg h, m 4 = 1021.68 kg h HwNH 3 L4 = 0.02122, m 4

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The appropriate flow rates are

(35)

From the overall balance it follows that the only relevant root is (36)

is given by Thus m 2

and given that HwNH 3 L2 = 2 HwNH3 L4 it follows that HwNH 3 L2 = 2 HwNH3 L4 = 0.04244

= 2000 -1021.68= 978.32 kg/h m 2

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and

HwN2 L2 = 1 - 0.04244 = 0.95756 HwS L4 = H1 - 0.02122L = 0.97878 L =m Hw L = H1021.68L H0.97878 L = 1000 kg hr Hm s 4 4 S 4

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while

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Finally as a check we determine the mass flow rate of solvent in stream #4

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ECH51FirstExam_07Soln.nb

Problem 3 (10 points)

As water flows over the dam illustrated in Figure 3, it accelerates because of the action of gravity. When the effect of gravity is much larger than the effect of the friction between the water and the surface of the dam, the magnitude of the velocity of the water can be expressed as #### v = "################ v2 0 +2gz (42)

in which z is measured as indicated in Figure 3. This expression for the velocity is based on the idea that potential and kinetic energy are conserved when frictional effects are negligible. If the width of the dam is constant and the water level in the dam does not change appreciably, what is the thickness of the fluid stream, h(z) , as a function of z. Assume that the density of the water is constant and that the velocity profile is flat everywhere as indicated in Figure 1

Figure 3

Solution
We will choose a control volume cuts the fluid passing over the weir with height ho an then cuts the fluid flow over the dam wall at some arbitrary location z with height h(z). We assume that the flow is steady and the density is constant. Under these assumptions the macroscopic balance becomes v n A = 0

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Note that v n is zero everywhere except at the entrance and exit of our control volume. Thus our macroscopic balance becomes - v 0 h o b + v HzL h H zL b = 0 (44)

where b is the width of the dam. v(z) and h(z) represent the velocity and height at the exit denoted by position 1 in the figure. We use the result

ECH51FirstExam_07Soln.nb

########### v = "######## v2 0 + 2 gz to solve for the fluid depth v0 h 0 h0 h HzL = = 2 g z# "################ # ### "######## ######## 2 1+ # v0 + 2 g z v2 0

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Problem 4 (10 points)

Titanium dioxide, TiO2 is white pigment used in the paint and paper industries. A new pigment plant processes an intermediate stream consisting of TiO2 precipitate suspended in an aqueous salt solution (stream #1). The salt removal is to be accomplished by washing the precipitate with pure water (stream #2). If the raw pigment stream (#1) contains 40% by mass of TiO2 , 20% by mass salt, and the rest water, and if the washed pigment (#4) is upon settling, projected to consist of about 50% (by mass) TiO2 solids, what will the composition of the waste wash water stream (#3) be. It is determined that the wash water utilization should be 6 lb H2 O lb feed. The process is designed so that stream #4 produces 4000 lb/h dry product (TiO2 + salt) that contains, on a water free basis, at most 100 parts per million (1 ppm=mass fraction of 10-6 ) of salt. A schematic of the process is shown in Figure 4.

Figure 4 Determine the compositions and flow rates of all streams.

Solution

We select a control volume that cuts all 4 streams of the washing unit. We have 3 species TiO2 HT L, water(W) and salt(S). The species balances are TiO2 : Salt : water : Hw L m1 HwT L1 = m 4 T 4

Hw L + Hw L + m Hw L m m2 HwW L2 = m 1 W 1 3 W 3 4 W 4

Hw L m1 HwS L1 = m3 HwS L3 + m 4 s 4

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In this problem it will be convenient to work with the overall balance + +m m m2 = m 1 3 4 We are told how much salt there is in the washed TiO2 on a dry basis (48)

8 m4 HwS L4 lb salt = = H100 ppmL H 10-6 L = 10-4 lb dry product m4 H0.5 + HwS L4 L Hws L4 = 5.0005 10-5

ECH51FirstExam_07Soln.nb

Solving for Hws L4 gives

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We are also told that

Noting that HwT L4 = 0.5 we get

m4 HHwT L4 + HwS L4 L = 4000 lb hr m4 = 7999.2 lb h

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Then from the TiO2 balance we have

m1 H0.4L = 7999.2 H0.5L m1 = 9999 lb h Hw L 1999.8 = 0.4 + m 3 S 3

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From the salt balance we get

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And from the total balance we have + 7999.2 9999 + m2 = m 3 The final bit of information we need to solve for the streams is that m 2 = 6 m 2 = H6L H9999 L = 59994 lb h m 1 (56) (55)

we get Solving for m 3

and solving for Hws L3 we get

- 7999.2 m3 = 9999 + m 2 = 9999 + 59994 - 7999.2 = 61993.8 lb h Hw L - m3 HwS L3 = m m4 Hws L4 1 S 1 m m 1 4 HwS L3 = HwS L1 - Hw s L 4 m3 m 3

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H9999L H7999.2L = H0.2L - H5.0005 10-5 L 61993.8 61993.8

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= 0.03225