Solutions to exam#2 (nos.

2,3,4 only)
#2
Basis: 1 hour
150 kmol
2.1)
Converter gas Reacted
SO2 2.625 0.07875
SO3 9.495
O2
11.49 0.0394
N2 126.49
total
(3 points)

Residual
2.546
9.5738
11.45
126.49

% in waste gas
1.814
8.156
90.03
100

Total so3 produced = 769.5 kg. ; let A = absorbing liquid, P = product

SO3 bal:
769.5 + A = P
--1
Over-all
769.5 +(80/98) A = [0.2+(0.8*80/98)]P
--2
2.2) A=950 kg (3 points)
2.3) P=1716.67kg (3 points)
2.4) [0.8 + (0.2*98/80)] = 104.5% H2SO4 (2 points)
Other points:
1. Able to construct elemental/ component balances and assumptions made = 3 points
2. Understanding of the problem = 3 points
Total = 17 points
#3
Rxns:
4.FeS2(s) + 11.O2(g) - 2.Fe2O3(s)
+ 8.SO2(g)
4.FeS2(s) + 15.O2(g) - 2.Fe2O3(s)
+ 8.SO3(g)
SO2(g)
+ 0.5. O2(g)
SO3(g)
Solution:
Basis: 100 kg dry pyrite (as stated in the problem..no need to set a different basis otherwise you will still have to
correct it)
S = 48kg or 1.5kmol
FeS2=90kg
Fe2O3=60kg
Gangue=10kg
C = wt. cinder = Fe2O3 + SO3 + gaunge
%Wt.So3,cinder = 100% - 95% (Note: this is the corrected)
C = 0.05C + 70 + 10
C=73.68kg
So3 in cinder = 0.05*73.68/80 = 0.046kmol
Let A = dry air; B = so3-free burner gas; x =so3 in burner gas
S bal:
1.5 = 0.046 + 0.0825B + x
N2 bal:

--1

0.79A = 0.839B
--2
O2 bal:
0.21A = 0.0785B + 0.0825B(11/8) + 0.046(15/8) + x(15/8) --3
A=16.03kmol dry air
B=15.125kmol so3-free burner gas
3.1) X=0.206kmol so3 in burner gas (5 points)
Burner gas analysis:
So2=1.248
So3=0.206
O2=1.187
N2=12.69
3.2) the answer is actually the given waste gas composition (3 points)..no need to compute but more points will
be added if one has solved the moles of gases leaving the converter
let x = o2 used for conversion of so2 to so3; y = additional oxygen used for the conversion; w = so3-free waste
gas
(it is not stated that there is no additional air used in the converter)
O2 bal:
1.187 + y = 0.0468w + x
--1
S02 bal only since all so3 will be absorbed:
1.248 = 0.0093w + x(1/0.5) --2
N2 bal:
12.69 + y(79/21) = 0.9439w
--3
x=0.5614, o2 used for the conversion
y=0.0044, kmol o2 additional
3 points
w=13.462,kmol so3-free waste gas
converter gas analysis:
so2 = 1.248 (0.5614/0.5) = 0.125
so3 = 0.206 + (0.5614/0.5) = 1.329
o2 = 1.187 (0.5614 + 0.004) = 0.622
n2=12.69 + (0.0044*79/21) = 12.675
a) Total SO3 produced = (0.5614*1/0.5) + 0.206 = 1.329 or 106.32kg.
Let A = absorbing liquid; P = product
So3 bal:
106.32 + 0.761(80/98)D = (80/98)P
Over-all:
106.32 +D = P
3.3)

P=206.4kg. (5 points)
D=100kg.

Other points:
1. Able to construct elemental/ component balances and assumptions made = 4 points
2. Understanding of the problem = 3 points
Total = 23 points (3 points bonus)

#4
Rxns:
CaCO3

CaO + CO2

C + O2 - CO2
H2 + 0.5.O2 - H2O

CaCO3
CaO
CO2

MW
100
56
44

Solution 1:
Assumptions:
1. Burnt lime is lime + ash = 1000
2. negligible N,S in coal
Basis: 1000kg/hr of burnt lime + inerts + ash
Let y=kg,CaO; A = kmol air; B = kg coal; E = kmol, kiln gas ; x = kmol H2O produced
Burnt Lime = 1000 = y + (0.0637B)
1000 = [y + (0.0637B)]
--1
C bal:
(0.7831/12)B + (y/56) = 0.191E
--2
H bal:
(0.0526/2)B = x
--3
N2 bal:
0.79A = 0.741E
--4
O2 bal:
0.21A + [0.0761/(16*2)]B = 0.068E + (0.7831/12)B + (x/2)

--5

A=200.6kmol air
B=358.5kg coal
E=213.9 kmol kiln gas
x=10.08kmol water produced
y=977.2kg CaO
4.1) fuel ratio = 977.2/358.5=2.73 (5 points)
4.2) excess air = 14.865kmol (5 points)
4.3)
Heat from coal
11,808,675.824kJ
Heat of CaCO3 decomposition
Sensible heat, kiln gas
Sensible heat, lime
Heat Loss
(5 points)

3,102,486.175kJ
1,984,280.737kJ
183,897.321kJ

% distribution
26.273
16.804
1.557
55.366

Other points:
1. Able to construct elemental/ component balances and assumptions made = (5 points)
2. Understanding of the problem = (5 points)
Total = 25 points

Solution 2:
Assumptions:
1. Burnt lime is lime = 1000kg
2. No ash in lime
3. negligible N,S in coal
Basis: 1000kg/hr of burnt lime, CaO
CaCO3 = 1000/56*100 = 1785.714kg.
Let A = kmol air; B = kg coal; E = kmol, kiln gas ; x = kmol H2O produced
Burnt Lime = 1000kg CaO
C bal:
(0.7831/12)B + (1,785.71/100) = 0.191E --1
H bal:
(0.0526/2)B = x
--2
N2 bal:
0.79A = 0.741E
--3
O2 bal:
0.21A + [0.0761/(16*2)]B = 0.068E + (0.7831/12)B + (x/2)
--4

A=208.63kmol,air
B=377.3kg.,coal
E=222.42kmol, kiln gas
x=9.92kmole water produced
4.1) fuel ratio = 1000/377.3=2.65 (5 points)
4.2) excess air = 15.125kmol (5 points)
4.3)
Heat from coal
12,426,950.416 kJ
Heat of CaCO3 decomposition
Sensible heat, kiln gas
Sensible heat, lime
Heat Loss
(5 points)

3,175,000 kJ
2,058,446.279 kJ
183,897.321 kJ

% distribution
25.55
16.564
1.48
56.406

Other points:
3. Able to construct elemental/ component balances and assumptions made = (5 points)
4. Understanding of the problem = (5 points)
Total = 25 points
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