CHE 231 Material & Energy

Balance Fundamentals
Fall 2024/2025

Lecture 8:
DOF of Multiple Reaction systems
 Mixer
Recycling
combined
Fresh
feed
feed Product
Reactor Separator

Recycle stream
(unreacted reactants)

Benefits of recycling in processes involving chemical

reactions:
 Increasing the overall conversion
 Recovery of catalysts and reagents
 Recycling of the unreacted reactants
 Saving money
 Single Pass Conversion and Overall Conversion
Mixer

Fresh combined
100 moles 75 moles
100
75 moles B 75 moles
feed Afeed B
AA Product
Reactor 25 moles Separator
A

Recycle stream25 moles

A
(unreacted reactants)

Single pass conversion=

Overall conversion=

A B
 Single Pass Conversion and Overall Conversion

100 moles 75 moles

75 moles B 75 moles
A B
Product
A
Reactor 25 moles Separator
A

Recycle stream25 moles

A
(unreacted reactants)

Single pass conversion=

Overall conversion=

A B
Example

For the recycle problem shown, A and B react according to:

A+3B 2C
The single pass conversion around the reactor is 20% and the ratio of B
to A in the combined feed stream to the reactor is 3.2. The separator
will separate all C and part of B as liquids from the bottom. An amount
of only 1% of B in stream 3 will be in the bottom product 5. Calculate
the flow rates and compositions of all streams based on a selected
(4)
basis. A
B

(1) (2) (3)

Mixer Reactor Separator
A A A
B B B
C (5)
B
C
 Mixer Reacto Separa Overal Proces
r tor l s
6 5+1 7 4+1 11+
nv
1
2 3 3 3 8 A+3B
ne
0 0 0 0 0 𝐁 2C
𝟐
ngv
=𝟑 . 𝟐
nAR 1 2 1 0 3 𝐀𝟐
Conversion
ndof 3 1 3 2 1
B(5) = 0.01
(Reactor)=0.2
Under specified B(3)

Needs one given to be solved

(4)
A
B

(1) (2) (3)

Mixer Reactor Separator
A A A
B B B
C (5)
B
C
 Basis: A2 = 1 mole/h, Start from Reactor 𝐁 𝟐
Mixer: =𝟑 . 𝟐
A+3B
1:
2 C A1 = A2 – A4 = 0.2 𝐀 𝟐
Conversion
B2 = 3.2 moles/h B1 = B2 – B4 = 0.626
A3 = A 2 = 1 𝐀 𝟏 moles/h 𝐁𝟏 B5 = 0.01 B3
(Reactor)=0.2
B3 = B2 = 3.2 =𝟎 . 𝟐𝟒𝟐 =𝟎 . 𝟕𝟓𝟕
moles/h
C3 = 𝐅𝟏 𝐅𝟏
r=-x =-0.2*0.2 moles/h

r0.2
moles/h
A3 = 0.8 moles/h
B3 = 2.6 moles/h
C3 =0.4 moles/h (4)
Separato A
B
A4 = A3 = 0.8
r:
C5 = C3 = 0.4 (1) (2) (3)
Mixer Reactor Separator
moles/h A
B5 = 0.026 moles/h A A
moles/h B B B
B4 = 2.574𝐁 moles/h C (5)
𝟓 𝟓
= 𝟎 .𝟗𝟑𝟖 =𝟎 . 𝟎𝟔𝟏 B
𝐅 C
 Purging
Mixer

combined
Fresh Product
feed
feed Separato
Reactor r

Recycle Purge
stream

splitter
A purge stream is one where a portion of a recycled stream is removed from
system in order to avoid accumulation of undesired material in a recycled
system.
 Note#6
Fresh
feed A+B r1 C Product
A+C r3 D
A+C r2 D

In the process degree of freedom: the number of stream

variables will be increased by 3: (r1 , r2 & r3).

In the Overall degree of freedom: the number of stream

variables will be increased ONLY by 2: (Since there is a repeated
reaction ).
For the overall: (r2+r3) is roverall
Example
The shift reaction is often conducted industrially in two separate reactor beds
each contain different type of catalyst. A mixture of producer and water gas
(same composition as previous problem) is reacted with steam to produce a
product stream containing hydrogen and nitrogen in a 3:1 ratio. If the steam
flow rate is adjusted to be twice the total dry gas flow rate and if 80%
conversion occurs in the first reactor, calculate the composition of the
N2
intermediate 78%
stream.
CO (1 Reactor Reactor
(4) (5)
20% ) 1 2
N2 N2
CO2 (2)
H2 H2
(3)
CO CO2
H2
CO2 H2O
50% H2O
H2O
CO
 Reactor Reactor Overall Proce
1 2 ss
11+1 9+1 10+ 15+
nv
1 2 CO + H2O CO2 +
ne 5 5 5 10
H2
ngv 3 0 3 3
F3= 2(F1+F2)
nAR 2 1 2 3
Conversion (R1)=0.8
ndof 2 4 1 1 𝐇 𝟐( 𝟓) 𝟑
=
Under specified 𝐍𝟐( 𝟓) 𝟏
Needs one given to be solved

N2
78%
CO (1 Reactor Reactor
(4) (5)
20% ) 1 2
N2 N2
CO2 (2)
H2 H2
(3)
CO CO2
H2
CO2 H2O
50% H2O
H2O
CO
Basis: F1 = 100 moles/h, Start from the
F3= 2(F1+F2)
CO + H2O CO2 + Reactor 1:
overall
N2(5) =N2(1) = 78 moles/h N2(1) =N2(4) = 78 moles/h 𝐇𝟐(𝟓) 𝟑
Conversion (R1)=0
H2 =
H2(5) = 234 moles/h 1
𝐍𝟐(𝟓) 𝟏
1
overall
1
overall
1
overall

overall r1=-x =-0.8*101.6 moles/h

F2 = 214 moles/h, overall = 127 moles / h
F3 = 628 moles/h moles/h
moles/h
moles/h
moles/h
moles/h
moles/h
N2 N782
78%
moles/h
CO CO
20 (1 Reactor Reactor
(4) (5)
20%
moles/h ) 1 2
N2 N2
CO2
CO2 2 (2)
H2 H2
moles/h (3)
CO CO2
H2
CO2 H2O
50% H2O
 CO + H2O CO2 + F3= 2(F1+F2)
= 127 moles / h
overall
H2 𝐇𝟐(𝟓) 𝟑
Conversion (R1)=0
Reactor 1: Reactor 2: =
N2(1) =N2(4) = 78 moles/h Conversion% = x 100
𝐍𝟐(𝟓) 𝟏
1

1
Conversion% = x 100
1

1
Conversion% = x 100= 100%
=101.6 moles/h
1

moles/h r2=-x =-1*25.4 moles/h

moles/h
moles/h r225.4 moles/h
moles/h
N2 N78
r overall r1+ 2
78%
moles/h
r2 CO CO
20 (1 Reactor
(4)
Reactor
(5)
20%
moles/h ) 1 2
N2 N2
CO2
CO2 2 (2)
H2 H2
moles/h (3)
CO CO2
H2
CO2 H2O
50% H2O
Example
Propane is dehydrogenated to form propylene in a catalytic reactor
C3H8 C3H6 + H2
The process is to be designed for 95% OVERALL CONVERSION of propane. The
reaction products are separated into two streams: the first; which contains H 2,

C3H6 and 0.555% of the propane that leaves the reactor, is taken off as a
product.
The second stream; which contains the balance of the unreacted propane and
5% of the propylene in the product stream is recycled to the reactor.

Separator
Calculate the composition of the product, the ratio (moles recycled)/(moles
fresh feed), and single pass conversion.
(1) (2) (3) (4)
M Reactor C3 H 8 C3 H 8
C3 H 8 C3 H 8
C3 H 6 C3 H 6 C3 H 6
(5) H2 H2
C3 H 8
C3 H 6
 Mixer Reacto Separa Overal Proces
r tor l s
5 5+1 8 4+1 11+
nv
1
2 3 3 3 8
ne C3H8 C3H6 + H2
ngv 0 0 0 0 0
C3H8(4) = 0.00555
nAR 0 0 2 1 3
Conversion
C3H8(3)
3 3 3 1 1 C3H6(5) = 0.05 C3H6(3)
ndof (Overall)=0.95
Under specified

Needs one given to be solved

Separato
(1) (2) (3) (4)

r
M Reactor C3 H 8 C3 H 8
C3 H 8 C3 H 8
C3 H 6 C3 H 6 C3 H 6
(5) H2 H2
C3 H 8
C3 H 6
 Basis: F1 = 100 moles/h, Start from the C3H8(4) = 0.00555
C3H8 C3H6 + H2 Conversion
overall: Mixer: C3H8(3)
overall C3H6(5) = 0.05 C3H6(3)
overall C3H6(2) C3H6(5) 5 moles/h(Overall)=0.95
overall C3H8(2) C3H6(1) C3H6(5) 995.9 moles/h
Single pass Conversion% = x 100%
overall =-x =-0.95*95 moles/h
Single pass Conversion% = x 100= 9.54%

moles/h
reactor =-x =-0.095*95 moles/h
C 3 H 6(𝟒) =𝟗𝟓 moles / h
H 2(𝟒) =𝟗𝟓 moles / h 𝐲𝐂 𝟑 𝐇𝟖 =𝟎 .𝟎𝟐𝟓𝟔 , 𝐲 𝐂 𝐇 =𝟎 . 𝟒𝟖𝟕 , 𝐲 𝐇 =𝟎 . 𝟒𝟖𝟕
𝟑 𝟔 𝟐

=
Separator:
H 2(𝟑)=H 2(𝟒) =𝟗 𝟓 moles / h

Separato
C3H8(3) 900.9
C3H6(4) 0.95* (1) (2) (3) (4)

r
moles/h M Reactor C3 H 8 C3 H 8
C3 H 8 C3 H 8
C3H
C H6(3) 100 moles/h C3 H 6
3 6(3) C3 H 6 C3 H 6
C3H8(5) C3H8(3) C3H8(4) 895.9 moles/h (5) H2 H2
C3H6(5) C3H6(3) C3H6(4) 5 moles/h C3 H 8
C3 H 6
Example
The fresh feed of an ammonia production process contains 24.75 mole% nitrogen,
74.25 mole% hydrogen, and the balance inerts (I). The feed is combined with the
recycle stream containing the same species, and the combined stream is fed to a
reactor in which a 25% single pass conversion of nitrogen is achieved. The
products pass through a condenser in which essentially all the ammonia is
removed, and the remaining gases are recycled. However, to prevent the build up
of the inerts in the system, a purge stream must be taken off. The recycle stream
(6)
contains 12.5 mole% inerts. Calculate the overall conversion of nitrogen, the ratio
(7) S N2
(5)
(moles purge gas/mole of N2gas leaving the condenser), the
N 2ratio (moles
H2 of fresh
H
H2 2
I 12.5
feed/moles fed to the reactor) I 12.5
I 12.5 %
%
Condense
M % Reactor
(1) (2) (3) r (4)
24.75% N2 N2 N2 NH3
74.25% H2 H2 H2
I I NH3
 Mixer React Condens Splitt Overa Proces
or er er ll s S= (N-1)(M-1) = (3-1)(2-1) =2
9 7+1 8 9 7+1 20+
nv
1
3 4 4 3 4 14
ne N2 + 3H2 2NH3
ngv 3 0 1 1 3 3
Conversion N2
nAR 0 1 0 S 0 1+S
(Reactor)=0.25
ndof 3 3 3 3 1 1

Under specified

Needs one given to be solved

(6)
(7) S N2
(5)
N2 N2
H2
H2
H2 I 12.5 I 12.5
I 12.5 %
%
Condense
M % Reactor
(1) (2) (3) r (4)
24.75% N2 N2 N2 NH3
74.25% H2 H2 H2
I I NH3
 Basis: F1 = 100 moles/h, Start from the Conversion N2
Noverall:
+ 3H 2NH Condenser:
2 2 3
NH3(3) NH3(4) 46 moles/h (Reactor)=0.25
mole/h
I (𝟔) =𝟏=𝟎 .𝟏𝟐𝟓 ∗ F 6 Reactor:
moles/h reator
23
reator
overall
moles/h
H 2(𝟔)=𝟕𝟒 .𝟐𝟓 −3 r overall
reator

overall
H 2(𝟑)=H 2(𝟐) −3 r reator ¿ H 2(𝟐) − 69
Conversion% = x 100%= x 100%= 25%
moles/h
moles/h moles/h
moles/h moles/h
N H3(𝟒) =𝟒𝟔 moles / h
N 2( 𝟔)=𝟏 . 𝟕𝟓 moles / h (7) S
(6)
H 2( 𝟔)=𝟓 . 𝟐𝟓 moles / h N2
(5)
N2
N2
H2 H2 H2
Overall Conversion% = x 100% I 12.5
I 12.5 % I 12.5
= x 100%= % Condense %
M % Reactor
(1)
(1) (2) (3) r (4)
24.75%
24.75 N2
moles/h N2 N2 NH3
N2
74.25% H2 H2 H2
74.25 moles/h
I I NH3
H I
 Conversion N2
Splitter:
N2 + 3H2 2NH3 = = =0.02536 (Reactor)=0.25
Condenser:
NH3(3) NH3(4) 46 moles/h 315.42 moles/h
Reactor:
307.428 moles/h
NH
reator3(3)
NH3(4) 46 moles/h
reator 23 407.428 moles/h
reator moles/h = =0.2454
H 2(𝟔)=H 2(𝟐) −3 r reator ¿ H 2(𝟐) − 69
Conversion% = x 100%= x 100%= 25%
moles/h
moles/h
Mixer:
67.25 moles/h
(7) (2) (1)

OR: Condenser:
(2) (5)

(7) (5) (6) 67.25 moles/h