2

LEARNING OBJECTIVES
By the end of this topic, you should be able to:

Performed material balance for system for multiple
unit.
3
What will we learn today?
The different between
Bypass and Recycle.
Distinguish mixing vs. splitting
points.
Material balances involving the
above mentioned processes.
BYPASS AND RECYCLE
Similar to a recycle, but a fraction of a stream
is diverted around a process unit, rather than
being returned to it.
Calculation approach is identical.
It is seldom cost effective to waste reactant fed that does not react
to product. More often, this material is separated (recovered), and
recycled (returned to its point of origin for reuse).
recover catalyst
typically most expensive chemical constituent
dilute a process stream
reduce slurry concentration
control a process variable
control heat produced by highly exothermic
reaction
circulation of a working fluid
refrigerant
7
OUTPUT INPUT
Recycle
OUTPUT
INPUT
Mixing
Points
Splitting
Points
Splitting
Points
Mixing
Points
Bypass
Note:
At splitting
points, the
components
mass
fractions
remain the
same. The
ONLY
difference is
the mass
flow rate.
BYPASS AND RECYCLE
8
Fresh orange juice contains 12.0 wt% solids and the
balance water, and concentrated orange juice contains
42.0 wt% solids. Initially a single evaporation process was
used for the concentration, but volatile constituents of the
juice escaped with the water, leaving the concentrate with
a flat taste. The current process overcomes the problem
by bypassing the evaporator with a fraction of fresh juice.
The juice that enters the evaporator is concentrated to 58
wt% solids, and the evaporator product stream is mixed
with the bypassed fresh juice to achieve the desired final
concentration.
Draw and label the flowchart. Perform the degrees of
freedom analyses. Calculate the amount of product (42%
concentrate) produced per 100 kg fresh juice fed to the
process and the fraction of the feed that bypasses the
evaporator.
EXAMPLE
9
Step 1. Draw and label the flowchart.
Evaporate
m
o
0.12 kg S / kg
0.88 kg W / kg
m
1
0.12 kg S / kg
0.88 kg W / kg
m
2
0.12 kg S / kg
0.88 kg W / kg
m
5
0.42 kg S / kg
0.58 kg W / kg
m
3
(kg W)

Bypas
s
Mixin
g
Point
m
4
0.58 kg S / kg
0.42 kg W / kg
EXAMPLE
10
Step 2. Choose a basis of calculation: Given 100 kg fresh juice.
Step 3. Perform the DoF analysis.
Evaporate
100 kg

0.12 kg S / kg
0.88 kg W / kg
m
5
0.42 kg S / kg
0.58 kg W / kg
m
3
(kg W)

m
1
0.12 kg S / kg
0.88 kg W / kg
m
2
0.12 kg S / kg
0.88 kg W / kg
m
4
0.58 kg S / kg
0.42 kg W / kg
Overall : 100 = m
3
+ m
5
S : (0.12)(100) = 0 + 0.42m
5
W : (0.88)(100) = m
3
+ 0.58m
5
Balances
Degrees of Freedom
2 Unks. (m
3
, m
5
)
- 2 IEs
0 DoF
EXAMPLE
11
Step 3. Perform the DoF analysis (Continuation).
Evaporate
100 kg

0.12 kg S / kg
0.88 kg W / kg
m
1
0.12 kg S / kg
0.88 kg W / kg
m
2
0.12 kg S / kg
0.88 kg W / kg
m
4
0.58 kg S / kg
0.42 kg W / kg
m
5
0.42 kg S / kg
0.58 kg W / kg
m
3
(kg W)

Overall : 100 = m
1
+ m
2
S : (0.12)(100) = 0.12m
1
+ 0.12m
2
Balances
W : (0.88)(100) = 0.88m
1
+ 0.88m
2
Degrees of Freedom
2 Unks. (m
1
,
m
2
)
- 2 IEs
0 DoF
B
y
p
a
s
s

EXAMPLE
12
Step 3. Perform the DoF analysis (Continuation).
Evaporate
100 kg

0.12 kg S / kg
0.88 kg W / kg
m
1
0.12 kg S / kg
0.88 kg W / kg
m
2
0.12 kg S / kg
0.88 kg W / kg
m
4
0.58 kg S / kg
0.42 kg W / kg
m
5
0.42 kg S / kg
0.58 kg W / kg
m
3
(kg W)

Overall : m
1
= m
3
+ m
4
S : 0.12m
1
= 0.58m
4


Balances
W : 0.88m
1
= 0.42m
4
+ m
3
Degrees of Freedom
3 Unks. (m
1
, m
3
,
m
4
) - 2 IEs
1 DoF
E
v
a
p
o
r
a
t
o
r

EXAMPLE
13
Step 3. Perform the DoF analysis (Continuation).
Evaporate
100 kg

0.12 kg S / kg
0.88 kg W / kg
m
1
0.12 kg S / kg
0.88 kg W / kg
m
2
0.12 kg S / kg
0.88 kg W / kg
m
4
0.58 kg S / kg
0.42 kg W / kg
m
5
0.42 kg S / kg
0.58 kg W / kg
m
3
(kg W)

Overall : m
4
+ m
2
= m
5
S : 0.12m
2
+ 0.58m
4
= 0.42m
5

Balances
W : 0.88m
2
= 0.42m
4
+ 0.58m
5
Degrees of Freedom
3 Unks. (m
2
, m
4
,
m
5
) - 2 IEs
1 DoF
M
i
x
i
n
g

P
o
i
n
t

EXAMPLE
14
Step 4. Do the algebra. Solve the balance equations.
Calculate the amount of product (42% concentrate) produced per
100 kg fresh juice fed to the process and the fraction of the feed
that bypasses the evaporator.
Lets start with the Overall Process because DoF = 0
Overall: 100 = m
3
+ m
5
S: (0.12)(100) = 0.42m
5
W: (0.88)(100) = m
3
+
0.58m
5
Recall the material balances for overall
process
1
2
3
From (2) : m
5
= 28.6
kg
From (1) : m
3
= 71.4 kg
Amount of product !
EXAMPLE
15
Step 4. Do the algebra. Solve the balance equations
(Continuation). Include the new values that we have
obtained.
Evaporate
100 kg

0.12 kg S / kg
0.88 kg W / kg
m
1
0.12 kg S / kg
0.88 kg W / kg
m
2
0.12 kg S / kg
0.88 kg W / kg
m
4
0.58 kg S / kg
0.42 kg W / kg
28.6
kg

0.42 kg S / kg
0.58 kg W / kg
71.4

(kg W)

DoF (updated)
2 unknowns (m
2
, m
4
)
- 2 IEs

0 DoF

Overall : m
4
+ m
2
= m
5
S : 0.12m
2
+ 0.58m
4
=
0.42m
5

Balances
W: 0.88m
2
= 0.42m
4
+
0.58m
5
Known m
5
= 28.60 kg
Solve for m
4
= 18.70 kg
m
5
= 9.95 kg
EXAMPLE
16
Step 4. Do the algebra. Calculate the amount of product
(42% concentrate) produced per 100 kg fresh juice fed to the
process and the fraction of the feed that bypasses the
evaporator (Continuation).
Evaporato
r
100 kg

0.12 kg S / kg
0.88 kg W / kg
m
1
0.12 kg S / kg
0.88 kg W / kg
9.95 kg

0.12 kg S / kg
0.88 kg W / kg
18.70 kg

0.58 kg S / kg
0.42 kg W / kg
28.6
kg

0.42 kg S / kg
0.58 kg W / kg
71.4

(kg W)

The bypass
fraction
0995 . 0
100
95 . 9
100
2

m
EXAMPLE
17
A liquid mixture containing 30.0 mole% benzene (B), 25.0%
toluene (T) and the balance xylene (X) is fed to a distillation
column. The bottoms product containing 98.0 mole% X and no B,
and 96.0% of the X in the feed is recovered in this stream. The
overhead product is fed to a second column. The overhead
product from the second column contains 97.0 % of the B in the
feed to this column. The composition of this stream is 94.0
mole% of B and the balance T.
(a) Draw and label flowchart. Do the degree-of-freedom analysis
to prove that for an assumed basis of calculation, molar flowrate
and compositions of all process streams can be calculated from
the given information.
(b) calculate (i) the percentage of the benzene in the process
feed (the feed to the first column) that emerges in the overhead
product from the second column and (ii) the percentage of
toluene in the process feed that emerges in the bottom product
from the second column.
EXAMPLE
18
(a) Draw and label flowchart. Do the degree-of-freedom analysis to
prove that for an assumed basis of calculation, molar flowrate and
compositions of all process streams can be calculated from the given
information.
100 mol/h


Column
1


(mol/h)
2
n

X
B2
(mol B/mol)
X
T2
(mol T/mol)
1 - X
B2
-X
T2
(mol
X/mol)
(mol/h)
3
n

0.300 mol B/mol

0.250 mol T/mol
0.450 mol X/mol
0.020 mol T/mol
0.980 mol X/mol
0.940 mol B/mol
0.060 mol T/mol


Column
2


X
B5
(mol B/mol)
X
T5
(mol T/mol)
1 - X
B5
-X
T5
(mol
X/mol)
(mol/h)
4
n

(mol/h)
5
n

EXAMPLE
19
(a) Draw and label flowchart. Do the degree-of-freedom analysis to
prove that for an assumed basis of calculation, molar flowrate and
compositions of all process streams can be calculated from the given
information.
DoF Column 1
4 unknowns
- 3 Independent
eq
n
- 1 Recovery of X
0 DoF
DoF Column 2
4 unknowns
- 3 Independent
eq
n
- 1 Recovery of X
0 DoF
Column 1
96% X Recovery: (1)
Total mole balance:
(2)
B Balance: (3)

T Balance: (4)
3
0 98 . 0 ) 100 )( 450 . 0 ( 960 . 0 n

3 2
100 n n


2 2
) 100 ( 300 . 0 n x
B

3
0.020
2 2
) 100 ( 250 . 0 n n x
T


Column 2
97% B Recovery: (5)
Total mole balance:
(6)
B Balance: (7)

T Balance: (8)

5 4 2
n n n


5 5 2
940 . 0
2 2
n x n n x
B B


5 5 4
060 . 0
2 2
n x n n x
T T


4
940 . 0
2 2
970 . 0 n n x
B


EXAMPLE
20
(b) Calculate (i) the percentage of the benzene in the process feed
(the feed to the first column) that emerges in the overhead product
from the second column and (ii) the percentage of toluene in the
process feed that emerges in the bottom product from the second
column.
mol/h 44.1
3
n

Solving all the balances and obtain these

results:
mol/h 55.9
2
n

B/h mol 0.536

2

B
x
mol/h 30.95
4
n

mol/h 24.96
5
n

T/h mol 0.431

2

T
x
B/h mol 0.036
5

B
x
T/h mol 0.892
5

T
x
EXAMPLE
21
(b) Calculate (i) the percentage of the benzene in the process feed
(the feed to the first column) that emerges in the overhead product
from the second column and (ii) the percentage of toluene in the
process feed that emerges in the bottom product from the second
column.
Overall Benzene Recovery:
97% 100% x
) 100 ( 300 . 0
) 95 . 30 ( 940 . 0

Overall Toluene Recovery:

89% 100% x
) 100 ( 250 . 0
) 96 . 24 ( 892 . 0

EXAMPLE
Degree-of-freedom analysis
overall system: 2 unknowns 2 balances = 0 (find m
3
, x
3
)
mixer: 4 unknowns 2 balances = 2
Unit 1: 2 unknowns 2 balances = 0 (find m
1
, x
1
)
mixer: 2 unknowns 2 balances = 0 (find m
2
, x
2
)
For either (just 1) extractor unit,
solve acetone, MIBK, and water
balances to determine m
A2
, m
M2
,
and m
W2
.
process cools and dehumidifies feed air
unknowns: n
1
, n
2
, n
3
, n
4
, n
5
(requested by problem)
degree-of-freedom analysis critical to solution
basis
Overall system
n
df
= 2 variables (n
1
, n
3
) 2 balances = 0
Mixer
n
df
= 2 variables (n
2
, n
5
) 2 balances = 0
Cooler
n
df
= 2 variables (n
2
, n
4
) 2 balances = 0
Splitter
n
df
= 2 variables (n
4
, n
5
) 1 balances = 1
only 1 independent balance can be written on the splitter
because the streams entering/leaving have the same
composition.
) ) ) )
) ) ) ) 100 017 . 0 017 . 0 017 . 0
100 983 . 0 983 . 0 983 . 0
5 4
5 4


n n
n n
Overall: n
df
= 2 variables (n
1
, n
3
) 2 balances = 0
Mixer: n
df
= 2 variables (n
2
, n
5
) 2 balances = 0
Cooler: n
df
= 2 variables (n
2
, n
4
) 2 balances = 0
Splitter: n
df
= 2 variables (n
4
, n
5
) 1 balances = 1
To find requested unknowns, solve overall
balances followed by mixing balances.
There is no need to solve the cooler or splitter
balances.
overall dry air balance
overall mole balance


0.960
)
n
1
0.983
)
100
)
n
1
102.4mol
n
1
n
3
100
)
n
3
2.4 mol H
2
O condensed
overall mole balance
water balance
solved simultaneously:
) ) )
mol 290 n ; mol 5 . 392 n
n 023 . 0 n 017 . 0 n 04 . 0
n n n
5 2
2 5 1
2 5 1



Calculate:
rate of evaporation
rate of production of crystalline K
2
CrO
4
feed rates to evaporator and crystallizer
recycle ratio (mass or recycle/mass of fresh feed)
Overall system:
n
df
= 3 unknowns (m
2
, m
4
, m
5
) 2 balances 1 spec = 0
specification: m
4
is 95% of total filter cake mass
)
5 4 4
m m 95 . 0 m


Feed/recycle mixer:
n
df
= 3 unknowns (m
6
, m
1
, x
1
) 2 balances = 1
underspecified
)
5 4 4
m m 95 . 0 m
Evaporator:
n
df
= 3 unknowns (m
3
, m
1
, x
1
) 2 balances = 1
underspecified
)
5 4 4
m m 95 . 0 m
Crystallizer:
n
df
= 2 unknowns (m
3
, m
6
) 2 balances = 0
solvable
Once m
3
, m
6
are known, mixer or evaporator balances can be
solved.
)
5 4 4
m m 95 . 0 m
Overall system:
K
2
CrO
4
balance
water balance
total mass balance
specification
) ) )
) ) )
)
5 4 4
5 4 2 h
kg
5 2 h
K kg
5 4 h
K kg
m m 95 . 0 m
m m m 4500
m 636 . 0 m 4500 667 . 0
m 364 . 0 m 4500 333 . 0








solve simultaneously for m
4
and m
5
h
kg
m
crystals K
4
1470
solu W/kg kg 0.636
solu K/kg kg 364 . 0
5 . 77
solution
5 h
kg
m
Overall system:
K
2
CrO
4
balance
water balance
total mass balance
specification
solve for m
2
with knowns m
4
and m
5
h
O H kg
2
2
2950 m
h
kg
m
crystals K
4
1470
solu W/kg kg 0.636
solu K/kg kg 364 . 0
5 . 77 m
h
solution kg
5

) ) )
) ) )
)
5 4 4
5 4 2 h
5 2 h
K
5 4 h
K
95 . 0
4500
636 . 0 4500 667 . 0
364 . 0 4500 333 . 0
m m m
m m m
m m
m m
kg
kg
kg








Overall system:
K
2
CrO
4
balance
water balance
total mass balance
specification
only 3 equations are independent

h
O H kg
2
2
2950 m
h
kg
m
crystals K
4
1470
solu W/kg kg 0.636
solu K/kg kg 364 . 0
5 . 77 m
h
solution kg
5

) ) )
) ) )
)
5 4 4
5 4 2 h
kg
5 2 h
K kg
5 4 h
K kg
m m 95 . 0 m
m m m 4500
m 636 . 0 m 4500 667 . 0
m 364 . 0 m 4500 333 . 0








Crystallizer:
total mass balance

water balance
)
) ) )
6 h
kg
3
6 5 3
6 h
kg
3
6 5 4 3
m 257 . 1 4 . 97 m
m 636 . 0 m 636 . 0 m 506 . 0
m 5 . 77 1470 m
m m m m








h
O H kg
2
2
2950 m

solve simultaneously for m

3
and m
6
h
kg
3
7200 m
h
kg
m
crystals K
4
1470
solu W/kg kg 0.636
solu K/kg kg 364 . 0
5 . 77 m
h
solution kg
5

h
kg
6
5650 m
feed/recycle mixer:
total mass balance
water or K
2
CRO
4
balance could be used tp find x
1
if desired
h
kg
1 1 6 h
kg
10150 m m m 4500

h
kg
1
10150 m
h
O H kg
2
2
2950 m
h
kg
3
7200 m
h
kg
6
5650 m
h
kg
m
crystals K
4
1470
If recycle is not used,
crystal production is 622 kg/h vs 1470 kg/h (w/
recycle)
discarded filtrate (m
4
) is 2380 kg/h, representing
866 kg/h of potassium chromate
What are cost consequences of using recycle
vs not?

48
Sea water with the below data is entering 10 units evaporators.
Roughly each unit, equally amount of water is vaporized then
condensed and combined to obtain a fresh water. determine the
fractional yield of fresh water from process (kg H
2
O recovered / kg
H
2
O in process feed) and the weight percentage of salt in the solution
leaving fourth stage.