Recycle: M.B.
Involving Reactions
Q. 1. A catalytic reactor is used to produce formaldehyde from methanol. [CH 3OH🡪 HCHO + H2 ]. A single
pass conversion of 60% is achieved in the reactor. The methanol in the reactor product is separated from the
formaldehyde and hydrogen in a multi-unit process. The production rate of formaldehyde is 900 kg/h. (i)
calculate the required rate of methanol to the process (kmol/h) if there is no recycle (ii) suppose the recovered
methanol is recycled to the reactor and the single pass conversion remains 60% determine the required fresh rate
of methanol (kmol/h) and the rates (kmol/h) at which methanol enters and leaves the reactor. Find the overall
conversion for case (ii). (iii)Comment from case (i) and case (ii) results. (End Sem 2017)
[5]
Q. 2. Sulphur dioxide may be converted to SO 3, which has many uses, including the production of H 2SO4 and
sulfonation of detergent. A gas stream having the composition shown in following figure is to be passed through
a two-stage converter (1 and 2). The fraction conversion of the SO 2 to SO3 (on one pass though) in the first stage
is 0.75 and in the second stage, 0.65. To boost the overall conversion to 0.95, some of the exit gas from stage 2
is recycled back to the inlet of stage 2. Find (i) the composition (mole%) of exit stream from first stage (ii)
composition (mole%) of exit stream from second stage and (iii) How much must be recycled per 100 mol of
inlet gas (stream F)? Ignore the effect of temperature on the conversion.
(End Sem 2018) [2+2+3]
SO2 10% SO
F
O2 9% 1 SO
2
N2 81% O
N
R
Q. 3. 2000 kg/day of HI is mixed with methanol, and the following chemical reaction takes place (HI +
CH3OH⟶CH3I + H2O). Methanol is the excess reactant. The output stream contains 81.6 wt% of CH 3I. The
purge stream contains 82.6 wt% HI and 17.4 wt% H 2O. The conversion of the reaction is 40%, and the rest of
the HI is returned to the reactor by a recycle sub-stream. Estimate (i) the mass of methanol needed daily (ii) the
mass of HI in the recycle stream. (END SEM 2022)
