Chemical Process Principles

(CLB10904)

CHAPTER 2 MATERIAL BALANCE:

(PART 4):
RECYCLE, BYPASS & PURGE
MARMY ROSHAIDAH
SCET UniKL MICET
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Bypass
Stream that skips one or more stages of the
process and goes directly to another
downstream stage.
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Bypass
• A stream that skip one or more stages of the process
and goes directly to another downstream stage.
• Used to control the composition of the final exit
stream proportions to obtain the desired final
composition.
• Method of diverting certain portion of flow without
going through that particular unit.
• Withdrawn (throw) out from the system to avoid
buildup in the system. If not removed it will cause
accumulation and can be harmful to the process.
• Purposes: To divert flow for certain reason, reduce
certain parameter such as concentration, volume or
mass and etc.
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Check Your Understanding 4

Fresh apple juice (AJ) contains 12.0 wt% solids and the
balance water, and concentrated AJ contains 42 wt%
solids. The concentrated AJ is prepared by feeding 100kg/h
of fresh AJ to an evaporator. Prior to entering the
evaporator, a fraction of the fresh AJ is removed and this
stream bypasses the evaporator and rejoins the evaporator
concentrate stream. The juice that enters the evaporator is
concentrated to 58 wt% solids (pure water removed) and
the evaporator AJ product stream is mixed with the
bypassed fresh juice to achieve the desired final
concentration.
Calculate the amount of water leaves the evaporator in the
pure water stream and the mass flow rate of the bypass
stream.
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An evaporator is used to make concentrated AJ (42 wt%

solids, 58 wt% water) from fresh AJ (12 wt% solids, 88 wt%
water).
Bypass stream Need to adjust further
to have final product
of 42 wt%

Fresh AJ
Concentrated AJ
12 wt% solid Evaporator 42 wt% solids
88 wt% water
58 wt% water

Water

However concentrated AJ has a flat taste since some of the

volatile constituents in the fresh juice leave with the water.
How can we overcome this problem??
Solution: Bypass the evaporator with some fresh juice
Bypass helps to control product composition
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B ??? (kg/h) xSF= 0.12, xWF = 0.88

100 kg/h C (kg/h)

xSF= 0.12 Evaporator xSC = 0.42
xWF = 0.88 E (kg/h)
xWC = 0.58
xSE = 0.58
xWE = 0.42
W ??? (kg/h)
xWW = 1.00 (all water)
Do Overall System Balance:
Solid Balance: 0.12 (100 kg/h) = 0.42 (C kg/h)
Therefore, C = 28.6 kg/h
Water Balance: 0.88(100 kg/h) = W kg/h + 0.58(C kg/h)
Therefore, W = 71.4 kg/h (amount of water leaves the
evaporator in the pure water stream)
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B ??? (kg/h) xSF= 0.12, xWF = 0.88

100 kg/h 28.6 kg/h

xSF= 0.12 Evaporator xSC = 0.42
xWF = 0.88 E (kg/h)
xWC = 0.58
xSE = 0.58
xWE = 0.42
71.4 kg/h
xWW = 1.00 (all water)

Do Mixing Point Balance:

Solid Balance: 0.12 (B kg/h) + 0.58 (E kg/h) = 0.42 (28.6 kg/h)
Water Balance: 0.88(B kg/h) + 0.42 (E kg/h) = 0.58 (28.6 kg/h)
Therefore, E = 18.63 kg/h
B = 9.97 kg/h (Amount of fresh AJ in bypass)
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Recycle
Recycle with Chemical Reaction
• Recycle occurs when the desired reaction did
not convert 100% of the reactant.
• The leftover (residue) is then reused in the
reaction.

Recycle without Chemical Reaction

• Recycle of material occurs in a variety of
processes that do not involve chemical
reactions, including distillation, crystallization
and heating and refrigeration system
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Recycle with Chemical Reaction

Feed to the Reactor

1 Reactor 3

Recycle

Feed to the “process”

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Recycle with Chemical Reaction

Overall Conversion:
Overall Conversion of A
Reactant input to process - Reactant output from process
=
Reactant input to process

Single-Pass Conversion:
Single Pass Conversion of A
Reactant input to reactor - Reactant output from reactor
=
Reactant input to reactor
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Check Your Understanding 5

75mol 100mol 75mol
A/min
Product
A/min 25mol A/min B/min
Reactor Separation
75mol B/min Unit

25mol
A/min

The overall conversion of A is

75 mol A/min (IN) - 0 mol A/min (OUT)
Overall Conversion of A = ´ 100% =100%
75 mol A/min (IN)

The single-pass conversion of A at the reactor

100 mol A/min (IN) - 25 mol A/min (OUT)
Single Pass Conversion of A = ´ 100% =75%
100 mol A/min (IN)
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Check Your Understanding 6

Recovery of an antibiotic (AB) involves centrifuging
and separating the AB from the process water.
R (kg/h)
0.4 kg AB/kg W

Centrifuge Filter
98 kg/h C (kg/h) P (kg/h)
20 wt% AB 60 wt% AB 96 wt% AB
80 wt% W 40 wt% W 4 wt% W

W (kg/h)
100 wt% W
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R ??? (kg/h)
0.4 kg AB/kg W

Centrifuge Filter
98 kg/h C ?? (kg/h) P ?? (kg/h)
XAB = 0.2 XAB = 0.6 XAB = 0.96
XW = 0.8 XW = 0.4 XW = 0.04

W ?? (kg/h)
XW = 1.00

Do Overall System Balance

Total Balance: 98 kg/h = W (kg/h) + P (kg/h)
AB Balance: 0.2 (98 kg/h) = 0.96 (P kg/h)
Therefore W = 77.6 kg/h and P = 20.4 kg/h
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R ??? (kg/h)
0.4 kg AB/kg W

Centrifuge Filter
98 kg/h C ?? (kg/h) 20.4 kg/h
XAB = 0.2 XAB = 0.6 XAB = 0.96
XW = 0.8 XW = 0.4 XW = 0.04
77.6 kg/h
XW = 1.00

0.4 kg AB 0.4 kg AB
Recycle Stream: Given Þ
kg W 1kg W
Total Weight Fraction = 0.4 kg AB +1kg W =1.4 kg total
0.4 kg AB
X AB = = 0.29; X W =1- 0.286 =0.71
1.4 kg total
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R ??? (kg/h)
XAB = 0.29 XW = 0.71

Centrifuge Filter
98 kg/h C ?? (kg/h) 20.4 kg/h
XAB = 0.2 XAB = 0.6 XAB = 0.96
XW = 0.8 XW = 0.4 XW = 0.04

77.6 kg/h
XW = 1.00

Do Filter Unit Balance

Total Balance: C (kg/h) = R (kg/h) + 20.4 (kg/h)
AB Balance: 0.6(Ckg/h) = 0.96(20.4kg/h) + 0.286(Rkg/h)
Therefore we obtained R = 23.4 kg/h and C = 43.8
kg/h
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Check Your Understanding 7

m2 (kg)
XS = 0.005
m1 (kg) XW = 0.995
Xs= 0.04
1000kg Xw = 0.96 m3 (kg) m4 (kg)
SEPARATION
Xs = 0.031 Xs = ??
PROCESS
Xw = 0.969 Xw = ??
Xs = ??
Xw = ??
Recycle Stream

mR (kg)
Xs = 0.0525
Xw = 0.9475
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m2 (kg)
XS = 0.005
m1 (kg) XW = 0.995
Xs= 0.04
1000kg Xw = 0.96 m3 (kg) m4 (kg)
SEPARATION
Xs = 0.031 Xs = ??
PROCESS
Xw = 0.969 Xw = ??
Xs = ??
Recycle Stream Xw = ??

mR (kg)
Xs = 0.0525, Xw = 0.9475
m3 m4 When one stream split into two streams,
REMEMBER: the fractions (Xs and Xw) are same in all
mR
streams.

Xs(Stream 3) = Xs(Recycle Stream) = Xs(Stream 4)

Xw (Stream 3) = Xw(Stream R) = Xw(Stream 4)
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m2 (kg)
XS = 0.005, XW = 0.995
m1 (kg)
Xs= 0.04 m4 (kg)
1000kg m3 (kg) Xs =
Xw = 0.96 SEPARATION
Xs = 0.031 0.0525
PROCESS
Xw = 0.969 Xs = Xw =
0.0525 0.9475
Recycle Stream Xw =
0.9475
mR (kg)
Xs = 0.0525, Xw = 0.9475

Do Overall System Balance

Total Balance: 1000 = m2 (kg) + m4 (kg)
Solid Balance: 1000(0.031)=0.005(m2 kg)+0.0525(m4 kg)
Therefore we obtain, m2 = 452.6kg and m4 = 547.4kg
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452.6 kg
m1 (kg) XS = 0.005, XW = 0.995
Xs= 0.04 547.4 kg
1000 kg Xw = 0.96 m3 (kg) Xs =
SEPARATION
Xs = 0.031 0.0525
PROCESS
Xw = 0.969 Xw =
Xs =
0.0525 0.9475
Recycle Stream Xw =
0.9475
mR (kg)
Xs = 0.0525, Xw = 0.9475

Do Balance in Mixing Point 1

Total Balance: 1000 + mR (kg) = m1 (kg)
Solid Balance: 1000(0.031) 0.0525(mR kg) = 0.04(m1 kg)
Therefore we obtain, mR = 720 kg and m1 = 1720 kg
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452.6 kg
1720 kg XS = 0.005, XW = 0.995
Xs= 0.04
547.4 kg
Xw = 0.96 m3 (kg) Xs =
1000 kg
SEPARATION
Xs = 0.031 0.0525
PROCESS
Xw = 0.969 Xw =
Xs =
0.0525 0.9475
Recycle Stream Xw =
0.9475
720 kg
Xs = 0.0525, Xw = 0.9475

Do Balance in Mixing Point 2

Total Balance: m3 (kg) = 547.4 kg + 720 kg
Therefore m3 = 1267.4 kg
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Purge
• Where a portion of a recycle stream is
removed from the system.
• In order to avoid accumulation of undesired
material in a recycled system.
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Purge

Problem with recycle

• Suppose a material that enters with the fresh feed or produced
in the reaction remains entirely in a recycle stream, rather than
being carried out in a process product.
• The substance would continuously enter the process and
would have no way of leaving, therefore steadily accumulate.
Therefore we need a purge stream.
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Purge

Total Total Recycle Total

Feed Xi (inert) Purge
Xi (inert) Xi (inert)

No Inert

Lets say we want to purge & recycle INERT

Mass balance for INERT: F*Xi = P*Xi
Inert fraction in Recycle = Inert fraction in Purge
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Bypass, Recycle, Purge

Bypass: Control composition and properties
of the product by splitting the feed stream
and bypassing part of the process.
Recycle: Recovery of a catalyst and/or
unreacted material. Improve product quality
and reduction of waste.
Purge: Purge removes build up of material in
recycle. Recycle and purge stream have
the same composition.
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Scale Up
• Scaling up: if the final flow larger than the actual designed flow
• Scaling down: if the final flow smaller than actual designed
flow

1 kg C6H6 2 kg

1 kg C7H8 0.5 kg C6H6/kg

0.5 kg C7H8/kg
x 300 Observe now that the masses of
kg kg/h all the streams can be multiplied
by a common factor

The stream mass can be

300 kg/h C6H6 600 kg/h changed to mass flow rate
and the mass units of all
300 kg/h C7H8 0.5 kg C6H6/kg the stream variables can be
0.5 kg C7H8/kg changed from kg to g or
lbm

Dr. Kelly YTL (Sept 2014)