This question paper Data tables are provided on page 6

consists of 6 printed pages,

each of which is identified
by the Code Number
CAPE201001

UNIVERSITY OF LEEDS

School of Chemical and Process Engineering

January 2016 Examinations

CAPE201001
ENGINEERING SCIENCE 2

Time allowed: 2 hours

Answer three questions

PLEASE SHOW ALL WORKINGS IN ANSWERS TO NUMERICAL QUESTIONS.

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1 A fuel gas containing 95 mole% methane (CH4) and the balance ethane (C2H6) is
burned completely with 25% excess air. The stack gas leaves the furnace at 900C
and is cooled to 430C in a waste heat boiler, a heat exchanger in which heat lost
by cooling gases is used to produce steam from liquid water for heating, power
generation, or process applications. The data for calculations are provided in the
tables on page 6.

CH4(g) + 2O2(g) CO2(g) + 2H2O(g)

C2H6(g) + O2(g) 2CO2(g) + 3H2O(g)

(a) Assuming 100 mol of the fuel gas is fed to the furnace, calculate the mol
amounts of oxygen and nitrogen in the boiler feedair, and product gases in
the stack gas. [3 marks]

(b) Based on the above mass balance calculations, calculate the amount of heat
in kJ that must be transferred from the gas in the waste heat boiler to
accomplish the indicated cooling. [8 marks]

(c) Assume all the heat transferred from the gas goes into the steam production.
How much saturated steam at 50 bar can be produced from boiler feedwater
at 40C for the same basis of calculation? [5 marks]

(d) At what rate (kmol/s) must fuel gas be burned to produce 1250 kg steam per
hour in the waste heat boiler? What is the volumetric flow rate (m3/s) of the
stack gas leaving the boiler at the standard temperature and pressure?
[4 marks]

2 Ethylene oxide (C2H4O) is produced by the following main reaction of catalytic

oxidation of ethylene (C2H4):

C2H4(g) + O2(g) C2H4O(g)

An undesired competing side reaction is the combustion of ethylene to CO 2.

C2H4(g) + 3O2(g) 2CO2 (g) + 2H2O(l)

Figure Q2

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Table Q2
n1 (mol) n2 (mol) n3 (mol) n4 (mol) n5 (mol) n6 (mol) n7 (mol)
0.5 0.625 1.50 0.375 0.350 0.300 0.300

A multiple-unit process separates the reactor outlet stream components: C2H4 and O2
are recycled to the reactor, C2H4O is sold, and CO2 and H2O are discarded as shown
in the flow chart (Figure Q2 on page 2) with the calculated mass balance results
given in Table Q2 above. The reactor inlet and outlet streams are each at 450C, and
the fresh feed and all species leaving the separation process are at 25C. The
combined fresh feed-recycle stream is preheated to 450C. The data for calculations
are provided in the tables on page 6.

(a) For both main and side reactions, calculate the extents of reactions and the
standard heats of reactions using the heats of formations given below.
[6 marks]
0
H f = 51.00 (kJ/mol) for C2H4O(g).
H 0f = 52.28 (kJ/mol) for C2H4(g).
H 0f = 285.84 (kJ/mol) for H2O(l).
0
H =
f 393.50 (kJ/mol) for CO2(g).

(b) Are the reactions exothermic or endothermic at 25 C? What would happen to

the temperature if the reactor ran adiabatically? [2 marks]

(c) Using the heat of reaction method, calculate the heat requirement in kJ for
the reactor. The heat of vaporization of water at 25 C is 44.013 kJ/mol and
data for the calculations are:

Cp [J/(molK)] = 4.69+0.2061T9.995 10 5T2 for C2H4O (g) where T is in

Kelvin.

Cp [J/(mol C)] = 40.75 10 3+11.47 10 5T6.891 10 8T2+17.66 10 12 3

T for
C2H4(g) where T is in C.

Cp [J/(mol C)] = 75.40 10 3 for H2O(l) where T is in C.

Cp [J/(mol C)] = 33.46 10 3+0.6880 10 5T+0.7604 10 8T23.5930 10 12T3

for H2O(g) where T is in C.
[10 marks]

(d) Calculate the reactor heat requirement in kW for a production rate of 1000 kg
C2H4O/day. [2 marks]

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3 (a) A process manufactures methyl iodide from the reaction of hydroiodic acid
with excess methanol:

HI + CH3OH CH3I + H2O

The reactor output is separated into three streams. A recycle stream

consisting of pure HI; a waste stream containing, by mass, 82.6% HI and
17.4% H2O; and a product stream containing, by mass, 81.6% CH3I and
18.4% CH3OH. A flow sheet is shown in Figure Q3(a) below. Assuming the
single pass conversion of HI is 30% calculate:

(i) The feed flowrate of methanol assuming 100 kmol/hr of HI feed.

[8 marks]

(ii) The overall conversion of HI. [1 mark]

(iii) The amount of HI recycled assuming 100 kmol/hr of HI feed.

[4 marks]

(iv) The feed flowrates required to make 1000 kg/hr of methyl iodide.
[2 marks]
Data: Molar mass iodine = 126.9 kg/kmol.

Figure Q3(a)

(b) Instant coffee (which is the soluble portion of ground roast coffee) is produced
by the process shown in the simplified flow sheet in Figure Q3(b) on page 5.
Calculate the rate of production of dried soluble coffee (stream 9). Note the
ratio of water to soluble component is the same in streams 3, 4, 5, 6 and 7.
[5 marks]

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Figure Q3(b)

4 A mixture of 75 mole% propane (C3H8) and 25 mole% hydrogen is burnt with 25%
excess air. The combustion of propane occurs according to the following two
reactions:

C3H8 + 5O2 3CO2 + 4H2O

C3H8 + O2 3CO + 4H2O

Fractional conversions of 90% of the propane and 85% of the hydrogen are
achieved; of the propane that reacts, 95% reacts to form CO2 and the rest reacts to
form CO. The hot combustion product gas passes through a boiler in which heat
transferred from the gas converts boiler feed water into steam.

(a) Calculate the air feed rate. [4 marks]

(b) Calculate the unreacted moles of propane and hydrogen in the stack gas.
[2 marks]

(c) Calculate the volume fraction of CO in the stack gas; and the mass fraction of
CO on both a wet and a dry basis. [12 marks]

(d) The CO in the stack gas is a pollutant. Its concentration can be decreased by
increasing the percent of excess air fed to the furnace. Give two cost related
implications of doing so. [2 marks]

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