Machine Problem No.

5
MATERIAL BALANCES WITH RECYCLE STREAMS

Objective

1. To perform mass balance using MS Excel

Summary of Results

Figure 5.1 Mass Balances from MS Excel

Results and Discussion

Problem Statement:

Ethyl chloride is manufactured in an integrated process. Ethane reacts with chlorine to make ethyl chloride and

hydrogen chloride, and ethylene reacts with hydrogen chloride to form ethyl chloride.

2 6 + 2 2 5 +

2 4 + 2 5

The process is fed with three streams: ethane, ethylene and chlorine. The ethane and ethylene streams have the

same molar flow rate, and the ratio of chlorine to ethane plus ethylene is 1.5. The ethane/ethylene stream also

contains 1.5% acetylene and 1.5% carbon dioxide. The feed streams are mixed with an ethylene recycle stream

and go to the first reactor (chlorination reactor) where the ethane reacts with chlorine with a 95% conversion per

pass. The product stream is cooled and ethyl chloride is condensed and separated. Assume that all the ethane

and ethyl chloride go out in the condensate stream. The gases go to another reactor (hydrochlorination reactor)

where the reaction with ethylene takes place with a 50% conversion per pass. The product stream is cooled to

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 Machine Problem No. 5
MATERIAL BALANCES WITH RECYCLE STREAMS

condense the ethyl chloride, and the gases (predominantly ethylene and chlorine) are recycled. A purge stream

takes off a fraction of the recycle stream (1%). Complete the mass balance for this process.

Figure 5.2 Process Flow Diagram

Shown in Figure 5.2 is the process flow diagram of the problem. Since no certain flow rates given, an

appropriate basis is necessary. 100 kilograms of stream A and B, since they have equal flow rate, is the basis of

this problem. Having these values, the flow rate of chlorine can be calculated using the given ratio of 1.5. The

data are insufficient to solve for the flow rate in stream D. So, an assumption has been made in the said stream

(Figure 5.3).

Figure 5.3 Initial Assumption in Stream D

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 Machine Problem No. 5
MATERIAL BALANCES WITH RECYCLE STREAMS

A reaction occurred in Chlorinator with C2H6 as the limiting reactant. The rate of reaction is calculated

using the given percentage conversion of 95%; negative values for reactants and positive values for products. The

sum of assumed values in stream D and the rate of reactions are the flow rates in stream E (See Figure 5.4).

Figure 5.4 Rate of Reaction (1) and Flow Rates in Stream E

As stated in the problem, the products from stream E go to condenser wherein ethane and ethyl chloride

are condensed. Then, the product gases go to a hydrochlorinator and another reaction occurs forming, again, ethyl

chloride. In this particular reaction, the limiting reactant is the HCl. Like what has been done in the previous

reaction, the rate of reaction is also calculated using the flow rates in stream and the percentage conversion of

50%. The flow rates in stream H is calculated by the addition of stream G and the rate of reaction (See Figure

5.5).

Figure 5.5 Rate of Reaction (2) and Flow Rates in Streams G and H

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 Machine Problem No. 5
MATERIAL BALANCES WITH RECYCLE STREAMS

The products from stream H go in the condenser wherein all the ethyl chloride is condensed. 99% of the

gas products are recycled while the remaining 1% goes to the purge (See Figure 5.6).

Figure 5.6 Flow Rates in Stream I, J, K and L

Since the values in stream D are just assumptions, these must be re-calculated. The theoretical value of

stream D are the sum of streams A, B, C and K (recycle stream). The assumed values are subtracted from the

theoretical value to get the difference. These differences contained a negative value, with this, the squared of

these are considered. To get the actual mass balance of the system, the solver in MS Excel is used. The sum of

the squares of the differences must be equal to zero to balance the system with varying values of the flow rates in

the stream D. The calculations are made simpler by solver analysis (See Figure 5.7).

Figure 5.7 Application of Solver in Calculating the Flow Rates of Streams

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 Machine Problem No. 5
MATERIAL BALANCES WITH RECYCLE STREAMS

After clicking solve, Figure 5.1 will show with mass balances in the streams.

However, MS Excel alone cannot solve this problem. Basic knowledge from Chemical Engineering Calculations

is also important in some instances in the problem. For example, in identifying the limiting reactant in the

reactions, ChE calculation is being applied.

Conclusion

The main objective of this machine problem which is to solve material balances MS Excel using was

met. An appropriate basis and where the assumptions should be placed make the calculations easier. Moreover,

knowledge from Chemical Engineering Calculations must be applied for this material balance problem. Without

knowing the basic calculations, MS Excel has no function in the problem.

Reference

Himmelbau, David M., Riggs, James B. (2004). Principles of Chemical Engineering, 7th edition. Pearson

Education, Inc.

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