U21CH301

Process Calculations
L T P J C Course Category:
Professional Core
3 1 0 0 4 Course (PCC)

Dr. S. Balasubramanian PhD

Department of Chemical Engineering

KPR Institute of Engineering and Technology
Coimbatore 641407
ChemE 1
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Byproduct
Solid, Liquid &
Gas

Raw Product
Process
material
Solid, Liquid & Solid, Liquid &
Gas

Waste
Gas

Energy Zero discharge

Mechanical , Chemical and Electrical
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Process

Dictionary Meaning

A process is one or series of actions or operations or treatments that results in

an end [Product]

Working Definition

In Chemical Engineering, the term process focus on operations such as Chemical

Reactions, fluid transport, size reduction and enlargement, heat generation and
transport, distillation, gas absorption, bioreactors and so on that cause physical or
chemical change in materials
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

System

An arbitrary portion or whole of process set out specifically for analysis

In other words, the system is the one where we focus our attentions
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Process Variables

The performance of the plant, individual equipment’s and the process

in a chemical industry requires the knowledge of the amount (or
quantity), composition and conditions (temperature, pressure,
concentration, composition, flowrate and so on) of the materials and
the process streams within the process units
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Variables

Quantities that can change or vary within a system, model, or process.

Variables are often the focus of the study or the analysis, as they change during
experiments, processes, or simulations.

Types

Dependent Variables Independent Variables

These depend on other factors These are controlled or set by the
(e.g., in chemical engineering, operator or system designer and
concentration of a product often drive changes in dependent
might depend on time or variables (e.g., time, space, flow rate
temperature and so on). and so on)
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Process Variables

Describe the state or operation of a process

Controllable or measurable quantities in a process and can change over time or

across different points in the process

The key process variables include, temperature, pressure, concentration, flow rate, level and so on

Temperature – measure of degree of hotness or heat present in the system

Pressure – force acting per unit area
Concentration – the amount of substance in a given volume or mass
Flow rate – the volume of mass of a fluid passing through a point in a system
over time
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Process Variables The process variables that characterizes the stream entering and leaving
a process unit can be grouped as follows:

State or Temperature and pressure

thermodynamic of inlet and outlet
variables streams

Dynamic variable Flow rates of inlet and

Process Variables

out streams

Geometric variable Length, volume, cross

sectional area and so on

Density, boiling point,

Physical variable melting point, viscosity
and so on

Amount of material,
Other Variables composition and concentration
of inlet and outlet streams
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Parameters
Parameters are fixed values in a specific context or situation that define or characterize a
system, but do not change during a specific process or analysis.

Examples
- In the same mathematical equation y = mx + c, m (the slope) and c (the intercept) are
parameters that determine the relationship between x and y.

- In a chemical process, parameters could include the physical dimensions of equipment,

reaction rate constants, or material properties (like heat capacity or viscosity) that are
considered fixed for the duration of the analysis.
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Properties
Properties describe the intrinsic characteristics of materials within the system
Properties can be classified into two types: i. Intensive and ii. extensive

Intensive property
Do not depend on the amount of material present or independent of mass
E.g. Density, specific gravity, melting point, boiling point, viscosity and so on

Intensive property
Depend on the amount of material present
E.g. Mass, volume, heat capacity, particle number, momentum and so on.
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture

Process streams occasionally contain one substance, but more often they consist of
mixtures of liquids or gases or solutions of one or more solutes in a liquid solvent. The
following terms are used to define the composition of a mixture of substances.

Typical composition of a gas mixture analysis by mass or moles

- Mass fraction
Oxygen 16%
- Mass percentage
4%
- Mole fraction Nitrogen
63%
17%
- Mole percentage Carbon dioxide

- Average molecular weight Carbon monoxide

UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture

Mass Fraction
If two components, say A and B are present in a mixture, then the mass
fraction of A and B is given by

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐴 The units are: kg A/kg, gm A/gm,

𝑀𝑎𝑠𝑠 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝐴 = lbm A/lbm
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 (𝐴 + 𝐵)

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐵 The units are: kg B/kg, gm B/gm,

𝑀𝑎𝑠𝑠 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝐵 =
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 (𝐴 + 𝐵) lbm B/lbm

Note: Sum of the mass fraction is equal to 1

UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture

Mass Percentage

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐴
𝑀𝑎𝑠𝑠 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑜𝑓 𝐴 = ×100 ; mass,% A
𝑇𝑜𝑡𝑎𝑙 𝑀𝑎𝑠𝑠 (𝐴 + 𝐵)

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐵
𝑀𝑜𝑙𝑒 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑜𝑓 𝐵 = ×100 ; mass,% B
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 (𝐴 + 𝐵)

Note: Sum of the mass percentage is equal to 100

UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture

Mole Fraction
If two components, say A and B are present in a mixture, then the mole
fraction of a is given by

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐴 The units are: kmol A/kmol, mol A/mol,

𝑀𝑜𝑙𝑒 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝐴 = gm mol A/gm mol, lb mol A/ lbmol
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 (𝐴 + 𝐵)

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵 The units are: kmol A/kmol, mol A/mol,

𝑀𝑜𝑙𝑒 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝐵 = gm mol A/gm mol, lb mol A/ lbmol
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 (𝐴 + 𝐵)
Note: Sum of the mole fraction is equal to 1
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture

Mole Percentage

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐴
𝑀𝑜𝑙𝑒 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑜𝑓 𝐴 = ×100 ; mol% A
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 (𝐴 + 𝐵)

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵
𝑀𝑜𝑙𝑒 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑜𝑓 𝐵 = ×100 ; mol% B
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 (𝐴 + 𝐵)

Note: Sum of the mole percentage is equal to 100

UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture (Granulated Sugar and Sugarcane) by Mass

An elemental analysis of Carbon (C), Hydrogen (H), Oxygen (O) in 20 gm granulated sugar and
500 sugarcane by mass is as follows: C = 8.44 gm, H = 1.30 gm and 10.26 gm (Granulated Sugar)
and C = 211.0 gm, 32.5 gm, 256.5 gm, (sugar cane). Calculate the mass percentage of the C, H, O in
granulated sugar and in the sugarcane.
C, H O
C, H O

Granulated Sugar Sugarcane

 UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture (Gas) Note: If basis is given we can use it, otherwise
it can also be assumed suitably

20 gm of granulated sugar 500 gm of sugar cane

S. No. Analysis by Mass Mass Analysis by Mass Mass

Components Mass Fraction Percentage Mass Fraction Percentage
(gm) (-) (%) (gm) (-) (%)

8.44 gm C 8.44 211.0 gm C 211.0

1 C 8.44 =0.422 ×100=42.2 211.0 =0.422 ×100=42.2%
20.00 gm sugar 20.00 500.0 gm sugar 500.0

1.30 gm H 1.30 32.5 gm C 32.5

2 H 1.30 =0.065 ×100=6.5 32.5 =0.065 ×100=6.5%
20.00 gm sugar 20.00 500.0 gm sugar 500.0

10.26 gm O 10.26 256.5 gm C 256.5

3 O 10.26 =0.513 ×100=51.3 256.5 =0.513 ×100=51.3%
20.00 gm sugar 20.00 500.0 gm sugar 500.0

Total 20.00 1.000 100.0 500.0 1.000 100.0

 UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture (Gas) Note: If basis is given we can use it, otherwise
it can also be assumed suitably
Solution

20 gm of granulated sugar 500 gm of sugar cane

S. No. Analysis by Mass Mass Analysis by Mass Mass
Components Mass Fraction Percentage Mass Fraction Percentage
(gm) (-) (%) (gm) (-) (%)

1 C 8.44 0.422 42.2 211.0 0.422 42.2%

2 H 1.30 0.065 6.5 32.5 0.065 6.5%

3 O 10.26 0.513 51.3 256.5 0.513 51.3%

Total 20.00 1.000 100.0 500.0 1.000 100.0

UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture (Gas) Note: If basis is given we can use it otherwise
assume it

A mixture of gases has the following composition by mass:

O2 = 16% , CO = 4.0% , CO2 = 17% , and N2=63% .
What is the molar composition and the average molecular weight of the
mixture? Take basis as 100 gm of gas mixture

Toal mass of the gas mixture

Average molecular weight of the mixture, M =
Total moles of the gas mixture

The units are: CGS (gm/gm mol), SI (kg/kmol), FPS (lbm/lbm mol)
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture (Gas) Note: If basis is given we can use it, otherwise
it can also be assumed suitably

Analysis by Mass Mass Molecular Mole Mole

Moles
S. No. Components Mass Fraction Percentage weight Fraction Percentage
(gm mol)
(gm) (-) (%) (gm/gm mol) (-) (-)

16.0 gm O2 16.0 16 0.500 0.500

1 O2 16.0 = 0.16 ×100 = 16 16 x 2 = 32 = 0.500 = 0.15 ×100 = 15
100 gm gas 100.0 32 3.279 3.279

4.0 gm CO 4.0 4 0.143 0.143

2 CO 4.0 = 0.04 ×100 = 4 12 + 16 = 28 = 0.143 = 0.04 ×100 = 4
100 gm gas 100.0 28 3.279 3.279

17.0 gm CO2 17.0 17 0.389 0.389

3 CO2 17.0 = 0.17 ×100 = 17 12 + (16 x 2) = 44 = 0.386 = 0.12 ×100 = 12
100 gm gas 100.0 44 3.279 3.279

63 2.250
63.0 gm N2 63.0 = 2.250 = 0.69 2.250
4 N2 63.0 = 0.63 ×100 = 63 14 x 2 = 28 28 3.279 x 100 = 69
100 gm gas 100.0 3.279

Total 100.00 1.00 100.0 3.279 1.00 100.00

Toal mass of the gas mixture 100 gm gm

Average molecular weight of the mixture, M = = =30.497 gm mol
Total moles of the gas mixture 3.279 mol
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture (Gas) Note: If basis is given we can use it, otherwise
it can also be assumed suitably
Solution
Analysis by Mass Mass Molecular Mole Mole
Moles
S. No. Components Mass Fraction Percentage weight Fraction Percentage
(gm mol)
(gm) (-) (%) (gm/gm mol) (-) (-)

1 O2 16.0 0.16 16 32 0.500 0.15 15

2 CO 4.0 0.04 4 28 0.143 0.04 4

3 CO2 17.0 0.17 17 44 0.386 0.12 12

2.250 0.69
4 N2 63.0 0.63 63 28 69

Total 100.00 1.00 100.0 3.279 1.00 100.00

Toal mass of the gas mixture 100 gm gm

Average molecular weight of the mixture, M = = =30.497 gm mol
Total moles of the gas mixture 3.279 mol
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture (Gas) Note: If basis is given we can use it, otherwise
it can also be assumed suitably

Calculate the average molecular weight of the air from the mass composition of 79% N2,
and 21% O2

21% Oxygen

Nitrogen
79%
 UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture (Gas) Note: If basis is given we can use it, otherwise
it can also be assumed suitably

Calculate the average molecular weight of the air from the mass composition of 79% N2, and 21% O2

Analysis by Mass Mass Molecular Mole Mole

Moles
S. No. Components Mass Fraction Percentage weight Fraction Percentage
(gm mol)
(gm) (-) (%) (gm/gm mol) (-) (-)

79 gm N2 79 79 2.821 2.821
1 N2 79 = 0.79 ×100 = 79 14 x 2 = 28 = 2.821 = 0.811 ×100 = 81.1
100 gm gas 100.0 28 3.477 3.477

21.0 gm O2 21 0.656
21.0 = 0.656 = 0.189 0.656
4 O2 21 = 0.21 ×100 = 21 16 x 2 = 32 32 3.477 x 100 = 18.9
100 gm gas 100.0 3.477

Total 100.00 1.00 100.0 3.477 1.000 100.0

Toal mass of the gas mixture 100 gm gm

Average molecular weight of the mixture, M = = =28.76
Total moles of the gas mixture 3.477 mol gm mol
 UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

Composition (or) Analysis of mixture (Gas) Note: If basis is given we can use it, otherwise
it can also be assumed suitably

Calculate the average molecular weight of the air from the mass composition of 79% N2, and 21% O2
Solution

Analysis by Mass Mass Molecular Mole Mole

Moles
S. No. Components Mass Fraction Percentage weight Fraction Percentage
(gm mol)
(gm) (-) (%) (gm/gm mol) (-) (-)

1 N2 79 0.79 79 28 2.821 0.811 81.1

0.656 0.189
4 O2 21 0.21 21 32 18.9

Total 100.00 1.00 100.0 3.477 1.000 100.0

Toal mass of the gas mixture 100 gm gm

Average molecular weight of the mixture, M = = =28.76
Total moles of the gas mixture 3.477 mol gm mol
UNITS, DIMENSIONS AND CONVERSIONS Process Variables and Properties

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