FE Chemical exam practice: cram pack

Formula sheets, the key method steps for every topic and 24 practice problems, with full solutions at the back.

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1Formulas and methods

Mass balance

Steady state
in = out
Total balance
ṁ1 + ṁ2 = ṁ3
Component balance
ṁ1x1 + ṁ2x2 = ṁ3x3
Evaporator
F·xF = P·xP, W = F − P

Energy balance

Sensible heat
Q = ṁ·cp·ΔT
Latent heat
Q = ṁ·hfg
Mixing
ΣṁcpTin = ΣṁcpTout
Water
cp ≈ 4.18 kJ/(kg·K)

Ideal gas law

Ideal gas law
pV = nRT
Gas constant
R = 8.314 J/(mol·K)
Combined gas law
p1V1/T1 = p2V2/T2
Moles
n = m/M
Temperature
T[K] = T[°C] + 273.15

Stoichiometry

Moles
n = m/M
Concentration
c = n/V
Mole ratio
use the coefficients of the balanced equation
Limiting reactant
the one that runs out first
Percent yield
actual / theoretical × 100%

Method

  1. Write and balance the chemical equation.
  2. Convert the given mass to moles: n = m/M.
  3. Use the coefficients as the mole ratio to find the moles of the substance you want.
  4. Convert back to mass with m = n·M. With two reactants, find the limiting reactant first.

Chemical equilibrium

Equilibrium constant
Kc = [C]c[D]d/([A]a[B]b)
ICE table
Initial, Change (×coefficient), Equilibrium
Quadratic
x = (−b + √(b² − 4ac))/(2a)

Method

  1. Write Kc with products over reactants, each raised to the power of its coefficient.
  2. Set up an ICE table: Initial, Change (in steps of x times the coefficients), Equilibrium.
  3. Put the equilibrium expressions into Kc and solve for x.
  4. Check whether x is small enough for an approximation; otherwise solve the quadratic.

Calorimetry & enthalpy

Heat
q = m·c·ΔT
Water
c = 4.18 J/(g·°C)
Calorimeter
heat lost = heat gained
Enthalpy of reaction
ΔH° = ΣΔH°f(products) − ΣΔH°f(reactants)

Reaction kinetics

First order
ln(CA/CA0) = −kt
Half-life (first order)
t½ = ln 2/k
Second order
1/CA = 1/CA0 + kt
Arrhenius
k = A·e−Ea/(RT)
Two temperatures
ln(k2/k1) = (Ea/R)(1/T1 − 1/T2)

Reactor sizing (CSTR & PFR)

Space time
τ = V/Q
CSTR, first order
τ = X/(k·(1 − X)), CA = CA0/(1 + kτ)
PFR, first order
τ = ln(1/(1 − X))/k, CA = CA0·e−kτ
Conversion from volume
CSTR: X = kτ/(1 + kτ), PFR: X = 1 − e−kτ
N equal CSTRs in series
X = 1 − 1/(1 + kτi)N

Heat exchangers (LMTD)

Heat duty
Q = U·A·ΔTlm
Log mean temperature difference
ΔTlm = (ΔT1 − ΔT2)/ln(ΔT1/ΔT2)
Stream balance
Q = ṁcp(Tin − Tout)

Heat conduction

Fourier’s law
Q̇ = kAΔT/L
Conduction resistance
R = L/(kA)
Convection resistance
R = 1/(hA)
Resistances in series
Q̇ = ΔTtotal/ΣR
U-value
U = 1/(ΣR·A)

Pipe friction & head loss

Reynolds number
Re = V·D/ν = ρ·V·D/μ
Flow regime
laminar below Re ≈ 2000, turbulent above Re ≈ 4000
Mean velocity
V = Q/A, A = π·D²/4
Darcy–Weisbach
hf = f·(L/D)·V²/(2g)
Minor losses
hm = ΣK·V²/(2g)
Typical K values
entrance 0.5, exit 1.0, 90° bend ≈ 0.3
Pressure drop
Δp = ρ·g·hf
Two open reservoirs
Δz = (f·L/D + ΣK)·V²/(2g)
Free outlet
H = (1 + f·L/D + ΣK)·V²/(2g)

Pumps & pump power

Hydraulic power
Ph = ρ·g·Q·H = Q·Δp
Shaft power
Pshaft = Ph/ηpump
Electrical power
Pel = Pshaft/ηmotor
Pump head
H = Δz + Δp/(ρ·g) + hL
System losses
hL = (f·L/D + ΣK)·V²/(2g)

2Practice problems

1.Mass balanceMedium
MixerStream 1450 kg/h · 20% NaOHStream 2ṁ₂ = ? · 45% NaOHProduct30% NaOH

How much of stream 2 must be added each hour to stream 1 so that the blended product contains 30% NaOH? Find ṁ2.

ṁ1 = 450 kg/hx1 = 20 %x2 = 45 %x3 = 30 %
ṁ2 = kg/h
2.Mass balanceHard
EvaporatorFeed F3500 kg/h · 12% saltProduct P35% saltVapour W (pure water)W = ? kg/h

An evaporator concentrates a salt solution by boiling off pure water. Find the water evaporated W in kg/h.

F = 3500 kg/hxF = 12 %xP = 35 %
W = kg/h
3.Energy balanceMedium
hot sidecold sidelight oil · 120 °C70 °Cwater · 10 °Ct = ? °C

Hot light oil cools water in a counter-flow heat exchanger with no heat loss. Find the water outlet temperature tout.

ṁh = 2 kg/scp,h = 2.1 kJ/(kg·K)Th: 120 → 70 °Cṁc = 3 kg/scp,c = 4.18 kJ/(kg·K)tin = 10 °C
tout = °C
4.Energy balanceHard
hot sidecold sideglycol mix · 150 °C70 °Cwater · 30 °C90 °C · ṁ = ?15% lost

Hot glycol mix heats water in an exchanger that loses 15% of the heat released by the hot stream to the surroundings. Find the water flow rate ṁc needed.

ṁh = 2 kg/scp,h = 3.6 kJ/(kg·K)Th: 150 → 70 °Ct: 30 → 90 °Ccp,c = 4.18 kJ/(kg·K)loss = 15 %
ṁc = kg/s
5.Ideal gas lawMedium
470 g of CO₂P = 550 kPaT = 10 °CV = ?

What volume V does 470 g of CO₂ occupy at 550 kPa and 10 °C? Treat it as an ideal gas.

m = 470 gM = 44.01 g/molP = 550 kPaT = 10 °CR = 8.314 J/(mol·K)
V = L
6.Ideal gas lawHard
State 1State 2

A fixed amount of O₂ goes from 150 kPa, 5 L, 15 °C to 300 kPa and 180 °C. Find the new volume V2.

P1 = 150 kPaV1 = 5 LT1 = 15 °CP2 = 300 kPaT2 = 180 °C
V2 = L
7.StoichiometryMedium
m(X)n(X)n(H2​O)m(H2​O)÷ M(X)× 4/ν× M(H2​O)

4 g of C3H8 and 48 g of O2 react according to C3H8 + 5O2 → 3CO2 + 4H2O. What mass m of H2O can form?

M(C3H8) = 44.1M(O2) = 32M(H2O) = 18.02 g/mol
m = g
8.StoichiometryHard
m(CH4​)n(CH4​)n(CO2​)m(CO2​)÷ M(CH4​)× 1/1× M(CO2​)

In the reaction CH4 + 2O2 → CO2 + 2H2O, 4 g of CH4 reacts completely (the other reactants are in excess) and 9.33 g of CO2 is collected. Find the percent yield Y.

M(CH4) = 16.04 g/molM(CO2) = 44.01 g/molactual: 9.33 g
Y = %
9.Chemical equilibriumMedium
H2​I2​HII0.20.20C−x−x+2xE0.2 − x0.2 − x2x

0.2 mol/L of H₂ and 0.2 mol/L of I₂ are put in a container and react: H₂ + I₂ ⇌ 2HI, with Kc = 54. Find the equilibrium concentration [H2].

[H₂]₀ = [I₂]₀ = 0.2 mol/LKc = 54
[H2] = mol/L
10.Chemical equilibriumHard
PCl5​PCl3​Cl2​I0.800C−x+x+xE0.8 − xxx

PCl₅ decomposes: PCl₅ ⇌ PCl₃ + Cl₂, with Kc = 0.2 at the reaction temperature. A container starts with 0.8 mol/L of PCl₅ only. Find the equilibrium concentration [Cl2].

[PCl₅]₀ = 0.8 mol/LKc = 0.2
[Cl2] = mol/L
11.Calorimetry & enthalpyMedium
Tf​ = ?Zincm = 250 gT = 120 °Cc = 0.388 J/(g·°C)Waterm = 250 gT = 20 °Cc = 4.18 J/(g·°C)

A 250 g block of zinc (c = 0.388 J/(g·°C)) at 120 °C is dropped into 250 g of water (c = 4.18 J/(g·°C)) at 20 °C in an insulated cup. Find the final temperature Tf.

mmetal = 250 gcmetal = 0.388 J/(g·°C)Tmetal = 120 °Cmwater = 250 gTwater = 20 °Ccwater = 4.18 J/(g·°C)
Tf = °C
12.Calorimetry & enthalpyHard
H50 g C3​H8​C3​H8​ + 5O₂reactants3CO₂ + 4H₂O(l)productsq = ?

Use the standard enthalpies of formation to find the heat q released when 50 g of C3H8 (M = 44.1 g/mol) burns completely: C3H8 + 5O₂ → 3CO₂ + 4H₂O(l). Give q as a positive number.

ΔH°f(C3H8) = −103.8 kJ/molΔH°f(CO₂) = −393.5 kJ/molΔH°f(H₂O, l) = −285.8 kJ/molΔH°f(O₂) = 0
q = kJ
13.Reaction kineticsMedium
t (min)X (%)t = ?99%

A first-order reaction in a batch reactor has k = 0.3 min⁻¹. How long does it take to reach 99% conversion? Find t.

k = 0.3 min⁻¹X = 99 %
t = min
14.Reaction kineticsHard
Tk35 °C0.0575 °C?

A reaction has a rate constant of 0.05 min⁻¹ at 35 °C and an activation energy of 40 kJ/mol. Find the rate constant k2 at 75 °C.

k1 = 0.05 min⁻¹T1 = 35 °CT2 = 75 °CEa = 40 kJ/molR = 8.314 J/(mol·K)
k2 = min⁻¹
15.Reactor sizing (CSTR & PFR)Medium
QX = 75%same Q, k and X as the CSTR

A first-order liquid-phase reaction must reach 75% conversion. How many times larger must a CSTR be than a PFR for the same feed rate, rate constant and conversion? Find the ratio VCSTR/VPFR.

X = 75%first order, same k and Q
VCSTR/VPFR =
16.Reactor sizing (CSTR & PFR)Hard
Q = 40 L/minX = ?V = 150 L

A first-order liquid-phase reaction (k = 0.3 min⁻¹) runs in a 150 L plug-flow reactor (PFR) fed at 40 L/min. The density is constant and the reactor is at steady state. Find the conversion X in percent.

V = 150 LQ = 40 L/mink = 0.3 min⁻¹
X = %
17.Heat exchangers (LMTD)Medium
lengthT90 °C40 °C45 °C25 °CΔT₁ΔT₂counter-flow

A shell-and-tube heat exchanger (one shell pass, two tube passes) must transfer 590 kW. The hot fluid cools from 90 to 40 °C and the cold fluid heats from 25 to 45 °C. The LMTD correction factor for this arrangement is F = 0.9, and U = 800 W/(m²·K). Find the heat transfer area A needed.

Q̇ = 590 kWF = 0.9U = 800 W/(m²·K)Th: 90 → 40 °CTc: 25 → 45 °C
A = m²
18.Heat exchangers (LMTD)Hard
lengthT130 °C105 °C23.37 °C15 °CΔT₁ΔT₂counter-flow

Hot oil (2 kg/s, cp = 2.1 kJ/(kg·K)) cools from 130 to 105 °C in a counter-flow exchanger. It heats 3 kg/s of water (cp = 4.18 kJ/(kg·K)) that enters at 15 °C. With U = 1500 W/(m²·K), find the heat transfer area A needed.

ṁh = 2 kg/scp,h = 2.1 kJ/(kg·K)Th: 130 → 105 °Cṁc = 3 kg/scp,c = 4.18 kJ/(kg·K)Tc,in = 15 °CU = 1500 W/(m²·K)
A = m²
19.Heat conductionMedium
Expanded polystyrene, k = 0.035250 mmWood, k = 0.1725 mm23 °C-3 °CQ̇ = ?

A wall is made of 250 mm of expanded polystyrene and 25 mm of wood, with an area of 20 m². The outer faces are at 23 °C and -3 °C. Find the heat flow Q̇ through the wall.

L1 = 250 mm, k1 = 0.035 W/(m·K)L2 = 25 mm, k2 = 0.17 W/(m·K)A = 20 m²T1 = 23 °CT3 = -3 °C
Q̇ = W
20.Heat conductionHard
Expanded polystyrene, k = 0.035250 mmGypsum board, k = 0.17150 mmroom 20 °Coutside -7 °CQ̇ = ?

A wall of 250 mm expanded polystyrene and 150 mm gypsum board separates a room at 20 °C from outside air at -7 °C. The convection coefficients are 6 W/(m²·K) inside and 30 W/(m²·K) outside, and the wall area is 20 m². Find the heat loss Q̇ through the wall.

L1 = 250 mm, k1 = 0.035 W/(m·K)L2 = 150 mm, k2 = 0.17 W/(m·K)A = 20 m²hi = 6 W/(m²·K)ho = 30 W/(m²·K)Troom = 20 °CTout = -7 °C
Q̇ = W
21.Pipe friction & head lossMedium
V = 1.6 m/sD = 300 mmL = 100 mf = 0.015

Water (ρ = 1000 kg/m³) flows at 1.6 m/s through a horizontal pipe, 100 m long, with an inside diameter of 300 mm. Use the Darcy friction factor f = 0.015 and g = 9.81 m/s². Find the pressure drop Δp over the pipe in kPa.

V = 1.6 m/sL = 100 mD = 300 mmf = 0.015ρ = 1000 kg/m³
Δp = kPa
22.Pipe friction & head lossHard
K = 5free outletH = ?L = 150 m, D = 150 mm, f = 0.0223× bend (K = 0.3)

A pipe 150 m long with an inside diameter of 150 mm (Darcy friction factor f = 0.022) runs from an open reservoir and discharges as a free jet into the air. The minor losses are a square-edged entrance (K = 0.5), 3 bends (K = 0.3 each) and a valve (K = 5). Use g = 9.81 m/s². How far H must the reservoir surface be above the pipe outlet for a flow rate of 25 L/s?

Q = 25 L/sL = 150 mD = 150 mmf = 0.022Kentrance = 0.5Kbend = 0.3 (×3)Kvalve = 5
H = m
23.Pumps & pump powerMedium
PQ = 80 L/sH = 48 m

A pump delivers 80 L/s of water (ρ = 1000 kg/m³) against a head of 48 m. The pump efficiency is 60% and the electric motor driving it has an efficiency of 94%. Use g = 9.81 m/s². Find the electrical power Pel the motor draws, in kW.

Q = 80 L/sH = 48 mηpump = 60%ηmotor = 94%g = 9.81 m/s²
Pel = kW
24.Pumps & pump powerHard
PQ = 100 L/sΔz = 13 mL = 300 m, D = 250 mm, f = 0.02, ΣK = 5

A pump moves 100 L/s of water (ρ = 1000 kg/m³) from an open lower reservoir to an upper tank whose water surface is 13 m higher. The pipe is 300 m long with an inside diameter of 250 mm and a Darcy friction factor f = 0.02; the minor-loss coefficients add up to ΣK = 5 (entrance and exit included). Use g = 9.81 m/s². The pump efficiency is 80%. Find the shaft power Pshaft in kW.

Q = 100 L/sΔz = 13 mL = 300 mD = 250 mmf = 0.02ΣK = 5η = 80%
Pshaft = kW

3Solutions

1.Mass balance

Answer: ṁ2 = 300 kg/h

Steady-state mass balance: in = out for the total and for each component. Blending problems combine both.

Balances

Total: ṁ3 = ṁ1 + ṁ2
NaOH: ṁ1x1 + ṁ2x2 = (ṁ1 + ṁ2)x3

Solve for ṁ2

ṁ2 = ṁ1(x1 − x3)/(x3 − x2) = 450·(20 − 30)/(30 − 45) = 300 kg/h

Answer

ṁ2 = 300 kg/h
2.Mass balance

Answer: W = 2300 kg/h

Tie component: a component that passes through unchanged in one stream (here the solute) links the flows directly. Then the total balance gives the rest.

Solute balance

F·xF = P·xP → P = 3500·12/35 = 1200 kg/h

Total balance

W = F − P = 3500 − 1200 = 2300 kg/h

Answer

W = 2300 kg/h
3.Energy balance

Answer: tout = 26.75 °C

Exchanger energy balance: with no losses, ṁhcp,h(Th,in − Th,out) = ṁccp,c(tout − tin).

Heat released by the hot stream

Q = 2·2.1·(120 − 70) = 210 kW

Heat picked up by the water

tout = tin + Q/(ṁccp,c) = 10 + 210/(3·4.18) = 26.75 °C

Answer

tout = 26.75 °C
4.Energy balance

Answer: ṁc = 1.952 kg/s

Energy balance with losses: heat released = heat absorbed + heat lost.

Heat released

Qh = 2·3.6·(150 − 70) = 576 kW

Heat that reaches the water

Qc = (1 − 0.15)·576 = 489.6 kW

Water flow rate

ṁc = Qc/(cp,c·Δt) = 489.6/(4.18·60) = 1.952 kg/s

Answer

ṁc = 1.952 kg/s
5.Ideal gas law

Answer: V = 45.71 L

Ideal gas law: PV = nRT, with n = m/M.

Moles

n = 470/44.01 = 10.68 mol
T = 10 + 273.15 = 283.1 K

Volume

V = nRT/P = 10.68·8.314·283.1/550 = 45.71 L

Answer

V = 45.71 L
6.Ideal gas law

Answer: V2 = 3.932 L

Combined gas law: for a fixed amount of ideal gas, P1V1/T1 = P2V2/T2.

Absolute temperatures

T1 = 288.1 K, T2 = 453.1 K

Combined gas law

V2 = V1·(P1/P2)·(T2/T1) = 5·(150/300)·(453.1/288.1) = 3.932 L

Answer

V2 = 3.932 L
7.Stoichiometry

Answer: m = 6.538 g

Stoichiometry: a balanced equation counts particles, not grams. Convert mass to moles with n = m/M, use the coefficients of the equation as the mole ratio, then convert back with m = n·M. With two reactants, the limiting reactant is the one that runs out first and fixes how much product forms.

Moles of each reactant

n(C3H8) = 4/44.1 = 0.0907 mol
n(O2) = 48/32 = 1.5 mol

Limiting reactant

0.0907/1 = 0.0907, 1.5/5 = 0.3 → C3H8

Mass of product

n(H2O) = 0.0907·4 = 0.3628 mol
m = 0.3628·18.02 = 6.538 g

Answer

m = 6.538 g
8.Stoichiometry

Answer: Y = 85.01 %

Stoichiometry: a balanced equation counts particles, not grams. Convert mass to moles with n = m/M, use the coefficients of the equation as the mole ratio, then convert back with m = n·M. With two reactants, the limiting reactant is the one that runs out first and fixes how much product forms.

Theoretical yield

n(CH4) = 4/16.04 = 0.2494 mol
m = 0.2494·1/1·44.01 = 10.98 g

Percent yield

Y = 9.33/10.98·100 = 85.01%

Answer

Y = 85.01%
9.Chemical equilibrium

Answer: [H2] = 0.04279 mol/L

Chemical equilibrium: for aA + bB ⇌ cC + dD, the equilibrium constant is Kc = [C]c[D]d/([A]a[B]b), using concentrations at equilibrium. An ICE table (Initial, Change, Equilibrium) links the starting amounts to the equilibrium amounts through one unknown x, scaled by the coefficients.

Equilibrium expression

54 = (2x)²/(0.2 − x)²

Take the square root

7.348 = 2x/(0.2 − x) → x = 0.2·7.348/(2 + 7.348) = 0.1572 mol/L

Equilibrium concentration

[H₂] = 0.2 − x = 0.04279 mol/L

Answer

[H2] = 0.04279 mol/L
10.Chemical equilibrium

Answer: [Cl2] = 0.3123 mol/L

Chemical equilibrium: for aA + bB ⇌ cC + dD, the equilibrium constant is Kc = [C]c[D]d/([A]a[B]b), using concentrations at equilibrium. An ICE table (Initial, Change, Equilibrium) links the starting amounts to the equilibrium amounts through one unknown x, scaled by the coefficients.

Equilibrium expression

0.2 = x²/(0.8 − x) → x² + 0.2·x − 0.16 = 0

Solve the quadratic

x = (−0.2 + √(0.2² + 4·0.16))/2 = 0.3123 mol/L

Equilibrium concentration

[Cl₂] = x = 0.3123 mol/L

Answer

[Cl2] = 0.3123 mol/L
11.Calorimetry & enthalpy

Answer: Tf = 28.49 °C

Heat and enthalpy: heating a substance takes q = m·c·ΔT. In a calorimeter the heat lost by the hot object equals the heat gained by the cold one. The enthalpy change of a reaction follows from enthalpies of formation: ΔH° = ΣΔH°f(products) − ΣΔH°f(reactants), each multiplied by its coefficient.

Heat balance

250·0.388·(120 − Tf) = 250·4.18·(Tf − 20)

Solve for the final temperature

Tf = (97·120 + 1045·20)/(97 + 1045) = 28.49 °C

Answer

Tf = 28.49 °C
12.Calorimetry & enthalpy

Answer: q = 2517 kJ

Heat and enthalpy: heating a substance takes q = m·c·ΔT. In a calorimeter the heat lost by the hot object equals the heat gained by the cold one. The enthalpy change of a reaction follows from enthalpies of formation: ΔH° = ΣΔH°f(products) − ΣΔH°f(reactants), each multiplied by its coefficient.

Enthalpy of reaction

ΔH° = [3·(−393.5) + 4·(−285.8)] − [1·(−103.8) + 5·0] = −2220 kJ

Heat for the given mass

n = 50/44.1 = 1.134 mol
q = n·|ΔH°/1| = 1.134·2220 = 2517 kJ

Answer

q = 2517 kJ
13.Reaction kinetics

Answer: t = 15.35 min

Reaction rates: for a first-order reaction −dC/dt = kC, so C = C₀·e−kt and the half-life ln 2/k does not depend on concentration. For a second-order reaction 1/C = 1/C₀ + kt. The rate constant rises with temperature following Arrhenius: k = A·e−Ea/(RT).

Conversion and concentration

C/C0 = 1 − X = 0.01

Solve for the time

t = −ln(1 − X)/k = −ln(0.01)/0.3 = 15.35 min

Answer

t = 15.35 min
14.Reaction kinetics

Answer: k2 = 0.3006 min⁻¹

Reaction rates: for a first-order reaction −dC/dt = kC, so C = C₀·e−kt and the half-life ln 2/k does not depend on concentration. For a second-order reaction 1/C = 1/C₀ + kt. The rate constant rises with temperature following Arrhenius: k = A·e−Ea/(RT).

Absolute temperatures

T1 = 308.1 K, T2 = 348.1 K

Arrhenius ratio

ln(k2/k1) = −(40000/8.314)·(1/348.1 − 1/308.1) = 1.794
k2 = 0.05·e1.794 = 0.3006 min⁻¹

Answer

k2 = 0.3006 min⁻¹
15.Reactor sizing (CSTR & PFR)

Answer: VCSTR/VPFR = 2.164

Ideal reactors, first-order reaction (−rA = k·CA) at steady state, with space time τ = V/Q. A CSTR is perfectly mixed, so the whole volume reacts at the low outlet concentration: τ = X/(k·(1 − X)) and CA = CA0/(1 + k·τ). In a PFR each slice of fluid reacts like a small batch reactor: τ = ln(1/(1 − X))/k and CA = CA0·e−k·τ. For the same conversion a CSTR always needs more volume than a PFR.

k·τ for each reactor

CSTR: k·τ = X/(1 − X) = 0.75/0.25 = 3
PFR: k·τ = ln(1/(1 − X)) = ln(4) = 1.386

Ratio of volumes

VCSTR/VPFR = 3/1.386 = 2.164

Answer

VCSTR/VPFR = 2.164

The gap grows quickly at high conversion.

16.Reactor sizing (CSTR & PFR)

Answer: X = 67.53 %

Ideal reactors, first-order reaction (−rA = k·CA) at steady state, with space time τ = V/Q. A CSTR is perfectly mixed, so the whole volume reacts at the low outlet concentration: τ = X/(k·(1 − X)) and CA = CA0/(1 + k·τ). In a PFR each slice of fluid reacts like a small batch reactor: τ = ln(1/(1 − X))/k and CA = CA0·e−k·τ. For the same conversion a CSTR always needs more volume than a PFR.

Space time

τ = V/Q = 150/40 = 3.75 min, kτ = 0.3·3.75 = 1.125

Conversion

X = 1 − e−kτ = 1 − e−1.125 = 67.53%

Answer

X = 67.53%
17.Heat exchangers (LMTD)

Answer: A = 30.01 m²

LMTD method: the temperature difference between the streams changes along the exchanger, so the rate equation uses its logarithmic mean: Q̇ = U·A·ΔTlm, with ΔTlm = (ΔT₁ − ΔT₂)/ln(ΔT₁/ΔT₂), where ΔT₁ and ΔT₂ are the differences at the two ends. Counter-flow gives a larger ΔTlm than parallel flow for the same inlet and outlet temperatures.

End temperature differences (counter-flow)

In counter-flow the hot inlet faces the cold outlet, and the hot outlet faces the cold inlet.

ΔT₁ = Th,in − Tc,out = 90 − 45 = 45 K
ΔT₂ = Th,out − Tc,in = 40 − 25 = 15 K

Log-mean temperature difference

ΔTlm = (ΔT₁ − ΔT₂)/ln(ΔT₁/ΔT₂) = (45 − 15)/ln(45/15) = 27.31 K

Area

A = Q̇/(U·F·ΔTlm,cf) = 590000/(800·0.9·27.31) = 30.01 m²

Answer

A = 30.01 m²
18.Heat exchangers (LMTD)

Answer: A = 0.7137 m²

LMTD method: the temperature difference between the streams changes along the exchanger, so the rate equation uses its logarithmic mean: Q̇ = U·A·ΔTlm, with ΔTlm = (ΔT₁ − ΔT₂)/ln(ΔT₁/ΔT₂), where ΔT₁ and ΔT₂ are the differences at the two ends. Counter-flow gives a larger ΔTlm than parallel flow for the same inlet and outlet temperatures.

Heat duty and water outlet temperature

Q̇ = ṁhcp,h(Th,in − Th,out) = 2·2.1·25 = 105 kW
Tc,out = 15 + 105/(3·4.18) = 23.37 °C

End temperature differences

In counter-flow the hot inlet faces the cold outlet, and the hot outlet faces the cold inlet.

ΔT₁ = Th,in − Tc,out = 130 − 23.37 = 106.6 K
ΔT₂ = Th,out − Tc,in = 105 − 15 = 90 K

Log-mean temperature difference

ΔTlm = (ΔT₁ − ΔT₂)/ln(ΔT₁/ΔT₂) = (106.6 − 90)/ln(106.6/90) = 98.08 K

Area

A = Q̇/(U·ΔTlm) = 105000/(1500·98.08) = 0.7137 m²

Answer

A = 0.7137 m²
19.Heat conduction

Answer: Q̇ = 71.33 W

Thermal resistance: steady heat flow through layers in series behaves like current through resistors in series: Q̇ = ΔT/ΣR, with R = L/(kA) for a conducting layer and R = 1/(hA) for a convecting surface. The temperature drop across each layer is proportional to its resistance.

Layer resistances

R1 = L1/(k1A) = (250/1000)/(0.035·20) = 0.3571 K/W
R2 = L2/(k2A) = (25/1000)/(0.17·20) = 0.007353 K/W

Heat flow

Q̇ = (T1 − T3)/(R1 + R2) = 26/0.3645 = 71.33 W

Answer

Q̇ = 71.33 W
20.Heat conduction

Answer: Q̇ = 65.65 W

Thermal resistance: steady heat flow through layers in series behaves like current through resistors in series: Q̇ = ΔT/ΣR, with R = L/(kA) for a conducting layer and R = 1/(hA) for a convecting surface. The temperature drop across each layer is proportional to its resistance.

Resistances in series

Ri = 1/(hiA) = 1/(6·20) = 0.008333 K/W
R1 = L1/(k1A) = (250/1000)/(0.035·20) = 0.3571 K/W
R2 = L2/(k2A) = (150/1000)/(0.17·20) = 0.04412 K/W
Ro = 1/(hoA) = 1/(30·20) = 0.001667 K/W
ΣR = 0.4113 K/W

Heat loss

Q̇ = (20 − (-7))/0.4113 = 65.65 W

Answer

Q̇ = 65.65 W
21.Pipe friction & head loss

Answer: Δp = 6.4 kPa

Pipe flow: the Reynolds number Re = V·D/ν = ρ·V·D/μ tells laminar flow (Re below about 2000) from turbulent flow (above about 4000). Friction along a pipe costs the Darcy–Weisbach head loss hf = f·(L/D)·V²/(2g). Fittings, valves, the entrance and the exit add minor losses hm = ΣK·V²/(2g). Between two open reservoir surfaces the energy equation gives Δz = hf + hm, with the exit loss K = 1 included.

Head loss

hf = f·(L/D)·V²/(2g) = 0.015·(100/0.3)·1.6²/(2·9.81) = 0.6524 m

Pressure drop

The pipe is horizontal and the velocity does not change, so the energy equation reduces to Δp = ρ·g·hf.

Δp = ρ·g·hf = 1000·9.81·0.6524 = 6400 Pa = 6.4 kPa

Answer

Δp = 6.4 kPa
22.Pipe friction & head loss

Answer: H = 2.999 m

Pipe flow: the Reynolds number Re = V·D/ν = ρ·V·D/μ tells laminar flow (Re below about 2000) from turbulent flow (above about 4000). Friction along a pipe costs the Darcy–Weisbach head loss hf = f·(L/D)·V²/(2g). Fittings, valves, the entrance and the exit add minor losses hm = ΣK·V²/(2g). Between two open reservoir surfaces the energy equation gives Δz = hf + hm, with the exit loss K = 1 included.

Velocity

V = Q/A = 0.025/0.01767 = 1.415 m/s
V²/(2g) = 0.102 m

Loss coefficients

f·L/D = 0.022·150/0.15 = 22
ΣK = 0.5 + 3·0.3 + 5 = 6.4

Energy equation

The outlet jet still carries its velocity head; it is not a loss but it has to be supplied.

H = (1 + 22 + 6.4)·0.102 = 2.999 m

Answer

H = 2.999 m
23.Pumps & pump power

Answer: Pel = 66.79 kW

Pump power: the power given to the water is the hydraulic power Ph = ρ·g·Q·H = Q·Δp. The shaft must deliver more because the pump loses some: Pshaft = Ph/ηpump, and the motor draws Pel = Pshaft/ηmotor. The pump head H follows from the energy equation: static lift + pressure head + all friction and minor losses.

Hydraulic power

Ph = ρ·g·Q·H = 1000·9.81·0.08·48 = 37.67 kW

Shaft power

Pshaft = 37.67/0.6 = 62.78 kW

Electrical power

Pel = 62.78/0.94 = 66.79 kW

Answer

Pel = 66.79 kW
24.Pumps & pump power

Answer: Pshaft = 23.46 kW

Pump power: the power given to the water is the hydraulic power Ph = ρ·g·Q·H = Q·Δp. The shaft must deliver more because the pump loses some: Pshaft = Ph/ηpump, and the motor draws Pel = Pshaft/ηmotor. The pump head H follows from the energy equation: static lift + pressure head + all friction and minor losses.

Velocity

V = Q/A = 0.1/0.04909 = 2.037 m/s
V²/(2g) = 0.2115 m

Head losses

hL = (f·L/D + ΣK)·V²/(2g) = (24 + 5)·0.2115 = 6.134 m

Pump head

H = Δz + hL = 13 + 6.134 = 19.13 m

Shaft power

Pshaft = ρ·g·Q·H/η = 1000·9.81·0.1·19.13/0.8 = 23.46 kW

Answer

Pshaft = 23.46 kW

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