Elementary Principles of Chemical Processes, Binder Ready Version
Elementary Principles of Chemical Processes, Binder Ready Version
4th Edition
ISBN: 9781118431221
Author: Richard M. Felder, Ronald W. Rousseau, Lisa G. Bullard
Publisher: WILEY

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Chapter 5, Problem 5.66P

The quantity of sulfuric acid used globally places it among the most plentiful of all commodity chemicals. In the modem chemical industry, synthesis of most sulfuric acid utilizes elemental sulfur as a feedstock. However, an alternative and historically important source of sulfuric acid was the conversion of an ore containing iron pyrites (FeS2) to sulfur oxides by roasting (burning) the ore with air. The following reactions occurred in an oven:

   2FeS 2 ( s ) + 11 2 O 2 ( g ) Fe 2 O 3 ( s ) +4SO 2 ( g ) (1)

   SO 2 ( g ) + 1 2 O 2 ( g ) SO 3 ( g )


The gases leaving the oven were fed to a catalytic converter in which most of the remaining SO2produced was oxidized to SO3. Finally, the gas leaving the converter was sent to an absorption column where the SO3was taken up by water to produce sulfuric acid (H3SO4).

(a) The ore fed to the oven was 90.0 wt% FeS2, and the remaining material may be considered inert. Dry air was fed to the oven in 30.0% excess of the amount required to oxidize all of the sulfur in the ore to S03. Eighty-?ve percent of the FeS2was oxidized, and 60% of the SO2produced was oxidized to SO3. Leaving the master were (i) a gas stream containing SO2, SO3, O2, and N2and (ii) a solid stream containing unconverted pyrites, ferric oxide (Fe2O3), and the inert material. Calculate the required feed rate of air in standard cubic meters per 100 kg of ore fed to the process. Also determine the molar composition and volume (SCM/100 kg ore) of the gas leaving the oven.

(b) The gas leaving the oven entered the catalytic converter, which operated at 1.0 atm. Reaction (2) proceeded to equilibrium, at which point the component partial pressures are related by the expression

   K p ( T ) = p SO 3 p SO 2 p O 2 0 .5

The gases were ?rst heated to 600°C to accelerate the rate of reaction, and then cooled to 400°C to enhance SO2conversion. The equilibrium constant KPat these two temperatures is 9.53 atm0.5 and 397 atm0.5, respectively. Calculate the equilibrium fractional conversions of SO2at these two temperatures.

(c) Estimate the production rate of sulfuric acid in kg/kg ore if all of the SO3leaving the converter was transformed to sulfuric acid. What would this value be if all the sulfur in the ore had been convened?

Exploratory Exercises—Research and Discover (d) Two of the important factors affecting the utility of a chemical reaction are the maximum extent of the reaction and the rate at which the reaction occurs. Consider these two factors and explain the steps in the converter in which the gas was heated ?rst and then cooled.

(e) Why has elemental sulfur come to be the dominant feedstock in sulfuric acid manufacturing?

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Chapter 5 Solutions

Elementary Principles of Chemical Processes, Binder Ready Version

Ch. 5 - Prob. 5.11PCh. 5 - Prob. 5.12PCh. 5 - Prob. 5.13PCh. 5 - Prob. 5.14PCh. 5 - Prob. 5.15PCh. 5 - Prob. 5.16PCh. 5 - Prob. 5.17PCh. 5 - Prob. 5.18PCh. 5 - Prob. 5.19PCh. 5 - A device has been designed to measure the flow...Ch. 5 - Prob. 5.21PCh. 5 - Prob. 5.22PCh. 5 - Spray drying is a process in which a liquid...Ch. 5 - Prob. 5.24PCh. 5 - Lewis12 describes the hazards of breathing air...Ch. 5 - A stream of air at 35°C and a gauge pressure of...Ch. 5 - Prob. 5.27PCh. 5 - In froth ?otation, air is bubbled through an...Ch. 5 - Prob. 5.29PCh. 5 - Prob. 5.30PCh. 5 - Bread is typically made by ?rst dissolving...Ch. 5 - Prob. 5.32PCh. 5 - Prob. 5.33PCh. 5 - Prob. 5.34PCh. 5 - Prob. 5.35PCh. 5 - Prob. 5.36PCh. 5 - Prob. 5.37PCh. 5 - Prob. 5.38PCh. 5 - Prob. 5.39PCh. 5 - A spray-drying operation similar to that described...Ch. 5 - Prob. 5.41PCh. 5 - Fermentation is a biochemical process in which a...Ch. 5 - Prob. 5.43PCh. 5 - Prob. 5.44PCh. 5 - Ethane at 25°C and 1.1 atm (abs) flowing at a rate...Ch. 5 - The ?ow of air to a gas-?red boiler furnace is...Ch. 5 - Prob. 5.47PCh. 5 - The oxidation of nitric oxide NO+12O2NO2 takes...Ch. 5 - Prob. 5.49PCh. 5 - 5.50.19 In chemical vapor deposition (CVD), a...Ch. 5 - A gas turbine power plant receives a shipment of...Ch. 5 - Prob. 5.52PCh. 5 - 5.53.20 Chemicals are stored in a laboratory with...Ch. 5 - Prob. 5.54PCh. 5 - Prob. 5.55PCh. 5 - A stream of ho dry nitrogen flows through a...Ch. 5 - Prob. 5.57PCh. 5 - You have purchased a gas cylinder that is supposed...Ch. 5 - The current global reliance on fossil fuels for...Ch. 5 - Two humid gas streams are combined in a heated...Ch. 5 - Most of the concrete used in the construction of...Ch. 5 - The ultimate analysis of a No. 4 fuel oil is 86.47...Ch. 5 - A stream of liquid n-pentane flows at a rate of...Ch. 5 - Alka-Seltzer( is an over-the-counter medicine used...Ch. 5 - Hydrogen sul?de has the distinctive unpleasant...Ch. 5 - The quantity of sulfuric acid used globally places...Ch. 5 - A small power plant produces 500 MW of electricity...Ch. 5 - You have been assigned the task of measuring the...Ch. 5 - Prob. 5.69PCh. 5 - Methanol is synthesized from carbon monoxide and...Ch. 5 - Prob. 5.71PCh. 5 - Prob. 5.72PCh. 5 - Steam reforming is an important technology for...Ch. 5 - A ?owchart of a methanol synthesis process is...Ch. 5 - The measured volumetric flow rate of ethane at...Ch. 5 - Prob. 5.76PCh. 5 - Methanol is to be delivered to a process unit at a...Ch. 5 - Prob. 5.78PCh. 5 - Prob. 5.79PCh. 5 - Prob. 5.80PCh. 5 - Prob. 5.81PCh. 5 - Prob. 5.82PCh. 5 - Prob. 5.83PCh. 5 - Prob. 5.84PCh. 5 - Prob. 5.85PCh. 5 - Prob. 5.86PCh. 5 - Prob. 5.87PCh. 5 - Prob. 5.88PCh. 5 - Prob. 5.89PCh. 5 - A fuel cell is an electrochemical device that...Ch. 5 - In a metered-dose inhaler (MDI), such as those...Ch. 5 - Prob. 5.92PCh. 5 - Prob. 5.93PCh. 5 - Approximately 150 SCFM (standard cubic feet per...Ch. 5 - Prob. 5.95PCh. 5 - Prob. 5.96PCh. 5 - Prob. 5.97PCh. 5 - The product gas from a coal gasification plant...Ch. 5 - Prob. 5.99PCh. 5 - Prob. 5.100PCh. 5 - A gas mixture consisting of 15.0 mole% methane....Ch. 5 - A system has been devised to store acetonitrile...Ch. 5 - Prob. 5.103PCh. 5 - Prob. 5.104P

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