Chapter 4

Material & Energy Balance
CHE2162
Assoc. Prof. Dr. Meng Nan Chong

Chemical Engineering Discipline
Monash University Malaysia
Semester 2, 2016
Week 2: Chapter 4 to 4.5
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Outline
Chapter 4, Fundamental of Material Balance

Process Classification
Material Balance and Calculations
Multiple-Unit Processes, Recycle and Bypass streams
Summary
M.N. Chong CHE2162 (Material & Energy Balance) 2 of 35

Process Classification Batch Process
Steady-State and
Chapter 4 Material Balance and Calculations Continuous Process
Transient Processes
Multiple-Unit Processes Semi-Batch Process
Batch Processes
No mass crosses system boundaries between the time feed is charged

and the time product is removed. Applicable for making small quantities.

Steady-State and
Transient Processes
Continuous Processes
Inlet and outlet (feed and product) streams continuously flow across the
system boundary. Applicable for production of large quantities.
Nitric Acid Production Process, Sinnott, Fig 4.3

Steady-State and
Transient Processes
Semi-Batch Processes
One or more streams are stationary while at least one stream is steadily
flowing.

Steady-State and
Transient Processes
Steady-State and Transient Processes
Steady-State:
The main process variables (temperature, pressure, composition, flow
rates) are not changing with time (minor fluctuation is alright); e.g. a
continuous processes may work steadily.
Unsteady-State (transient, time-dependent):

The values of process variables change by time. Batch and semi-batch
process are examples of unsteady-state operation. Also, start-up/shut-
down of a continuous process are unsteady-state.

Material Balance Equations
Chapter 4 Material Balance and Calculations
Material Balance Calculations for Single-Unit Processes
Multiple-Unit Processes
General Balance Equation
Input Output + Generation Consumption = Accumulation
(I-O+G-C=A)
Input: enters through system boundaries

Output: leaves through system boundaries
Generation: produced within the system
Consumption: consumed within the system
Accumulation: built-up/diminished within the system (might
be positive or negative)
.

Types of Balance Equation
Integral Balance:
The general balance equation is written for a fixed period of time (whole processing
time), as a results, net amount of quantities are applied:
Net Input Net Output + Net Generation Net Consumption = Net Accumulation
Differential Balance:
The general balance equation is written for a short period of time (between two
instants of time), as a results, rate of quantities are applied:
Rate of Input Rate of Output + Rate of Generation Rate of Consumption = Rate of Accumulation

Application of the General Balance Equation for Material Balance
Application Criteria:
total mass and mass of components (multicomponent system)
mole balance (Non-reactive: molecular and atomic balance, Reactive systems: only
atomic balance)
Once only for each species (must be independent equation)
Special Cases:
Accumulation = 0 (steady-state)
Input = Output = 0 (batch process, or any closed system)
Generation = Consumption = 0 (non-reactive systems, total mass balance)

Example 1 (Hexane Vaporizer, a Semi-Batch Process)

Air is bubbled through a drum of liquid hexane at a rate of 0.100 kmol/min. The gas
stream leaving the drum contains 10.0 mole% hexane vapor. Air may be considered
insoluble in liquid hexane. Use an integral balance to estimate the time required to
vaporize 10.0 m3 of liquid hexane.

Example 1 (Solution)
In terms of air, the system is classified as continuous process. So, starting by a differential balance on
air. Since we assume that air neither dissolves in the liquid (accumulation = 0) nor reacts with hexane in
the process unit (generation = consumption = 0). the balance reduces to input = output:
In terms of hexane, the system is classified as batch process. So, applying an integral balance on hexane
provides for the whole period of processing (start by t=0 to t=tf) we obtain: (accumulation = - output)
Note: The amount of hexane accumulation is given by the problem which is 10 m 3. Since this amount is
evaporated, it is lost from the system, so it has a negative sign (Accumulation= -10 m3). By applying
the mass balance equation (accumulation= - output):
-10 m3 0.659 kg 1000 L 1 kgmol

= - 0.1 n tf = 6880 min
3
tf min 1 L 1 m 86.2 kg
Note: density and molecular weight could be found in Appendix B, Table B.1 (convert SG to density)

Example 2 (Distillation Column, a Continuous Process)

Consider a benzene/toluene distillation column shown by a Fig 6, and determine the
unknown mass flow rates.
Distillation
column

Applying the general balance equation (at differential condition):
Since the system is classified as continuous process operating at steady-state condition with no
reaction (generation=consumption = 0, accumulation=0), the balance reduces to input = output
How to write the mass balance equations?

1. Draw a system boundary
2. If there are N components then

N independent mass balance equations Distillation
can be written for: either for N components column
or (N 1) components and 1 for Total Mass

balance:
Benzene balance
500 kg B/h = 450 kg B/h + m2 m2 = 50 kg B/h
Toluene balance
500 kg T/h = 475 kg T/h + m1 m1 = 25 kg T/h
Total mass balance (to check the validity of results)
500 kg B/h + 500 kg T/h = (450 + 50) kg B/h + (475+ 25) kg T/h 1000 kg/h = 1000 kg/h

Example 3 (Mixer, a Continuous Process)

Two methanol-water mixtures are available in separate flasks. The first mixture
contains 40.0 wt% methanol, and the second contains 70.0 wt% methanol. If 200 g
of the first mixture is combined with 150 g of the second, what are the mass and
composition of the product?
Mixer

Applying the general balance equation (at integral condition, the notation on Fig 7 shows initial and
final steps):
By assuming the final mixed product is completely removed from the mixer at the end of the
process, there is no accumulation. Since the system is non-reactive (generation=consumption = 0),
accordingly, the general balance equation is reduced to input = output
Total mass balance

200 g + 150 g = m m= 350 g
Methanol balance
200 g * 0.4 g MtOH/g + 150 g * 0.7 g MtOH/g = m g * x g MtOH/g x= 0.53 g MtOH/g
Water balance (only to verify and get % error due to sig fig)
200 g * 0.6 g W/g + 150 g * 0.3 g W/g = 350 g (1-0.53) g W/g (less than 1% error)

Flowchart Drawing and Labeling

Draw boxes (or other symbols) for all equipment
Draw arrows indicating all streams and their (major flows from left to right)
Label all equipment and all streams
Streams:
Material amount or flow (mass- or mole-based) n (mol/h)
Composition (mass fraction or mole fraction) 0.21 mol O2/mol
0.79 mol N2/mol
Temperature and Pressure
T= 320 (C), P= 1.4 atm
Assign symbols for unknown variables
Equipment:
Name, number, symbol (where applicable)

Basis of Calculations
The first step in balancing a process is to chose a basis of calculation; all unknown quantities
are then determined to be consistent with this basis.
How to chose a basis?

1. use an amount or rate of one stream (usually feed or product), if it is known
2. if none are known, assume one for a stream of known composition
Note that if mole fractions are known, use a molar basis.

Degree of Freedom Analysis
Degree of freedom (ndf) is determined by counting the unknown variables (nunknowns) and the
number of independent equations (nindep_eqns) relating these variables using the following
equation:
ndf = nunknowns nindep_eqns
If ndf = 0, problem can be solved (in principle).
If ndf > 0, problem is under-specified (additional variables must be specified).
if ndf < 0, the problem is over-specified (there are some inconsistent equations).
Notes: make sure all equations are independent (adding, subtracting, dividing, or multiplying the
independent equations are not acceptable).
A multicomponent system with N components has only N independent mass balance equations.
Independent equations comprising all process constraints (such as yield, recovery, purity
percent, equilibrium condition, reaction stoichiometry ...)

General Procedure for Single-Unit Process Material Balance
1. Choose a basis
2. Draw a fully labeled flowchart
3. Convert all quantities to a consistent unit basis (mass and mole)
4. Do the degree-of-freedom analysis (the result must be zero)
5. Minimize the number of equations (by minimizing simultaneous equations) and circle
the variables for which you will solve
6. Solve the equations and calculate the unknown variables.
7. If you have chosen/calculated a basis (nc) which is different from the basis given in
the problem statement (ng), then scale up/down the balanced process by the ratio of
ng/nc to obtain the final result.

Example
A liquid mixture containing 45.0% benzene (B) and 55.0% toluene (T) by mass is
fed to a distillation column. A product stream leaving the top of the column (the
overhead product) contains 95.0 mole% B, and a bottom product stream contains
8.0% of the benzene fed to the column (meaning that 92% of the benzene leaves
with the overhead product). The volumetric flow rate of the feed stream is 2000. L/h
and the specific gravity of the feed mixture is 0.872.
Determine the mass flow rate of the overhead product stream and the mass flow
rate and composition (mass fractions) of the bottom product stream.

Solution
1. Choosing a basis: no need as the feed flow rate is given by the problem (200 L/h)
2. Draw a label the flowchart:
3. Write expressions for the quantities requested in the problem statement: m3 = mB3 + mT3,
yB3 = mB3 / m3, yT3 = 1 yB3
4. Perform the degree-of-freedom analysis (4 unknowns: m1, m2, mB3, and mT3, 2 material
balance, 1 density relationship, 1 recovery equation that is specified by the given equation for
benzene split, 8% bottom; totally: Dfd= 0)
5. Write system of equations and outline a solution: (see next slide)
Contnd.

Solution
Calculating Benzene mass fraction in stream 2 (yB2):
By taking n2=1 kgmol of overhead product as the basis for this calculation: m2 = mB2 + mT2,
yB2 = mB2 / m2, yT2 = 1 yB2
mB2 = n2 * YB2 * MB= 1 kgmol * 0.95 kgmol B/ kgmol * 78.11 kg B/ kgmol B mB2 = 74.20 kg B
mT2 = n2 * YT2 * MT = 1 kgmol * 0.05 kgmol T/ kgmol * 92.13 kg T/ kgmol T mT2 = 4.61 kg T
m2 = mB2 + mT2 m2 =78.81 kg, yB2 = mB2 / m2 yB2 = 0.942 yT2 = 1 yB2 yT2 = 0.058
Converting feed volumetric flow rate to mass flow rate:
m1 = V1 * = 2000. L/h * 0.872 kg/L = 1740 kg/h
Calculating benzene split fraction for stream 3:
mB3 = 0.08 * yB1 * m1 = 0.08 * 0.45 * 1744 kg/h = 60. kg/h
Benzene balance:
0.45 m1 = m2 * yB2 + mB3 m2 =760 kg/h
Toluene balance:
0.55 m1 = m2 * (1-yB2) + mT3 mT3 =920 kg T/h
Calculating the other parameters:
m3 = mB3 + mT3 m3 =980 kg/h
yB3 = mB3 / m3 yB3 = 60. kg B /980 kg/h = 0.06 kg B/ kg, yT3 = 1 yB3 =0.94 kg T / kg

Bypass, Recycle, and Purge Streams
Material Balance Calculations for Multi-Unit Processes
Bypass Stream
A bypass stream is used to skip one or more stages of the process in order to
adjust the composition (or temperature) of downstream
have temporary replacement/overhaul of the process unit.
Splitting Mixing

Recycle Stream
Recycle stream is used to return the raw materials (unconsumed, unreacted, unconverted)
back to the process (reactor) which reduces.
the wasted products
the cost of process
and increases:
the overall conversion
the productivity of whole process

Purge Stream
Purge stream is a portion of recycle stream which is removed from the process in order to
prevent the accumulation of inert materials (diluting agents for reactants) in the process
(reactor).
0.1 kg I/min
0.2 kg I/min 0.2 kg I/min
0.1 kg I/min
0.1 kg I/min
Purge stream

General Procedure for Multi-Unit Process Material Balance

The calculation steps are the same as for a single unit. It is necessary to perform balances on
several process subsystems including:
1. overall process (overall dashed-line, A in above figure)
2. individual units or pieces of equipment (blocks dashed-line, C and E in above figure)
3. stream junctions (i.e., mixing or splitting points, B and D in above figure)
Note:
Recycle and bypass streams: treated the same by considering as the mixing/splitting
points
Purge streams: treated as an output stream

Example (Evaporative Crystallization Process)

Crystalline potassium chromate (K 2CrO4) is recovered from an aqueous solution of this salt
in a steady state continuous process. 4500 kg/h of a solution that is one-third K2CrO4 by
mass is joined by a recycle stream containing 36.4% K2CrO4, and the combined stream is
fed into an evaporator. The concentrated stream leaving the evaporator contains 49.4%
K2CrO4. This stream is fed into a crystallizer in which it is cooled (causing crystals of
K2CrO4 to come out of solution) and then filtered. The filter cake consists of K2CrO4
crystals and a solution containing 36.4% K2CrO4 by mass; the crystals accounts for 95% of
the total mass of the filter cake. The filtrate solution (also 36.4% K2CrO4) is the recycle
stream.
1. Calculate the rate of evaporation, the rate of product of crystalline K2CrO4, the feed rates
that the evaporator and the crystallizer must be designed to handle, and the recycle ratio
(mass of recycle)/(mass of fresh feed).
2. Suppose that the filtrate were discarded instead of being recycled. Calculate the
production rate of crystals. What are the benefits and costs of the recycling?

Solution
Basis: no need as it is given by the problem statement (4500 kg/h of feed stream)
Draw a fully labeled flowchart:
H2 O
m3
m5 kg/h
4500 kg/h m 1 m4 kg/h Crystalliser 0.95 kg K(S)/kg
0.333 kg K/kg Evaporator 0.494 kg K/kg 0.05 kg
and Filter
0.667 kg W/kg x kg K/kg 0.506 kg W/kg
solution/kg
(1 x ) kg
Solution =
W/kg
0.364 kg
m2 kg/h Filtrate Solution
K/kg(sol)
0.364 kg K/kg
0.636 kg W/kg 0.636 kg
W/kg(sol)
Contnd.

Solution
Degree of freedom analysis
Overall System
Unknowns = 2 (m3 , m5 )
Equations = 2 (total mass and K2CrO4 balance)
ndf = 0 (Fully Specified)
Feed / Recycle Mixing Point
Unknowns = (m 1 , m2 and x)
ndf = 1 (under specified)
Evaporator
Unknowns = 4 (m 1 , m3 , m4 , x)
ndf = 2 (under specified)
Crystallizer
Unknowns = 2 (m2 , m4 )
ndf = 0 (Fully Specified)
Contnd.

Solution
Material Balance equations:
Overall System
Total Mass: 4500 = m3 + m5
K2CrO4 balance:4500 0.333 = m3 0 + 0.95 m5 + 0.05 m5 0.364
m5 = 1500 kg/h, therefore m3 = 3000 kg/h
H2 O
m3
4500 kg/h
m5 kg/h
0.333 kg K/kg
0.667 kg W/kg Crystalliser 0.95 kg K(S)/kg
Evaporator
and Filter 0.05 kg
solution/kg
Solution =
0.364 kg
K/kg(sol)
0.636 kg
Contnd. W/kg(sol)

Solution
Crystallizer
Total Mass:m4 = m2 + m5 m4 = m2 + 1500 kg/h
K2CrO4 balance:0.494 m4 = 0.364 m2 + 0.95 m5 + 0.05 m5 0.364
m2 = 5700 kg/h, therefore m4 = 7200 kg/h
m5 kg/h
m4 kg/h Crystalliser 0.95 kg K(S)/kg
and Filter
0.494 kg K/kg 0.05 kg solution/kg
0.506 kg W/kg
Solution =
0.364 kg
m2 kg/h K/kg(sol) 0.636 kg
Filtrate Solution
0.364 kg K/kg W/kg(sol)
0.636 kg W/kg
Contnd.

Solution
Mixing point
Total Mass: m1 = 4500 + m2 m1 = 4500 + 5700 = 10200 kg/h
K2CrO4 balance:m1 x = 4500 0.333 + 5700 0.364
Therefore x = 0.35
Evaporator (to check validity of calculation)
Total Mass: m1 = m3 + m4 10200 = 3000 + 7200
K2CrO4 balance:m1 .x = m3 0 + m4 0.494
10200 0.35 = 0 + 7200 0.494 3600 = 3600 (no error)
Mixing point
4500 kg/h m1 W/kg

0.333 kg K/kg x kg K/kg
0.667 kg W/kg (1 x ) kg
m2 kg/h
Filtrate Solution
0.364 kg K/kg
0.635 kg W/kg Contnd.

Summary
By the end of this lecture and also the lecture handout, you have to be able to
define batch, semi-batch, continuous, transient and steady state processes
draw and understand a flowchart (and also a basic block flow diagram) for a chemical process
calculate the degrees of freedom
solve the material balance for a process description
define and perform calculations for recycle, purge, and bypass streams

Study Schedule
Review the lecture handout and the lecture slides again. The text book also
provides a broader explanation for the discussed subjects followed by very
good examples, that is recommended to be reviewed as well.
Attend in the tutorials (both handcalcs and computer labs)
Do practice problems to improve your problem solving skills

The End
Thank you

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Chapter 4

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Material & Energy Balance

Assoc. Prof. Dr. Meng Nan Chong

Chapter 4, Fundamental of Material Balance

M.N. Chong CHE2162 (Material & Energy Balance) 2 of 35

No mass crosses system boundaries between the time feed is charged

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Nitric Acid Production Process, Sinnott, Fig 4.3

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Steady-State and Transient Processes

Unsteady-State (transient, time-dependent):

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General Balance Equation

Input Output + Generation Consumption = Accumulation

Input: enters through system boundaries

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Types of Balance Equation

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Application of the General Balance Equation for Material Balance

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Example 1 (Hexane Vaporizer, a Semi-Batch Process)

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-10 m3 0.659 kg 1000 L 1 kgmol

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Example 2 (Distillation Column, a Continuous Process)

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How to write the mass balance equations?

2. If there are N components then

or (N 1) components and 1 for Total Mass

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Example 3 (Mixer, a Continuous Process)

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Total mass balance

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Flowchart Drawing and Labeling

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How to chose a basis?

Note that if mole fractions are known, use a molar basis.

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Degree of Freedom Analysis

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General Procedure for Single-Unit Process Material Balance

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General Procedure for Multi-Unit Process Material Balance

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Example (Evaporative Crystallization Process)

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4500 kg/h m1 W/kg

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Attend in the tutorials (both handcalcs and computer labs)

Do practice problems to improve your problem solving skills

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