Material and Energy Balance

Course code: NKB10704

Rationale for Inclusion of the Course in the Programme:

This course is aimed at introducing students to the

fundamental principles of mass and energy balance as
applicable a wide range of equipment and processes. It
prepares the students to formulate and solve material and
energy balances on chemical process systems, and lays
the foundation for subsequent courses in thermodynamics,
unit operations, reaction engineering, kinetics, and process
dynamics.
Material and Energy Balance
Course code: NKB10704
Learning Outcomes:
Upon completion of this course students should be able to:

Determine the dimension of an equation and conversion of

units.
Calculate the material balance of process streams and
stream components under a range of conditions.
Analyze phase systems with various equations of state.
Evaluate the overall energy balance of process streams
and stream components.
Apply computer software in solving material and energy
balance calculations.
Material and Energy Balance
Course code: NKB10704
Assessment Methods and Types:
Test 20%
Assignment 20%
Final Examination 60%
Total 100%
Main References:
Felder, R.M. and Rousseau, R.W. (1999). Elementary of
Chemical Process, 3rd Edition. John Wiley & Sons.
Introduction to Engineering
Calculations

1. Units and Dimensions

2. Conversion of Units
3. Process Variables
4. Dimensional Homogeneity and
Dimensionless Quantities
1. Units and Dimensions
Units useful in most engineering
calculations & essential to write down both
value and the unit of each quantity
appearing in an equation.

2 meters 2 second 2 kilograms

Same value, but different unit totally
different meaning.

5
1. Units and Dimensions
The numerical values of two quantities
may be added or subtracted only if the
units are the same.

3 cm + 1 cm = 4 cm (YES)

3 cm 1 cm = 2 cm (YES)

3 cm 1 m = (Units are not same)

6
1. Units and Dimensions
Numerical values and their corresponding
units may always be combined by
multiplication or division.

3 km / 1 h = 3 km/h

3 km/h X 1 h = 3 km

3 km / 1 km = 3 (dimensionless)

7
1. Units and Dimensions
Dimensions property that can be
measured.

Examples: Length (m), time (s), mass

(kg), temperature (C)

Multiplying or dividing other dimensions

Length/time (velocity), length3 (volume),
mass/ length3 (density)

8
Base Unit Dimensions

Quantity SI Unit Dimension

Mass Kilogram M

Length Meter L

Temperature K

Time s T

9
2. Conversion of Units
A measured quantity can be expressed in
terms of any units having the appropriate
dimension.

Example: Velocity (ft/s, miles/h, cm/yr, or

any other ratio of a length unit to a time
unit)

The numerical value of the velocity

naturally depends on the units chosen.
10
2. Conversion of Units
Conversion factors two expression of
the same quantity defined in terms of a
ratio.
1 cm 10 mm
or
10 mm 1 cm
To convert a quantity expressed in terms
of one unit to its equivalent in terms of
another unit, multiply the given quantity by
the conversion factor (new unit / old unit)
11
2. Conversion of Units
Example: convert 36 mg to its equivalent
in grams,
36 mg (old unit) 1 g (new unit)
1000 mg (old unit)
Conversion Factor
= 0.036 g (new unit)

Old unit cancel, leaving the desired new

unit.
12
2. Conversion of Units
Example: Lets say we want to convert 1 cm/s2 to km/yr2
1. Write the given quantity and units on the left hand side.
2. Write the units of conversion factors that cancelled the existing
unit and replace them with the desired unit.

1 cm s2 h2 day2 m km
s2 h2 day2 yr2 cm m
3. Fill the values of the conversion factors

1 cm 36002 s2 242 h2 3652 day2 1m 1 km

s2 12 h2 12 day2 12 yr2 100 cm 1000 m

36002 x 242 x 3652 km

100 x 1000 yr2 = 9.95 x 10
13
9
km/ yr 2
 Quiz 1
Convert:

14
Systems of Units

MULTIPLE
UNITS

BASE DERIVED
UNITS UNITS

SYSTEMS
OF UNITS
15
 Systems of Units
Base Units
SI CGS
Quantity (system of Symbol American Symbol (Centimetergram Symbol
units) second system)

Length meter m foot ft centimeter cm

Mass kilogram kg pound mass lbm gram g

Moles gram-mole mole pound mole lbmole gram-mole mole

Time second s second s second s

Temperature Kelvin K Rankine R Kelvin K

16
 Systems of Units
1. SI system widespread acceptance in the scientific
and engineering.
2. CGS system almost identical to SI system, the
principle difference being that grams (g) and
centimeters (cm) are used instead of kilograms and
meters as the base units of mass and length.
3. American Engineering System has 2 principal
difficulties. The 1st is the occurrence of conversion
factors (such as 1 ft/12 in), which, unlike those in the
metric systems, are not multiples of 10; the 2nd, which
has to do with the unit of force, is discussed in the next
section.

17
 Systems of Units
Multiple Units
Fractions of base unit
Example : Years
Days
Hours
Seconds
Minutes
Multiple Unit prefixes
Example : Multiple Unit Preferences
tera (T) = 10 12 centi (c) = 10 -2
giga (G) = 10 9 milli (m) = 10 -3
mega (M) = 10 6 micro () = 10 -6
kilo (k) = 10 3 nano (n) = 10 -9
18 18
 Systems of Units

Derived SI Units
Equivalent to the Base
Quantity Unit Symbol
Unit
Volume Liter L 0.001m3 = 1000 cm3
Newton (SI) 1 kg.m/s2
Force N
Dyne (CGS) 1 g.cm/s2
Pressure Pascal Pa 1 N/m2
Energy/ Joule J 1 N.m = 1 kg.m2/s2
Work Calorie cal 4.184 J = 4.184 kg.m2/s2
Power Watt W 1 J/s = 1 kg.m2/s3
19
Force & Weight
Force is proportional to product of mass and acceleration
(length/time2).
Natural force units are therefore kg.m/s2 (SI), g.cm/s2
(CGS), and Ibm.ft/s2 (American engineering)
To avoid these complex natural force units, we usually
defined using derived force units (Newton, dyne and lbf)
1 Newton (N) = 1 kg.m/s2
1 dyne = 1 g.cm/s2
In the American engineering system, the derived force
unit called a pound-force (lbf) is defined as the
product of a unit mass (1 lbm) and the acceleration of
gravity at sea level and 45 latitude, which is 32.174 ft/s2:
1 Ibf = 32.174 Ibm.ft/s2 20
Force & Weight
Weight of an object is force exerted on the
object by gravitational attraction of the earth
i.e. force of gravity, g.

W = mg
Value of gravitational acceleration:
g = 9.8066 m/s2
= 980.66 cm/s2
= 32.174 ft/s2 21
Force & Weight
The symbol gc is sometimes used to
denote the conversion factor from a natural
force unit to a derived force unit.
1 kg.m/s2 32.174 lbm.ft/s2
gc =
1N
=
1 lbf

Not to be confused with gravitational

acceleration, which is usually denoted by g.
22
Weight & Mass
Example:
Given the density of 2 ft3 water is 62.4 lbm/ft3. At the sea level,
the gravitational acceleration is 32.174 ft/s2.
lbm
3
The mass of water is M 62.4 2 ft3
124.8lbm
ft

The weight of water is = mg

Mass ( m) Gravity ( g) g
Conversion factor ( c)

lbm 3 ft 1lbf
W 62.4 3 2 ft 32.174 2 124.8lbf
ft s 32.174lb ft
s23
m 2
3. Processes & Process Variables
Evaluation of performance of process
operation requires the knowledge of the
amounts, composition, conditions of
materials that enter and leave each
process units.
This sub-topic presents methods of
calculating variables that characterize the
operation of processes and individual
process units.

24
Process
Process Process
Input/Feed Unit Unit Output/Product
Output/Product

Process- any operation that cause a

physical or chemical change in a substance.
Can consist of several process unit.
Process streams connecting process units
and form the process flow sheet.
Chemical engineer is responsible to design
and operate the process.
25
3. Process Variables
The quantities used to describe a process
and these must be measured and
computed.

Feed
PROCESS Products
INPUT OUTPUT
To design or analyze a process, we need to
know the amounts, compositions, and
conditions of materials entering, leaving
and within the process.
26
3. Process Variables
Processes and
Process Variables

Density and
Specific Gravity Chemical
Composition

Flow rate

Temperature
Pressure
27
Density & Specific Volume
1. Density ()
Mass per unit volume of a substance.
Density of a substance can be used as
conversion factor to relate the mass and
the volume of the substances.
Unit: g/cm3; kg/m3; lbm/ft3.

2. Specific Volume
Volume per unit mass of a substance.
Inverse of density.
28

Unit: cm3/g; m3/kg; ft3/lb

 condition:

S
G
Specific Gravity (SG)
Ratio of the density () of a substance to the

R
E
F
density of a reference (ref) substance at a specific

Density of water at 4C is used as the reference density;

ref = H2O(l) (4C) = 1.000 g/cm3
= 1000 kg/m3
= 62.43 lbm/ft3

SG is dimensionless. To get the density of a substance,

29
multiply the SG value with the reference density, ref.
 Flow Rate
Continuous process involve movement of
materials from one point to another with certain
rate.
Flow rate: The amount of material that moves into
or out of a process unit per unit time.
Flow rate can be expressed as :
Mass flow rate (mass/time) = m
Volumetric flow rate (volume/time) = V
Molar flow rate (moles/time) = n
30
 Flow Rate
If Velocity, v (length/time) and Area (length2) is measured,
Volumetric flow rate, V (volume/time) is calculated as:

volume length

2
V A(length )
time time

V
We can relate between Volumetric flow rate, (volume/time)
which is easiest to measure and Mass flow m
rate,
(mass/time) using Density, (mass/volume):
mass mass volume
m
V
time volume time
31
 Flow Rate Measurement
Flow meter device mounted in a
process line that provides a continuous
reading of the flow rate in the line.
Two commonly used flow meter are
rotameter and orifice meter.

32
 Flow Meter

Orifice meter
(based on pressure drop)

Rotameter
(vertical tube containing a float) 33
 Chemical Composition
Chemical
Composition

Moles and
Molecular Weight
Concentration

Mass and
Mole Fractions
Parts per Million (ppm)
& Part per Billion (ppb)

Average
Molecular Weight
34
 Moles & Molecular Weight
Atomic weight - mass of an atom based on
carbon isotope 12C.
Molecular weight - Sum of the atomic weights
of atoms that represent a molecule of the
compound.
Eg.: Oxygen atomic weight (O) = 16.0 g/mol.
Thus, molecular oxygen (O2) has a molecular
weight of = 16.0 + 16.0 = 32.0 g/mol
Unit: kg/k-mol, g/mol, and lbm/lb-mole
35

m
Moles & Molecular Weight

n
1. At 1 mol of a substance, its mass in gram is equal to its

M
W
molecular weight.
2. Example: CO has molecular weight of 28. Therefore;
1 mol of CO contains 28 g
1Ib-mole CO contains 28 Ibm
1 ton-mole CO contains 28 tons
3. A gram-mol (g-mol, or mol in SI units), n is the amount of a
species (atom/molecule) whose mass in grams is
numerically equivalent to its molecular weight.
n = no. of moles (mol)
m = mass (g)
MW = molecular weight 36
(g/mol)
 n 3 mM W 34kg k
1m
7o
kgl
k
m
o
2l
Moles & Molecular Weight

NH NH
Example 1: 34 kg of NH3 is equivalent to how many

3
moles? Given MW NH3 = 17.0 kg/kmol

n
m
14.0(1.04)14(163)lb
M W
Solution:

7
2
N
H
N
lb
O N
H NO l
b-mole
0
.
9l
b
m
-o
l
e
Example 2: How many Ib-moles in 72 pounds of

43 4
3
NH4NO3. Given MW: N = 14.0 , H = 1.0 , O = 16.0)

m m 37
 Mass and Mole Fraction
Process input/output streams can
contain mixtures of liquids/gases,
solutions of one/more solutes in a
solvent.
Need mass fraction and mole fraction
to define the compositions.

38
 Mass and Mole Fraction
Mass fraction, xA
mass of A kg A gA lbm A
xA Units : or or
total mass kg total g total lbm total

Mole fraction, yA
moles of A kmol A mol A lb-mol A
yA Units: or or
total moles kmol total mol total lb-mol total

39
 Example
A mixture of gases has the following
mass composition:
O2 16%
CO 4%
CO2 17%
N2 63%

What is the molar composition?

40
 Solution
4 steps to convert from mass fractions to moles fractions:

Assume a mass of the mixture as the basis of

calculation (e.g. 100 kg or 100 lbm).

Use the known mass fractions to calculate the mass

of each component in the basis quantity.

Convert these masses to moles using respective

molecular weight, MW.

Calculate the ratio of the moles of each component

to the total number of moles in the mixture.

41
 Solution
From question: The mass composition is O2 (16%), CO (4%),
CO2 (17%) and N2 (63%)
Basis: 100g of mixture
Mass MW Mole
Comp. Mass Fraction Moles (mol)
(g) (g/mol) Fraction
i xi mi Mi ni yi

O2 16% = 16/100 0.16 x 100 16/32 0.500/3.279

32
= 0.16 = 16 = 0.500 = 0.152
4% = 4/100 0.04 x 100 4/28 0.143/3.279
CO 28
= 0.04 =4 = 0.143 = 0.044

CO2 17% = 17/100 0.17 x 100 44

17/44 0.386/3.279
= 0.17 = 17 = 0.386 = 0.118

N2 63%= 63/1.0 0.63 x 100 63/28 2.250/3.279

28
= 0.63 = 63 = 2.250 = 0.686
100g
Total 1.00 3.279 mol 1.000
(Basis) 42
 Average Molecular Weight
Mean molecular weight of a mixture (kg/kmol,
lbm/lbmole).
If yi is the mole fraction of the component i of the
mixture and Mi is the molecular weight of this
component: M
M y1M1 y2 M 2 ..... yi M i
all component
If xi is the mass fraction of the component i of the
mixture and Mi is the molecular weight:
1 x1 x2 xi
.....
M M1 M 2 all component M i
43
 Average Molecular Weight
Example: Determine the average molecular weight of refinery
waste gas component. The analysis by volume is given as:
CH4 (78.0%), C2H6 (10.0%), C3H8 (8.0%), and C4H10 (4.0%).

Assume as basis Use the known

of calculation the mole fractions and Convert these moles Sum all the masses
number of moles for molecular weights to to mass using the and divided by the
the mixture (e.g. 100 calculate the mass of molecular weight. basis.
mol) each component.

Vol. MW
NOTE:%Use basis
Comp. of 100
Moles (kmol) kmol and Units allWeight
(kg/kmol) in kg (kg)
and kmol Therefore,
CH4 78.0 78.0% x 100 = 78.0 16.0 16.0 kg/kmol x 78.0 kmol = 1248 kg 2133kg
C2H6 10.0 10.0% x 100 = 10.0 30.1 30.1 kg/kmol x 10.0 kmol = 301 kg
M
C3H8 8.0 8.0% x 100 = 8.0 44.1 44.1 kg/kmol x 8.0 kmol = 352 kg
100kmol
C4H10 4.0 4.0% x 100 = 4.0 58.1 58.1 kg/kmol x 4.0 kmol = 232 kg 21.33kg/ kmol
TOTAL 100.0 100.0 kmol 2133 kg
44
 Concentrations
Moles of component per unit volume of
Molar solution. moles of A
=
concentration Unit : mol/m , Ibmol/ft
3 3 C A
Volume of mixture

Mass of component per unit volume of

Mass solution. mass of A
Unit : g/cm , Ibm/ft , kg/in
3 3 3 c
concentration A
Volume of mixture

Molar concentration in units mol/liter

Symbol "M. E.g. 10.5 M solution of LiBr in
Molarity water. moles of A
= Molarity
Volume of mixture in Liter
45
 Concentrations
The concentration of a substance in a
mixture/solution
= can be used as a
conversion factor to relate the mass/moles of
a component of a continuous stream to the
total volumetric flow rate of the stream.

Example: 2 L/min, 0.02 molar solution of

NaOH
2L 0.02 mol NaOH mol NaOH
L = 0.0 min
4 46
min
 Parts per Million (ppm)&
Parts per Billion (ppb)
To express the concentrations of trace
species in mixtures of gases or liquids.
May refer to mass ratios (usual for liquids) or
mole ratios (usual for gases).
How many parts (in gram or moles) of the
species are present per million or billion
parts of the mixture.

47
 Parts per Million (ppm)&
Parts per Billion (ppb)
ppmi= yi x 106
ppbi = yi x 109

Example: Suppose air in the vicinity of a

power plant is said to contain 15 ppm SO2
(15 parts per million sulfur dioxide).
This statement means that every million
moles of air contains 15 moles of48SO 2.
 Pressure

A pressure ratio of a force to the

area on which the force acts (P= F/A).

Pressure units:
N/m2, dynes/cm2, lbf /in2, psi, Pa.

49
 Hydrostatic Pressure
Take a column of fluid with height, h (m) and
cross sectional area, A (m2)
The fluid has a density of (kg/m3)
The pressure, P at the base of the column is
by definition the force, F exerted on the base
divided by the area, A.
Force equals the weight of the fluid in the
column plus any force on the top surface.

50
 Hydrostatic Pressure
This is the formula for the pressure of the
fluid at the base of the column (hydrostatic
pressure)
P P gh
0 Po

Derivation:
F ma mg h

F (m) g ( Ah) g
P F / A gh
P P0 gh
51
 Head Pressure
Pressure maybe expressed as a head of a
particular fluid- that is in terms of a height of fluid.
Usually, water (H2O) or mercury (Hg) is used
We can thus speak of a pressure of 14.7 psi or
equivalently of a pressure (or head) of 33.9 ft 3 of
water (33.9 ft3 H2O) or 760 mm of mercury (760
mmHg).
lbf
14.7 2
14.7psi 33.9 ft H 2 O (head) = 760 mmHg (head)
in
Head units are mostly used for very low pressures
52
and expressed as "mm Hg" or "in H2O
 Atmospheric, Absolute
& Gauge Pressure
The Atmospheric Pressure pressure at
the base of a column of fluid (air) located at
the point of measurement (e.g. at sea level).
A typical value of the atmospheric pressure
at sea level, 760.0 mm Hg, has been
designated as a standard pressure of 1
atmosphere.
1 atm 14.696 psi 101.325 kPa = 760 mmHg
53
 Atmospheric, Absolute
& Gauge Pressure
Absolute Pressure Gauge Pressure plus
Atmospheric Pressure. In a perfect vacuum, the
pressure is zero.
Gauge Pressure Pressure relative to the
atmospheric pressure at measurement point.
Relationship between absolute pressure and gauge
pressure is:

Pabsolute Pgauge Patmopheric

The abbreviation psia and psig are commonly used
to represent absolute and gauge pressure
54 in lbf / in
2
 Fluid Pressure Measurement
Common pressure measurement devices:
Bourdon gauge and manometer.
Manometer: U-shaped tube partially filled
with fluid of known density.
Manometer gives the measurement of
pressure in terms of pressure difference, P
(P1-P2).

55
Fluid Pressure Measurement
Manometer Pressure gauge

56
 Temperature
Temperature of a substance in a particular
state of aggregation (solid, liquid, or gas) is a
measure of the average kinetic energy
possessed by the substance molecules.
Example of temperature measuring devices:
Resistance thermometer (based on the
resistance of a conductor), thermocouple
(voltage at the junction of 2 dissimilar
metals), pyrometer (spectra of emitted
radiation) and thermometer (volume of a
fixed mass of fluid). 57
 Temperature
The following relationship may be used to
convert a temperature expressed in one
defined scale unit to its equivalent in another
unit
T K = T( C) + 273.15
o

o o
T ( R) = T( F) + 459.67
o
T ( R) = 1.8 T (K)
o o
T( F) = 1.8 T( C) + 32 58
 Temperature Interval, T
We can use these conversion factor for temperature intervals,
T. These conversion factor refer to temperature intervals,
T NOT temperature, T.
o o o o
1.8 F 1 .8 R 1F 1C
1o C 1o K 1o R 1o K

For example to find the number of Celsius degrees1 obetween

C
32 F and 212 F, we do:
o o T( o
C) (212 32) o
F o
100 o
C
1.8 F
From: T( oF ) 1.8T( oC) 32
But to find the temperature of
32 F in C, we do:
o o 32 1.8T( o
C) 32
59 0 C
Therefore,T( oC) o
4. Dimensional Homogeneity and
Dimensionless Quantities
Quantities can be added and subtracted
only if their units are the same.
If their units are the same, it follows that
the dimensions of each term must be the
same.
Every valid equation must be
dimensionally homogeneous.
That is, all additive terms on both sides of
the equation must have the same
dimensions. 60
4. Dimensional Homogeneity and
Dimensionless Quantities
Example:

u (m/s) = u0 (m/s) + g (m/s2) t (s)

g (m/s2) t (s) = gt (m/s)

This equations is dimensionally

homogeneous, since each of them has the
same dimensions (length/time)
61
4. Dimensional Homogeneity and
Dimensionless Quantities
If the equation is dimensionally
homogeneous but have inconsistent units,
the terms may be made consistent by
applying the appropriate conversion
factors.
An equation may be dimensionally
homogeneous and invalid.
Example: M = 2M dimensionally
homogeneous but obviously incorrect and
invalid.
62
4. Dimensional Homogeneity and
Dimensionless Quantities
Dimensionless quantity pure number or
a multiplicative combination of variables
with no net dimensions
Also called a dimensionless group
Exponents (X2), transcendental functions
(log, exp e, and sin) and arguments of
transcendental functions (sin X) must be
dimensionless quantities.

63
 Tutorial
Derive unit for velocity in the
SI System?
The CGS System?
The American Engineering System?
length m ft cm
Velocity = (SI unit) = (American) = (CGS )
time s s s

64
Tutorial
Convert 1 miles per hour to meter per second
Length
1 m= 100 cm = 1000 mm =106 microns = 1010 angstrom
= 39.37 in = 3.2808 ft= 1.0936 yd = 0.0006214 mile
1 ft = 12 in = 1/3 yd = 0.3048 m = 30.48 cm

mi mile 1 m 1 hr m
1 1 0.447
hr hr 0.0006214 mile 3600 s s

65
 Tutorial
Convert 23 Ibm.ft/min2 to its equivalent kg.cm/s2
Mass
1 kg = 1000 g = 0.001 metric tonne = 2.20462 Ibm = 35.2739 oz
1 Ibm = 16 oz = 5 x 10-4 ton = 453.593 g = 0.453593 kg
Length
1 m = 100 cm = 1000 mm = 106 microns = 1010 angstrom = 39.37 in
= 3.2808 ft = 1.0936 yd = 0.0006214 mile
1 ft = 12 in = 1/3 yd = 0.3048 m = 30.48 cm

Ibm. ft Ibm. ft 0.453593 kg 100 cm 12 min 2 kg.cm

23 23 0. 088
min 2 min 2 1 Ibm 3.2808 ft 60 2 s 2 s2

66
 Tutorial
The density of CCl4 is 1.595 g/cm3; what is the
a) Mass of 20 cm3 of CCl4
20 cm3 1.595 g
= 31.9 g
cm 3

6.20 lbm 453.593 g cm3

= 1760 cm3
b) Volume of 6.20 lb1mlbof CCl4
m 1.595 g
67
Tutorial

A liquid has a SG of 0.50. Find;

a) Density in g/cm3
b) Density in lbm/ft3
c) Mass for 3 cm3 of the liquid volume
d) Volume occupied by 18 g of this
liquid

68
 Solution
a) Density in g/cm3 0.5 1g
= = 0.5 g/cm3
cm 3

0.5 62.43 lbm

b) Density in lbm/ft3 = = 31.215 lbm/ft3
ft 3

c) Mass for 3 cm33cm

of3 the0.5
liquid
g volume
= 1.5 g
cm 3

d) Volume occupied
18 gby 18
cm3g of this liquid
=
3
36 cm
0.5 g 69
 Tutorial
Consider the interval from 20F to 80F.
1.Calculate the equivalent temperature in C and the interval between them.
2.Calculate directly the interval in C between these temperatures.

SOLUTION 1
T(F ) 32
From equation: T(F ) 1.8T(C) 32, we get T(C)
1.8
20 32 80 32
For 20F, T1 (C) 6.7C, For 80F, T2 (C) 26.6C
1.8 1.8
Temperature Interval, T = T2 T1 (26.6 (6.7))C 33.3C

SOLUTION 2
o
1 C
T( C) (80 20) F o 33.3 oC
o o

1.8 F 70