PCS-FKKKSA

Slide 1 - 1
Material Balances
Introduction to Engineering
Principles and Units
Kamarul Asri Ibrahim, PhD
PCS-FKKKSA
Slide 1 - 2
Material Balances
Course Instructor
! Professor Dr. Kamarul Asri Ibrahim
! Academic Qualifications
" B.Sc. Chem. Eng. (Ohio)
" M.Sc. Chem. Eng. (Colorado State)
" Ph.D. Chem. Eng. - Multivariate Active SPC (Newcastle upon Tyne)
! Specialization
" Process Modeling, Control, and Optimization
" Application of Multivariate SPC in Plant Operation
! Contact
" email : kamarul@fkkksa.utm.my
" Tel: 07-5535573 Fax:07-5536165
PCS-FKKKSA
Slide 1 - 3
Material Balances
Course Synopsis
This course introduces students to the chemical
engineering profession and the fundamental operations of
chemical process equipment. It also provides students
with the basic principles of chemical engineering material
balances as well as calculation techniques to solve
material balance problems for chemical process systems
and equipment.
PCS-FKKKSA
Slide 1 - 4
Material Balances
Learning Outcomes of the SKKK 1113 Course
By the end of this course, students should have the:
CO1 Ability to carry-out unit conversion and equipment
identification for various chemical processes, process
variables and unit operations in chemical industry
CO2 Ability to calculate mass balance on single or multiple
process units with or without recycle, purge, or
bypass streams for non-reactive processes.
CO3 Ability to solve mass balance calculations on single or
multiple process units with or without recycle, purge,
or bypass streams for reactive processes
CO4 Ability to perform and analyze mass balance
calculations of single phase system
PCS-FKKKSA
Slide 1 - 5
Material Balances
Learning Outcomes of the SKKK 1113 Course
By the end of this course, students should have the:
CO5 Ability to demonstrate mass balance calculations of
multiple component gas-liquid systems at equilibrium
CO6 Ability to solve the problems using first law of
thermodynamics and conservative equations by
identifying forms of energy, reference state
conditions and state properties
CO7 Ability to conduct problem solving solution of mass and
energy problem using principle of conservation.
CO8 Ability to commit in the preparation of learning
experience process using E-Portfolio
PCS-FKKKSA
Slide 1 - 6
Material Balances
Units and Dimensions
! Dimension - property that can be measured such as
" length
" time
" mass
" temperature
" multiplying or dividing other dimensions
! Unit - measured and counted quantity has
" value (2.35)
" unit (2.35 gram)
! It is essential to write the value and unit in equation
2 meters, 0.3 second, 4.5 kilograms, 5 gold rings
PCS-FKKKSA
Slide 1 - 7
Material Balances
Properties of Units
! Units can be treated like algebraic variables
" added and subtracted when having same units
3 cm - 1 cm = 2 cm (3x - x = 2x)
but
3 cm - 1 mm (or 1 s) = ? (3x - y = ?)
" can always be combined by multiplication or divisions
3 N x 4 m= 12 N.m



( 3 is a dimensionless quantity)
PCS-FKKKSA
Slide 1 - 8
Material Balances
Conversion of Units
! When having appropriate dimensions, measured quantity can be
expressed in term of other units
ft/s miles/hr cm/yr
! The equivalence between two expressions is given by ratio known
as conversion factor
( 1 centimeter per 10 millimeters)
(10 millimeters per 1 centimeter )
PCS-FKKKSA
Slide 1 - 9
Material Balances
Conversion Factors
! A given quantity is expressed into new unit by using
a conversion factor (new unit/old unit)
! Alternative way to write this equation
36 mg 1g = 0.036 g
1000 mg
PCS-FKKKSA
Slide 1 - 10
Material Balances
! Set up a dimensional equation
" write the given quantity and its unit on the left
" write the units of conversion factors (new unit/old unit)
" fill in the values of the conversion factors
" carry out the indicated arithmetic operations to find the desired
values
! Example : Convert acceleration of 1 cm/s
2
to km/y
2
(km/y
2
) = 1 cm 3600
2
s
2
24h
2
365
2
day
2
1 m 1 km
s
2
h
2
day
2
y
2
10
2
cm

10
3
m

= 9.95 x 10
9
km/y
2

Method for using Conversion Factor
PCS-FKKKSA
Slide 1 - 11
Material Balances
Systems of Units
! Base Units - units for dimensions of mass, length, time,
temperature, electrical current, and light intensity
" kilogram, meter, second, kelvin, ampere, candela
! Multiple units - multiples or fraction of base unit
" minutes, hours, milliseconds or all in term of base unit second
! Derived units - obtained in one of two ways
" Multiplying and dividing base units (cm
2
, ft/min, kg.m/s
2
) which
are known as compound units
" Defined as equivalents of compound units
( 1 erg = 1 g.cm/s
2
, 1 lb
f
= 32.174 lb
m
.ft/s
2
)
PCS-FKKKSA
Slide 1 - 12
Material Balances
Systems of Units
! System Internationale dUnites
Length meter (SI)
centimeter (CGS)
Mass kilogram (SI)
gram (CGS)
Moles gram-mole (mol)
Time second (s)
Temperature kelvin (K)
Electric current ampere (A)
Light intensity candela (cd)
! American Engineering System
Length foot (ft)

Mass pound mass (lb
m
)

Moles lb
m
-mole (lb
m
mol)
Time second (s)
Temperature Rankin (
o
R)
Electric current ampere (A)
Light intensity candela (cd)
PCS-FKKKSA
Slide 1 - 13
Material Balances
Force
! Force is proportional to the product of mass and acceleration
(length/time
2
)
1 newton (N) = 1 kg.m/s
2
1 dyne = 1 g.cm/s
2

1 lb
f
= 32.174 lb
m
.ft/s
2
! To convert force from defined unit to a natural units, conversion
factor known as g
c
is required:
PCS-FKKKSA
Slide 1 - 14
Material Balances
Weight
! Weight of an object is due to the gravitational force
W = mg/g
c
! The value of gravitational force (g) is varies to location of earth
surface
! The value of the corresponding g/g
c
at 45
o
latitude
g = 9.8066 m/s
2
g/g
c
= 9.8066 N/kg
g = 980.66 cm/s
2
g/g
c
= 980.66 dyne/g
g = 32.174 ft/s
2
g/g
c
= 1 lb
f
/ lb
m
PCS-FKKKSA
Slide 1 - 15
Material Balances
Dimensional Homogeneity
! Valid equation must be dimensionally homogenous
! Both sides of equation must have same dimensions
V(m/s) = V
o
(m/s) + g(m/s
2
)t(s)
Example : Consider the the equation D(ft) = 3t(s) + 4
What is the dimension and unit for constants 3 and 4?
Constant 3 length/time
Constant 4 length
ft/s
ft
PCS-FKKKSA
Slide 1 - 16
Material Balances
Dimensionless Quantity
! Dimensionless Quantity can be pure numbers (2, ! , 1.3 etc) or
a multiplicative combination of variables with no net dimensions
Example:-
let M (g) = D(cm) u(cm/s) ! (g/cm
3
) and Mo = (g/cm.s)

and M/Mo = Du! / = (cm)(cm/s)(g/cm
3
)/ (g/cm.s)
Thus, M/Mo or Du! / is also called a dimensionless group

ft
What multiplicative combination of ! (m), !(m/s
2
) and t(s) would
constitute a dimensionless group?
PCS-FKKKSA
Slide 1 - 17
Material Balances
Scientific Notation
! Large and very small number often encountered in
process calculations
! Convenient way to represent such number is to use
scientific notation
! Expressed between 0.1 and 10 and a power of 10
123 000 000 = 1.23 x 10
8
(or 0.123 x 10
9
)
0.000028 = 2.8 x 10
-5
(or 0.28 x 10
-4
)
PCS-FKKKSA
Slide 1 - 18
Material Balances
Significant Figure
! The significant of a number are the digits from the first
nonzero on the left to either
" the last digit (zero or nonzero) on the right if there is decimal
point
" the last nonzero digit of the number if there is no decimal point
2300 or 2.3 x 10
3
has two significant figures
2300. or 2.300 x 10
3
has four significant figures
2300.0 or 2.3000 x 10
3
has five significant figures
23040 or 2.304 x 10
4
has four significant figures
0.035 or 3.5 x 10
-2
has two significant figures
0.03500 or 3.500 x 10
-2
has four significant figures
PCS-FKKKSA
Slide 1 - 19
Material Balances
Rule of Thumb on Significant Figure
! Multiplication and division
" The answer should be equal to the lowest significant
figure of any multiplicands or divisors
(3) (4) (7) (3)
(3.57)(4.286) = 15.30102 15.3
(2) (4) (3) (9) (2) (2)
(5.2 x 10
-4
)(0.1635 x 10
7
)/(2.67) = 318.426966 3.2 x10
2
= 320
PCS-FKKKSA
Slide 1 - 20
Material Balances
Rule of thumb on significant figure
! Addition and subtraction
" The position of the last significant figures of each number
should be compared
" The one farthest to the left is the permissible significant
figure

1530
- 2.56
1527.44 1530
" rounding the last digit 5 to even number
1.35 => 1.4
1.25 => 1.2
PCS-FKKKSA
Slide 1 - 21
Material Balances
Process Data Representation
! Two-Point Linear Interpolation
" Use to find estimate value from tabulation of data
x 1.0 2.0 3.0 4.0
y 0.3 0.7 1.2 1.8
" The objective is to estimate value of y from given value of x
Interpolation - y and x between tabulated points
Extrapolation - y and x beyond the range of data in table
" The equation of the line through (x
1
,y
1
) and (x
2
,y
2
)
PCS-FKKKSA
Slide 1 - 22
Material Balances
Fitting a Straight Line
! Convenient way to indicate how one variable depends on another
is with an equation
y = 3x + 4
y = 4.24 (x - 3)
2
- 23
y = 1.3 x 10
7
sin(2x)/(x
1/2
+ 58.4)
! If the line is straight, the relationship can be presented
y = ax + b
Slope Intercept
PCS-FKKKSA
Slide 1 - 23
Material Balances
Fitting Nonlinear Data
! If the data is not linear and we wish to linearize it
" Calculate the f(y) and g(x) for each tabulated (x,y)
" Plot f(y) versus g(x)
" If the plotted points fall on straight line, the equation fits the
data
" Several examples plot that yields straight lines
(1) y = ax
2
+ b Plot y versus x
2
(2) y
2
= a/x + b Plot y
2
versus a/x

(3) sin (y) = a(x
2
- 4) Plot sin (y) versus (x
2
- 4)
PCS-FKKKSA
Slide 1 - 24
Material Balances
Logarithmic Coordinate
! Two nonlinear function that normally occur are
" exponential function y = ae
bx
or y = a exp (bx)
" power law y = ax
b
! Natural logarithmic (ln) is the inverse of exponential function
P = exp(Q) <=> ln P = Q
ln[exp (Q)] = Q and exp(ln P) = P
y = a exp (bx) => ln y = ln a + bx (Use semilog paper)
Plot ln y versus x. Slope = b, intercept = ln a
y = ax
b
=> ln y = ln a + b ln x (Use log-log paper)
Plot ln y versus ln x. Slope = b, intercept = ln a
PCS-FKKKSA
Slide 1 - 25
Material Balances
Processes and Process Variables
PCS-FKKKSA
Slide 1 - 26
Material Balances
Process and Process Variables
! Process - any operation that causes a physical or chemical change
in a substance or a mixture of substances
! Material enters a process is referred as input or feed
! Material leaves is called as output or product
! Process Unit is an apparatus for carried out the process
" Distillation Column
" Absorption Column
" Evaporator Column
" Extraction Column
" Reactor
Process
Unit
input
feed
output
product
PCS-FKKKSA
Slide 1 - 27
Material Balances
Mass and Volume
! Density (!) is mass per unit volume
" kg/m
3
, g/cm
3
, and lb
m
/ft
3
" use to relate mass and volume
! Specific Volume is volume per unit mass
" m
3
/kg, cm
3
/g, and ft
3
/lb
m
" an inverse of density
! Specific Gravity is the ratio of density ! and !
ref

" SG = ! / !
ref
" The reference ! most commonly used is water at 4.0
o
C
" !
ref
(H
2
O, 4.0
o
C ) = 1.000 g/cm
3

1000 kg/m
3

62.43 lb
m
/ft
3


PCS-FKKKSA
Slide 1 - 28
Material Balances
Mass, Volume and Density
! Example - Calculate the density of mercury in lb
m
/ft
3
from a
tabulated specific gravity, and calculate the volume in ft
3
occupied by
215 kg of mercury.
From Table B.1 (pp 631) the Specific Gravity of mercury is 13.546
!
Hg
=13.546(62.46 lb
m
/ft
3
) = 845.7 lb
m
/ft
3

V = 215 kg 1 lb
m
1 ft
3
= 0.560 ft
3

0.454 kg 845.7 lb
m

PCS-FKKKSA
Slide 1 - 29
Material Balances
Flowrate
! Flow rate - rate at which material is transported through
process line
" Mass flow rate (mass/time) kg/s or lb
m
/s
" Volumetric flow rate (volume/time) m
3
/s or ft
3

/s
! The mass and volume is related by the fluid density (!)
! The density (!) of a fluid can be used to convert known
volumetric flow rate to the mass flow rate and vice versa
m (kg fluid/s)
V (m
3
fluid/s)
PCS-FKKKSA
Slide 1 - 30
Material Balances
Chemical Composition
! Atomic Weight - the mass of atom on a scale that assign
12
C a
mass exactly 12.
! Molecular Weight - the sum of atomic weight of atoms that
constitute a molecule
" Atomic weight of Oxygen (O) = 16
" Molecular Weight of molecular Oxygen (O
2
) = 32
! Gram-mole - amount whose mass is equal to its molecular weight
" units used - gmol, lb
m
-mole, kmol
" If Molecular weight of a substance is M, then there are
M kg/kmol, M g/mol and M lb
m
/lb-mole of this substance
" Carbon monoxide (CO) has a molecular weight of 28;
1 mol of (CO) therefore contains 28 g
1 lb
m
- mole of (CO) contains 28 lb
m
and
1 kgmol of (CO) contains 28 kg
PCS-FKKKSA
Slide 1 - 31
Material Balances
Molecular Weight
! Example : 34 kg of ammonia (NH
3
): M = 17 are equivalent to
34 kg NH
3
1 kmol NH
3
= 2 kmol NH
3

17 kg NH
3
4 lb-moles of ammonia are equivalent to



4 lb-mole NH
3
17 lb
m
NH
3
= 68 lb
m
NH
3

1 lb-mole NH
3
! One gram-mole of any species contains 6.02 x 10
23
(Avogadros
number) molecules of that species
PCS-FKKKSA
Slide 1 - 32
Material Balances
Conversion of mass flowrate to molar flow rate
! The molecular weight of a species can be used to relate the mass flow
rate to corresponding molar flow rate
! Example: If ammonia (NH
3
): M = 17 flows through a pipeline at a rate
of 100 kg/h the molar flowrate of the of are equivalent to
100 kg NH
3
1 kmol NH
3
= 5.88 kmol NH
3

h 17 kg NH
3
h
If the output stream of a reactor contains NH
3
flowing at a rate of
850 lb-moles/min, the corresponding flowrate is
850 lb-moles NH
3
17 lb
m
NH
3
= 14 450 lb
m
NH
3

min 1 lb-mole NH
3
min
PCS-FKKKSA
Slide 1 - 33
Material Balances
Mass and Mole Fractions
! Process streams occasionally contain more than one substance
! To define the composition of mixture we need
Mass Fraction :
Mole Fraction :
The percent by mass of A is 100 x
A
, and the mole percent of A is
100 y
A
PCS-FKKKSA
Slide 1 - 34
Material Balances
Average Molecular Weight
! Average molecular weight - Average of molecular weight of a
mixture
! Base on mole fraction
! Base on mass fraction
M = y
1
M
1
+ y
2
M
2
+= y
i
M
i
all components
!

1
M
=
x
1
M
1
+
x
2
M
2
+=
x
i
Mi
all components
!
PCS-FKKKSA
Slide 1 - 35
Material Balances
! Natural gas has the following molar composition;
Methane (CH
4
) 93.0%
Ethane (C
2
H
6
) 4.00%
Propane (C
3
H
8
) 0.80%
Butane (C
4
H
10
) 0.15%
Carbon dioxide (CO
2
) 0.45%
Nitrogen (N
2
) 1.60%
Taking 1 mol of natural gas as a basis of calculation, calculate
a) the average molecular weight of natural gas
b) the mass fraction (%) of each component of natural gas
c) the average molecular weight of natural gas based on the mass
fraction in part (b)
Conversion of mole percent to mass percent
PCS-FKKKSA
Slide 1 - 36
Material Balances
Concentration
! Mass concentration is the mass of component per unit volume of
the mixture (g/cm
3
, lb
m
/ft
3
or kg/m
3
)
! Molar concentration is the number of moles of the component per
unit volume of the mixture (mol/cm
3
, lb-mole/ft
3
or kmol/m
3
)
! Molarity is the value of the molar concentration of the solute
expressed in gram-moles solute/liter solution
" 2-molar solution of A contains 2 mol A/ liter solution
! Concentration factor can be used to relate mass (molar) flow rate
of a component of a continuous stream to the total volumetric
flow rate of the stream
! Given: 6 liters of 0.02-molar solution of NaOH contains

6 liters 0.02 mol NaOH = 0.12 mol NaOH
liter
PCS-FKKKSA
Slide 1 - 37
Material Balances
Conversion of mass, molar and volumetric flow rate
A 0.5 molar aqueous solution of sulfuric acid flows into a process unit
at a rate of 1.25 m
3
/min. The specific gravity of the solution is 1.03.
Calculate
(1) the mass concentration of H
2
SO
4
in kg/m
3
,
(2) the mass flow rate of H
2
SO
4
in kg/s, and
(3) the mass fraction of H
2
SO
4
= 0.5 mol H
2
SO
4
98 g 1 kg 10
3
liter
liter mol 10
3
g 1 m
3

= 49 kg H
2
SO
4

m
3
PCS-FKKKSA
Slide 1 - 38
Material Balances
Solution for (2) and (3)
1.25 m
3
49 kg H
2
SO
4
1 min
min 1 m
3
60s
!
solution
= (1.03)( 1000 kg/m
3
) = 1030 kg/m
3

Q
solution
(kg/s) = 1.25 m
3
solution 1030 kg 1 min = 21.46 kg/s
min m
3
solution 60 s

PCS-FKKKSA
Slide 1 - 39
Part Per Million (ppm)
! Parts per million (ppm) - is commonly used as a
measure of small levels of pollutants in air, water, and
body fluids.
! Parts per million is the mass ratio between the
pollutant component and the solution and ppm is
defined as:
ppm = 1,000,000 mc/ms
where
mc = mass of component (kg, lbm) or moles
ms = mass of solution (kg, lbm) or moles
PCS-FKKKSA
Slide 1 - 40
Mass per Unit Volume (ppm)
! The concentration of a component can be measured as mass per unit
volume as mg/liter and mg/cm
3
.
! Weight of substance added to one unit volume of water to give one part
per million (ppm)
! 1 ppm
= 2.72 pounds per acre-foot
= 1,233 grams per acre-foot
= 1.233 kilograms per acre-foot
= 0.0283 grams per cubic foot
= 0.0000624 pounds per cubic foot
= 0.0038 grams per US gallon
= 0.058419 grains per US gallon
= 0.07016 grains per Imperial gallon
= 1 milligram per liter
= 1 microlitre ( L ) per liter
= 0.001 gram per litre
= 8.345 pounds per million gallons of water
PCS-FKKKSA
Slide 1 - 41
Material Balances
Pressure
! Pressure is the ratio of a force to the area
" Units N/m
2
, dynes/cm
2
, and lb
f
/in
2

" the SI pressure unit is N/m
2
or called pascal (Pa)
P = P
o
+ ! g/g
c
h

The relationship between the base and
the top can be given as head:

P
h
(mm Hg) = P
o
(mmHg) + h (mmHg)

Fluid pressure and measurement
P
absolute
= P
gauge
+ P
atmospheric
P
o
(N/m
2
)
P (N/m
2
)
h (m)
fluid
density
A (m
2
)
PCS-FKKKSA
Slide 1 - 42
Material Balances
Temperature
! Two most common temperature scales are defined using the freezing point
(T
f
) and boiling point (T
b
) of water at 1 atm
" Celsius (or centigrade) scale
T
f
is assigned 0
o
C and T
b
is 100
o
C
Absolute zero on this scale falls at -273.15
o
C
" Fahrenheit scale
T
f
is assigned 32
o
F and T
b
is 212
o
F
Absolute zero on this scale falls at -459.67
o
F
" The Kelvin and Rankin scale are defined at absolute value of Celsius and
Fahrenheit
T(K) = T(
o
C) + 273.15
T(
o
R) = T(
o
F) + 459.67
T(
o
R) = 1.8 T(K)
T(
o
F) = 1.8T (
o
C) + 32
PCS-FKKKSA
Slide 1 - 43
Material Balances
Temperature Scale
PCS-FKKKSA
Slide 1 - 44
Material Balances
Degree (
o
) definition as Temperature Interval
Degree as Temperature Interval
! Consider the temperature
interval between 0
o
C and 5
o
C
! There are 9
o
F and Rankin
degree in this interval
! An interval of 1
o
C or Kelvin
contains 1.8
o
F or Rankin degree
Conversion factor for the interval
Example
Find the number Celsius degrees
between 32
o
F and 212
o
F
To find the Celsius temperature
corresponding to 32
o
F you cannot use
this formula
Temp reading
Temp interval
PCS-FKKKSA
Slide 1 - 45
Material Balances
Working Session I
A container holds 50 g of water (B) and 50 g of NaOH (A). Calculate
the weight fraction and mole fraction of NaOH. Also calculate the lb
m
of NaOH (A) and H
2
O (B).
Basis : 100 g of solution
Weight Fraction : H
2
0 = 50/100 = 0.5
NaOH = 50/100 = 0.5
Mole Fraction : H
2
O = 50/18 = 2.78 2.78/4.03 = 0.690
: NaOH = 50/40 = 1.25 1.25/4.03 = 0.310
4.03
lb
m
A = 50 g A = 0.1102 lb
m
A
(453.6 g A/lb
m
A)
Also. Calculate the Ib-moles of water and NaOH and its respective
mole fraction.
PCS-FKKKSA
Slide 1 - 46
Material Balances
Working Session II
A mixing container holds a solution containing 50
kmol of water and 500 mol of NaOH.
a. Calculate the lb-moles of water and NaOH.
b. Calculate the mass fraction and mole fraction of water
and NaOH.
c. Calculate the molarity of NaOH in the solution.
d. Calculate the specific gravity of the solution.