Mass and Energy Balance Lecture

Series

Dr. Raja Razuan Raja Deris

Faculty of Applied Science, UiTM, Shah Alam

Office: 03-55444604 email: cmt435massnengybal@gmail.com; razuan@salam.uitm.edu.my

 Education is the kindling of a flame, not
the filling of a vessel - Socrates.

Learning is not a spectator sport.

You do not learn much just sitting in classes
listening to teachers, memorizing prepackaged
assignments, and spitting out answers. You
must talk about what you are learning, write
reflectively about it, relate it to past experiences,
and apply it to your daily lives. You must make
what you learn part of yourselves.

-Source:"Implementing the Seven

Principles: Technology as Lever" by Arthur
W. Chickering and Stephen C. Ehrmann

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 Learning
Objectives/Intended Learning Outcome:

1. Explain in your own word the meaning of the following

terms: batch, semi batch, continuous, transient and
steady-state processes.
2. Explain the following process terms: recycle, purge, by-
pass, limiting reactant and combustion reaction.
3. Draw and fully label a flowchart based on given process
description.
4. Solve a simple material balance calculations.
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 CHAPTER
3

FUNDAMENTALS OF
MATERIAL BALANCES

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Concepts
The law of conservation of mass- which state that
mass can neither be created nor destroyed.
E.g: Total mass of input = Total mass of output or
(kgsulfur/day)in = (kgsulfur/day)out.

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Process Classifcation
Before writing any material balances for a process,
you first need to specify what the system is for
which you making the balance and outline its
boundaries.
Types of system:
1) BATCH PROCESS- the process which involves the feed
is charged (fed) into a vessel or reactor at the beginning of
the process. Then the contents (products) are removed
sometime later. No mass crosses the system boundaries
between the time the feed charged and the time the
product is removed. Involves small quantity of a product at
a particular time.
E.g.: making a cup cake, etc.
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Process Classifcation
2) CONTINUOUS PROCESS- The inputs and outputs
flow continuously throughout the duration of the
process and usually run as close to steady state as
possible.
E.g.: Pump a mixture of liquids into a distillation column at a
constant rate and steadily withdraw product streams from the
top and bottom of the column.

3) SEMIBATCH PROCESS- Any process that is neither

batch nor continuous.
E.g.: Releases the contents of a pressurised gas container to
escape to the atmosphere.

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Process Classifcation
1) STEADY STATE- is the situation where the values of
all the variables in a process stream such as
temperatures, pressures, volumes, flow rates etc do not
change with time. Normally involves continuous
process.

2) UNSTEADY STATE OR TRANSIENT- if any of the

process variables change with time. Usually involves
batch and semi batch process and occur during the
start-up of a process.

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Process Classifcation
3) MATERIAL BALANCE- is a systematic approaches
methods use to keep track with the amount of
materials that flow in and out of process units . An
analogy for this is just like bookkeeping that is used
by firms to keep track with their cash flow.

4) Knowledge and skills in material balance are of

utmost importance and are prerequisites to almost all
chemical engineering calculations such as unit
operations, kinetics, chemical thermodynamics,
process control, heat and mas transfer.

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Process Classifcation
5) Material balance calculation utilises the law of
conservation of mass, MASS CAN NEITHER BE
CREATED NOR DISTROYED
6) The general material balance equation has been
derived from the above law and can be expressed as
follows:

Eq:3.1


.
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Process Classifcation
OUTPUTS
.

GENERATION= Amount of all materials that are generated within

a system boundary due to chemical reactions.

CONSUMPTION= Amount of all materials that are consumed within a system

boundary by chemical reactions.

ACCUMULATION= A net change in amount of material within a system

boundary.
(+ve) change means there is an increase in materials
within a system.
(-ve) change means that there is a decrease in materials
within the system.

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Process Classifcation

Inputs cross the Generation within Outputs cross

system the system
the system by reaction
boundary to boundary to
enter the system leave the system

Consumption within
the system by reaction

System boundary

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Process Classifcation
Example:
A typical university student saving account, the
following transactions takes place within a
semester:
Scholarship: RM 1000.00
Parent fund: RM180.00
Food & Hostel: RM 400.00
Social activities: RM100.00
Mobile Phone: RM 200.00
Book & stationeries: RM500.00
Debited from account to pay for GIRO fees: RM 20.00
Interest: RM 5.00
Use the general balance equation to determine the change in the
students saving account.
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Process Classifcation
OUTPUTS
Solution:
Food & Hostel:
INPUTS Account boundary RM 400.00

Scholarship: Book & Sta:

RM 1000.00 Generation (Interest)= RM 5.00 RM 500.00

Parent: Consumption (Giro fees): RM 20.00 Social activities:

RM 180.00 RM 100.00

Mobile phone:
RM 200.00

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Process Classifcation
Solution:

1000 180 5 400 500 200 20 35.00

35.00

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Process Classifcation
The most important step in solving material balance
problems is constructing and labelling an block-and-
arrow diagram or process flow chart (PFC).
PFC is essential because it presents a layout of the
particular process flow.

The construction of PFC and properly labelled them is

quit a challenging process, because you need to
understand what the problems statement tells about the
particular process.

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Constructing and labeling block and arrow diagram
The PFC consists of a combination of one or more
rectangular blocks and arrows.
A rectangular block represent a process unit or a series
of process units.
An arrow pointing inward and outward of a system is
to represent an input and output of a process stream.

Input stream Output stream

Process unit

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Constructing and labeling block and arrow diagram
There are two methods of labelling PFC:
1) First Method:
Rates and amount of process streams are normally written on the arrows while
compositions of the process stream are written beneath the arrows.
Known mass flow rates of Unknown flow rates of
Process stream 450 kg/h water Process streams

1000 kg/h P kg/h

sugar solution Product sugar
Drying unit
0.5 water x water
0.5 dry sugar (1-x) dry sugar
------------------ -------------------
1 1
Known composition in terms
of mass fractions of the species

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Constructing and labeling block and arrow diagram
There are two methods of labelling PFC:
1) First Method:
Rates and amount of process streams are normally written on the arrows while
compositions of the process stream are written beneath the arrows.
Known mole flow rates of Unknown flow rates of
Process stream 450 kmol/h water Process streams

1000 kmol/h P kmol/h

sugar solution Product sugar
Drying unit
0.5 water x water
0.5 dry sugar (1-x) dry sugar
------------------ -------------------
1 1
Known composition in terms
of mole fractions of the species

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Constructing and labeling block and arrow diagram
Important!!!
Unknown composition in terms of mass fractions (x) or mole
fraction (y) of a species.
If number of species with unknown mass or mole fractions is n
then you should assign symbols to n-1 species only.
For example:
If the stream has a total of 4 species which are all unknown, then you
should assign 3 symbols only (x, y, and z) to 3 species. The mass or mole
fraction of forth species is simply 1-x-y-z since the total mass fraction of the
stream is =1 or 100%.
All streams must use the same unit (e.g.: kg/h, Kmol/h).
Streams flow must correspond to compositions. (e.g.: if
streams are in mass or molar, then the compositions must be
mass or molar compositions).
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Constructing and labeling block and arrow diagram
2) 2nd Method:
Composition in terms of mass or molar flow rates of each species in a stream is
known.

Known flow rates of

Process streams 450 kg/h water

P kg/h
Wet sugar Product sugar
Drying unit
500 kg/h water W water
500 kg/h dry sugar V dry sugar
Known composition in terms Unknown composition in terms
of mass flow rates or molar of mass flow rates or molar flow rates
flow rates of each species in a of each species in a process streams.
process stream. Each unknown species must be assigned
A symbol

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Constructing and labeling block and arrow diagram
The labelling of the PFC lies in how compositions of process streams are
labelled.
In the 1st methods, compositions of process streams are labelled in term of mass
or mole fractions of each species present in the streams.
Always minimise the number of unknown species (n )to (n-1).
For example:
If a stream has a total of 6 species which are all unknown species, then
assign 5 (6-1=5) symbols e.g.: x, y, z, w, v. The mass or mole fraction of the
sixth species is simply (1 - x y z - w v).

If a stream has 3 species and one species mass fraction is given or known,
let say 0.2. Then the number of unknown species is only 2 and therefore 2-1
= 1 unknown or assign symbol (m). So the mass fraction of the last species is
simply (1 0.2 m) or (0.8 m).

In the second method, the compositions of streams are labelled in terms of mass
flow rates, molar flow rates, or amount of each species present in the streams.
Unlike the first method, all unknown species must be assigned with symbols.
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Constructing and labeling block and arrow diagram
EXAMPLE 1:
1) A stream containing 30 wt% MeOH in water is to be diluted with a second
stream containing 5 wt% MeOH to produce a product containing 20 wt%
MeOH. Draw a completely labelled flow chart for this process.

SOLUTION:
All compositions are in weight (mass) percent. Therefore, the stream must use
mass NOT moles.

A kg/h 30%MeOH P kg/h 20 % MeOH

Dilution process
0.30 MeOH 0.20 MeOH
0.70 water 0.80 water

B kg/h 5 %MeOH
0.05 MeOH
0.95 water
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Constructing and labeling block and arrow diagram
EXAMPLE 2:
2) 10 kmol/h of acid solution containing 10 %H2SO4, 4 %HCl, 5 %HNO3 all by
moles is to be concentrated by adding 6.3 kg of pure liquid HNO3. Determine
the molar composition of the product.

SOLUTION:
All compositions are in mole percent. Therefore, the stream must use mole instead
of mass.

10 kmol/h Acid sol. P kmol/h product

0.10 H2SO4 Dilution process x H2SO4
0.04 HCl y HCl
0.05 HNO3 z HNO3
0.81 water 1-x-y-z water

6.3/63 kmol/h HNO3

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Constructing and labeling block and arrow diagram
EXAMPLE 3:
3) 1000 kg/h of a mixture containing equal parts mass of Benzene and Toluene
are to be distilled. The flow rate of the overhead product stream is 488 kg/h
and the bottom stream contains 7.11 wt.% of Benzene. Calculate :
a) The mass and mole fractions of Benzene.
b) The molar flow rates of Benzene and Toluene (mole/h) in the overhead
product stream.

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Constructing and labeling block and arrow diagram
Solution Ex.3:
488 kg/h Overhead Product
x Toluene
1-x Benzene

1000 kg/h mixture

Distillation Unit
0.5 Benzene
0.5 Toluene

B kg/h Bottom Product

0.9289 Toluene
0.0711 Benzene

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Constructing and labeling block and arrow diagram
DIY
1) Classify the following processes:
Process Classification
(batch, semi batch, transient
or steady state)
1) A balloon is filled with air at a steady rate of 2 g/min. Semi batch, transient
2) A bottle of milk is taken from the refrigerator and left on Batch, transient
the kitchen table.
3) Water is boiled in an open flask. Semi batch, transient
4) Carbon monoxide and steam are fed into a tubular
reactor at a steady rate and react to form carbon dioxide
and hydrogen.
products and unused reactants are withdrawn at the
other end. The reactor contains air when the process is
started up. The temperature of the reactor is constant
and the composition and flow rate of the entering
reactant stream are also independent of time. classify the
process:
a) Initially Continuous, transient
b) After a long period of time has elapsed. Continuous, steady state
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Constructing and labeling block and arrow diagram
DIY
Draw and completely labelled the following process.
1) A municipal sewage sludge produce by Indah Water Konsortium containing
60 % water and 40 % solid by mass. Prior disposal, the sludge has to be dried
to at least 25 % water. How much water is evaporated per ton of the sludge
sent to the drier?
2) A stream containing 25 wt% MeOH in water is to be diluted with a second
stream containing 10 wt% MeOH to form a product containing 17 wt%
MeOH.
3) A mixture containing 45 wt% Benzene (B) and 55 wt% Toluene (T) is fed to a
distillation column. An overhead stream of 95 wt% B is produced and 8 wt%
of B remain in the bottom stream.

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Material Balance- Step-by-Step
IMPORTANT!!!

1) Read problem statement carefully and understand the process description and
what a question want.
2) Once you know exactly what the question wants, begin drawing the flowsheet
according to the process information described in the question. Label the flow
chart and assign proper symbols to the unknown.
3) Choose basis of calculation- is a quantity or a flowrate of a process stream or
of a processing material which we choose to enable us to solve material
balances problems.
4) The purpose of assigning a basis is to facilitate the mass balance calculation.
Without a basis of calculation, it is almost impossible to solve material balance
problems.
5) A known basis of calculation is a basis based on a process stream whose
quantity or rate is known or already given in the prob. Statement.

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Material Balance- Step-by-Step
IMPORTANT!!!
6) When all stream amounts or flow rates are unknown, you need to assume one.
This basis is known as assumed basis of calculation. Choose an amount or
flow rate of a stream with a known composition as follows:
a) If mass fractions are known, choose a total mass flow rate as a basis.
b) If mole fractions are known, choose a total molar flow rate as a basis.
7) After the basis has been established perform analysis by checking how many
independent equations that could be written and how many unknowns are
present.
8) An independent equation is an equation that exists on its own without
depending on the presence of any other equations. An equation which results
from an addition or subtraction of two or more other equations is not an
independent simply because its existence depends on availability of the other
two equations.

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Material Balance- Step-by-Step
IMPORTANT!!!
10) There are two main source of independent equations which are:
a) Independent equations from material balances. The total number of independent equation
from material balances is always equal to the total number of species that are present within
the process system described by the problem statement.
b) Independent equations process specifications. Process specifications are direct assignment of
values to the stream variables or the imposition of relationships between stream variables.

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