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:
INTEGRAL MATERIAL
BALANCE

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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. This step known as Degree of freedom Analysis.
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!!!
9) 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.
10) Once the total number of independent equations ( from both
material balance and process specifications) and the number of
unknown have been analysed and identified, you would
probably be left with either one of the following conditions:
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Material Balance- Step-by-Step
IMPORTANT!!!
a) Total number of independent equations = total number of
unknowns
The problem has a unique solution and so you can proceed and solve
the simultaneous equations

b) Total number of independent equations < total number of

unknowns.
The problem has been underspecified and thus it can not be solved
without extra information are known. Do not waste your time solving
this kind of problem.
c) Total number of independent equations > total number of
unknown
The problem has been over specified and has no unique solution.
Instead it has many solutions. Do not solve this problem.

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 How to Solve Material Balance:
Degree of Freedom Analysis
Before you start doing any calculation, do a DOF
analysis to determine whether you have enough info
to solve the material balance
DOF: NF = Nunknown Nind. equations
Nind. equations comes from:
Material balance for each species
Energy balance
Process specifications
Physical properties and laws
Physical constraints
 How to Solve Material Balance:
Degree of Freedom Analysis

NF = 0 material balance can be solved

NF > 0 problem underspecified, you will need
more info or you forget an important relations
NF < 0 problem overspecified, flow diagram
incompletely labeled or too many inconsistent
relations

If you have NF = 0, you can proceed to solving the

material balance
Material Balance- Step-by-Step
If you are left with condition (a)- NF =0, where the
total number of independent equations is equal to
the total number of unknowns, then you can
proceed to solve for unknowns using simultaneous
equations.

It is highly recommended that you solve those

equations using elimination rather than
substitution method.

12/14/2013 Copyright Dr.RR 2013

Material Balance- Step-by-Step
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 and analyse the
unknowns and independent equations.
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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Material Balance- Step-by-Step
Analysis:
Number of unknowns = 3 (A, B and P)
Number of independent equations = 2 (Mat. Balance)
Thus unknowns have unique solutions and can be
solved.

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Material Balance- Step-by-Step
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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Material Balance- Step-by-Step
Analysis:
Number of unknowns = 4 (P, x, y, z)
Number of independent equations = 4 (Material
Balance + 0 information)
Thus unknowns have unique solutions and can be
solved.

[ 4- since the number of species is 4 (H2SO4, HCl,

HNO3 and H2O)]

12/14/2013 Copyright Dr.RR 2013

Material Balance- Step-by-Step
EXAMPLE 3:
2) 1000 kg/h of a mixture containing equal parts by mass of Benzene and Toluene
are distilled. The flowrate of the overhead product stream is 488 kg/h and the
bottom stream contains 7.11 wt.% Benzene. Draw a completely labelled flow
chart for this process, indicate a basis and analyse the unknowns and
independent equations.

488 kg/h Overhead product

SOLUTION:
x Toluene
1-x Benzene
Distillation
1000 kg/h mixture
process
0.5 Toluene
0.5 Benzene
B kg/h Bottom product

0.9289 Toluene
0.0711 Benzene
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Material Balance- Step-by-Step
Analysis:
Since two streams are known, just pick up any stream
as a basis of calculation.
Basis: 1000 kg/h mixture
Number of unknowns = 2 (x,B)
Number of independent equations = 2 (2 Material
Balance + 0 information)
Thus unknowns have unique solutions and can be
solved.
[ 2- since the number of species is 2 (Toluene and
Benzene)]
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DIY
DRAW A COMPLETELY LABELLED FLOW CHART
FOR EACH OF THE FOLLOWING PROCESS,
INDICATE A BASIS AND ANALYSE THE UNKNOWNS
AND INDEPENDENT EQUATIONS. (DO NOT SOLVE
YET).

1. Sludge is wet solids which remains after processing

municipal sewage by Indah Water Konsortium (IWK).
If a sludge containing 60% water and 40% solid by
mass is pass through a drier, and the resulting product
contains 25% water, how much water is evaporated per
ton of the sludge sent to the drier?

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DIY
2. A stream containing 25 wt.% methanol in water is to
be diluted with a second stream containing 10 wt.%
methanol to form a product containing 17 wt.%
methanol.
a) Choose a convenient basis of calculation, draw and label a
flowchart of this process, and calculate the ratio (kg 17%
solution/kg 25% solution).
b) What feed rate of the 10% solution would be required to
produce 1250 kg/h of the product?

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DIY
3. A mixture containing 45% Benzene (B) and
55% Toluene (T) by mass is fed to a distillation
column. An overhead stream of 95 wt.% B is
produced and 8 wt.% of B in the bottom stream.
a) Determine the fraction of the bottom stream mass to
the overhead stream.
b) Calculate how much Benzene is produced in the
overhead stream per ton of Benzene fed to the
column.

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DIY
4. A gas stream containing 79.1 %N2, 1.7 %O2 and
19.2 %SO2 is mixed with another stream
containing 43.47 %N2, 6.53 %O2 and 50.00
%SO2 to produce a product gas containing 21.45
%SO2, 2.05 %O2 and the rest N2. All
compositions are in mole %. Calculate the ratio
in which the streams should be mixed.

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DIY
5. The feed to a distillation column contain 36 %
Benzene by weight and the remainder being
Toluene. The overhead distillate is to contain 52
% Benzene by weight. Calculate:
a) The percentage of the Benzene feed which is contained in
the distillate.
b) The percentage of the total feed which leaves as distillate.

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MATERIAL BALANCE
There are two types of balances may be written:
1. Differential balance:
Balance that indicate what is happening in a system
at an instant in time.
Each term of the balance equation is a rate (rate of
input, rate of generation, etc.) and has units of the
balanced quantity unit divided by a time unit
(people/yr, gSO2/s, barrel/day etc.).
This type of balance normally applied to a
continuous process.

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MATERIAL BALANCE
2. Integral balance:
Balance that describe what happens between two
instants of time.
Each term of the equation is an amount of the
balanced quantity and has the corresponding unit
(people, gSO2, barrels).
This type of balance normally applied to a batch
process, with the two instants of time being the
moment after the input takes place and the moment
before the product withdrawn.

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MATERIAL BALANCE
2. Rules used to simplify the material balance
equation:
If the balanced quantity is total mass, set generation
= 0 and consumption = 0. (except in nuclear
reactions).
If the balanced substance is a nonreactive species
(neither a reactant nor a product), set generation = 0
and consumption = 0.
If a system is at steady-state, set accumulation = 0,
regardless of what is being balanced. By definition,
in a steady-state system nothing can change with
time, including the amount of the balanced quantity.

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MATERIAL BALANCE
INTEGRAL MATERIAL BALANCES ON A
STEADY-STATE BATCH PROCESS WITH NO
CHEMICAL REACTIONS:
An integral process is a process where all inputs are
dumped into a process unit and then at a later time,
all products are taken out of the process unit.
Recall: A process is at steady state when the values
of all of its process variables do not change with time
except for a very minor fluctuations. Therefore, in
principle, there is no such thing as steady state batch
process since the values of its process variables do
change significantly with time during the process.

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MATERIAL BALANCE
Recall: A steady state process has no accumulation
of mass. Thus, for the sake of simplicity, we could
assume that a batch process is at a steady-state if all
inputs that come into the process unit all at once and
all products that come out all at once, so that there is
no accumulation of mass at the end of process.
The generation and consumption terms are also
dropped since there are no chemical reactions.
Therefore the integral material balance equation
reduced to:
[Amount of inputs = Amount of outputs]

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Material Balance- Step-by-Step
EXAMPLE 1: Balances on an evaporation process
250 kg solution containing 20 % salt is to be evaporated to yield a solution of 50 %
salt. Calculate the amount of water evaporated and the amount of the final
solution.

SOLUTION:

W kg water

Evaporation P kg Final solution

250 kg solution
process
0.20 Salt 0.50 Salt
0.80 Water 0.50 Water

[Known Basis: 250 kg solution]

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Material Balance- Step-by-Step
EXAMPLE 3: Balances on an evaporation process

SOLUTION:
DOF analysis:

Number of unknowns = 2 (W + P)
Number of independent equations = 2 (2 material bal.
+ 0 information)

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Material Balance- Step-by-Step
EXAMPLE 3: Balances on an evaporation process

SOLUTION:

Total mass balance: input = output

(Overall balance) 250 = (W + P)

Component Balance: 0.2(250) = 0.5P

(Salt mass Balance) P = 100 kg final solution
W = 150 kg water eva.

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Material Balance- Step-by-Step
EXAMPLE 2: Batch mixing process
A syrup is a mixture of sugar and water. Syrup A and B are to be mixed together.
Syrup A contains 3.50 % sugar and syrup B is 4.20 % sugar. To this mixture is
added 17.5 kg of pure dry sugar, while 120 kg of water is boiled away. This results
in 1900 kg of syrup that is 5.00 % sugar. How much of each syrup (A and B) was
added initially?

SOLUTION:
17.50 kg Sugar 120 kg water

A kg Syrup A Evaporation 1900 kg Final solution

0.035 Sugar process
0.965 Water
0.050 Sugar
B kg Syrup B 0.950 Water

0.042 Sugar
0.958 Water

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Material Balance- Step-by-Step
SOLUTION:
Basis of calculation: 1900 kg final syrup solution
Number of unknowns: 2 (A, B)
Number of ind. Eq.: 2 (2 mat. Bal. + 0 information)
Total Mass Bal.: Input = Output
17.5 + A + B = 120 + 1900 ----(a)
Component bal.:
Bal. on sugar: 17.5 + 0.035(A) + 0.042(B) = 0.050(1900)
Divide by 0.035: A + 1.2(B) = 2214.29 ----(b)
(a) (b): 17.5 0.2(B) = -194.29
B = 1058.95 kg B
A = 943.55 kg A
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Material Balance- Step-by-Step
EXAMPLE 3: Batch mixing process
The house special at Oswalds Oasis is a mixture containing 75 % C2H5OH by
mass, and the balance is water. The cost of alcohol has been increasing, however,
Oswald has decided that perhaps a 60 % blend would be just as effective. He has
on hand vat containing 350 gallons of the 75 % mixture (SG = 0.877) and can
purchase any desired amount of a 40 % mixture (SG = 0.952). How many gallons
of the latter mixture (40 % blend) must he buy?

SOLUTION:

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