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INTRODUCTION
Material quantities, as they pass through
processing operations, can be described by
material balances. Such balances are statements
on the conservation of mass.
Energy quantities can be described by energy
balances .
If there is no accumulation, what goes into a
process must come out.
Energy balances are used in the examination
of the various stages of a process, over the
whole process /over the total production
system from the raw material to the finished
product.
Material Balance
The first material balances Design stages of
a new process.
The next material balances Improved during
pilot plant experiments when the process is
being tested, checked out when the plant is
commissioned.
Then refined and maintained as a control
instrument as production continues.
When any changes occur in the process, the
material balances need to be determined
again. Material balances are fundamental to
the control of processing, particularly in the
control of yields of the products.
BASIC PRINCIPLE
If
Products out
mP1mP2mP3
Raw
Materials in
mR1mR2mR3
Waste products
Energy in
Heat, Work,
Chemical, Electrical
ER1ER2ER3
Unit
Operation
mW1mW2mW3
Stored Materials
mS1mS2mS3
Energy in
products
Stored Energy
ES1ES2ES3
EP1EP2EP3
Energy in
Waste
EW1EW2EW3
Energy losses
To surroundings
EL1EL2EL3
MASS BALANCE
Materials.
mR = mP + mW + mS
(where (sigma) denotes the sum of all terms).
= Total Products.
If
ENERGY BALANCE
Just as mass is conserved, so is energy conserved
in processing operations. The energy coming
into a unit operation can be balanced with the
energy coming out and the energy stored.
Energy In = Energy Out + Energy Stored
ER = EP + EW + EL + ES
where
ER = ER1 + ER2 + ER3 + = Total Energy Entering
Ep = EP1 + EP2 + EP3 + = Total Energy Leaving
with Products
SANKEY DIAGRAM
MATERIAL BALANCES
The first step is to look at the three basic categories:
CONCENTRATIONS
Concentrations can be expressed in many ways: weight/ weight
(w/w), weight/volume (w/v), molar concentration (M), mole
fraction.
The weight/weight concentration is the weight of the solute
divided by the total weight of the solution and this is the
fractional form of the percentage composition by weight.
The weight volume concentration is the weight of solute in
the total volume of the solution.
The molar concentration is the number of molecular weights
of the solute expressed in kg in 1 m3 of the solution.
The mole fraction is the ratio of the number of moles of the
solute to the total number of moles of all species present in the
solution.
EXAMPLE
A solution of common salt in water is prepared by
adding 20 kg of salt to 100 kg of water, to make a
liquid of density 1323 kg/m3. Calculate the
concentration of salt in this solution as a (a)
weight fraction, (b) weight/volume fraction, (c)
mole fraction, (d) molal concentration.
(a) Weight fraction:
20 / (100 + 20) = 0.167
% weight / weight = 16.7%
(b) Weight/volume:
A density of 1323kg/m3 means that lm3 of solution
weighs 1323kg, but 1323kg of salt solution
contains
pV = nRT
n / V = p/RT
and the weight concentration is then Nm / V
where M is the molecular weight of the gas.
The SI unit of pressure is the N/m2 called the
Pascal (Pa). As this is of inconvenient size
for many purposes, standard atmospheres
(atm) are often used as pressure units, the
conversion being 1 atm = 1.013 x 105 Pa, or
very nearly 1 atm = 100 kPa.
EXAMPLE
If air consists of 77% by weight of nitrogen and 23%
by weight of oxygen calculate:
(a) the mean molecular weight of air,
(b) the mole fraction of oxygen,
(c) the concentration of oxygen in mole/m 3 and kg/m3
if the total pressure is 1.5 atmospheres and the
temperature is 25 oC.
(a)
EXAMPLE
If 35,000kg of whole milk containing 4% fat
is to be separated in a 6 hour period into
skim milk with 0.45% fat and cream with
45% fat, what are the flow rates of the two
output streams from a continuous centrifuge
which accomplishes this separation?
Basis 1 hour's flow of whole milk
Mass
Total
in
Mass
out
balance on fat:
HEAT BALANCES
The most common important energy form
is heat energy and the conservation of this
can
be
illustrated
by
considering
operations such as heating and drying.
In these, enthalpy (total heat) is conserved
and as with the mass balances so enthalpy
balances can be written round the various
items of equipment. or process stages, or
round the whole plant, and it is assumed
that no appreciable heat is converted to
other forms of energy such as work.
30 kg/hr
6.8 x 104
standard
1 mole
SUMMARY
Input
Process
Step-1
Waste
Input
Process
Step-2
Waste
Output
Process Flow Chart
Steam
HP Dosing
(Phosphate)
3 Bar
180o C
Fur.Oil
Tank
4.5 KL
Heater/3.5 kw
Filter units
BOILER
30 TPH
12 Bar
12 Bar/190o C
Air
160o C
66m
170o C
75 KW
35640m3
540mm WC
Chimney
LP dosing
(Oxytreat)
Condensate return
125o C
Deareator
10m 3
Condensate
tank 25m3
8.95 KW
36 m3/hr
1.5m
DM water tank
250 m3
2.8 KW
48.1 m3/hr
21.5m
Economiser
Blowdown
tank
4.5 KW
48.1 m3/hr
21.5m
Drain
GENERATION
DISTRIBUTION
UTILISATION/
END USE APPLICATION
Extraction
Filter Press
110 kw
850 m3/hr.
Activated
Alumina Drier
Instrumentation
& Controls
Fermenter
530 Nm3/hr for Filter Press
150 minutes/day
Air Receiver
7 Bars
110 kw
850 m3/hr.
225 Nm3/hr
110 kw
850 m3/hr.
Compressor - 3 No.
Two stage, double
acting, reciprocating,
water cooled nonlubricated, heavy duty
Boiler
Atomisation
Vent
Chilled
Water Heat
Exchanger
Receiver
5 Bars
N2 Plant
630 Nm3/hr
Moisture Air
Drain
150 Nm3/hrN2
N2 Receiver
Westfalia
(Extraction)
Centrifuge
(Extraction)
8.1 %
100 %
Fuel
STEAM
BOILER
0.3 %
2.4 %
1.0 %