Material and Energy Balance-General
Material and Energy Balance-General
Material and Energy Balance-General
org/Guide%20Books/Book
1/1.4%20MATERIAL%20%20AND%20ENERGY%20BALANCE.pdf.
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4.MaterialandEnergyBalance
4.MATERIALANDENERGYBALANCE
Syllabus
MaterialandEnergybalance:Facilityasanenergysystem,Methodsforpreparing
processflow,Materialandenergybalancediagrams.
Materialquantities,astheypassthroughprocessingoperations,canbedescribedby
materialbalances.Suchbalancesarestatementsontheconservationofmass.Similarly,
energyquantitiescanbedescribedbyenergybalances,whicharestatementsonthe
conservationofenergy.Ifthereisnoaccumulation,whatgoesintoaprocessmustcome
out.Thisistrueforbatchoperation.Itisequallytrueforcontinuousoperationoverany
chosentimeinterval.
Materialandenergybalancesareveryimportantinanindustry.Materialbalancesare
fundamentaltothecontrolofprocessing,particularlyinthecontrolofyieldsofthe
products.Thefirstmaterialbalancesaredeterminedintheexploratorystagesofanew
process,improvedduringpilotplantexperimentswhentheprocessisbeingplannedand
tested,checkedoutwhentheplantiscommissionedandthenrefinedandmaintainedasa
controlinstrumentasproductioncontinues.Whenanychangesoccurintheprocess,the
materialbalancesneedtobedeterminedagain.
Theincreasingcostofenergyhascausedtheindustriestoexaminemeansofreducing
energyconsumptioninprocessing.Energybalancesareusedintheexaminationofthe
variousstagesofaprocess,overthewholeprocessandevenextendingoverthetotal
productionsystemfromtherawmaterialtothefinishedproduct.
Materialandenergybalancescanbesimple,attimestheycanbeverycomplicated,but
thebasicapproachisgeneral.Experienceinworkingwiththesimplersystemssuchas
individualunitoperationswilldevelopthefacilitytoextendthemethodstothemore
complicatedsituations,whichdoarise.Theincreasingavailabilityofcomputershas
meantthatverycomplexmassandenergybalancescanbesetupandmanipulatedquite
readilyandthereforeusedineverydayprocessmanagementtomaximiseproductyields
andminimisecosts.
4.1BasicPrinciples
Iftheunitoperation,whateveritsnatureisseenasawholeitmayberepresented
diagrammaticallyasabox,asshowninFigure.4.1.Themassandenergygoingintothe
boxmustbalancewiththemassandenergycomingout.
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4.MaterialandEnergyBalance
Productsout
mP1 mP2 mP3
Raw
M aterialsin
mR1 mR2 mR3
Wasteproducts
Unit
Operation
StoredMaterials
mS1mS2mS3
StoredEnergy
ES1ES2ES3
Energyin
Heat,Work,
Energyin
products
Chemical,Electrical
ER1ER2ER3
Energylosses
Tosurroundings
EL1EL2EL3
Figure4.1:MassandEnergyBalance
Thelawofconservationofmassleadstowhatiscalledamassoramaterialbalance.
MassIn=MassOut+MassStored
RawMaterials=Products+Wastes+StoredMaterials.
mR=mP +mW+mS
(where(sigma)denotesthesumofallterms).
mR=mR1+mR2+mR3
mP =mP 1+mP 2+mP 3
=TotalRawMaterials
=TotalProducts.
mW =mW1+mW2+mW3=TotalWasteProducts
mS=mS1+mS2+mS3
=TotalStoredProducts.
Iftherearenochemicalchangesoccurringintheplant,thelawofconservationofmass
willapplyalsotoeachcomponent,sothatforcomponentA:
mAinenteringmaterials=mAintheexitmaterials+mAstoredinplant.
Forexample,inaplantthatisproducingsugar,ifthetotalquantityofsugargoinginto
theplantisnotequalledbythetotalofthepurifiedsugarandthesugarinthewaste
liquors,thenthereissomethingwrong.Sugariseitherbeingburned(chemically
changed)oraccumulatingintheplantorelseitisgoingunnoticeddownthedrain
somewhere.Inthiscase:
MA=(mAP +mAW+mAU )
wheremAUistheunknownlossandneedstobeidentified.Sothematerialbalanceis
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4.MaterialandEnergyBalance
now:
RawMaterials=Products+WasteProducts+StoredProducts+Losses
whereLossesaretheunidentifiedmaterials.
Justasmassisconserved,soisenergyconservedinfoodprocessingoperations.The
energycomingintoaunitoperationcanbebalancedwiththeenergycomingoutandthe
energystored.
EnergyIn=EnergyOut+EnergyStored
ER=EP +EW+EL+ES
where
ER=ER1+ER2+ER3+.=TotalEnergyEntering
Ep=EP 1+EP 2+EP 3+.=TotalEnergyLeavingwithProducts
EW=EW1+EW2+EW3+=TotalEnergyLeavingwithWasteMaterials
EL=EL1+EL2+EL3+.=TotalEnergyLosttoSurroundings
ES=ES1+ES2+ES3+.=TotalEnergyStored
Energybalancesareoftencomplicatedbecauseformsofenergycanbeinterconverted,
forexamplemechanicalenergytoheatenergy,butoverallthequantitiesmustbalance.
4.2TheSankeyDiagramanditsUse
TheSankeydiagramisvery
usefultooltorepresentan
entireinputandoutputenergy
flowinanyenergyequipment
orsystemsuchasboiler
generation,firedheaters,
furnacesaftercarryingout
energybalancecalculation.
Thisdiagramrepresents
visuallyvariousoutputsand
lossessothatenergymanagers
canfocusonfinding
improvementsinaprioritized
manner.
Figure4.2:EnergyBalanceforaReheatingFurnace
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4.MaterialandEnergyBalance
Example:TheFigure4.2showsaSankeydiagramforareheatingfurnace.Fromthe
Figure4.2,itisclearthatexhaustfluegaslossesareakeyareaforpriorityattention.
Sincethefurnacesoperateathightemperatures,theexhaustgasesleaveathigh
temperaturesresultinginpoorefficiency.Henceaheatrecoverydevicesuchasair
preheaterhastobenecessarilypartofthesystem.Thelowertheexhausttemperature,
higheristhefurnaceefficiency.
4.3MaterialBalances
Thefirststepistolookatthethreebasiccategories:materialsin,materialsoutand
materialsstored.Thenthematerialsineachcategoryhavetobeconsideredwhetherthey
aretobetreatedasawhole,agrossmassbalance,orwhethervariousconstituentsshould
betreatedseparatelyandifsowhatconstituents.Totakeasimpleexample,itmightbe
totakedrysolidsasopposedtototalmaterialthisreallymeansseparatingthetwo
groupsofconstituents,nonwaterandwater.Morecompletedissectioncanseparateout
chemicaltypessuchasminerals,orchemicalelementssuchascarbon.Thechoiceand
thedetaildependonthereasonsformakingthebalanceandontheinformationthatis
required.Amajorfactorinindustryis,ofcourse,thevalueofthematerialsandso
expensiverawmaterialsaremorelikelytobeconsideredthancheaperones,and
productsthanwastematerials.
BasisandUnits
Havingdecidedwhichconstituentsneedconsideration,thebasisforthecalculationshas
tobedecided.Thismightbesomemassofrawmaterialenteringtheprocessinabatch
system,orsomemassperhourinacontinuousprocess.Itcouldbe:somemassofa
particularpredominantconstituent,forexamplemassbalancesinabakerymightbeall
relatedto100kgofflourenteringorsomeunchangingconstituent,suchasin
combustioncalculationswithairwhereitishelpfultorelateeverythingtotheinert
nitrogencomponentorcarbonaddedinthenutrientsinafermentationsystembecause
theessentialenergyrelationshipsofthegrowingmicroorganismsarerelatedtothe
combinedcarboninthefeedortheessentiallyinertnonoilconstituentsoftheoilseeds
inanoilextractionprocess.Sometimesitisunimportantwhatbasisischosenandin
suchcasesaconvenientquantitysuchasthetotalrawmaterialsintoonebatchorpassed
inperhourtoacontinuousprocessareoftenselected.Havingselectedthebasis,thenthe
unitsmaybechosensuchasmass,orconcentrationswhichcanbebyweightorcanbe
molarifreactionsareimportant.
4.3.1Totalmassandcomposition
Materialbalancescanbebasedontotalmass,massofdrysolids,ormassofparticular
components,forexampleprotein.
Example:Constituentbalance
Skimmilkispreparedbytheremovalofsomeofthefatfromwholemilk.Thisskimmilk
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4.MaterialandEnergyBalance
isfoundtocontain90.5%water,3.5%protein,5.1%carbohydrate,0.1%fatand0.8%
ash.Iftheoriginalmilkcontained4.5%fat,calculateitscompositionassumingthatfat
onlywasremovedtomaketheskimmilkandthattherearenolossesinprocessing.
Basis:100kgofskimmilk.
Thiscontains,therefore,0.1kgoffat.Letthefatwhichwasremovedfromittomake
skimmilkbexkg.
Totaloriginalfat=(x+0.1)kg
Totaloriginalmass=(100+x)kg
andasitisknownthattheoriginalfatcontentwas4.5%so
(x+0.1)/(100+x)=0.045
where=x+0.1=0.045(100+x)
x=4.6kg
Sothecompositionofthewholemilkisthenfat=4.5%,water=90.5/104.6=86.5%,
protein=3.5/104.6=3.3%,carbohydrate=5.1/104.6=4.9%andash=0.8%
Concentrations
Concentrationscanbeexpressedinmanyways:weight/weight(w/w),weight/volume
(w/v),molarconcentration(M),molefraction.Theweight/weightconcentrationisthe
weightofthesolutedividedbythetotalweightofthesolutionandthisisthefractional
formofthepercentagecompositionbyweight.Theweightvolumeconcentrationisthe
weightofsoluteinthetotalvolumeofthesolution.Themolarconcentrationisthe
3
numberofmolecularweightsofthesoluteexpressedinkgin1m
ofthesolution.The
molefractionistheratioofthenumberofmolesofthesolutetothetotalnumberof
molesofallspeciespresentinthesolution.Noticethatinprocessengineering,itisusual
toconsiderkgmolesandinthischapterthetermmolemeansamassofthematerial
equaltoitsmolecularweightinkilograms.Inthischapterpercentagesignifies
percentagebyweight(w/w)unlessotherwisespecified.
Example:Concentrations
Asolutionofcommonsaltinwaterispreparedbyadding20kgofsaltto100kgof
3
water,tomakealiquidofdensity1323kg/m
.Calculatetheconcentrationofsaltinthis
solutionasa(a)weightfraction,(b)weight/volumefraction,(c)molefraction,(d)molal
concentration.
(a)Weightfraction:
20/(100+20)=0.167:%weight/weight=16.7%
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(b)Weight/volume:
Adensityof1323kg/m
solutioncontains
meansthatlm
ofsolutionweighs1323kg,but1323kgofsalt
(20x1323kgofsalt)/(100+20)=220.5kgsalt/m
1m solutioncontains220.5kgsalt.
Weight/volumefraction=220.5/1000=0.2205
Andsoweight/volume=22.1%
c)Molesofwater=100/18=5.56
Molesofsalt=20/58.5=0.34
Molefractionofsalt=0.34/(5.56+0.34)=0.058
d)Themolarconcentration(M)is220.5/58.5=3.77molesinm
Notethatthemolefractioncanbeapproximatedbythe(molesofsalt/molesofwater)as
thenumberofmolesofwateraredominant,thatisthemolefractioniscloseto0.34/
5.56=0.061.Asthesolutionbecomesmoredilute,thisapproximationimprovesand
generallyfordilutesolutionsthemolefractionofsoluteisacloseapproximationtothe
molesofsolute/molesofsolvent.
Insolid/liquidmixturesofallthesemethodscanbeusedbutinsolidmixturesthe
concentrationsarenormallyexpressedassimpleweightfractions.
Withgases,concentrationsareprimarilymeasuredinweightconcentrationsperunit
volume,oraspartialpressures.Thesecanberelatedthroughthegaslaws.Usingthegas
lawintheform:
pV=nRT
wherepisthepressure,Vthevolume,nthenumberofmoles,Ttheabsolutetemperature,
3
andRthegasconstantwhichisequalto0.08206m
atm/moleK,themolar
concentrationofagasisthen
n/V=p/RT
andtheweightconcentrationisthennM/VwhereMisthemolecularweightofthegas.
2
TheSIunitofpressureistheN/m
calledthePascal(Pa).Asthisisofinconvenientsize
formanypurposes,standardatmospheres(atm)areoftenusedaspressureunits,the
5
conversionbeing1atm=1.013x10
Pa,orverynearly1atm=100kPa.
Example:AirComposition
Ifairconsistsof77%byweightofnitrogenand23%byweightofoxygencalculate:
(a)themeanmolecularweightofair,
(b)themolefractionofoxygen,
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4.MaterialandEnergyBalance
(c)theconcentrationofoxygeninmole/m
atmospheresandthetemperatureis25
andkg/m
ifthetotalpressureis1.5
C.
(a)Takingthebasisof100kgofair:itcontains77/28molesofN2and23/32molesofO2
Totalnumberofmoles=2.75+0.72=3.47moles.
Someanmolecularweightofair=100/3.47=28.8
Meanmolecularweightofair=28.8
b)Themolefractionofoxygen=0.72/(2.75+0.72)=0.72/3.47=0.21
Molefractionofoxygen=0.21
(c)Inthegasequation,wherenisthenumberofmolespresent:thevalueofRis0.08206
3
o
m atm/moleKandatatemperatureof25
C=25+273=298K,andwhereV=1m
pV=nRT
andso,1.5x1=nx0.08206x298
3
n=0.061mole/m
weightofair=nxmeanmolecularweight
=0.061x28.8=1.76kg/m
andofthis23%isoxygen,soweightofoxygen=0.23x1.76=0.4kgin1m
Concentrationofoxygen=0.4kg/m
or0.4/32=0.013mole/m
Whenagasisdissolvedinaliquid,themolefractionofthegasintheliquidcanbe
determinedbyfirstcalculatingthenumberofmolesofgasusingthegaslaws,treatingthe
volumeasthevolumeoftheliquid,andthencalculatingthenumberofmolesofliquid
directly.
Example:Gascomposition
Inthecarbonationofasoftdrink,thetotalquantityofcarbondioxiderequiredisthe
o
equivalentof3volumesofgastoonevolumeofwaterat0
Candatmosphericpressure.
Calculate(a)themassfractionand(b)themolefractionoftheCO2inthedrink,ignoring
allcomponentsotherthanCO2andwater.
Basis1m
ofwater=1000kg
3
Volumeofcarbondioxideadded=3m
Fromthegasequation,pV=nRT
1x3=nx0.08206x273
n=0.134mole.
Molecularweightofcarbondioxide=44
Andsoweightofcarbondioxideadded=0.134x44=5.9kg
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4.MaterialandEnergyBalance
(a)Massfractionofcarbondioxideindrink=5.9/(1000+5.9)=5.9x10
(b)Molefractionofcarbondioxideindrink=0.134/(1000/18+0.134)=2.41x10
4.3.2TypesofProcessSituations
Continuousprocesses
Incontinuousprocesses,timealsoentersintoconsiderationandthebalancesarerelated
tounittime.Thusinconsideringacontinuouscentrifugeseparatingwholemilkintoskim
milkandcream,ifthematerialholdupinthecentrifugeisconstantbothinmassandin
composition,thenthequantitiesofthecomponentsenteringandleavinginthedifferent
streamsinunittimeareconstantandamassbalancecanbewrittenonthisbasis.Suchan
analysisassumesthattheprocessisinasteadystate,thatisflowsandquantitiesheldup
invesselsdonotchangewithtime.
Example:Balanceacrossequipmentincontinuouscentrifugingofmilk
If35,000kgofwholemilkcontaining4%fatistobeseparatedina6hourperiodinto
skimmilkwith0.45%fatandcreamwith45%fat,whataretheflowratesofthetwo
outputstreamsfromacontinuouscentrifugewhichaccomplishesthisseparation?
Basis1hour'sflowofwholemilk
Massin
Totalmass=35000/6=5833kg.
Fat=5833x0.04=233kg.
AndsoWaterplussolidsnotfat=5600kg.
Massout
Letthemassofcreambexkgthenitstotalfatcontentis0.45x.Themassofskimmilkis
(5833x)anditstotalfatcontentis0.0045(5833x)
Materialbalanceonfat:
Fatin=Fatout
5833x0.04=0.0045(5833x)+0.45x.andsox=465kg.
Sothattheflowofcreamis465kg/hrandskimmilk(5833465)=5368kg/hr
Thetimeunithastobeconsideredcarefullyincontinuousprocessesasnormallysuch
processesoperatecontinuouslyforonlypartofthetotalfactorytime.Usuallythereare
threeperiods,startup,continuousprocessing(socalledsteadystate)andclosedown,
anditisimportanttodecidewhatmaterialbalanceisbeingstudied.Alsothetime
intervaloverwhichanymeasurementsaretakenmustbelongenoughtoallowforany
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4.MaterialandEnergyBalance
slightperiodicorchancevariation.
Insomeinstancesareactiontakesplaceandthematerialbalanceshavetobeadjusted
accordingly.Chemicalchangescantakeplaceduringaprocess,forexamplebacteriamay
bedestroyedduringheatprocessing,sugarsmaycombinewithaminoacids,fatsmaybe
hydrolysedandtheseaffectdetailsofthematerialbalance.Thetotalmassofthesystem
willremainthesamebuttheconstituentpartsmaychange,forexampleinbrowningthe
sugarsmayreducebutbrowningcompoundswillincrease.
Blending
Anotherclassofsituationswhichariseareblendingproblemsinwhichvarious
ingredientsarecombinedinsuchproportionsastogiveaproductofsomedesired
composition.Complicatedexamples,inwhichanoptimumorbestachievable
compositionmustbesought,needquiteelaboratecalculationmethods,suchaslinear
programming,butsimpleexamplescanbesolvedbystraightforwardmassbalances.
Drying
Insettingupamaterialbalanceforaprocessaseriesofequationscanbewrittenforthe
variousindividualcomponentsandfortheprocessasawhole.Insomecaseswhere
groupsofmaterialsmaintainconstantratios,thentheequationscanincludesuchgroups
ratherthantheirindividualconstituents.Forexampleindryingvegetablesthe
carbohydrates,minerals,proteinsetc.,canbegroupedtogetheras'drysolids',andthen
onlydrysolidsandwaterneedbetaken,throughthematerialbalance.
Example:DryingYield
Potatoesaredriedfrom14%totalsolidsto93%totalsolids.Whatistheproductyield
fromeach1000kgofrawpotatoesassumingthat8%byweightoftheoriginalpotatoesis
lostinpeeling.
Basis1000kgpotatoentering
As8%ofpotatoesarelostinpeeling,potatoestodryingare920kg,solids129kg
Massin(kg)
Potatosolids140kg
Water
860kg
Massout(kg)
Driedproduct
92
Potatosolids140x(92/100)
=129kg
Associatedwater10kg
Totalproduct139kg
Losses
Peelingspotato
Solids11kg
Water69kg
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4.MaterialandEnergyBalance
Waterevaporated781kg
Totallosses
861kg
Total
1000kg
Productyield=139/1000=14%
Oftenitisimportanttobeabletofollowparticularconstituentsoftherawmaterial
throughaprocess.Thisisjustamatterofcalculatingeachconstituent.
4.4EnergyBalances
Energytakesmanyforms,suchasheat,kineticenergy,chemicalenergy,potentialenergy
butbecauseofinterconversionsitisnotalwayseasytoisolateseparateconstituentsof
energybalances.However,undersomecircumstancescertainaspectspredominate.In
manyheatbalancesinwhichotherformsofenergyareinsignificantinsomechemical
situationsmechanicalenergyisinsignificantandinsomemechanicalenergysituations,
asintheflowoffluidsinpipes,thefrictionallossesappearasheatbutthedetailsofthe
heatingneednotbeconsidered.Weareseldomconcernedwithinternalenergies.
Thereforepracticalapplicationsofenergybalancestendtofocusonparticulardominant
aspectsandsoaheatbalance,forexample,canbeausefuldescriptionofimportantcost
andqualityaspectsofprocesssituation.Whenunfamiliarwiththerelativemagnitudesof
thevariousformsofenergyenteringintoaparticularprocessingsituation,itiswiseto
putthemalldown.Thenaftersomepreliminarycalculations,theimportantonesemerge
andotherminoronescanbelumpedtogetherorevenignoredwithoutintroducing
substantialerrors.Withexperience,theobviouslyminoronescanperhapsbeleftout
completelythoughthisalwaysraisesthepossibilityoferror.
Energybalancescanbecalculatedonthebasisofexternalenergyusedperkilogram
ofproduct,orrawmaterialprocessed,orondrysolidsorsomekeycomponent.The
energyconsumedinfoodproductionincludesdirectenergywhichisfuelandelectricity
usedonthefarm,andintransportandinfactories,andinstorage,selling,etc.and
indirectenergywhichisusedtoactuallybuildthemachines,tomakethepackaging,to
producetheelectricityandtheoilandsoon.Fooditselfisamajorenergysource,and
energybalancescanbedeterminedforanimalorhumanfeedingfoodenergyinputcan
bebalancedagainstoutputsinheatandmechanicalenergyandchemicalsynthesis.
IntheSIsystemthereisonlyoneenergyunit,thejoule.However,kilocaloriesarestill
usedbysomenutritionistsandBritishthermalunits(Btu)insomeheatbalancework.
Thetwoapplicationsusedinthischapterareheatbalances,whicharethebasisforheat
transfer,andtheenergybalancesusedinanalysingfluidflow.
HeatBalances
Themostcommonimportantenergyformisheatenergyandtheconservationofthiscan
beillustratedbyconsideringoperationssuchasheatinganddrying.Inthese,enthalpy
(totalheat)isconservedandaswiththemassbalancessoenthalpybalancescanbe
writtenroundthevariousitemsofequipment.orprocessstages,orroundthewhole
plant,anditisassumedthatnoappreciableheatisconvertedtootherformsofenergy
suchaswork.
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4.MaterialandEnergyBalance
Enthalpy(H)isalwaysreferredtosomereferencelevelordatum,sothatthequantities
arerelativetothisdatum.Workingoutenergybalancesisthenjustamatterof
consideringthevariousquantitiesofmaterialsinvolved,theirspecificheats,andtheir
changesintemperatureorstate(asquitefrequentlylatentheatsarisingfromphase
changesareencountered).Figure4.3illustratestheheatbalance.
HeattoSurroundings
HeatfromElectricity
HeatfromfuelCombustion
HeatfromM echanicalSources
HeatoutinProducts
Heat
Stored
HeatoutinWastes
HeatinRawM aterials
HeatBalance
Figure4.3:HeatBalance
Heatisabsorbedorevolvedbysomereactionsinprocessingbutusuallythequantities
aresmallwhencomparedwiththeotherformsofenergyenteringintofoodprocessing
suchassensibleheatandlatentheat.Latentheatistheheatrequiredtochange,at
constanttemperature,thephysicalstateofmaterialsfromsolidtoliquid,liquidtogas,or
solidtogas.Sensibleheatisthatheatwhichwhenaddedorsubtractedfrommaterials
changestheirtemperatureandthuscanbesensed.TheunitsofspecificheatareJ/kgK
andsensibleheatchangeiscalculatedbymultiplyingthemassbythespecificheatby
thechangeintemperature,(mxcx T).TheunitsoflatentheatareJ/kgandtotallatent
heatchangeiscalculatedbymultiplyingthemassofthematerial,whichchangesits
phasebythelatentheat.Havingdeterminedthosefactorsthataresignificantinthe
overallenergybalance,thesimplifiedheatbalancecanthenbeusedwithconfidencein
industrialenergystudies.Suchcalculationscanbequitesimpleandstraightforwardbut
theygiveaquantitativefeelingforthesituationandcanbeofgreatuseindesignof
equipmentandprocess.
Example:Dryerheatbalance
3
Atextiledryerisfoundtoconsume4m
/hrofnaturalgaswithacalorificvalueof800
kJ/mole.Ifthethroughputofthedryeris60kgofwetclothperhour,dryingitfrom55%
moistureto10%moisture,estimatetheoverallthermalefficiencyofthedryertakinginto
accountthelatentheatofevaporationonly.
60kgofwetclothcontains
60x0.55kgwater=33kgmoisture
and60x(10.55)=27kgbonedrycloth.
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4.MaterialandEnergyBalance
Asthefinalproductcontains10%moisture,themoistureintheproductis27/9=3kg
AndsoMoistureremoved/hr=333=30kg/hr
Latentheatofevaporation=2257kJ/K
Heatnecessarytosupply=30x2257=6.8x10
kJ/hr
Assumingthenaturalgastobeatstandardtemperatureandpressureatwhich1mole
occupies22.4litres
Rateofflowofnaturalgas=4m
/hr=(4x1000)/22.4=179moles/hr
Heatavailablefromcombustion=179x800=14.3x10
kJ/hr
Approximatethermalefficiencyofdryer=heatneeded/heatused
=6.8x10
/14.3x10
=48%
Toevaluatethisefficiencymorecompletelyitwouldbenecessarytotakeintoaccount
thesensibleheatofthedryclothandthemoisture,andthechangesintemperatureand
humidityofthecombustionair,whichwouldbecombinedwiththenaturalgas.However,
asthelatentheatofevaporationisthedominanttermtheabovecalculationgivesaquick
estimateandshowshowasimpleenergybalancecangiveusefulinformation.
Similarlyenergybalancescanbecarriedoutoverthermalprocessingoperations,and
indeedanyprocessingoperationsinwhichheatorotherformsofenergyareused.
Example:Autoclaveheatbalanceincanning
Anautoclavecontains1000cansofpeasoup.Itisheatedtoanoveralltemperatureof
o
o
100 C.Ifthecansaretobecooledto40
Cbeforeleavingtheautoclave,howmuch
o
o
coolingwaterisrequiredifitentersat15
Candleavesat35
C?
o
Thespecificheatsofthepeasoupandthecanmetalarerespectively4.1kJ/kg
Cand
o
0.50kJ/kg C.Theweightofeachcanis60ganditcontains0.45kgofpeasoup.Assume
o
4
thattheheatcontentoftheautoclavewallsabove40
Cis1.6x10 kJandthatthereisno
heatlossthroughthewalls.
Letw=theweightofcoolingwaterrequiredandthedatumtemperaturebe40
temperatureofthecansleavingtheautoclave.
C,the
Heatentering
Heatincans=weightofcansxspecificheatxtemperatureabovedatum
3
=1000x0.06x0.50x(10040)kJ=1.8x10
kJ
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Heatincancontents=weightpeasoupxspecificheatxtemperatureabovedatum
=1000x0.45x4.1x(10040)=1.1x10
kJ
Heatinwater=weightofwaterxspecificheatxtemperatureabovedatum
=wx4.186x(1540)
=104.6wkJ.
Heatleaving
Heatincans=1000x0.06x0.50x(4040)(cansleaveatdatumtemperature)=0
Heatincancontents=1000x0.45x4.1x(4040)=0
Heatinwater=wx4.186x(3540)=20.9w
HEATENERGYBALANCEOFCOOLINGPROCESS40
CASDATUMLINE
HeatEntering(kJ)
HeatLeaving(kJ)
Heatincans
1800
Heatincans
0
Heatincancontents110000
Heatincancontents0
Heatinautoclavewall16000
Heatinautoclavewall0
Heatinwater
104.6w
Heatinwater
20.9W
Totalheatentering
127.800104.6wTotalheatleaving
20.9W
Totalheatentering=Totalheatleaving
127800104.6w=20.9w
w=1527kg
Amountofcoolingwaterrequired=1527kg.
OtherFormsofEnergy
Motorpowerisusuallyderived,infactories,fromelectricalenergybutitcanbeproduced
fromsteamenginesorwaterpower.Theelectricalenergyinputcanbemeasuredbya
suitablewattmeter,andthepowerusedinthedriveestimated.Therearealwayslosses
fromthemotorsduetoheating,frictionandwindagethemotorefficiency,whichcan
normallybeobtainedfromthemotormanufacturer,expressestheproportion(usuallyasa
percentage)oftheelectricalinputenergy,whichemergesusefullyatthemotorshaftand
soisavailable.
Whenconsideringmovement,whetheroffluidsinpumping,ofsolidsinsolidshandling,
oroffoodstuffsinmixers.theenergyinputislargelymechanical.Theflowsituationscan
beanalysedbyrecognisingtheconservationoftotalenergywhetherasenergyofmotion,
orpotentialenergysuchaspressureenergy,orenergylostinfriction.Similarly,chemical
energyreleasedincombustioncanbecalculatedfromtheheatsofcombustionofthe
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4.MaterialandEnergyBalance
fuelsandtheirratesofconsumption.Eventuallyenergyemergesintheformofheatand
itsquantitycanbeestimatedbysummingthevarioussources.
EXAMPLERefrigerationload
Itisdesiredtofreeze10,000loavesofbreadeachweighing0.75kgfromaninitialroom
o
o
temperatureof18
Ctoafinaltemperatureof18
C.Thebreadfreezingoperationisto
becarriedoutinanairblastfreezingtunnel.Itisfoundthatthefanmotorsareratedata
totalof80horsepowerandmeasurementssuggestthattheyareoperatingataround90%
oftheirrating,underwhichconditionstheirmanufacturer'sdataclaimsamotor
efficiencyof86%.If1tonofrefrigerationis3.52kW,estimatethemaximum
refrigerationloadimposedbythisfreezinginstallationassuming(a)thatfansandmotors
areallwithinthefreezingtunnelinsulationand(b)thefansbutnottheirmotorsarein
thetunnel.Theheatlossratefromthetunneltotheambientairhasbeenfoundtobe6.3
kW.
Extractionratefromfreezingbread(maximum)=104kW
Fanratedhorsepower
=80
Now0.746kW=1horsepowerandthemotorisoperatingat90%ofrating,
Andso(fan+motor)power=(80x0.9)x0.746=53.7kW
(a)Withmotors+fansintunnel
Heatloadfromfans+motors
=53.7kW
Heatloadfromambient
=6.3kW
Totalheatload
=(104+53.7+6.3)kW=164kW
=46tonsofrefrigeration
(b)Withmotorsoutside,themotorinefficiency=(10.86)doesnotimposealoadon
therefrigeration
Totalheatload
=(104+[0.86x53.7]+6.3)
=156kW
=44.5tonsofrefrigeration
Inpractice,materialandenergybalancesareoftencombinedasthesamestoichiometric
informationisneededforboth.
Summary
1.Materialandenergybalancescanbeworkedoutquantitativelyknowingtheamounts
ofmaterialsenteringintoaprocess,andthenatureoftheprocess.
2.Materialandenergybalancestakethebasicform
Contentofinputs=contentofproducts+wastes/losses+changesinstoredmaterials.
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4.MaterialandEnergyBalance
3.Incontinuousprocesses,atimebalancemustbeestablished.
4.Energyincludesheatenergy(enthalpy),potentialenergy(energyofpressureor
position),kineticenergy,workenergy,chemicalenergy.Itisthesumoverallofthese
thatisconserved.
5.Enthalpybalances,consideringonlyheatareusefulinmanyprocessingsituations.
TheobjectiveofM&Ebalanceistoassesstheinput,conversionefficiency,outputand
losses.AM&Ebalance,usedinconjunctionwithdiagnosis,isapowerfultoolfor
establishingthebasisforimprovementsandpotentialsavings.
.
4.5MethodforPreparingProcessFlowChart
Theidentificationanddrawingupaunitoperation/processisprerequisiteforenergyand
materialbalance.Theprocedurefordrawinguptheprocessflowdiagramsisexplained
below.
Flowchartsareschematicrepresentationoftheproductionprocess,involvingvarious
inputresources,conversionstepsandoutputandrecyclestreams.Theprocessflowmay
beconstructedstepwisei.e.byidentifyingtheinputs/output/wastesateachstageofthe
process,asshownintheFigure4.4.
Inputs
PROCESS
STEP1
Wastes
Wastes
Inputs
PROCESS
STEP2
Output
Figure4.4:ProcessFlowChart
Inputsoftheprocesscouldincluderawmaterials,water,steam,energy(electricity,etc)
ProcessStepsshouldbesequentiallydrawnfromrawmaterialtofinishedproduct.
Intermediatesandanyotherbyproductshouldalsoberepresented.Theoperatingprocess
parameterssuchastemperature,pressure,%concentration,etc.shouldberepresented.
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4.MaterialandEnergyBalance
Theflowrateofvariousstreamsshouldalsoberepresentedinappropriateunitslikem
orkg/h.Incaseofbatchprocessthetotalcycletimeshouldbeincluded.
Wastes/byproductscouldincludesolids,water,chemicals,energyetc.Foreachprocess
steps(unitoperation)aswellasforanentireplant,energyandmassbalancediagram
shouldbedrawn.
Outputoftheprocessisthefinalproductproducedintheplant.
Example:Processflowdiagramrawmaterialtofinishedproduct:Papermakingisa
highenergyconsumingprocess.Atypicalprocessflowwithelectrical&thermalenergy
flowforanintegratedwastepaperbasedmillisgiveninFigure4.5
Trees
UsedPap er
Bark(fuel)
Barking
Electricity
WoodPreparation
Chipping
Steam
Pulping
Electricity
Mechanical
ChemicalPulping
WastePaper
Pulping
Bleaching
Pulping
Steam
BleachPlant
Electricity
BleachPlant
Kneading
ChemicalRecovery
Electricity
Steam
Liquorconcentration
Refiner
Electricity
Steam
EnergyRecovery
Electricity
Fu el
Recausticization
Electricity
Papermaking
Steam
StockPreparation
Electricity
Electricity
Steam
Forming
Pressing
Electricity
Steam
Drying
Electricity
Paper
Figure4.5:ProcessFlowDiagramofPulp&PaperIndustry
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4.MaterialandEnergyBalance
4.6FacilityasanEnergySystem
Therearevariousenergysystems/utilityservicesprovidestherequiredtypeofsecondary
energysuchassteam,compressedair,chilledwateretctotheproductionfacilityinthe
manufacturingplant.AtypicalplantenergysystemisshowninFigure4.6.Although
variousformsofenergysuchascoal,oil,electricityetcentersthefacilityanddoesits
workorheating,theoutgoingenergyisusuallyintheformoflowtemperatureheat.
Rawmaterial
EnergyFacility/Utility
Energy
Input
(Coal,oil,gas,
electricity)
Transformer
DGSet
Boilers
Chillers
WaterSupplies
Air
compressors
ProductionFacility
Electricity
Heat
Output
Steam
ChilledWater
Water
(WasteStream
Fluegas,
Watervapour,
heatand
emissions)
CompressedAir
EnergyConversion
EnergyUtilisation
Figure4.6:PlantEnergySystem
Product
Theenergyusageintheoverallplantcanbesplitupintovariousformssuchas:
Electricalenergy,whichisusuallypurchasedasHTandconvertedintoLTsupply
forenduse.
SomeplantsgeneratetheirownelectricityusingDGsetsorcaptivepowerplants.
Fuelssuchasfurnaceoil,coalarepurchasedandthenconvertedintosteamor
electricity.
Boilergeneratessteamforheatinganddryingdemand
Coolingtowerandcoolingwatersupplysystemforcoolingdemand
Aircompressorsandcompressedairsupplysystemforcompressedairneeds
Allenergy/utilitysystemcanbeclassifiedintothreeareaslikegeneration,distribution
andutilisationforthesystemapproachandenergyanalysis.
Afewexamplesforenergygeneration,distributionandutilizationareshownbelowfor
boiler,coolingtowerandcompressedairenergysystem.
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4.MaterialandEnergyBalance
BoilerSystem:Boileranditsauxiliariesshouldbeconsideredasasystemforenergy
analyses.EnergymanagercandrawupadiagramasgiveninFigure4.7forenergyand
materialbalanceandanalysis.Thisdiagramincludesmanysubsystemssuchasfuel
supplysystem,combustionairsystem,boilerfeedwatersupplysystem,steamsupplyand
fluegasexhaustsystem.
5Bar,Comp.air/steamfor
Steam
atomisation
HPDos ing
12Bar/190oC
(Phos phate)
3Bar
Fur.Oil
180oC
Tank
4.5KL
Heater/3.5kw
Filterunits
B OILER
30TPH
12B ar
BioGas fromETP
FD
Air
Economis er
160oC
66m
Fan
170oC
75KW
35640m3
Chimney
540mmWC
LPdos ing
125oC
(Oxytreat)
Condens atereturn
Deareator
Condens ate
10m3
tank25m3
Blowdown
tank
8.95KW
4.5KW
36m3/hr
48.1m3/hr
1.5m
21.5m
DM watertank
Drain
250m3
2.8KW
48.1m3/hr
Figure4.7B oilerPlantSystemEnergyFlowDiagram
21.5m
CoolingTower&CoolingWaterSupplySystem:Coolingwaterisoneofthecommon
utilitydemandsinindustry.Acompletediagramcanbedrawnshowingcoolingtower,
pumps,fans,processheatexchangersandreturnlineasgiveninFigure4.8forenergy
auditandanalysis.Alltheenduseofcoolingwaterwithflowquantitiesshouldbe
indicatedinthediagram.
M3/hr
2000
Fan4Nos.x30 kw
VAHP
Condensor
10
Co olin gTower
Pump
InstrumentAirCompressor
Intercooler
Aftercoo ler
5 000 m3/hr
Flo wMeter
ProcessAirCompressor
600
3000m3/hr
370kw
Heavy Blow
2500m3/h r
drain
41.5 m
Coo ler
Hotaircooler
32 oC
170
BrinePlant
Condenser
OilCooler
SolventRecov ery
220
ColumnCondenser
Pro ductCooler
SoftWater
Tan k
1.5
BoilerPlant
FWPu mp
Drain
2 00m3
GlandCooling
40m3/hr
Fermentor
Continuo usBlowd own
Germinator
1 5m3/hr(0.3%)
Prefermentor
38.5
Pump 30kw
Fermento r
Continuo usSteriliser
Iron Corrosion
Test
DGSet
Coo lingTower
Drain,2 m3/hr
Figure4.8CoolingTowerWaterSystem
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4.MaterialandEnergyBalance
CompressedairSystem
Compressedairisaversatileandsafemediaforenergyuseintheplants.Atypical
compressedairgeneration,distributionandutilizationdiagramisgiveninFigure4.9.
Energyanalysisandbestpracticesmeasuresshouldbelistedinallthethreeareas.
GENERATION
DISTRIBUTION
UTILISATION/
ENDUSEAPPLICATIO
Extraction
FilterPress
110kw
Activated
850m 3/hr.
AluminaDrier
Instrumentation
&Controls
110kw
850m 3/hr.
Fermenter
530Nm3/hrfor
er
iv
e rs
c
e
FilterPress
150minutes/day
7Ba
Boiler
AirR
Atomisation
225Nm3/hr
110kw
850m 3/hr.
Vent
Compressor3No.
Twostage,double
acting,reciprocating,
watercoolednon
lubricated,heavyduty
Westfalia
Chilled
WaterHeat
Receiver
5Bars
N2Plant
Exchanger
630Nm 3/hr
Moisture
Air
150Nm 3/hr
N2
N2
Receiver
Drain
Figure4.9InstrumentAirSystem
4.7HowtoCarryoutMaterialandEnergy(M&E)Balance?
MaterialandEnergybalancesareimportant,sincetheymakeitpossibletoidentifyand
quantifypreviouslyunknownlossesandemissions.Thesebalancesarealsousefulfor
monitoringtheimprovementsmadeinanongoingproject,whileevaluatingcostbenefits.
Rawmaterialsandenergyinanymanufacturingactivityarenotonlymajorcost
componentsbutalsomajorsourcesofenvironmentalpollution.Inefficientuseofraw
materialsandenergyinproductionprocessesarereflectedaswastes.
GuidelinesforM&EBalance
(Extraction)
Centrifuge
(Extraction)
Foracomplexproductionstream,itisbettertofirstdrafttheoverallmaterial
andenergybalance.
Whilesplittingupthetotalsystem,choose,simplediscretesubsystems.The
processflowdiagramcouldbeusefulhere.
Choosethematerialandenergybalanceenvelopesuchthat,thenumberof
streamsenteringandleaving,isthesmallestpossible.
Alwayschooserecyclestreams(materialandenergy)withintheenvelope.
Themeasurementunitsmayinclude,timefactororproductionlinkages.
Considerafullbatchasthereferenceincaseofbatchoperations.
Itisimportanttoincludestartupandcleaningoperationconsumptions(of
materialandenergyresources(M&E).
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4.MaterialandEnergyBalance
Calculatethegasvolumesatstandardconditions.
Incaseofshutdownlosses,averagingoverlongperiodsmaybenecessary.
Highlightlossesandemissions(M&E)atpartloadoperationsifprevalent.
Foreachstream,whereapplicable,indicateenergyquality(pressure,
temperature,enthalpy,Kcal/hr,KW,Amps,Voltsetc.).
WhilepreparingM&Ebalances,precisionofanalyticaldata,flowandenergy
measurementshavetobeaccurateespeciallyincaseofshorttimespan
references.
Thematerialandenergy(M&E)balancesalongtheaboveguidelines,arerequiredto
bedevelopedatthevariouslevels.
1.OverallM&Ebalance:Thisinvolvestheinputandoutputstreamsforcomplete
plant.
2.SectionwiseM&Ebalances:Inthesequenceofprocessflow,materialand
energybalancesarerequiredtobemadeforeachsection/department/costcentres.
Thiswouldhelptoprioritizefocusareasforefficiencyimprovement.
3.EquipmentwiseM&Ebalances:M&Ebalances,forkeyequipmentwouldhelp
assessperformanceofequipment,whichwouldinturnhelpidentifyandquantify
energyandmaterialavoidablelosses.
EnergyandMassBalanceCalculationProcedure:
TheEnergyandMassbalanceisacalculationprocedurethatbasicallychecksifdirectly
orindirectlymeasuredenergyandmassflowsareinagreementwiththeenergyandmass
conservationprinciples.
Thisbalanceisoftheutmostimportanceandisanindispensabletoolforaclear
understandingoftheenergyandmasssituationachievedinpractice.
Inordertouseitcorrectly,thefollowingprocedureshouldbeused:
Clearlyidentifytheproblemtobestudied.
Defineaboundarythatenclosestheentiresystemorsubsystemtobeanalysed.
Enteringandleavingmassandenergyflowsmustbemeasuredattheboundary.
Theboundarymustbechoseninsuchawaythat:
a)Allrelevantflowsmustcrossit,allnonrelevantflowsbeingwithinthe
boundary.
b)Measurementsattheboundarymustbepossibleinaneasyandaccurate
manner.
Selectanappropriatetestperioddependingonthetypeofprocessandproduct.
Carryoutthemeasurements.
Calculatetheenergyandmassflow.
Verifyanenergyandmassbalance.Ifthebalancesareoutsideacceptablelimits,
thenrepeatthemeasurements.
Theenergyreleaseoruseinendothermicandexothermicprocessesshouldbe
takenintoconsiderationintheenergybalance.
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4.MaterialandEnergyBalance
Example/Formula
i)EnergySuppliedbyCombustion:Q=FuelconsumedxGrossCalorificvalue
ii)EnergySuppliedbyElectricity:Q=kWhx860kCals
Where,Q=thermalenergyflowrateproducedbyelectricity(kCals/hr)
iii)ContinuityEquation
A1 V1=A2 V2
v1
v2
Where,V1andV2arethevelocityinm/s,v1 andv2 thespecificvolumeinm
2
Aisthecrosssectionalareaofthepipeinm
.
iv)Heataddition/rejectionofafluid=mCp T
where,misthemassinkg,CpisthespecificheatinkCal/kg.C,Tisthedifferencein
temperatureink.
Example1:HeatBalanceinaBoiler
Aheatbalanceisanattempttobalancethetotalenergyenteringasystem(e.gboiler)
againstthatleavingthesystemindifferentforms.TheFigure4.10illustratestheheat
balanceanddifferentlossesoccurringwhilegeneratingsteam.
73.8%HeatinSteam
/kgand
12.7%
8.1%
100%
Steam
Boiler
1.7%
0.3%
Fuel
2.4%
1.0%
Figure4.10
DryFlueGasLoss
Heatlossduetohydrogeninfuel
Heatlossduetomoistureinfuel
Heatlossduetomoistureinair
Heatlossduetounburntsinresidue
Heatlossduetoradiation&
otherunaccountedloss
Example2:MassBalanceinaCementPlant
Thecementprocessinvolvesgas,liquidandsolidflowswithheatandmasstransfer,
combustionoffuel,reactionsofclinkercompoundsandundesiredchemicalreactionsthat
includesulphur,chlorine,andAlkalies.
Atypicalbalanceisshowninthefigure4.11(Source:BasedonfigurefromAustrian
BATproposal1996,CembureauforMassbalanceforproductionof1Kgcement)
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4.MaterialandEnergyBalance
Figure4.11
Example3:MassBalanceCalculation
Thisproblemillustrateshowamassbalancecalculationcanbeusedtochecktheresults
ofanairpollutionmonitoringstudy.Afabricfilter(bagfilter)isusedtoremovethedust
fromtheinletgasstreamsothatoutletgasstreammeetstherequiredemissionstandards
incement,fertilizerandotherchemicalindustries.
Duringanairpollutionmonitoringstudy,theinletgasstreamtoabagfilteris1,69,920
3
3
m /hrandthedustloadingis4577mg/m
.Theoutletgasstreamfromthebagfilteris
3
3
1,85,040m /hrandthedustloadingis57mg/m
.
Whatisthemaximumquantityofashthatwillhavetoberemovedperhourfromthebag
filterhopperbasedonthesetestresults?
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4.MaterialandEnergyBalance
Figure4.12ConservationofMatter
Solution:
Basedondustbalance,
Mass(in)=Mass(out)
Inletgasstreamdust=outletgasstreamdust+HopperAsh
1.Calculatetheinletandoutletdustquantitiesinkgperhour
3
Inletdustquantity=169920(m
/hr)x4577(mg/m
=777.7kg/hr
Outletdustquantity=185040(m
=10.6kg/hr
/hr)x57(mg/m
)x1/1000000(kg/mg)
)x1/1000000(kg/mg)
2.Calculatethequantityofashthatwillhavetoremovedfromthehopperperhour
Hopperash=InletgasdustquantityOutletgasdustquantity
=777.7kg/hr10.6kg/hr
=767.1kg/hr
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Example4:MaterialRequirementforProcessOperations
Ascrubberisusedtoremovethefinematerialordustfromtheinletgasstreamwithaspray
ofliquid(typicallywater)sothatoutletgasstreammeetstherequiredprocessoremission
standards.
HowmuchwatermustbecontinuallyaddedtowetscrubbershowninFigurebelowinorder
tokeeptheunitrunning?Eachofthestreamsisidentifiedbyanumberlocatedinadiamond
symbol.Stream1istherecirculationliquidflowstreambacktothescrubberanditis4.54
3
m /hr.Theliquidbeingwithdrawfortreatmentanddisposal(stream4)is0.454kgm
/hr.
Assumethatinletgasstream(number2)iscompletelydryandtheoutletstream(number6)
has272.16kg/hrofmoistureevaporatedinthescrubber.Thewaterbeingaddedtothe
scrubberisstreamnumber5.
Figure4.13ExampleofMaterialBalance
Solution:
Step1.Conductamaterialbalancearoundthescrubber.
1.ForStream6,convertfromkg/hrtom
conversionfactorbelowappliesonlytopurewater.
Stream6=272.16kg/hrxm
/hrtokeepunitsconsistent.The
/1000kg
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4.MaterialandEnergyBalance
=0.272m /hr
2.SetupthematerialbalanceequationandsolveforStream3.
InputScrubber
=OutputScrubber
Stream1+Stream2=Stream3+Stream6
3
4.54m /hr+0=ym
Stream3=ym
/hr+0.272m
/hr=4.27m
/hr
/hr
Step2.Conductamaterialbalancearoundtherecirculationtank.SolveforStream5.
InputTank
=OutputTank
Stream3+Stream5=Stream1+Stream4
3
4.25m /hr+xm
/hr=4.54m
Stream5=xm
/hr+0.454m
/hr
/hr=5m3/hr4.27m
/hr
=0.73m /hr
Ifitistocalculateonlythemakeupwaterat5,
Stream5=Stream4+Stream6
=0.454+0.272
=0.73m3/hr
OneofthekeystepsinsolvingExample4wasdrawingasimplesketchofthesystem.Thisis
absolutelynecessarysothatitispossibletoconductthematerialbalances.Drawingsarea
valuablefirststepwhensolvingawidevarietyofproblems,evenonesthatappearssimple.
Thedrawingisaveryusefulwaytosummarizewhatweknowandwhatweneedtoknow.It
helpsvisualizethesolution.Iftheprobleminvolvesdimensionalquantities(suchasstream
flowquantities),thedimensionsshouldbeincludedonthesketch.Theyserveasremindersof
theneedtoconvertthedataintoconsistentunits.
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4.MaterialandEnergyBalance
QUESTIONS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Drawatypicalinputoutputdiagramforaprocessandindicatethevarious
energyinputs.
Whatisthepurposeofmaterialandenergybalance?
HowSankeydiagramisusefulforenergyanalysis?
Drawaprocessflowchartforanyproductmanufacture.
Listdownthevariousguidelinesrequiredformaterialandenergybalance.
Amaterialbalanceisbasedon
(a)Mass(b)Volume(c)Concentration(d)Temperature
Biscuitsaretobebakedinacontinuousoven.Theinletmoisturecontentis
25%.Theoutletmoistureis1%.Theproductionis2tonnes/houronadry
basis.Makeamaterialbalanceandfindouthowmuchquantityofmoistureis
removedperhour.
Afurnaceisloadedwithmaterialsat5T/hr.Thescalelossesare2%.Find
outthematerialoutput?
o
Inaheatexchanger,inletandoutlettemperaturesofcoolingwaterare28
C&
o
33 C.Thecoolingwatercirculationis200litres/hr.Theprocessfluidenters
o
o
theheatexchangersat60
Candleavesat45
C.Findouttheflowrateofthe
processfluid?
(Cpofprocessfluid=0.95)
Steamoutputofboilerismeasuredbymeasuringfeedwater.Thetanklevel
3
readingfrom8.00a.m.to8.00p.m.was600m
.Continuousblowdownwas
givenat1%oftheboilerfeedrateduringtheaboveperiod.Findoutthe
averageactualsteamdeliveredperhour?
Thefollowingarethecoolingwaterrequirementsforaprocessindustry:
3
2
Heatexchanger1:300m
/hr.at3kg/cm
3
2
Heatexchanger2:150m
/hr.at2.5kg/cm
3
2
Heatexchanger3:200m
/hr.at1kg/cm
Findoutthetotalcoolingwaterrequirementperhourfortheplant?
(allheatexchangersareinparallel)
Inadryer,thecondensatewasmeasuredtobe80kg/hr.Theflashsteamwas
calculatedtobe12kg/hr.Findouttheactualsteamconsumptionofthedryer?
REFERENCES
1.EnergyauditreportsofNationalProductivityCouncil
2.EnergyManagementHandbook,JohnWileyandSonsWayneC.Turner
3.UnitOperationsinFoodProcessing,R.L.Earle,NZIFST
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