Process Engineering 1

Mass Balance-
in Non-Reactive System
Multiple Units
 LEARNING OBJECTIVES

By the end of this topic, you should be able to:

• Performed material balance for system for multiple unit.

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 SYSTEM OF MULTIPLE-UNIT PROCESSES

• Material Balance Calculation

Industrial chemical processes involved more than
one unit operation
PRODUCT 1
FEED 2

COMPONENT
FEED 1 SPLITTER
MIXER
CATALYTIC
REACTOR

PRODUCT 2

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 SYSTEM OF MULTIPLE-UNIT PROCESSES

System of Multiple-Unit Processes

• How many system boundaries exist in this process?
FEED 2
PRODUCT 1

Specific Balance

FEED 1 COMPONENT
SPLITTER

CATALYTIC
REACTOR

Overall Balance PRODUCT 2

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 EXAMPLE 6.1

A liquid mixture containing 30.0 mole% benzene (B), 25.0% toluene

(T) and the balance xylene (X) is fed to a distillation column. The
bottoms product containing 98.0 mole% X and no B, and 96.0% of
the X in the feed is recovered in this stream. The overhead product is
fed to a second column. The overhead product from the second
column contains 97.0 % of the B in the feed to this column. The
composition of this stream is 94.0 mole% of B and the balance T.
(a) Draw and label flowchart. Do the degree-of-freedom analysis to prove
that for an assumed basis of calculation, molar flowrate and compositions
of all process streams can be calculated from the given information.
(b) calculate (i) the percentage of the benzene in the process feed (the feed
to the first column) that emerges in the overhead product from the second
column and (ii) the percentage of toluene in the process feed that emerges
in the bottom product from the second column.

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 EXAMPLE 6.1 (Cont.)

(a) Draw and label flowchart. Do the degree-of-freedom analysis to prove that for an
assumed basis of calculation, molar flowrate and compositions of all process streams can
be calculated from the given information.

100 mol/h n2 (mol/h) n4 (mol/h)

0.300 mol B/mol Column XB2 (mol B/mol) Column
0.940 mol B/mol
0.250 mol T/mol 1 XT2 (mol T/mol) 2
0.060 mol T/mol
0.450 mol X/mol 1 - XB2 -XT2 (mol X/mol)

n3 (mol/h) XB5 (mol B/mol)

n5 (mol/h)
0.020 mol T/mol XT5 (mol T/mol)
0.980 mol X/mol 1 - XB5 -XT5 (mol X/mol)

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 EXAMPLE 6.1 (Cont.)

(a) Draw and label flowchart. Do the degree-of-freedom analysis to prove that for an
assumed basis of calculation, molar flowrate and compositions of all process streams can
be calculated from the given information.

Column 1
DoF Column 1
96% X Recovery: 0.960(0.450)(100) = 0.980n3 (1)
4 unknowns
- 3 Independent eqn
Total mole balance:100 = n2 + n3 (2)
B Balance: 0.300(100) = xB 2n2 (3)
- 1 Recovery of X
0 DoF T Balance: 0.250(100) = xT 2n2 + 0.020n3 (4)

Column 2
DoF Column 2
97% B Recovery: 0.970xB2n2 = 0.940n4 (5)
4 unknowns
- 3 Independent eqn Total mole balance: n2 = n4 + n5 (6)
- 1 Recovery of B B Balance: xB 2 n2 n + xB5n5
= 0.940 4 (7)
0 DoF
T Balance: xT 2n2 = 0.060n4 + xT 5n5 (8)

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 EXAMPLE 6.1 (Cont.)

(b) Calculate (i) the percentage of the benzene in the process feed (the feed to the
first column) that emerges in the overhead product from the second column and (ii)
the percentage of toluene in the process feed that emerges in the bottom product
from the second column.

Solving all the balances and obtain these results:

n3 = 44.1mol/h n4 = 30.95 mol/h

n2 = 55.9 mol/h n5 = 24.96 mol/h
xB2 = 0.536 mol B/h xB5 = 0.036 mol B/h
xT 2 = 0.431mol T/h xT 5 = 0.892 mol T/h
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 EXAMPLE 6.1 (Cont.)

(b) Calculate (i) the percentage of the benzene in the process feed (the feed to the
first column) that emerges in the overhead product from the second column and (ii)
the percentage of toluene in the process feed that emerges in the bottom product
from the second column.

Overall Benzene Recovery:

0.940(30.95)
x 100% = 97%
0.300(100)

Overall Toluene Recovery:

0.892(24.96)
x 100% = 89%
0.250(100)

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 LEARNING OBJECTIVES

By the end of this topic, you should be able to:

• Performed material balance for bypass and recycle.

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 BYPASS AND RECYCLE

What will we learn today?

• The difference between
Bypass and Recycle.
Distinguish mixing vs. splitting
points.
Material balances involving the
above mentioned processes.

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 BYPASS AND RECYCLE

Note:
At bypass, Process Unit
INPUT OUTPUT
the
components
mass
“Splitting “Mixing
fractions Bypass
Points” Points”
remain the
same. The
ONLY
difference is OUTPUT Process Unit INPUT
the mass
flow rate.
Recycle

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 EXAMPLE 6.2

Fresh orange juice contains 12.0 wt% solids and the balance water,
and concentrated orange juice contains 42.0 wt% solids. Initially a
single evaporation process was used for the concentration, but
volatile constituents of the juice escaped with the water, leaving the
concentrate with a flat taste. The current process overcomes the
problem by bypassing the evaporator with a fraction of fresh juice.
The juice that enters the evaporator is concentrated to 58 wt%
solids, and the evaporator product stream is mixed with the
bypassed fresh juice to achieve the desired final concentration.
Draw and label the flowchart. Perform the degrees of freedom
analyses. Calculate the amount of product (42% concentrate)
produced per 100 kg fresh juice fed to the process and the fraction
of the feed that bypasses the evaporator.

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 EXAMPLE 6.2 (Cont.)

Step 1. Draw and label the flowchart.

Mixing
Bypass Point
m3 (kg W)

mo m1 m4 m5
0.12 kg S / kg 0.12 kg S / kg
Evaporator 0.42 kg S / kg
0.58 kg S / kg
0.88 kg W / kg 0.88 kg W / kg 0.42 kg W / kg 0.58 kg W / kg
m2
0.12 kg S / kg
0.88 kg W / kg

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 EXAMPLE 6.2 (Cont.)

Step 2. Choose a basis of calculation: Given 100 kg fresh juice.

Step 3. Perform the DoF analysis.

m3 (kg W)

100 kg m1 m4 m5
0.12 kg S / kg 0.12 kg S / kg
Evaporator 0.58 kg S / kg 0.42 kg S / kg
0.88 kg W / kg 0.88 kg W / kg 0.42 kg W / kg 0.58 kg W / kg
m2
0.12 kg S / kg
0.88 kg W / kg

Balances Degrees of Freedom

Overall : 100 = m3 + m5 2 Unks. (m3, m5)
S : (0.12)(100) = 0 + 0.42m5 - 2 IE’s
W : (0.88)(100) = m3 + 0.58m5 0 DoF

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 EXAMPLE 6.2 (Cont.)

Step 3. Perform the DoF analysis (Continuation).

m3 (kg W)

100 kg m1 m4 m5
0.12 kg S / kg 0.12 kg S / kg
Evaporator 0.58 kg S / kg 0.42 kg S / kg
0.88 kg W / kg 0.88 kg W / kg 0.42 kg W / kg 0.58 kg W / kg
m2
0.12 kg S / kg
0.88 kg W / kg

Balances Degrees of Freedom

Overall : 100 = m1 + m2 2 Unks. (m1, m2)
Bypass

- 1 IE’s
S : (0.12)(100) = 0.12m1 + 0.12m2

W : (0.88)(100) = 0.88m1 + 0.88m2 1 DoF

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 EXAMPLE 6.2 (Cont.)

Step 3. Perform the DoF analysis (Continuation).

m3 (kg W)

100 kg m1 m4 m5
0.12 kg S / kg 0.12 kg S / kg
Evaporator 0.58 kg S / kg 0.42 kg S / kg
0.88 kg W / kg 0.88 kg W / kg 0.42 kg W / kg 0.58 kg W / kg
m2
0.12 kg S / kg
0.88 kg W / kg

Balances Degrees of Freedom

3 Unks. (m1, m3, m4)
Evaporator

Overall : m1 = m3 + m4
- 2 IE’s
S : 0.12m1 = 0.58m4
1 DoF
W : 0.88m1 = 0.42m4 + m3

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 EXAMPLE 6.2 (Cont.)

Step 3. Perform the DoF analysis (Continuation).

m3 (kg W)

100 kg m1 m4 m5
0.12 kg S / kg 0.12 kg S / kg
Evaporator 0.58 kg S / kg 0.42 kg S / kg
0.88 kg W / kg 0.88 kg W / kg 0.42 kg W / kg 0.58 kg W / kg
m2
0.12 kg S / kg
0.88 kg W / kg

Balances Degrees of Freedom

Mixing Point

Overall : m4 + m2 = m5 3 Unks. (m2, m4, m5)

- 2 IE’s
S : 0.12m2 + 0.58m4 = 0.42m5
1 DoF
W : 0.88m2 = 0.42m4 + 0.58m5

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 EXAMPLE 6.2 (Cont.)

Step 4. Do the algebra. Solve the balance equations.

Calculate the amount of product (42% concentrate) produced per 100 kg fresh
juice fed to the process and the fraction of the feed that bypasses the
evaporator.

Let’s start with the Overall Process because DoF = 0

Recall the material balances for overall process
Overall: 100 = m3 + m5
1
S: (0.12)(100) = 0.42m5 2
W: (0.88)(100) = m3 + 0.58m5 3

From (2) : m5 = 28.6 kg Amount of product !

From (1) : m3 = 71.4 kg

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 EXAMPLE 6.2 (Cont.)

Step 4. Do the algebra. Solve the balance equations (Continuation).

Include the new values that we have obtained.

71.4 (kg W)

100 kg m1 m4 28.6 kg
0.12 kg S / kg 0.12 kg S / kg
Evaporator 0.58 kg S / kg 0.42 kg S / kg
0.88 kg W / kg 0.88 kg W / kg 0.42 kg W / kg 0.58 kg W / kg
m2
0.12 kg S / kg
0.88 kg W / kg

DoF (updated) Balances

Overall : m4 + m2 = m5
2 unknowns (m2, m4)
S : 0.12m2 + 0.58m4 = 0.42m5
- 2 IE’s
0 DoF W: 0.88m2+ 0.42m4 = 0.58m5

Known m5 = 28.60 kg
Solve for m4 = 18.70 kg ; m2 = 9.95 kg
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 EXAMPLE 6.2 (Cont.)

Step 4. Do the algebra. Calculate the amount of product (42% concentrate)

produced per 100 kg fresh juice fed to the process and the fraction of the feed
that bypasses the evaporator (Continuation).

71.4 (kg W)

100 kg m1 18.70 kg 28.6 kg

0.12 kg S / kg 0.12 kg S / kg
Evaporator 0.58 kg S / kg 0.42 kg S / kg
0.88 kg W / kg 0.88 kg W / kg 0.42 kg W / kg 0.58 kg W / kg

9.95 kg
0.12 kg S / kg
0.88 kg W / kg

m2 9.95
The bypass fraction = =
100 100
= 0.0995

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 Class Activity 6.1- Bypass & Recycle
An evaporation-crystallization process is used to obtain solid potassium sulphate (K2SO4) from
an aqueous solution. The fresh feed, F, to the process contains 19.6 wt% K2SO4. The wet filter
cake consists of solid 95 wt% K2SO4 crystals, P, and a 40.0 wt% K2SO4 solution, W, in a ratio 10
kg crystals/kg K2SO4 solution. The filtrate, R, also a 40.0 wt% K2SO4 solution, is recycled to join
the fresh feed with the ratio of R/W=5. It is noted that the water fed to the evaporator, 45.0% is
evaporated. The evaporator has a maximum capacity of 175 kg water evaporated/s. Assume the
process is operating at maximum capacity. By using the given flowchart in FIGURE Q3, perform
the degree of freedom analysis for the overall system, the recycle-fresh feed mixing point, the
evaporator and the crystallizer. Calculate the maximum production rate of solid K2SO4, P, the rate
at which fresh feed, F, must be supplied to achieve this production rate, and the ratio kg recycle,
R, over feed to crystallizer, C.

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 CONCLUSION

You have learnt:

• Mass balance for bypass & recycle

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