Compiled Lectures on Chemical Engineering Calculations I

Mary Rose F. Persincula

Chapter V
MATERIAL BALANCE ON NON-REACTIVE SYSTEMS

At the end of this chapter, the student will be able to:

1. Draw a process flowchart that will best describe the phenomena in specific problems.
2. Establish a balance equation for specific problems.
3. Solve material balances problems.

The following rules in writing a material balance are applicable to systems without
chemical reactions:

1. For a non-reactive system, the maximum number of independent equations that can be
derived by writing material balances equals the number of chemical species in the input
and output streams.

2. The unknown variables would be easier to determine if balances with the fewest
unknowns are solved first.

SINGLE EQUIPMENT PROCESSES

Feed 1, F1
Components A, C, E
Mass fractions xA1, x C1, x E1 Process Unit Product, P
Components A, B, C, E
Feed 2, F2 Mass fractions xA, x B,
x C, x E
Components A, B, C
Mass fractions xA2, x B2, x C2
Figure 5. Steady State Process on a Single Unit.

Consider Figure 5, since there are four components in the input and output streams,
four independent material balance equations may be written. These are:

A Balance:
xA1F1 + xA2 F2 = xA P (107)

B balance:
xB2 F2 = xB P (108)

C Balance:
xC1F1 + xC2 F2 = xC P (109)

47
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula

E Balance:
xE1 F1 = xE P (110)
Or

Overall Material Balance

F1 + F2 = P (111)

1. DRYING

Drying is a unit operation reduction of moisture content on a wet material by

humidification of the air which is used as a medium for drying.

SAMPLE PROBLEM No. 17

A wet paper pulp contains 68% wt H2O. After the pulp was dried, it was found that 55% of the
original H2O in the wet pulp was removed. Calculate the composition of the dried pulp and
weight for a feed of 1000kg/min of wet pulp.

Given:

drying
Wet paper pulp,W dried pulp
1000 kg/min % H2O
68 wt % H2O D

55% H2O removal Figure 6. Schematic Diagram, Drying

H
Required: %H2O or D
Solution:

OMB: W = H + D = 1000 (1)

H2O balance: 0.68(1000) = H + %H2O D (2)

0.68(1000) (0.55) = H (3)

pulp balance: (1-0.68)(1000) = (1-%H2O) D (4)

Using equation (2) & (3) to obtain D:

0.68(1000) = 0.68(0.55)(1000) + %H2O D

680 = 374 + %H2O D

48
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula
306 = %H2O D
%H2O = 306/D
320 = (1- 306/D)D
321 = D – 306
D = 626 kg/min

%H2O = 306/626 x 100 = 46.88%

2. MIXING

Mixing is a unit operation that involves agitation of the mixture combined in one
storage location.

SAMPLE PROBLEM No. 18

A mixed acid containing 40% H2SO 4, 43% HNO3, 17% H2O is made by blending the
following:
a. spend acid containing 33% H2SO4, 36% HNO3, 31% H2O
b. concentrated H2SO4 containing 95% H2SO4
c. concentrated HNO3 containing 78% HNO3
How much of the said mixtures will be added to come up with the mixed acid of the aid
composition

Given: 95% H2SO4 (H)

5% H2O

spent acid (S) mixed acid (A)

33% H2SO4 mixer 40% H2SO4
36% HNO3 43% HNO3
31% H2O 17% H2O

(N)
conc. HNO3
78% HNO3
22% H2O Figure 7. Schematic Diagram, Mixing

Basis: 100kg sample

H2SO4 balance : 0.33S + 0.95H = 0.40(100)

0.33S + 0.95H = 40 (1)

49
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula
HNO3 balance : 0.36 S + 0.78N = 0.43(100) (2)
0.36S + 0.78N = 43

H2O balance: 0.31S + 0.05 H + 0.22N = 0.17(100)

0.31S + 0.05H + 0.22N = 17 (3)

OMB: S + H + N = A = 100kg (4)

Combine equation (1) and (2), followed by combining with equation (3)
0.33S + 0.95H = 40
0.36S + 0.78N = 43
(0.69S + 0.95H + 0.78N = 83)0.31 = 0.2139S + 0.2945H + 0.2418N = 25.73
0.31S + 0.05H + 0.22N = 17)0.69 = -0.2139S + 0.0345H + 0.1518N = 11.73
0.26H + 0.09N = 14 (6)

Multiplying equation (4) with 0.05 then combining equation (4) with (3)
0.05S + 0.05H + 0.05N = 5
-0.31S - 0.05H - 0.22N = -17
(0.26S + 0.17N = 12) 0.36 (5)
(0.36S + 0.78N = 43) 0.26 (2)
-0.0936S + 0.0612N = 4.32
- 0.0936S + 0.2028N = 11.18
= 0.1416N = 6.86

N = 48.4463kg

0.36S + 0.78 (48.4463) = 43

S = 14.4775 kg

(0.33)(14.4775) + 0.95H = 40
H = 37.0762 kg

50
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula
SAMPLE PROBLEM No. 19

FERTILIZER PROBLEM

NPK, 2-12-10
2%N2, 12% P2O5, 10% K2O

97% murate of potash KCl (C)

filler (D) 1000kg NPK

Mixer 2-12-10

Ca3(PO4)2 NaNO3
(A) (B) Figure 8. Fertilizer Problem, Schematic Diagram

Basis: 1000 kgmole

OMB: 1000kgmole = A + B + C + D

N2 balance: 0.02(1000) = B ( 1 N2 ) 2Na+ + N2 + 3O2

(2 NaNO3) 3Ca+ + P2O5 + 3/2 O2

P2O5 balance : 0.12(1000kgmole) = A x 1P2O5 KCl K+ + Cl-

1Ca3(PO4)2 K2O 2K+ + O-

K2O balance : 0.1(1000 kgmole) = 0.97 (C) x 1K+ x 1K20

Murate of potash or KCl 2K+
A = 120 kgmole B = 40 kgmole C = 206.1856 kgmole

1000kg = 120 + 40 + 206.1856 + D

D = 633.8144 kgmole

Basis: 1000 kg

N2 balance: 0.02(1000) = B x (1N2) __ x (28 kg/kgmole)_____

2NaNO3 (84.9898 kg/kgmole)
B = 121.414 kg

P2O5 balance = 0.12(1000) = A x 1P2O5;MW=141.9476

1Ca3(PO4)2;MW=310.1816
A = 262.2378 kg

51
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula
K2O balance = 0.1(1000) = C x 1K+ x 1K2O = 1K2O;MW=94.1966
1KCl 2K+ 2KCl;MW=74.551
100 = C x 94.1966
74.551(2)

100 = C (0.6318) (0.97)

100 (158.2779) = C (0.6128)
C = 163.1854

1000kg = A + B + C + D
1000kg = 262.2378 + 121.4329 + 163.1854 + D
D = 453.1459

Drying

5% moisture (wet basis) = 5 parts H2O

5 parts H2O + 95 parts bone dry solid

5% moisture (dry basis) = 5 parts H2O

100 parts bone dry solid

wet basis = 5 parts H2O

100 parts BDs + 5 parts H2O

SAMPLE PROBLEM No. 20

H2O (W)
Figure 9. Drier Schematic
Diagram

Wet mat’l dry mat’l (D)

Drier
1000kg/hr 9% H2O
30% H2O (wet basis) (dry basis)

9 parts H2O = 8.256%

100+9
OMB = 1000 = W + D
H2O balance : 0.3 (1000) = W + 0.0856D
Solid Balance : 0.7 (1000) = (1-0.0856)D
D = 762.9927 kg/hr

W = 1000 – 762.9927 kg/hr

W = 237.0073 kg/hr

EVAPORATOR

52
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula

1. Single Effect Evaporator

Vapor (V)

S, Steam

F, thin liquor thick liquor (L)

Figure 10. Single Effect

Condensate (C) Evaporator

OMB: F=V+L (112)

S=C (113)

2. Double Effect Evaporator

V1 V2

F L1 L2

C1
C2 Figure 11. Double Effect

53
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula
SAMPLE PROBLEM No. 21

A solution containing 15% dissolved solids is to be concentrated to 60% dissolved solids. If

the evaporator will evaporate 20,000 kg of water/hr, what must be the feed rate? How much
product is obtained per hour?

H2O vapor = 20000kg/hr

F, Feed thin liquor thick liquor

15% solids Evaporator product, L
60% solid
Figure 12. Evaporator Diagram

OMB : F = 20000 + L

Solid balance : 0.15(F) = 0.6L

H2O balance : 0.85(F) = 20000kg + 0.4L

F = 4L

4L = 20000 + L

3L = 20000

L = 6666.6667

F = 20000 + 6666.6667 kg/hr

F = 26666.6667 kg/hr

DISTILLATION Condenser

distillate

Feed

reboiler

bottoms B

Figure 13. Distillation

Schematic Diagram

54
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula

%recovery = amt. of MVC in D

amt. of MVC in F (114)

%loss = amt. of MVC in B

amt. of MVC in F (115)

SAMPLE PROBLEM No. 22

A mixture containing 70% methanol and 30% H 2O is to be distilled. If the distillate product is
to contain 99.9% methanol and the bottom product 0.004% methanol, how much distillate and
bottoms product are obtained / 100 kg of feed distilled.

99.9% methanol
0.1% H2O

F 100 kg feed

70% methanol
30% H2O

Figure 14. Distillation Diagram

0.004 % CH3OH
99.996 H2O

OMB : F = D + B = 100 kg

CH3OH balance : 0.7(100) = 0.999D + 0.00004B

H2O balance = 0.3(100) = 0.001D + 0.99996 H2O(B)

0.7(100) = 0.999D + 0.00004B = (0.001)
0.3(100) = 0.001 D + 0.99996B = (0.999)

(100 = D + B) 0.999
99.9 = 0.999D + 0.999B
70 = 0.999D + 0.00004B
29.9 = 0.99896B
B = 29.9311 kg

100 = D + 29.9311 kg
D = 70.0689 kg

55
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula

CRYSTALLIZATION
H2O

Mother liquor
magma
crystallizer
Figure 15. Crystallization
crystals

Solubility- amount of soluble present in a given amount of solvent of solution based on a

temperateure.

SAMPLE PROBLEM No. 23

1000kg of a 64% NaNO3 solution in water is at a temperature of 100 0C. This is sent to a
crystallizer where it is cooled to 300C. At this temperature the solubility of NaNO3 is 96 parts
per 100 parts of water (the solubility of NaNO3 is maximum amount of NaNO3 that can stay
in solution, the rest crystallizes out). Calculate the amount of crystals precipitates out if
a. No water evaporates during cooling
b. 5% of the original water evaporates during cooling

Solution:

Feed crystallizer solution

64% NaNO3 ( mother liquor)

Figure 16. Crystallization Diagram

NaNO3 crystals

a. OMB = 1000 = C + M

NaNO3 balance: 0.64 (1000) = crystal or NaNO3 M + C

H2O balance : 0.36 ( 1000) = H2O M

NaNO3 M = 0.36 (1000) x 96kg NaNO3 = 345.6 kg NaNO3 in M

100kg H2O
Substitute NaNO3 M in NaNO3 balance

0.64 ( 1000) = 345.6 + C

C = 294.4 kg

56
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula
b. OMB : F = E + C + M
E acts as an H2O evaporated
E = 0.36 (1000) (0.05) = 18 kg H2O

H2O balance : 0.36 (1000) = 18 + H2O M

NaNO3 balance : 0.64 (1000) = C + M x 96

100+96
640 = C + M 0.489795918
1000 = 18 + C + M
M = 1000 – 18 –C
M = 982 – C

Substitute M to NaNO3 balance

NaNO3 balance: 0.64 (1000) = C + (982-C) (0.489795918)

C = 311.68 kg

BALANCES ON MULTIPLE UNIT PROCESSES

Most of industrial chemical processes are comprised of not just one process unit. There might
be one or more chemical reactors present, as there are units for mixing reactants, blending
products, heating and cooling process streams, and separating products from each other and
from unused reactants. The chemical engineer’s job includes keeping track of materials that
flow from one unit to another unit within the process.

When several process units are involved in the process, the systems on which material
balances may be written are:

a. The whole process –material balances made on the whole process are known as
overall balances.

b. An interconnected portion of more than one process units

c. A single process unit

d. Mixing point - A point at which two or more streams are mixed

e. Split point- A point at which a single stream is split

The determination of all unknown stream flow rates (or amounts) and compositions for a
multiple unit process usually require choosing several such systems and successively writing
balances on each of them.

57
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula

Feed 2
a
b c d e

Feed 1 Unit 1 Unit 2 Product 1

Product 2 Product 3 Feed 3

Figure 17. Multiple Unit Process.

Consider the multiple unit process in Figure 17. The dashed lines denote boundaries of
systems about which balances can be written. The procedure for solving material balance
problems is essentially the same whether a single unit or multiple unit processes are involved.
However, in processes involving multiple units, you may have to isolate and write balances on
several subsystems (b,c,d, & e in Figure 17) to obtain enough equations to determine all the
unknown stream variables. Generally, it is recommended to set up overall balances first to
determine unknown process feed and product streams variables; after that, balances on
various process subsystems may be used to solve for interior stream variables.

When choosing subsystems on which to write balances, consider first the boundaries that
intersect streams containing the fewest unknown variables.
1. Establish overall unit balance.
2. Establish individual unit balance.
3. Establish material balance on mixing points and splitting points.
4. Make a solution.

SAMPLE PROBLEM No. 24: Multi-Unit system

3-47
/137
A double effect evaporator is to concentrate 1000 000 kg/day oaf a liquor containing
5% solids to 40% solids. Assuming equal evaporations are obtained from such effect,
calculate the composition of the solution from the first effect and the flowrate of the product
in kg/hr. how much evaporation is obtained?
V1 V2

E1 E2

S Figure 18. Double Effect

Evaporator
F L1 L2 40% solid
1 000 000 kg/day C1 C2
5% solid

58
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula

OMB:
S + 1 000 000 = C1 + C2 + V2 + L2 ; E1 : S = C1
1 000 000 = C2 + V2 + L2
E1 : 1 000 000 = V1 + L1
E2 : L1 = V2 + L2 ; V1 + C2

Solute Balance in L2:

0.05(1000 000kg/day) = 0.4L2

L2 = 125 000 kg/ day  1 day = 5 208.3333kg/hr

24 hr
V 1 = V 2 = C2
1000 000 = C2 + V2 + L2
1000 000 = 2V2 + 125 000
V1 = V2 = C2 = 437 500 kg/day

L 1 = V2 + L 2
L1 = 437 500 + 125 000
L1 = 562 500 kg/day

Solute Balance in L1:

0.05(1000 000) = x(562 500)
x = 0.0889
solute in L1 = 8.89%

Recycle

Recycle stream is primarily used in a chemical process in order to recover and reuse
unconsumed reactants. However, this is not the only reason for using a recycle stream in a
process. Some of the other uses of recycle streams are the following: (1) to recover catalyst,
(2) to dilute a process stream, (3) to control a process variable and (4) to circulate a working
fluid. Figure 19 shows a process with recycle stream.

59
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula

Feed Unit 1 Unit 2 Product

Recycle

Figure 19. Flow Chart of a Process with Recycle Stream.

1. Balance on the whole system.

2. Balance on the process with in the recycle loop.
3. Balance on the mixing point.
4. Balance on the splitting point.
5. Make a solution.
Recycle to fresh feed ratio=R/F
Total feed to fresh ratio= T/F

SAMPLE PROBLEM No. 25

3-50
/137Air conditioning system supplies 1000m3/min of air containing 0.01mol H2O/mole dry
air. It is at 20C and 1atm. To conserve energy, part of the exhaust air containing 0.08mol
H2O/mol dry air is recycled and mixed with the fresh air from the air conditioner to produce a
gross air feed to the room containing 0.035 mol H2O/mol dry air. How many kg of water is
picked up by the air per minute? What is the volumetric flow rate of the recycle stream?
(27C, 99kPa).
Recycle (R)

20C, 1atm 0.08mol H2O

mol dry air
gross air feed (T)
Air Conditioning
F P
x
1000m3/min 0.035mol H2O
0.01mol H2O mol dry air Figure 20. Air-conditioning system
mol dry air H2O (W) Schematic Diagram

Req’d: W(kg); R(m3)

Sol’n:
n = PV = (1atm)(1000m3/min) .
atmm3
RT (0.08205 /kgmolK)(20+273.15)
n = 41.5749 kgmol/min

60
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula
OMB:
41.5749 + W = P

Unit Balance: T + W = x
@ mixing point: 41.5749 + R = T
@ splitting point: x = P + R

0.01mol H2O  0.01mol H2O .= 0.0099 mol H2O/mol sol’n

mol dry air 0.01mol H2O + 1 mol dry air

0.035mol H2O  0.0338 mol H2O/mol sol’n

mol dry air

0.08mol H2O  0.0741 mol H2O/mol sol’n

mol dry air

Solute Balances:

OMB: 0.0099(41.5749) + W = 0.0741P

- 41.5749 +W =P a
P = 44.4576 kgmol/min
W = P – 41.5749
W = 44.4576 - 41.5749 = 2.8827 kgmol/min  18kg H2O /kgmol H2O
W = 51.8886 kg/min

Solution Balance @ mixing point:

0.0099 (41.5749) + R(0.0741) = T(0.0338)
- 0.0338 (41.5749) + R(0.0338) = T(0.0338)
R = 24.6561 kgmol/min

R = 24.6561 kgmol/min
V = nRT = (24.6561kgmol/min)(0.08205atmm3/kmoK)(273.15 + 27)K
P (99kPa)(1atm/101.325kPa)

R(V) = 621.4737 m3/min

Another solution:
R = (24.6561kgmol/min)  (22.4m3/kgmol)  (273.15+27)  (101.325kPa)
273.15 99kPa
R(V) = 621.9740 m3/min

61
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula

Bypass

Bypass is a procedure in which a fraction of the feed to a process unit is diverted around the
unit and combined with the output stream from the unit.

Consider a flow chart for a unit process shown below:

Feed Process Product

Unit

Bypass stream

Figure 21. Flow chart of a process with bypass stream

By varying the fraction of the feed, which is bypassed, the composition and properties of the
product can be varied.
1. Balance around the whole system.
2. Process with in the bypass loop.
3. Balance on splitting point & mixing point.
4. Make a solution.

SAMPLE PROBLEM No. 26

3-48
/137
It is desired to produce 7% NaNO3 solution continuously.

NaNO3 (N)
Saturation (x) 0.07% NaNO3, P
Water, W 500kg/hr Process 47.9%
NaNO3 Figure 22. Sodium nitrate schematic
Diagram Flow

The water line (NaNO3 free) is split into two: 500kg/hr is sent to a tank where NaNO 3
is added. The mixture is stirred well to form a saturated solution of NaNO 3 (47.9%). The other
line bypasses the tank and is mixed with the 47.9% solution. What is the flow rate of the
bypass stream and the final product?

OMB: W + N = P

Process: 500 + N = x

62
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula

Split point: W = B + 500

Mixing point: x + B = P

Solution Balance:

OMB: N = 0.07P

Process: N = 0.479x

Mixed point: 0.479x = 0.07P

500 + 0.479x = x
500 = (1 – 0.479)x
x = 959.6929kg/hr

N = 0.479x
N = 459.6929kg/hr
N = 0.07P
P = 6567.0414kg/hr

W+N=P
W = 6107.3485kg/hr
W = B + 500
B = 5607.3485kg/hr

Purge

Purge is a procedure used to prevent material build up in processes that involve recycling. If
a material that enters with the fresh feed or is produced in a reaction remains entirely in a
recycle stream, rather than being carried out in a process product, the substance would
continuously enter the process and would have no way of leaving. It would therefore steadily
accumulate, making the attainment of steady state impossible. To prevent this from
happening, a portion of the recycle stream must be withdrawn as a purge stream to rid the
process of the undesired material. Figure 24 shows a process with purge stream.

Fresh Feed Unit 1 Unit 2 Product

Recycle Purge Stream

Figure 23. Flow Chart of a Process with Recycle and Purge Streams.

63
Compiled Lectures on Chemical Engineering Calculations I
Mary Rose F. Persincula

SAMPLE PROBLEM No. 27

Product 98%C2H6
2% C6H6
Distillate

reflux
_______ 30% of reflux, purge stream, (P)
_______
_______
100 kg/day ____
40%C2H6
60% C6H6

bottoms, 5% C2H6
(B)
Figure 24. Distillation Setup
Solution:

OMB: 100 = D + B + P

Solute balance (C2H6): 0.4(100) = 0.98D + 0.98P + 0.05B

Relationship: R/D = 3/5; P = 0.3R

R = 3D/5
P = (0.3)(3/5)D

100 = D + B + (0.3)(3/5)D  (100= 1.18D + B) (1)

40 = 0.98D + 0.05B + (0.98)(0.3)(3/5)D  (40 = 1.1564D + 0.05B) (2)

Eliminate equation (1) & (2):

Multiply (1) by 0.05

5 = 0.059D + 0.05B
- 40 = 1.1564D + 0.05B)
-35 = - 1.0974D
D = 31.8936kg/day
B = 62.3656kg/day
P = 5.7408kg/day

64