5/5/2019

MATERIAL BALANCE OF UNIT

OPERATIONS AND PROCESSES
INDUSTRIAL PROCESSES
The material balance of a unit
operation is an exact accounting of
the materials that enter, leave,
accumulate or are depleted during a
Prepared By: given time interval of operation. It is
Prof. Rene D. Estember an application of the law of
conservation of mass.
May 6, 2019

MATERIAL BALANCE OF UNIT

OPERATIONS AND PROCESSES UNIT OPERATIONS

Types of Materials Balance: a. Mixing and Dilution

Mixing – the process of combining two or more
1. Over-all Material Balance (OMB) – takes into substances into a single product.
account all the streams of materials involved F3

in the process. F1
B, H2O

A, B, H2O M
MIXER
A, B, H2O
2. Component Balance – considers only the flow
or movement of a single component in the F2
system. A, H2O

Dilution – a special form of mixing wherein one of b. Drying – the process of removing most, if not all of
the substances being combined is pure water. the moisture (H2O) content of material.
F2 (H2O)
Bone Dry Material (bdm) - a material that is absolutely
dry; that is, it doesn’t contain any moisture.
F1 concentrated solution M, dilute solution
- Solute, H2O - Solute, H2O
Wet Material – composed of a bone-dry material plus
moisture content.
DILUTION TANK

Weight of wet material – weight of bdm + weight of

H2O

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W (H2O)
Percent moisture (% H2O) – an expression of the H2O
content of material (wet material).
F (wet material)
a) % H2O (wet basis) = wt. of H2O in wet material x 100% H2O, bdm P (dried material)
wt. of wet material bdm, H2O (in small
amount)
DRYER
b) % H2O (dry basis) = wt. of H2O in wet material x 100%
wt. of bdm in wet material

c. Evaporation – the process of concentrating a dilute Saturated Solution – one whose concentration is the
solution by heating, thereby changing the solvent same as its solubility. Any solute added to it remains
(H2O) to steam or vapor and thus removed. undissolved.

Solution – made up of solute and solvent. In most Saturation Point – the condition of being saturated, the
practical cases, the solvent is H2O and hence the point at which there is equilibrium between the solid
solute is the valuable component. and dissolved solute.

Solubility – the amount of solute dissolved in a given The composition of a solution is usually expressed in
amount of H2O at the specified temperature. terms of the % solute. For example, a 25% sugar
solution, that in 100g of the solution, there are 25g of
sugar.

d. Distillation – the process whereby mixtures of

1) Single Effect Evaporator liquids are subjected to repeated partial
E (H2O) vaporizations and condensations in order to separate
them into more or less pure components.

F (dilute solution C (concentrated

solution) In order for distillation to be effective, the liquids to be
separated must be of large boiling point difference.
H2O Solute In this case, the low-boiling liquids or more volatile
Solute H2O components (MVC) are vaporized readily and thus
easily separated from the high-boiling liquids or less
2) Double Effect Evaporator volatile components (LVC), which are left as residue
in the process equipment.
3) Multiple Effect Evaporator

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a) Feed (F) - the mixture of liquids to be separated into more or

less pure components.
D
b) Distillate (D) – the overhead product made up basically the MVC
MVC.
LVC
c) Bottoms (B) – the residue left in the column containing
mostly of the LVC. F S
MVC MVC
d) Side Stream (S) – an optional product stream with LVC LVC
composition intermediate between the distillate and the B
bottoms. It is usually taken during the early stages of
distillation for sampling purposes. MVC
LVC

e. Extraction – the process by which the desired substances is Types of Extraction

recovered from a sample or raw material by the application of
pressure or by the use of a suitable extracting agent.
A) Expression - the recovery of valuable (desired)
a) Feed (F) - the sample or raw material containing the desired substance by applying pressure on the feed.
substance. It may be solid or a solution.
F (sugar cane) E (sugar sol’n)
b) Extract (E) – the output material (usually liquid) containing a
large quantity of the desired substance.
Sugar Sugar
c) Residue ( R) – the waste material left after extraction is H2O EXTRACTION H2O
carried out.
d) Solvent (S) – a liquid used to recover the desired substance. R (bagasse)
In this liquid, the valuable material is highly soluble. Pulp
Sugar in small
quantity
H2O

Types of Extraction
Types of Extraction
B) Liquid-Liquid Extraction - the recovery of the solute
B) Solid-Liquid Extraction - the recovery of valuable from its aqueous solution with the use of more
material from solid sample using a suitable liquid appropriate solvent.
solvent. Oil
S, Hexane
E (ether layer); base S, ether
F (peanuts) E Hexane
ether
SM
EXTRACTION H2O in small qty
Oil Sugar
Insoluble Material H2O
Soluble materials IM EXTRACTION
Hexane
R Oil
F (aq. Sol’n) R (water layer)
SM
- base H2O
- H2O base in small ether qty.

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f. Filtration – the separation of the solid and the liquid

components of a mixture by passing it through a filter 1) The feed is a mixture of H2O and an insoluble
medium. material (IM).

Feed (F) – the mixture to be separated. It is composed of

water and either one of an insoluble material or slightly
soluble salt.
Filtrate (L) – the liquid that passed through the filters. It F FC
may be pure water or saturated solution. H2O, IM FILTER
Filter Cake (FC) – the solid residue that settles above the PRESS
filter screen usually containing adhering liquid. IM + adhering
H2O

L, H2O

g. Crystallization – the precipitation of the solute in a

2) The feed is a mixture of H2O and a slightly soluble solution or sample by lowering the temperature
salt (cooling); decreasing the amount of solvent
(evaporation); or by formation of hydrated crystals
hydration).

F FC 1. Feed (F) – a dilute solution of a highly soluble

FILTER salt/solid or a saturated solution at high
H2O, PRESS Undissolved salt + temperature.
adhering sol’n 2. Crop (C) – the crystals or precipitate formed
Slightly soluble salt together with some adhering solution.
3. Mother Liquor (ML) – the liquid decanted or
separated from the crystals. It is saturated solution
L, saturated solution
at the temperature of crystallization.
- H2O, dissolved salt

Types of Crystallization and Material Balances:

4. Evaporate (E) – the water removed during cooling or 1. Crystallization by Cooling – crystal formed due to the decreased
evaporation. In some cases, no H2O evaporates solubility of the solute at lower temperature.
from cooling.
F, saturated solution ML (saturated sol’n)
Cooler
oC$$
Note: The adhered solution to the crystals and the At high temp. Crystal At crystallization
mother liquor are of the same composition since hey - solute - solute
are both solution at the temperature of crystallization. - H 2O - H 2O

OMB: F = ML + C C-solute cystals

Solute Balance: solute] F = solute] ML adh. Sol’n (sat’d sol’n at
+ solute] C + solute in adhering crystallizer)
solution ] C
H2O Balance: H2O ] F = H2O ] ML +
H2O in adh. Sol’n] C

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Types of Crystallization and Material Balances: Types of Crystallization and Material Balances:
2. Crystallization by Evaporation – some of the solute crystallizes 3. Crystallization by Hydration – the crystals precipitate out in the
out or precipitate because of the decreased amount of solvent form of hydrates. For example; Na2CO3 forms Na2CO3 . 10H2O
(H2O). E, H2O
E, H2O F, (dilute sol’n) ML (saturated sol’n)
F, (dilute sol’n) ML (saturated sol’n)
oC$$
Evaporator
oC$$
Evaporator At crystallization T
Crystal At crystallization T - Na2CO3 Crystal - Na2CO3 solute
- solute - solute - H 2O - H 2O
- H2O - H2O
C
OMB: F = E + ML + C - Na2CO3 . 10H2O
C-solute cystals OMB: F = E + ML + C crystals
Solute Balance: solute] F = solute] ML
+ solute crystal ] C + solute in adh. Sol’n Na2CO3 Balance: Na2CO3 ] F = Na2CO3 ] - adh. Sol’n (sat’d sol’n)
ML
adhering solution ] C + Na2CO3 in Na2CO3 . 10H2O ] C +
H2O Balance: H2O ] F = E + H2O ] ML Na2CO3 in adhering solution ] C
+ H2O in adh. Sol’n] C H2O Balance: H2O ] F = E + H2O ] ML +
H2O in Na2CO3 .10H2O in adh. Sol’n] C

SOME BASIC AND SECONDARY MANUFACTURING SOME BASIC AND SECONDARY MANUFACTURING
PROCESSES PROCESSES

1. Hot-working is the process when metals are formed at
temperatures that exceed their re-crystallization
temperature, which is about 50 percent of their absolute
melting temperature. The products of such hot-working
operations are called wrought metals.
3. Extrusion is the process of shaping a material by forcing it,
under pressure, to flow through a die. In hot extrusion, the
material is heated to a temperature that will cause it to
become plastic without becoming liquid as it is forced
through the die.

2. Cold-working is a secondary manufacturing process that 4. Extrusion molding combines hot-extrusion process with
metals undergo at temperatures below the re-crystallization molding. The dies are closed firmly so that the enormous
temperature. internal pressures will not separate them. The plastic
material is then forced in under extreme pressures.

SOME BASIC AND SECONDARY MANUFACTURING
PROCESSES
5. Transfer molding is the process of forming articles in a closed mold to
which the thermosetting material is conveyed under pressure from an
auxiliary chamber.
6. Compression molding is that basic forming process in which an
appropriate amount of material is introduced into a heated mold that is
subsequently closed under pressure.
7. Injection Molding is the process of forming articles by placing raw
materials (pellets, granules, etc.) into one end of a heated cylinder,
heating the material in the heating chamber, and pushing it out the other
end of the cylinder through a nozzle into a closed mold, where the
molding material hardens to the configuration of the mold cavity.
SOME BASIC AND SECONDARY MANUFACTURING
PROCESSES
8. Die-castings involve the process of reproducing accurate casting in
large quantities and with good die life. They are able to
incorporate features that minimize or eliminate subsequent
machining and finishing operations.
9. Forging may be defined as shaping a metal under impact or
pressure and improving its mechanical properties through
controlled plastic deformation.
10. Upsetting refers to the process of increasing the size of the part by
forcing material from the rest of the part.
11. Forming processes are secondary manufacturing process that
metals undergo and are carried-out below the re-crystallization
temperature. The forming of metals is concerned with bending
operations that may or may not be accompanied by stretching and
do not materially change the thickness of the metal.

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SOME BASIC AND SECONDARY MANUFACTURING SOME BASIC AND SECONDARY MANUFACTURING
PROCESSES PROCESSES

12. Compression processes entail the passing of hot-rolled metals

15. Swaging is the shaping of material by a series of blows from
such as bars, sheets, or strips of cleaned stock through a set
of rolls. It is passed through the rolls many times, using light a die made to the desired shape. It is usually used for making
reductions each time, until the correct size is obtained. round shapes such as rod and wire.

13. Coining is a cold-forging process in which the material
inserted into the die is at room temperature. The operation is
frequently used for striking up jewelry and medals of all types
for which clear-cut designs are required.
14. Embossing is the placing of configurations on the surface of a
part by means of dies that draw the material into position
with very little effect on the thickness.
16. Thread rolling involves producing screw thread by the
displacement of materials. To produce a screw thread by
rolling, a cylindrical blank of a predetermined diameter,
approximately the pitch diameter of the screw being
produced, is placed between two hardened-steel dies.

SOME BASIC AND SECONDARY MANUFACTURING

PROCESSES
17. Fatigue - This is a phenomenon that occurs during cycle loadings
wherein material failure would occur at a level below during static
loading.
SAMPLE PROBLEMS
18. Creep - This is the permanent elongation of a component under a
static load maintained for a long period of time.

19. Wood - This material is subject to insect attack, flammable and

lacks isotropy.

20. Annealing - This is the process in order to increase strength and

hardness of a metal, it is heated below re-crystallization
temperature, and then cooled.

Sample Problem # 1 continued:

Mixing
F2 (concentrated nitric)
Sample Problem # 1: 90% HNO3, 10% H2O
M = 1,000 lbs mixed acids
A mixed acid containing 65% H2SO4, 20 % HNO3, and 15% H2O is to be made by F1 (spent acid)
blending the following liquids: BLENDER
60 % H2SO4 65% H2SO4
10% HNO3 20% HNO3
a.) a spent acid containing 60% H2SO4, 10% HNO3, and 30% H2O; 30% H2O 15% H2O
b.) a concentrated nitric acid containing 90% HNO3, and 10% H2O;
c.) a concentrated sulfuric acid containing 95% H2SO4 and 5% H2O. F3 conc. Sulfuric acid

How many lbs each of the three liquids must be mixed to obtain 1,000 lbs of the 95% H2SO4
desired blend? 5% H2O
Required: a.) F1
b.) F2
c.) F3

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Dilution
Sample Problem # 1 continued:
Sample Problem # 2:

Twenty liters of a concentrate sulfuric acid of density 1.80 g/mL and containing 96
Solution: Basis ~ 1,000 lbs of mixed acids, M
2/3 of HSO, is mixed with water to produce 100 liters of dilute solution. Assuming
volumes, may be added, determine the: a.) density in g/mL and, b.) composition of
OMB: F1 + F2 + F3 = 1000 lbs eq. 1
the dilute solution.
HNO3 Balance: 0.10 F1 + 0.90 F2 + 0.20 (1000) eq. 2
F2 (H2O)
H2SO4 Balance: 0.60 F1 + 0.95 F3 = 650 eq. 3
96 2/3 H2SO4; 3 1/3 H2O ρF2 = ρ H2O = 1.0 g/mL = 1 kg/L
H2O Balance: 0.30 F1 + 0.10 F2 + 0.05 F3 =150 eq. 4
VF1 = 20 L
After solving equations 1, 2, 3, and 4 simultaneously, ρF1 = 1.8 g/mL
F1 (conc. soln) M (dilute solution)
DILUTION TANK
F1 = 363.636 lbs spent acid - solute - Solute = H2SO4
F2 = 181.818 lbs conc. nitric acid - H2O - H2O
F3 = 454.545 lbs conc. sulfuric acid VM = 100 L

Sample Problem # 2 continued:

Sample Problem # 2 continued:

Required: a.) Density of M
b.) Composition of M
H2SO4 Balance:

Solution: H2SO4|F1 = H2SO4|M = 36 kg conc. acid x 96 2/3 kg H2SO4/100 kg conc. acid

= 34.8 kg H2SO4
OMB: F1 + F2 = M
H2O Balance:
Solute Balance: H2SO4|F1 = H2SO4|M
H2O|F1 + H2O|F2 = H2O|M
H2O|M = 36 kg conc. acid x 3 1/3 kg H2O/100 kg conc. acid + 80 kg = 81.2 kg H2O
Basis ~ 100 L of M
VM = 100 L = VF1 + VF2 Composition of M:
VF2 = 100 L – 20 L = 80 L %H2SO4 = 34.8 kg H2SO4/(34.8 kg + 81.2 kg) x 100% = 30% H2SO4
M = F 1 + F 2 = ρ1 V F 1 + ρ2 V F 2 %H2O = 81.2 kg H2O /(34.8 kg + 81.2 kg) x 100% = 70% H2O
M = [1.8 g/mL x 20 L x 1000 mL/L x Kg/1000 g ] + 1.0 kg/L x 80L = 36 + 80 = 116 kg.
ρM = MM / VM = 116 kg / 100 L = 1.16 g/ml

Sample Problem #4. Solved Problem on Drying:

Sample Problem #3. Solve the following Problem: Raisins with 25% moisture content are fed in a dryer at a rate of 1000 kg per hour.
What should be the drying rate in kg water removed per hour if the product should
have 15% moisture? How many tons of product can be produced per day?
You were tasked to prepare mais con hielo for a party of 70. Each serving consists (Assume 8 hours operation per day.)
of 300 grams with 50% ice, 15% sugar, 20% corn, 15% milk. How many kg of ice, Given:
sugar, corn and milk must be made available? W = ? kg/hr
F, Raisins = 1000 kg/hr P, Dried Raisins
Dryer
F2 25% Moisture 15% Moisture

Required: a) W(kg/hr) b) P (tons/day)

Solution: Basis of 1 hr operation
F1
M
Miixer Bdm balance: Bdm|F = Bdm|P; 1000(1.00 - 0.25) = (1.00 - 0.15) P
P = 882.35 kg/hr.

Water balance: Water|F = Water|P + W

1000(0.25) = 882.35(0.15) + W; W = 117.65 kg/hr. or 941.2 kg/day (a)
F3
Tons P/day = 882.35 kg/hr. x ton/1000kg x 8 hrs/day = 7.06 tons/day Product (b)
F4

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Sample Problem #5. Solved Problem on Drying: Sample Problem #6. Solved Problem on Mixing:
A drying equipment is capable of removing 500kg/hr of moisture from grains. Dog food must contain 18% protein, 10 % fat and other substances. How many kg
What will be the feed and the product rates in tons/hr if the grains enter with 20% of meal A having 20% protein and 5% fat must be mixed with meal B having 5%
moisture and leaves with 9% moisture? protein and 15% fat and meal C with 80% fat to get 20 tons per day of the dog food?
Given: Given: F2, Meal B (5% protein, 15% fat)
W = 500 kg/hr F1, Meal A P, Dog Food = 20 tons/day
F, grains = ? kg/hr P, Dried grains = ? kg/hr Mixer
Dryer 20% protein, 5% fat 18% Protein, 10% fat
20% Moisture 9% Moisture F3, Meal C (80% fat)

Required: a) F(tons/hr) b) P (tons/hr) Required: kgs of F1 , F2, and F3

Solution: Basis of 1 hr operation Solution: Basis of 1 day operation

OMB: F = W + P ; F - P = 0.5 (1) OMB: F1+ F2 + F3 = 20 ------ (1)

Moisture balance: moist|F = W + moist|P; 0.20F = 0.5 + 0.09P Protein balance: 0.2F1+ 0.05F2 = 20 (0.18) ; 4F1+ F2 = 72 ------(2)
2.22F - P = 5.56 (2)
Subtract (1) from (2): 1.22F = 5.06 Fat balance: 0.05F1+ 0.15F2 +0.80F3 = 20(0.10); 0.0625F1 + 0.1875F2 + F3 = 2 -----(3)
F = 4.148 tons/hr (a) Subtracting eq. 3 from eq. 1: 0.9375F1 + 0.8125F2 = 18; 1.1538F1 + F2 = 22.1538 -----(4)
P = 3.648 tons/hr (b)
Subtracting eq. 4 from eq. 2: F1 = 17.5132 tons = 17,513.2 kgs/day
and substituting to other eq. F2 = 1.9472 tons = 1,947.2 kgs/day
F3 = 0.5403 ton = 540.3 kgs/day

Sample Problem #7. Solved Problem on Drying:

An army cook was choosing between rice A at P15.0/kg and rice B at P14.50/kg. Sampling Problem #8. Solved Problem on Filtration:
Alternatives A and B are essentially the same type of rice only that their moisture How much filtrate and filter cake would be collected if a well mixed brine solution
contents are different i.e., 8% and 14% respectively. a) Which one should he containing 350 kg sodium chloride and 1150 kg water is filtered using an ordinary
buys? b) How much money does he saved per metric ton if he made the correct filter? (Solubility is 36 g NaCl/100 g water)
choice?
Given:
Given: Wt NaCl = 350 kg
Price of Rice A = P15.00/kg Wt water = 1150 kg
% Moisture of Rice A = 8% Solubility NaCl = 36g/100g water
Price of Rice B = P14.50/Kg
% Moisture of Rice B = 14% Required: a) FC and b) L
Required: a) Better Alternative b) Money Saved
Minimum wt of water reqd for the NaCl = 350 kg NaCl x 100 kg water/36 kg NaCl
Solution: The correct choice is one in which he pays for more rice (bdm) for his = 972.22 kg
money, therefore the alternative with the lower peso per kg bdm is the better
choice. Since the weight of water present in the solution is greater than the minimum
amount of water required to dissolve the given amount of salt, it therefore
Price per kg of bdm A = P15.00/kg x 100 kg A/(100-8) kg bdmA = P16.30
follows that the mixture is below the saturation point. This being the case:
Price per kg of bdm B = P14.50/kg x 100 kg A/(100-14) kg bdmA = P16.86
a) FC = 0 and
a) Since Rice A has a lower price per bdm, it is therefore the better alternative.
b) L = 1150 + 350 = 1500 kg
b) Saving per metric ton = (P16.86-P16.30)/kg x 1000 kg/ton = P556.12

Sample Problem #9. Solved Problem on Filtration: Sample Problem # 10. Solved Problem on Evaporation:
8000 kg of salt mixture was fed in a filter press. The process yields a filter cake A solution containing 12% MgCl2 is to be evaporated to saturation. The solubility of
with 82.5% salt and 17.5% water while a total of 1400 kg was recovered as filtrate. MgCl2 is 45 g/100 g water. A) What should be the feed rate in tons per hour for a
Find a) the weight of the filter cake; b) solubility of the salt in g salt/100 g water; requirement of 5 tons concentrate per hour? B) How many days to process 10,000
and c) the weight of adhering solution in the filter cake. tons of feed on a continuous operation.
Given: E = ? Ton/hr
Given:
F, = 8000 kg FC = ?
Filter Press
72.6% salt, 27.4 % water 82.5% Salt, 17.5% water F = ? Ton/hr C = 5 tons/hr

L = 1400 kg 12% salt, 88% water Solubility = 45 g MgCl2 /100 g water

Required: a) FC b) Solubility (g/100g water) c) kg adhering solution in FC
Solution: Basis of 8000 kg F Required: a) F in tons/hr b) days to process 10,000 tons solution
OMB: F = FC + L ; FC = 8000 - 1400 = 6600 kg (a) Solution: Basis of 1 hour operation
MgCl2 Balance: MgCl2|F = MgCl2|C
Salt Balance: Salt|L = Salt|F - Salt|FC = 8000(0.726) - 6600(0.825) = 363 kg Salt
0.12 F = 5 tons conc x 45 tons MgCl2 /145 tons conc. = 1.5517
F = 12.93 tons/hr. (a)
Solubility = 363/(1400 - 363) = 0.35 kg salt/kg water or 35 g salt/100 g water
(b)
Time to process = 10,000 tons x 1hr/12.93 tons = 32.2 days (b)
Wt adh solution = 0.175(6600) kg water x 135 kg adh soln/100 kg water
= 1559.25 kg adhering solution (c)

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Sample problem # 11. A filtration process yields 640 kg filtrate of 20% salt solution and filter Sample Problem # 12. A salt solution containing 22% salt is to be concentrated to
cake containing 360 kg salt and 50 kg adhering solution. Calculate the weight and composition saturation. The solubility of the salt in water is 36% (w). If the feed rate is 1,000 kg/hr.,
of the feed. calculate the stream rates of the evaporate and concentrate.
F Filter FC
- Salt
E =?
Press Undissolved Salt = 360 kg
- Water Adhering Solution = 50 kg
F = 1000 kg/hr C=?
L = 640 kg Solubility of Salt = 36%
22% Salt
Required: 20% Salt
a)Weight of Feed, F
b)Composition of the Feed
Solution to this problem is to account for all the salt in the output streams which are: undissolved salt + salt in Required:
adhering solution + salt in the filtrate. a) Weight of Evaporate, E
b) Weight of Concentrate, C
Solution based on 640 kg Filtrate: % Water may be computed directly as:
Undissolved Salt = 360 kg Water| FC = 50*0.80 = 40 kg Solution: Since the concentrate is saturated, the % of salt in it is 36%
Water| L = 640*0.80 = 512 kg Basis of one hour operation:
Salt|Adh Solution = 50*0.20 = 10 kg
Salt|L = 640*0.20 = 128 kg Total Water = 552 kg Salt Balance: Salt|F = Salt| C
Total Salt = 498 kg % Water = Total Water*100%/F 0.22 (1000) = 0.36 C
By OMB: F = FC + L = (360 + 50) + 640 = 1050 kg = 552*100%/1050 C = 0.22 (1000)/0.36 = 611.1 kg Concentrate (a)
% Salt = Total Salt*100%/F = 498*100%/1050 = 47.4% Salt = 52.6% Water By OMB: E = F – C = 1000 – 611.1 = 388.9 kg Evaporate (b)
% Water = 100.0% - 47.4% = 52.6% Water

Sample Problem #14. How many kg of zinc sulfate can be potentially recovered (by filtration)
Sample Problem # 13. A certain brand of fine filter medium must be replaced if the from a well agitated mixture containing 720 kg zinc sulfate crystals and 480 kg zinc sulfate
accumulated filter cake of insoluble mineral reaches 10 kilograms. The filter is used to solution if the recovered filter cake contains 20% adhering solution? The solubility of zinc sulfate
treat water with a 0.05% mineral at the rate of 1000 kg. per hour. Assuming that this
is 70 g /100 g water?
rate is constant throughout the operation, how many hours is the life of the filter
medium? Note: Assume also that 100% of the mineral are filtered out. F Filter FC
720 kg zinc Sulfate Press 20% adh. solution
F = 1,000 kg/hr Filter FC Plus: 480 kg. zinc
0.05% Mineral Press - Mineral sulfate solution
Solubility = 70g zinc sulfate/100 g water
Required: L
L Kg of recoverable zinc sulfate

Solution:
Required: Life of the Filter Medium in hours
Since the mix is well agitated, the solution must be saturated.
The solution will be ten kg divided by the amount of mineral caught on the filter per hour. Based on 720 kg zinc sulfate:
Basis of 1 hour operation Solution Balance: Sln|F = Sln|FC + L
Mineral Balance: Mineral |FC = Mineral |F = 0.0005*1,000 = 0.5 kg 480 = 0.20FC + L; L = 480 - 0.20FC : Equation 1
Filter Medium Life = 10 kg * 1 hr/0.5 kg = 20 hours OMB: F = FC + L
The Filter Medium must be replaced every 20 hours 720 + 480 = 1200 = FC + L : Equation 2
Substituting 1 to 2: 1200 = FC + (480 - 0.20 FC)
FC = 900; L = 300
Recoverable zinc sulfate = 720 + zinc sulfate|Adh Sln = 720 + 0.20(300)(70/170)
Recoverable zinc sulfate = 720 + 24.7 = 744.7 kg. zinc sulfate

Sample Problem #15. A solution containing 9% salt is concentrated through an evaporator Sample Problem 16. A plant is capable of producing 1 ton per day of solid caustic soda when
system that was able to remove 60% of its water content. What will be the composition of the its evaporator system concentrates 4% caustic soda to 25%. When the plant is fed with 5%
resulting concentrate? E = 60% of water|F caustic soda and if it is concentrated to 50%, find the capacity of the plant in terms of solid
caustic soda, assuming that water evaporating capacity to be the same in both cases.
EA EB
F C
9% Salt FA CA FB CB
4% NaOH 25% NaoH 5% NaOH 50% NaoH
Required: Composition of C NaOH|CA = 1ton
Required: Solid NaOH = NaOH| CB = ?
Solution based on 100 kg F: Solution to this problem lies in establishing that NaOH| FA = NaOH| CA = 1 ton. Compute the amount of
evaporate in case A on this basis. Keeping evaporate in case B equal to that of case A, 50% of C B will be
E = 0.60(1.00 – 0.09)100 = 54.6 kg Evaporate the “solid” NaOH produced.
OMB: C = F – E = C = 100 – 54.6 = 45.4 kg Concentrated Solution
Solution based on 1 ton solid NaOH: Solution based on EA = EB = 21 tons:
Salt Balance: Salt|C = Salt|F
Salt|C = 0.09(100) = 9 kg. Salt NaOH Balance: 0.25 CA = 1 By OMB: FB = EB + CB = 21 + CB - eq 1
% Salt|C = (9/45.4)100% = 19.82% Salt CA = 1/0.25 = 4 NaOH Balance: 0.05 FB = 0.50 CB
% Water|C = (Water|F – E)*100%/C = (0.91*100 – 54.6)100%/45.4 0.04 FA = 0.25 CA CB = 0.05 F/0.50 = 0.1 FB - eq 2
= 80.18% Water FA = 0.25*4/0.04 = 25 Substituting 2 to 1 : FB = 21 + 0.1 FB
Composition of C = 19.82% Salt & 80.18% Water By OMB: EA = FA – CA = 25 – 4 FB = 23.33 & CB = 2.33
= 21 tons Evaporate NaOH| CA = 0.50*2.33 = 1.167 tons Solid NaOH

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Sample Problem #17. A plant is capable of producing 2.4 tons per day of solid caustic soda Sample Problem #18. Two tons of certain fruit is fed in a juice extractor. The residue weighs
when its evaporator system concentrates 6% caustic soda to 24%. When the plant is fed with 800 kg. and contains 70% pulp and small amount of juice in it. The extracted juice contains 15%
7% caustic soda and if it is concentrated to 49%, find the capacity of the plant in terms of solid sugar and 85% non-sugar liquid. Calculate the following: a) weight (kg) of the extract b) % juice
caustic soda, assuming that water evaporating capacity to be the same in both cases. in the Feed c) % sugar in Feed d) kg of unextracted sugar e) % sugar in the residue.
EA EB
Solution based on 2 tons of F :
F= 2 tons Fruits
OMB: F=E+R
- pulp
FA CA FB CB E = 2000 – 800 = 1200 kg E (a)
- juice
6% NaOH 24% NaoH 7% NaOH 49% NaoH Juice Balance:
NaOH|CA = 2.4 ton Juice|F = E + Juice|R
Juice R = 800 kg = 1200 + 0.30*800
Required: Solid NaOH = NaOH| CB = ?
= 1440 kg juice
Solution to this problem lies in establishing that NaOH| FA = NaOH| CA = 2.4 tons. Compute the amount of Extractor - 70% Pulp
- 30% Juice %Juice|F = (1440/2000)*100%
evaporate in case A on this basis. Keeping evaporate in case B equal to that of case A, 49% of C B will be
the “solid” NaOH produced. = 72% Juice (b)
E
- 15% Sugar Sugar|F = (2000*0.72)*0.15
Solution based on 2.4 tons solid NaOH: Solution based on EA = EB = 30 tons:
- 85% Non-sugar Liquid = 216 kg Sugar
NaOH Balance: 0.24 CA = 2.4 By OMB: FB = EB + CB = 30 + CB - eq 1 %Sugar|F = (216/2000)*100%
Required:
CA = 2.4/0.24 = 10 NaOH Balance: 0.07 FB = 0.49 CB = 10.8% Sugar (c)
a) E
0.06 FA = 0.24*10 FB = 0.49/0.07CB = 7CB - eq 2 b) % Juice|F Sugar|R = (0.30*800)*0.15
FA = 0.24*10/0.06 = 40 Substituting 2 to 1 : 7CB = 30 + 0.1CB c) % Sugar|F = 36 kg Unextracted Sugar (d)
By OMB: EA = FA – CA = 40 – 10 CB = 5 tons & FB = 35 tons d) Sugar|R
= 30 tons Evaporate NaOH| CA = 0.49*5 = 2.45 tons Solid NaOH e) %Sugar|R %Sugar|R = (36/800)*100% = 4.5% (e)

Sample Problem # 19.

Problems on mixing, filtration & evaporation W
F (rock salt)
1.5 MT/hr
1 MT/hour
Mixer
IM= 75%
A saturated salt solution containing 20% salt is recovered at the Salt= 25%
evaporator. The process starts at the mixer where fine rock salt P FC
Filter press
(IM=75%, salt=25%) at 1 metric ton per hour is agitated with Salt sol’n 15% adh sol’n
water at 1500 kg per hr. The resulting mix is fed into the filter IM 85% IM
press where a filter cake with 15% adhering salt solution is E (H2O)
L Evaporator
obtained. The filtrate goes into the evaporator in which the Required: Salt sol’n
concentration process takes place. For every hour of operation C
a) P
calculate the following: a) kg of mix b)% salt in the solution Conc. Sol’n
before filtration c) filter cake d) kg filtrate e) kg evaporate. (note: b) % salt in sol’n at P 20% salt
IM means insoluble material) c) FC
d) L
e) E

Solution: Basis of 1 hr operation

Material balance around the mixer e) Material balance around the evaporator:
a) OMB: P= 1000 + 1500 = 2500 kg Salt balance: salt|L = salt|C;
b) % salt in sol’n = salt|F x 100% 250 x 100% 0.1429 (1617.14) = 0.20C;
=
salt|F + W 250 + 1500 C = 1155.45 kg

= 14.29% salt OMB: L = E + C;

c) Material balance around the filter press E = 1617.14 – 1155.45 = 461.69 kg
750
IM balance: IM|P= IM|FC; 0.75 (1000)= (1 – 0.15)FC; FC = 0.85 = 882.35 kg

d) Salt balance: salt|P= salt|FC + salt|L ;

0.25(1000)= 0.15(882.35)(0.1429) + 0.1429L
250 – 18.91
L= = 1617.14 kg
0.1429

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