Mass & Energy Balance

MET 248E

Bora Derin,
Faruk Kaya

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The first mid-exam will
be held on April 19th

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 MATERIALS BALANCE

The law of conservation of matter

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 Material Balances and Energy Balances may be carried out on:

isolated systems in which there is no material or

energy transfer across the system boundary.
closed systems in which there is energy transfer but
no material transfer across the system boundary, or
open systems in which both material and energy are
transferred across the system boundary,
- steady-state
- unsteady-state

These types of calculations are very often the starting point for

• Solving operational problems

• Optimising existing or proposed processes
• Establishing design criteria for new equipment
• Designing new processes and equipment, and
• Process analysis at the theoretical level.
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Vacuum arc remelting (VAR)
 The methodology consists of a series of steps to be carried out in the order
indicated; namely

• Formulating the problem

• Identifying the basis of the calculation
• Identifying all assumptions
• Undertaking preliminary calculations
• Deciding an a solution strategy
• Solving the material/energy balance
• Cross-checking the answers

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EXAMPLE: A total mass balance on a continuous casting process.

1000 tonnes of steel per day are supplied to a continuous casting shop which
has both slab and billet casting operations running in parallel. If the slab caster
produces 800 tonnes of steel per day, what is the daily production of billet?

Continuous casting, also called strand casting, is

the process whereby molten metal is solidified into
a "semifinished" billet, bloom, slab etc. for
subsequent rolling in the finishing mills.

mass input = mass output

1000 t/d = 800 t/d slab + ??? t/d billet

that is, production of billet : 200 t/d. 6
EXAMPLE: A solid/liquid separation process

A slurry containing 20 wt% mineral concentrate and 80 wt% water is fed into a
solid/liquid separation process. There are two outputs from the process one of
pure water, the other concentrate containing 10 wt% water. If a 100 t of
concentrate is fed into the process, calculate the weight of water recovered and
the weight of material in the other output stream.

Slurry: a semi-liquid mixture, typically of

fine particles of ores, concentrates, coal
etc. suspended in water.

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Drying (Kurutma)
Drying usually means the removal of mechanically held water or moisture from
concentrate, or other solid materials by evaporation, i.e. expensive operation, usually done
in a drying furnace (fixed or fluidized bed, or kiln) and usually accomplished by passing
hot combustion gases through or above the substance.

Drying may be accomplished either at atmospheric pressure by heating the substance

above the normal boiling point of water, or, under reduced pressure where the
atmospheric pressure is brought below the vapor pressure of water at the temperature in
question.

Rotary drum dryer

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EXAMPLE: A solid/liquid separation process

A slurry containing 20 wt% mineral concentrate and 80 wt% water is fed into a
solid/liquid separation process. There are two outputs from the process one of
pure water, the other concentrate containing 10 wt% water. If a 100 t of
concentrate is fed into the process, calculate the weight of water recovered and
the weight of material in the other output stream.

Fout + W = 100 t
0.1Fout + W = 80 t

W = 77.78 t Fout = 22.22 t 9

EXAMPLE: Materials balances in size separation processes.

Experimental data is obtained from the operation of a hydrocyclone. A single

slurry (solids + water) feed is divided into two process streams. From the data
provided, calculate the following,

i) the masses of solid and water in the overflow, and

ii) of the solids in the overflow what % are less than 0.125 mm.

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A hydrocyclone is a high-throughput gravity separation device used for
separating slurry particles based on particle weight. For example, particles of
similar size but different specific gravity, or particles of different size but identical
specific gravity.

An animated GIF showing how particles 11

move through a cyclonic separator.
i)

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ii)

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Solid in overflow
EXAMPLE: Reactions involving an excess of one or more reagents.

Consider the reaction when one tonne of carbon is completely combusted to

CO2 gas in a reactor with 15 tonnes of air. Assuming there is more than the
stoichiometric amount of oxygen required to carry out this reaction, how
many tonnes of each of the product gases will be produced?

C:12 g/mol, O:16 g/mol, N:14 g/mol

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What are approximate mole and mass ratios of N2 and O2 for air?

For gaseous reactants and products that are at

the same temperature and pressure, the mole ratio is equal to
the volume ratio.

Approximate Air for 100 mol: 21 O2 + 79 N2 (mole basis)

(21 x 32) + (79 x 28) = 672 + 2212 = 2884 g

N2 wt%= 100 x (2212 / 2884) = 76.7

O2 wt%= 100 x (672 / 2884) = 23.3

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The results of the calculations are:

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EXAMPLE Stoichiometric calculation for an SHS reaction

In a Self-propagating High Temperature Synthesis (SHS) reactor, raw

materials of Co3O4, Fe2O3, Cr2O3, NiO (all of 100% purity) are being
reduced by using Al (aluminothermic reaction) to produce AlCo0.5CrFeNi
high entropy alloy (HEA).

Draw the process flow diagram, indicating all streams properly.

Calculate the amount of alloy produced and the amount of slag formed
(gas species excluded) for 100 g of charge mixture.

Co3O4 = 240.8 g/mol, Fe2O3=159.6 g/mol Cr2O3=151.99 g/mol,

NiO = 74.69 g/mol, Al = 26.98 g/mol, Al2O3 =101.96 g/mol

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Case 2:

Self Propagating High Temperature Synthesis

= Combustion Synthesis
Self-propagating High-temperature
synthesis (SHS) is the synthesis of
compounds (or materials) in a wave
of chemical reaction (combustion)
that propagates over starting
reactive mixture owing to layer-by-
layer heat transfer.

In a SHS process, after ignition, the

combustion front is formed and
propagates throughout the reactant
mixture yielding the desired
product.
Movie clip: Institute of Structural Macrokinetics and Materials
Science - Russian Academy of Sciences (ISMAN)

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SHS is known to yield the following
classes of compounds:
• Advanced materials, biomaterials, magnetic
and thermoelectric materials, refractory
compounds, oxides, intermetallics, borides,
nitrides, phosphides, hydrides, etc.
• Reduced elements, alloys (B, Ti, Mo, FeCr,
FeMo etc.)
• inorganic composites (ceramics, cermets,
mineraloceramics, composite materials,
etc.)
• organic compounds (piperazine malonate,
quinhydrone, ferrozerone, etc.)
Synthesis from the elements
• Ti + C = TiC
• Ni + Al = NiAl
• 3Si + 2N2 = Si3N4
• Zr + H2 = ZrH2
Redox reactions
• B2O3 +3Mg + N2 = 2BN + 3MgO
• B2O3 + TiO2 +5Mg = TiB2 + 5MgO
• 3TiO2 + C + 4Al = TiC + 2Al2O3
• 2TiCl4 + 8Na + N2 = 2TiN + 8NaCl
• Cr2O3+Fe2O3+Al=FeCr+Al2O3
Oxidation of metals with complex oxides
• 3Cu + 2BaO2 + 1/2Y2O3 + 0.5(1.5 - x)O2 = YBa2Cu3O7-x
• Nb + Li2O2 + 1/2Ni2O5 = 2LiNbO3
• 8Fe + SrO + 2Fe2O3 + 6O2 = SrFe12O19
Synthesis from compounds
• PbO + WO3 = PbWO4
Reaction of the elements with decomposition products
• 2TiH2 + N2 = 2TiN + 2H2
• 4Al + NaN3 + NH4Cl = 4AlN + NaCl + 2H2
Thermal decomposition
• 2BH3N2H4 = 2BN + N2 + 7H2
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Typical operation parameters of SHS
• Burning velocity: 0.1–20 cm/s
• Combustion temp.: 2300–3800 K
• Heating rate: 103–106 K/s
• Duration for ignition: 0.2–1.2 s
• Ignition temp.: 800–1200 K

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 SHS PROCESS for Tungsten Boride (WxBy) Production

CaWO3 + x Mg + y B2O3
Calcination of
H3BO3 @ Mixing
800 °C - 2 h CaWO4

Grinding

Glassy B2O3
Mg SHS
SHS
Leaching

Grinding
B2O3
SHS- Leach
Filtering
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High Entropy Alloys

High entropy alloys (HEAs) are

multicomponent alloys having constituents in
equiatomic or near equiatomic ratios. They
exhibit simple solid solution structures owing to
their high configurational entropy. An atomic structure model for a HEA

HEAs have been shown to possess good

creep strength, excellent oxidation corrosion
and wear resistance, high hardness, superior
thermal and chemical stability and good
magnetic properties.

Therefore, HEAs are being explored for variety

of applications and have gathered attention of
scientific community worldwide.

Strength versus ductility properties for

some HEAs 22
 Solution:
The process flow diagram:
Fout-alloy (AlCo0.5CrFeNi)
Fin=100 g SHS
(Oxide Raw Materials+ Al) Reactor Fout-slag

if AlCo0.5CrFeNi alloy contains 1 mol of Al, then each of Cr, Fe, Ni will be 1
mole and Co will be 0.5 mol

Reduction reactions:

• Co3O4 + 2.66Al = 3Co + 1.33Al2O3 (0.5/3) x (Co3O4 + 2.66Al = 3Co + 1.33Al2O3)

• Cr2O3 + 2Al = 2Cr + Al2O3 (0.5) x (Cr2O3 + 2Al = 2Cr + Al2O3)

• Fe2O3 + 2Al = 2Fe + Al2O3 (0.5) x (Fe2O3 + 2Al = 2Fe + Al2O3)

• NiO + 0.66Al = Ni + 0.33Al2O3 (1) x (NiO + 0.66Al = Ni + 0.33Al2O3)

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 INPUTS (mol) OUTPUTS (mol)
Oxide Raw Metallic Product Slag
Materials Al Metal (Al2O3)
(0.5/3) x (Co3O4 + 2.66Al = 3Co + 1.33Al2O3) 0.166 0.444 0.5 (Co) 0.222
(0.5) x (Cr2O3 + 2Al = 2Cr + Al2O3) 0.5 1 1 (Cr) 0.5
(0.5) x (Fe2O3 + 2Al = 2Fe + Al2O3) 0.5 1 1 (Fe) 0.5
(1) x (NiO + 0.66Al = Ni + 0.33Al2O3) 1 0.66 1 (Ni) 0.33

Charge mixture Total Al needed: (0.444 + 1 extra mol for

+ 1+ 1+ 0.66) alloying
Co3O4 0.166 mol x 240.8 g/mol = 39.97 g
Cr2O3 0.5 x 151.99 g/mol = 75.995 g

Fe2O3 0.5 mol x 159.6 g/mol = 79.8 g Total slag

NiO 1 x 74.69 g/mol = 74.69 g = (0.222+0.5+0.5+0.33)x101.96 g/mol
Al (3.104 + 1) x 26.98 g/mol = 110.72 g = 158.24 g

Total mixture: 381.175 g

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Normalization to 100 g charge mixture:

Charge mixture

Co3O4 39.97 g x (100 g / 381.175 g) = 10.48 g

Cr2O3 75.995 g x (100 g / 381.175 g) = 19.93 g
Fe2O3 79.8 g x (100 g / 381.175 g) = 20.93 g Fin=100 g
NiO 74.96 g x (100 g / 381.175 g) = 19.66 g
Al 110.72 g x (100 g / 381.175 g) = 29.04 g

Al2O3 Slag = 158.24 g x (100 g / 381.175 g) = 41.51 g Fout-slag

AlCo0.5CrFeNi alloy = 100 g – 41.51 g (slag) = 58.49 g Fout-alloy (AlCo0.5CrFeNi)

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Please search for the Metallurgical
Terms discussed in the slides via
Internet.

See you next week : )