Notes 3 Material Balance Calculations

SKF 1113 - Material Balances
Material Balance Calculations
Kamarul ‘Asri Ibrahim, PhD
Page 3-1
© copyright PCS-FKKKSA Material Balance
Introduction
Material Balance (Mass Balance)

Based on the law of conservation of the mass
(total mass input) = (total mass output)
Objectives of this chapter

Drawing process diagrams
Writing material balance equations
Understanding process variables
Solving equations with unknown variables
Page 3-2
Instructor: Dr Azeman Mustafa

Process Classification
Classification of processes
Batch : feed is charged, products are removed some time later
Continuous : inputs and outputs flow continuously
Semi batch process : semi continuous process
Condition of processes
Steady state : process variables do not change with time
Transient (unsteady) state : process variables change with time
Usage of processes
Batch processing is for relatively small quantity of products
Continuous processing is better suited to large production rates.
Page 3-3
Material Balance
qin(kg CH4/h) qout (kg CH4/h)

SYSTEM
Suppose methane is a component of both the input and output streams

of a continuous process unit but the mass flow rates of methane in both
streams are measured and found to be different.
There are four possible explanations for the observed difference?
Methane is leaking from the unit
Methane is either being consumed as a reactant or being generated as a
product within the unit
Methane is accumulating in the unit – possibly adsorbing on the walls
The measurements are wrong
Page 3-4

General Balance Equation

qin(kg CH4/h) qout (kg CH4/h)
SYSTEM
Input - Output + Generation - Consumption = Accumulation

Input : Enters through system boundaries
Output : Leaves through system boundaries
Generation : Produced within the system
Consumption : Consumed within system
Accumulation : Buildup within system
Page 3-5
Types of Balances
Differential Balances
Indicate what is happening in the system at an instant of time
Each term of the balance equation is then a rate (eg: flow rate)
Unit: balanced quantity unit divided by a time unit (kg SO2/hr).
Integral Balances
Describe what happens between two instants of time.
Each term of the equation is then amount of the balanced quantity
Unit: amount of quantity (kg SO2)
Normally applied to batch process
Steady state balance
No accumulation term
Page 3-6

Balance on Continuous Steady-State

Process
General material balance

Input - Output + Generation - Consumption = Accumulation
For steady state, accumulation = 0
dy
accumulation = =0
dt
Then
Input - Output = Generation - Consumption
PROCESS
Page 3-7
Example
Process diagram
450 kg B/hr
Problem q1 kg T/hr
1000 kg/hr of a mixture of

benzene (B) and toluene (T) that Process
contains 50% benzene by mass 500 kg B/hr
500 kg T/hr q2 kg B/hr
are separated by distillation into 475 kg T/hr
two fractions. The mass flow
rate of benzene in the product Material Balance
top stream is 450 kg B/hr and * Benzene balance
that of toluene in the bottom 500 = 450 + q2
* Toluene Balance
stream is 475 kg T/hr. The 500 = q1 + 475
operation is at steady state.
Write balances on benzene and
toluene to calculate unknown Solution
component flow rate in the Q1 = 25 kg T/hr
output streams. Q2 = 50 kg B/hr
Page 3-8

Working Session I
100.0 kg/hr of a liquid mixture of benzene (B) and toluene

(T) that contains 55% benzene by mass is partially
evaporated to yield m v (kg/h) of a vapor containing 85.0%
benzene and m l (kg/h) of a residual liquid containing
89.4% toluene by mass. The operation is continuous and at
steady state.
1. Draw a process flowchart

2. Write balances on total mass and on benzene
3. Determine the expected values of mv and ml.
Page 3-9
Solution to Working Session I

1. Process flowchart
mv kg /h
xB= 0.85
xT = 0.15
100 kg /h Distillation
xB= 0.55 column
xT = 0.45 ml kg /h
xB= 0.106
xT = 0.894
2. Material Balance 3. Solution

Input + generation – output – consumption = accumulation
mv = 59.7 kg T/h
Steady state , accumulation = 0 ml = 40.3kg B/h
No reaction involved , generation = consumption = 0
Hence, Input = Output Verify solution with Toluene bal.

0.45(100) = 0.15mv + 0.894ml
Total balance : 100 = mv + ml
Benzene balance : 0.55(100) = 0.85mv + 0.106ml 45 = 0.15(59.7) + 0.894(40.3) ~ 45 OK!
Page 3-10

Integral Balances on Batch Process
Inputinitial + Generation = Outputfinal + Consumption
Accumulation = Outputfinal - Inputinitial
Accumulation = Generation - Consumption
Page 3-11
Integral Balances on Batch or Semi-batch

Processes
Integral balance on batch processes

Sometimes it can be treated like steady-state processes
Integral balance on Semi-batch and continuous process

Sometimes it can be easily solved.
Require integration over period of time
Page 3-12

Balances on a Batch Mixing Process

200 g
0.4 g CH3OH/g
0.6 g H2O/g Q
PROCESS x (g CH3OH/g)
150 g
0.7 g CH3OH/g
0.3 g H2O/g
Total Mass Balance

Problem 200 g + 150 g = Q
Two methanol-water mixtures
Q = 350 g
contained in separate flasks. The
first mixture contains 40 wt%
methanol, and the second contains Methanol Balance
70 wt% methanol. If 200 g of the (200 g)(0.4 gM/g) + (150 g)(0.7 g M/g) = (350g) (x gM/g)
mixture are combined with 150 g x = 0.529 g CH3OH/g
of the second, what are the mass
and composition of the product? Water Balance (For checking)
(200)(0.6) + (150)(0.3) = (350)(1-0.529) ok!
Page 3-13
Working Session II
100.0 kg of a liquid mixture of benzene (B) and toluene (T)

that contains 45% toluene by mass in a closed container is
partially evaporated to yield mv (kg) of a vapor containing
15.0% toluene and ml (kg) of a residual liquid containing
10.6% benzene by mass. The operation is in equilibrium.
1. Draw a process flowchart

2. Write integral balances on total mass and on
benzene
3. Determine the expected values of mv and ml.
Page 3-14

Solution to Working Session II

1. Process flowchart
mv kg
xB= 0.85
xT = 0.15
100 kg Closed
xB= 0.55 Container
xT = 0.45 ml kg
xB= 0.106
xT = 0.894
2. Material Balance
Inputinitial + generation = outputfinal + consumption
No reaction involved , generation = consumption = 0 3. Solution

mv = 59.7 kg T
Hence, Inputinitial = Outputfinal
ml = 40.3 kg B
Total balance : 100 = mv + ml
Benzene balance : 0.55(100) = 0.85mv + 0.106ml
Page 3-15
Material Balance Calculations
Objective :
Given values of input, output calculate unknown values
Flow Charts : simple way to visualize process flow

PFD (Process flow diagram)
P&ID (Process and Instrumentation diagram)
Page 3-16

Benefits of using flowcharts

Process Description Flowchart
The catalytic dehydrogenation of propane is
carried out in a continuous packed bed reactor.
One thousand pounds per hour of pure propane Reactor
are fed to preheater where they are heated to a Preheater (dehygdro Cooler
temperature of 670oC before they pass into the 100 lbm/h -genation)
670oC 800oC
reactor. The reactor effluent gas, which includes propane
Propane
propane, propylene, methane and hydrogen, is Propylene
cooled from 800oC to 110oC and fed to an Recycle Methane
absorption tower where the propane and Stream Hydrogen 110oC
(97% Propane)
propylene are dissolved in oil. The oil then goes
to a stripping tower in which it is heated,
releasing the dissolved gases; these gases are High P Stripping Absorption
recompressed and sent to a high pressure Distillation Tower Tower
distillation column in which the propane and Methane
propylene are separated. The product stream Hydrogen
from the distillation column contains 98%
propylene, and the recycle stream is 97%
propane. The stripped oil is recycled to the
98% Propylene Oil Oil
absorption tower.
Complex, not easy to understand Compact, easy to understand
Page 3-17
Example: Development of Flowcharts

Gas containing N2 and O2 is combined with propane in a batch
combustion chamber in which some (but not all) of the O2 and C3H8
react to form CO2 and H2O. and the product is then cooled, condensing
water. The flowchart is given below:
50 mol C3H8
750 mol O2
3760 mol N2
100 mol C3H8 50 mol C3H8
150 mol CO2
200 mol H2O
750 mol O2
Combustion
Chamber Condenser
3760 mol N2
1000 mol O2 150 mol CO2
3760 mol N2
200 mol H2O
Page 3-18

Rules for Labeling Flowchart (1)

Write the values and units of all known stream variables at the
locations of the streams on the chart.
Example: A stream containing 21 mol % O2 and 79 mol % N2

at 3200C and 1.4 atm flowing at the rate of 400 mol/h might
be labeled :
400 mol/h
0.21 mol O2/mol

0.79 mol N2/mol
T = 3200C and P = 1.4 atm
Page 3-19

The information can be given in two ways: as the total amount or
flow rate of the stream and the fractions of each component:
1. Amount or Flow rate of each component
60 kmol N2/min
40 kmol O2/min
2. Flow rate of the stream and the fractions of each components
100 kmol/min
0.6 kmol N2/kmol
0.4 kmol O2/kmol
Page 3-20


Assign algebraic symbols to unknown stream variables (such as
Q kg solution/min, x kg N2/kg, n kmol C3H8, etc.) and write these
variable names and their associated units on the chart .
Unknown : flow rate Unknown : fraction
N (mol/h) 400 mol/h
0.21 mol O2/mol y (mol O2/mol)
0.79 mol N2/mol 1-y (mol N2/mol)
T = 320 oC, P = 1.4 atm T = 320 oC, P = 1.4 atm
Try to limit the unknown to the minimum
Page 3-21
Example: Development of Flowchart

Air Humidification and Oxygenation Process
An experiment on the growth rate of certain organisms requires the

establishment of an environment of humid air enriched in oxygen. Three
inputs streams are fed into an evaporation chamber to produce an output
stream with the desired composition
A: Liquid water, fed at a rate of 20.0 cm3/min.

B: Air (21 mol% O2, the balance N2).
C: Pure O2, with a molar flow rate 1/5 of the molar flow rate of stream B.
The output gas is analyzed and is found to contain 1.5 mole% water. Draw
and label flowchart of the process, and calculate all unknown stream
variables.
Page 3-22

Air Humidification and Oxygenation

Process
Let Q = molar flow rate of air of stream B
Let W = molar flow rate of liquid water of stream A
Given : molar flow rate of water in stream A = one fifth of air molar flow rate
of stream B
0.2Q mol O2/min

F mol/min
Q mol air/min
0.015 mol H2O/mol
0.21 mol O2/mol y mol O2/mol
0.79 mol N2/mol 0.985 - y mol O2/mol
Please work on ‘TEST

20.0 cm3 H2O L/min YOURSELF’ questions
W mol H2O/min in page 93)
Page 3-23
Flowchart Scaling and Basis of Calculation

1 kg C6H6
2 kg
1 kg C7H8 0.5 kg C6H6/kg
0.5 kg C7H8/kg
The process is balanced, since material balances on both system components

C6H6 and C7H8 are satisfied [1 kg in = (2 x 0.5) kg out in both cases]
Masses (but not the mass fractions) of all streams could be multiplied by a
common factor and the process remain balanced
This procedure of multiplication is referred as scaling the flowchart

scaling up – final stream quantities are larger than original quantities
scaling down - if they are smaller
Page 3-24

Flowchart Scaling and Basis of Calculation

1 kg C6H6
2 kg
1 kg C7H8 Process 0.5 kg C6H6/kg I am telling you
0.5 kg C7H8/kg this time only
!!!!
multiply by 300 mass or mol
300 kg C6H6 fractions will
600 kg not change with
300 kg C7H8 Process 0.5 kg C6H6/kg scaling
0.5 kg C7H8/kg
kg kg/h
replace kg with lbm
300 lbm/h C6H6
600 lbm/h
300 lbm/h C7H8 Process 0.5 lbm C6H6/lbm
0.5 lbm C7H8/lbm
Page 3-25
Scale-up of a Separation Process Flowchart
A 60-40 mixture (by moles) of A and B is separated into two fractions. A

flowchart of the process is shown. It is desired to achieve the same
separation with a continuous feed of 1250 lb-moles/h. Scale the flowchart
accordingly.
50 mol
0.95 mol A/mol
0.05 mol B/mol
100 mol
Process
0.60 mol A/mol
0.40 mol B/mol 12.5 mol A
37.5 mol B
Page 3-26

Scale-up of a Separation Process Flowchart

The scale factor is
Required flow rate 1250 lb − moles/h lb − moles/h
= = 12.5
Original flow rate 100 mol mol
Top Product Stream: (50.0)(12.5) = 625 lb-moles/h

Bottom product stream: (12.5)(12.5) = 156 lb-moles/h
(37.5)(12.5) = 469 lb-moles/h
625 lb-moles/h
0.95 lb-mole A/lb-mole
0.05 lb-mole B/lb-mole
1250 lb-moles/h
Process
0.60 lb-mole A/lb-mole
0.40 lb-mole B/lb-mole
156 lb-mole A/h
469 lb-mole B/h
Page 3-27
BASIS
The first step is to choose an amount (mass or moles) or a mass or
molar flowrate of a stream as a basis of calculations
The input flowrate: 100 mol/h CO2
The production of 5 kg/h of product.
If a stream amount or flow is given in a problem statement, it is usually

most convenient to use this quantity as a basis of calculations
all unknown variables are then determined to be consistent with this basis
For rule of thumbs for process with no reaction :
mass is normally use with liquid
number of mol is use for gas
If no stream amounts or flow rates are known, assume one preferably

with that of a stream with a known composition
Page 3-28

Material Balances Basis
Flowchart scaling up/down

Changing values of all amounts or flow rates by proportional amount.
Compositions remain unchanged.
Basis of calculation
If flow rates are given, use specified values and units.
If flow rates are not given, assume one of input flow rates.
Page 3-29
Balancing a Process
3 kg C6H6/min
Q kg/min
PROCESS x kg C6H6 /kg
1 kg C7H8/min 1 – x kg C7H8/kg
Problem Total Mass Balance

3 kg/min + 1 kg/min = Q
Suppose that 3 kg/min of Benzene Q = 4 kg/min
and 1 kg/min of Toluene are
mixed. The process flowchart Benzene Balance
might be drawn and labeled as 3 kg C6H6/min = 4 kg/min ( x C6H6/kg)
shown: x = 0.75 kg C6H6 /kg
Page 3-30

Problem Bookkeeping
A procedure to discover that all the required information is
available to solve specified problem.
Procedure
Drawing flowchart
Identifying variables
Identifying equations
Degree of freedom analysis
#df = Number of Unknowns – Number of independent equations
A problem is solvable if the value of #df = 0
Page 3-31
Degrees of Freedom
#df = (number of species) - (number of independent equations)
Case 1 (exactly determined – exactly specified) x+y =3

If #df = 0, Solution is unique
#df = 0
2x + y = 4
Process is exactly specified
Case 2 (underdetermined – underspecified) x+ y+z =3

#df = 1
If #df > 0, There are a lot of solutions. 2x + y = 4
Process is underspecified by #df equation
x+y =3
Case 3 (over determined – over specified)
If #df < 0, No solution for this system. 2x + y = 4 #df = -1
Process is over specified by #df equation x + 2y = 3
Page 3-32

Sources of equations relating unknown

process stream variables (pg. 99)
Material balances
No. of species (N) = No. of independent equations for nonreactive process
An energy balance
One unknown ( T, Q, or m)
Process specification
Requirement (based on economics,…)
Physical properties and laws

Thermodynamic relations and physical properties data e.g.. PV = nRT
Physical constraints
x1 =1 then x2 = 1 - x1, …
Page 3-33
Degrees of Freedom - example

The following flowchart shows a distillation column
with two feed streams and three product streams
a) How many independent material balances may be

written for this system?
3 ind. bal. (species bal. A, B &C)
b) How many unknowns may be written for this system?

7 unknowns : m1, m3, m5, x2, y2, y4, z4
c) How many of the unknown flow rates and/or mole

fractions must be specified before the others may be
calculated? (Remember what you know about the
component mole fractions of a mixture—for example,
the relationship between x2 and y2 )
x2 (= 1- y2 ), y4 (= 1- z4), m1, m3, m5
7 unknowns – 3 ind. Bal. – 2 fraction relationship

2 unknowns must be specified
Page 3-34

Outline of a Procedure for Material

Balance Calculations
Draw a flow chart, and fill in all given values.
Choose as a basis of calculation an amount or flow rate of one of the process
streams.
Label unknown stream variables on the chart.
Do the problem bookkeeping.
Convert volume flow rates to mass or molar flow rates.
Convert mixed mass and molar flow rates to mass or molar flow rates.
Translate given information to equations.
Write material balance equations.
Solve equations.
Scale up/down.
Page 3-35
Material Balances on a Distillation Column
A mixture containing 45% benzene (B) and (55%) toluene (T) by mass
is fed to a distillation column. An overhead stream 95 wt% B is
produced, and 8% of the benzene fed to the column leaves in the
bottom stream. The feed rate is 2000 kg/h. Determine the overhead
flow rate and the mass flow rates of benzene and toluene in the bottom
stream.
Solution
(1) Basis: Given Feed rate

(2) Draw flowchart and label it
(3) Label unknown stream variables on the chart. Write the
relationship between known and unknown variable
(e.g. Contains “8 % of the B in the feed”).
Page 3-36

Balances on a Distillation Column

D kg/h
0.95 kg B/kg
0.05 kg T/kg
2000 kg/h
0.45 kg B/kg
0.55 kg T/kg contains 8% of the B
in the feed
wB kg B/kg
wT kg T/kg
(4) Do the problem book keeping.
- How many unknowns?
- How many independent equations?
- If the numbers are equal, the problem can in principal be solved
Page 3-37
Problem Bookkeeping
In General,
Mass Balances – for non reactive process, up to N material balances may be
written (N = number of independent species involved in the process)
Energy balance.
Process specifications.
Physical Properties and law. Example: Two of the unknown variables may
be the mass and volume of a stream material, in which tabulated specific
gravity (for liquid and solid) or a gas law may provide relationship between
variables.
Physical constraints. Sum of mole fraction = 1.0
For Distillation problem,
Unknowns - D, wB and wT. Needs 3 independent equations.
Mass balance equations - 2
Other relation – relative quantity of benzene in the bottom flow rate
Page 3-38

Working session III
Strawberries contain about 15 wt% solids (assuming sugar) and 85 wt%

water. To make strawberry jam, crushed strawberries and sugar are mixed
in a 45:55 mass ratio, and the mixture is heated to evaporate water until
the residue contains one-third water by mass.
(a) Draw and label a flowchart of this process.

(b) Do the degree-of-freedom analysis and show that the system has
zero degrees of freedom.
(c) Calculate how many pounds of strawberries are needed to
make a pound of jam.
(d) Repeat (a), (b) and (c), assuming the 15 wt% solids in the feed contain
mainly orange fibers (not sugar as initially assumed)
Page 3-39
Solution to Working session III

(a) Draw and label a flowchart of this process.
mf Ibm strawberry (SB) 1 Ibm jam

0.85 Ibm H2O/Ibm SB 0.333 Ibm H2O/Ibm jam
0.15 Ibm Sugar (S)/Ibm SB 0.667 Ibm S/ Ibm jam
Evaporator
mH2O Ibm H2O
ms Ibm S
(b) Do the degree-of-freedom analysis
- 3 unknowns ( mf, ms, mH2O)

- 2 material balances (water & sugar)
- 1 specified feed-sugar ratio (mf/ms = 45/55)
0 degree of freedom
Page 3-40

Solution to Working session III

(c) Calculate how many pounds of strawberries (mf) are needed to make a pound of
jam.
Basis : 1 Ibm jam

Sugar balance : 0.15mf + ms = 0.667(1) …..(eq. 1)
Water balance : 0.85mf = mH2O + 0.333(1) …….(eq.2)
Given feed-sugar ratio : mf/ms = 45/55 ……(eq. 3)
Substitute eq. (3) in eq. (1) ……. mf = 0.486 Ibm
Check !!
and ms = 0.594 Ibm mf/ms = 0.486/0.594
Hence from eq. (2) ….. mH2O = 0.0801 Ibm ~ 45/55
OK!
(d) Repeat (a), (b) and (c), assuming the 15 wt% solids in the feed contain mainly
orange fibers (not sugar as initially assumed) … YOU BETTER SOLVE THIS
PART !
Page 3-41

Notes 3 Material Balance Calculations

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SKF 1113 - Material Balances

Material Balance Calculations

Kamarul ‘Asri Ibrahim, PhD

Material Balance (Mass Balance)

Objectives of this chapter

Instructor: Dr Azeman Mustafa

qin(kg CH4/h) qout (kg CH4/h)

Suppose methane is a component of both the input and output streams

Instructor: Dr Azeman Mustafa

General Balance Equation

Input - Output + Generation - Consumption = Accumulation

Instructor: Dr Azeman Mustafa

Balance on Continuous Steady-State

General material balance

1000 kg/hr of a mixture of

Instructor: Dr Azeman Mustafa

100.0 kg/hr of a liquid mixture of benzene (B) and toluene

1. Draw a process flowchart

Solution to Working Session I

2. Material Balance 3. Solution

Hence, Input = Output Verify solution with Toluene bal.

Instructor: Dr Azeman Mustafa

Integral Balances on Batch Process

Inputinitial + Generation = Outputfinal + Consumption

Accumulation = Outputfinal - Inputinitial

Accumulation = Generation - Consumption

Integral Balances on Batch or Semi-batch

Integral balance on batch processes

Integral balance on Semi-batch and continuous process

Instructor: Dr Azeman Mustafa

Balances on a Batch Mixing Process

Total Mass Balance

100.0 kg of a liquid mixture of benzene (B) and toluene (T)

1. Draw a process flowchart

Instructor: Dr Azeman Mustafa

Solution to Working Session II

No reaction involved , generation = consumption = 0 3. Solution

Material Balance Calculations

Flow Charts : simple way to visualize process flow

Instructor: Dr Azeman Mustafa

Benefits of using flowcharts

Complex, not easy to understand Compact, easy to understand

Example: Development of Flowcharts

200 mol H2O

Instructor: Dr Azeman Mustafa

Rules for Labeling Flowchart (1)

Example: A stream containing 21 mol % O2 and 79 mol % N2

0.21 mol O2/mol

Rules for Labeling Flowchart (2)

Instructor: Dr Azeman Mustafa

Rules for Labeling Flowchart (3)

Try to limit the unknown to the minimum

Example: Development of Flowchart

An experiment on the growth rate of certain organisms requires the

A: Liquid water, fed at a rate of 20.0 cm3/min.

Instructor: Dr Azeman Mustafa

Air Humidification and Oxygenation

0.2Q mol O2/min

Please work on ‘TEST

Flowchart Scaling and Basis of Calculation

The process is balanced, since material balances on both system components

This procedure of multiplication is referred as scaling the flowchart

Instructor: Dr Azeman Mustafa

Flowchart Scaling and Basis of Calculation