4.

Material and Energy Balance

4. MATERIAL AND ENERGY BALANCE

Syllabus
Material and Energy balance: Facility as an energy system, Methods for preparing process
flow, Material and energy balance diagrams.

4.1 Introduction to Material and Energy Balance

Material and Energy (M&E) balances are crucial for the Energy Audit. The basic purpose is

• to quantify all the material, energy and waste streams in a process or a system.
• to find out the difference between calculated/designed values and measured/actual
values thereby making it possible to identify previously unknown losses and
emissions.

Gaseous Emissions
Raw Materials

Chemicals Product
The objective of M&E balance is
Water /Air Process or Unit Byproduct
to assess the input, conversion Operations
Energy/Power Wastewater
efficiency, output and losses. A
Liquid Waste
M&E balance, used in conjunction Recycle for storage
with diagnosis, is a powerful tool and disposal
Reusable Waste
for establishing the basis for in other operation
Solid waste
for stroage
improvements and potential and disposal
savings.
Figure 4.1:Components of Material Balance

Energy in vapours
Electricity

Steam Radiation loss

The various components of inputs, Cooling Water Process or Unit Energy in
hot products
outputs and waste steams are Chilled Water Operations
Energy in hot
illustrated in Material and Energy Compressed air Residue
Balance (See Figure 4.1 & Figure Energy in
4.2). Condensate
Energy in Raw
Energy in
material
Cooling
Water

Figure 4.2: Components of Energy Balance

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4.2 The Sankey Diagram and its Use

The Sankey diagram is very useful tool to represent an entire input and output energy flow in
any energy equipment or system such as boiler generation, fired heaters, furnaces after
carrying out energy balance calculation. This diagram represents visually various outputs and
losses so that energy managers can focus on finding improvements in a prioritized manner.

Example: The Figure 4.3 shows a Sankey diagram for a reheating furnace. From the Figure
4.3, it is clear that exhaust flue gas losses are a key area for priority attention.

Figure 4.3: Energy Balance for a Reheating Furnace

Since the furnaces operate at high temperatures, the exhaust gases leave at high temperatures
resulting in poor efficiency. Hence a heat recovery device such as air preheater has to be
necessarily part of the system. The lower the exhaust temperature, higher is the furnace
efficiency.

4.3 Method for Preparing Process Flow Chart

The identification and drawing up a unit operation/process is prerequisite for energy and
material balance. The procedure for drawing up the process flow diagrams is explained
below.

Flow charts are schematic representation of the production process, involving various input
resources, conversion steps and output and recycle streams. The process flow may be
constructed stepwise i.e. by identifying the inputs / output / wastes at each stage of the
process, as shown in the Figure 4.4.

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 4. Material and Energy Balance

PROCESS Wastes
Inputs STEP – 1

Wastes
Inputs PROCESS
STEP – 2

Output

Figure 4.4: Process Flow Chart

Inputs of the process could include raw materials, water, steam, energy (electricity, etc);

Process Steps should be sequentially drawn from raw material to finished product.
Intermediates and any other byproduct should also be represented. The operating process
parameters such as temperature, pressure, % concentration, etc. should be represented. The
flow rate of various streams should also be represented in appropriate units like m3/h or kg/h.
In case of batch process the total cycle time should be included.

Wastes / by products could include solids, water, chemicals, energy etc. For each process
steps (unit operation) as well as for an entire plant, energy and mass balance diagram should
be drawn.

Output of the process is the final product produced in the plant.

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 4. Material and Energy Balance

Example: -Process flow diagram - raw material to finished product: Papermaking is a

high energy consuming process. A typical process flow with electrical & thermal energy flow
for an integrated waste paper based mill in given in Figure 4.5

Trees
Used Paper
Bark ( fuel)
Barking
Electricity

Wood Preparation
Chipping

Steam
Pulping Electricity
Mechanical Waste Paper
Chemical Pulping
Pulping Pulping

Bleaching Steam
Electricity
Bleach Plant Bleach Plant Kneading

Chemical Recovery
Electricity
Steam Liquor concentration
Electricity Refiner

Steam
Energy Recovery
Electricity

Fuel
Recausticization
Electricity

Steam
Paper making Stock Preparation
Electricity

Electricity Forming

Steam
Pressing
Electricity

Steam
Drying
Electricity

Paper

Figure 4.5: Process Flow Diagram of Pulp & Paper Industry

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4.4 Facility as an Energy System

Although various forms of energy enters the facility (industry) and does its work, the
outgoing energy is usually in the form of heat. Even an entire facility can be considered as an
energy system as shown in Figure 4.6.

Raw material

Energy Facility Production Facility

Energy
Input
Transformer Heat
DG Set Electricity
Output
Coal, oil, gas, Boilers Steam
electricity Chillers Chilled Water
Water Supplies Water Waste
Air Stream
compressors Compressed Air Flue
gas,
Water
vapour,,
heat and
emissions

Product
Figure 4.6: Plant Material and Energy System

The energy usage in the overall plant can be split up into various forms such as:

• Electrical energy, which is usually purchased as HT and converted into LT supply for
end use.
• Some plants generate their own electricity using DG sets or captive power plants.
• Fuels such as furnace oil, coal are purchased and then converted into steam or
electricity.
• Boiler and steam supply system for heating demand
• Cooling tower and cooling water supply system for cooling demand
• Air compressors and compressed air supply system for compressed air needs

A typical energy conversion facility in a chemical plant is given in Figure 4.7. This diagram
shows various forms of energy inputs into the facility, which are converted into secondary
energy such as fuel to steam, fuel to electricity and HT power supply to LT power supply etc.

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 4. Material and Energy Balance

ENERGY SOURCE ENERGY CONVERSION SECONDARY ENERGY

Loss 2%

20% EB Power
EB Power (70%)
358 Lakh KW H
TRANSFORMER 350 Lakh kwh
Eff. = 98%

Electrical Energy
500 Lakh kwh/year
73%
LT DG Set 5 Lakh
5% HSD
1 No. x 1MW
746.2 KL
DG Power (30%)
150 Lakh kwh
Loss

100% 27%
4%
70%
HT DG Set
W HR Steam (3%)
2 Nos. x 4MW
32% 145 Lakh 3.8 x 10 3 Ton/year
70% Furnace Eff. = 38%
Oil
10586.6 KL

68% Boiler Steam (97%)

Boiler 133 x 103 Ton/year
2 Nos. x 30 TPH
5% Biogas
Eff. = 79% Thermal Energy
1438 x 103 m 3
136.8 x 103 Ton/year

Loss

(% share in terms of Kcals) Figure 4.7 Energy Generation

All energy/utility system can be classified into three areas like generation, distribution and
utilisation for the system approach and energy analysis.

Boiler System Boiler and its auxiliaries should be considered as a system for energy
analyses. Energy manager can draw up a diagram as given in Figure 4.8 for energy and
material balance and analysis. This diagram includes many subsystems such as fuel supply
system, combustion air system, boiler feed water supply system, steam supply and flue gas
exhaust system.

5 Bar, Comp. air/steam for

atomisation Steam
HP Dosing
12 Bar/190o C
(Phosphate)

3 Bar
Fur.Oil 180o C
Tank
4.5 KL Heater/3.5 kw
Filter units
BOILER
Bio Gas from ETP 30 TPH Economiser 160o C

12 Bar
FD Air 66m
Fan 170o C
75 KW
35640m3
Chimney
540mm WC
LP dosing
125o C
(Oxytreat)
Condensate return

Deareator
Condensate
10m3
tank 25m3

Blowdown
tank
8.95 KW
4.5 KW
36 m3/hr
48.1 m3/hr
1.5m
21.5m
DM water tank Drain
250 m3
2.8 KW
48.1 m3/hr
21.5m Figure 4.8 Boiler Plant System Energy Flow Diagram

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Cooling Tower & Cooling Water Supply System

Cooling water is one of the common utility demands in industry. A complete diagram can be
drawn showing cooling tower, pumps, fans, process heat exchangers and return line as given
in Figure 4.9 for energy audit and analysis. All the end use of cooling water with flow
quantities should be indicated in the diagram.

M3/hr
Fan 4 Nos. x 30 kw 2000 VAHP
- Condensor

10 Instrument Air Compressor

Pump - Inter cooler
Cooling Tower
5000 m3/hr - After cooler
Flow Meter Process Air Compressor
600 Cooler
3000 m3/hr - Hot air cooler
370 kw 32o C
170 Brine Plant
Heavy Blow 2500 m3/hr
- Condenser
drain 41.5 m
- Oil Cooler

Solvent Recovery
220 - Column Condenser
- Product Cooler

Soft Water 1.5 Boiler Plant

Tank - FW Pump
200 m3 -Gland Cooling Drain
3
40 m /hr
Fermentor
Continuous Blow down - Germinator
15 m3/hr (0.3%) - Pre fermentor
38.5 - Fermentor
Pump 30 kw - Continuous Steriliser

Iron Corrosion
Test DG Set
Cooling Tower
Drain, 2m3/hr
Figure 4.9 Cooling Tower Water System

Compressed air System

Compressed air is a versatile and safe media for energy use in the plants. A typical
compressed air generation, distribution and utilization diagram is given in Figure 4.10.
Energy analysis and best practices measures should be listed in all the three areas.

GENERATION DISTRIBUTION UTILISATION/

END USE APPLICATIO

Extraction
Filter Press

110 kw Activated
850 m3/hr. Alumina Drier Instrumentation
& Controls

110 kw Fermenter
530 Nm3/hr for Filter Press
Air Receiver

850 m3/hr.
150 minutes/day
7 Bars

Boiler
Atomisation
225 Nm3/hr
110 kw
850 m3/hr.
Vent
Compressor - 3 No. Westfalia
Chilled 5 Bars
Two stage, double Water Heat Receiver N2 Plant (Extraction)
acting, reciprocating,
Exchanger
water cooled non- 630 Nm3/hr 150 Nm3/hrN2
lubricated, heavy duty Moisture Air N2 Receiver
Centrifuge
Drain
(Extraction)

Figure 4.10 Instrument Air System

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4.5 How to Carryout Material and Energy (M&E) Balance?

Material and Energy balances are important, since they make it possible to identify and
quantify previously unknown losses and emissions. These balances are also useful for
monitoring the improvements made in an ongoing project, while evaluating cost benefits.
Raw materials and energy in any manufacturing activity are not only major cost components
but also major sources of environmental pollution. Inefficient use of raw materials and
energy in production processes are reflected as wastes.

Guidelines for M&E Balance

• For a complex production stream, it is better to first draft the overall material and
energy balance.
• While splitting up the total system, choose, simple discrete sub-systems. The
process flow diagram could be useful here.
• Choose the material and energy balance envelope such that, the number of
streams entering and leaving, is the smallest possible.
• Always choose recycle streams (material and energy) within the envelope.
• The measurement units may include, time factor or production linkages.
• Consider a full batch as the reference in case of batch operations.
• It is important to include start-up and cleaning operation consumptions (of
material and energy resources (M&E).
• Calculate the gas volumes at standard conditions.
• In case of shutdown losses, averaging over long periods may be necessary.
• Highlight losses and emissions (M&E) at part load operations if prevalent.
• For each stream, where applicable, indicate energy quality (pressure, temperature,
enthalpy, Kcal/hr, KW, Amps, Volts etc.).
• While preparing M&E balances, precision of analytical data, flow and energy
measurements have to be accurate especially in case of short time span references.

The material and energy (M&E) balances along the above guidelines, are required to be
developed at the various levels.

1. Overall M&E balance: This involves the input and output streams for complete plant.

2. Section wise M&E balances: In the sequence of process flow, material and energy
balances are required to be made for each section/department/cost centres. This would
help to prioritize focus areas for efficiency improvement.

3. Equipment-wise M&E balances: M&E balances, for key equipment would help
assess performance of equipment, which would in turn help identify and quantify
energy and material avoidable losses.

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 4. Material and Energy Balance

Energy and Mass Balance Calculation Procedure:

The Energy and Mass balance is a calculation procedure that basically checks if directly or
indirectly measured energy and mass flows are in agreement with the energy and mass
conservation principles.

This balance is of the utmost importance and is an indispensable tool for a clear
understanding of the energy and mass situation achieved in practice.

In order to use it correctly, the following procedure should be used:

• Clearly identify the problem to be studied.

• Define a boundary that encloses the entire system or sub-system to be analysed.
Entering and leaving mass and energy flows must be measured at the boundary.
• The boundary must be chosen in such a way that:
a) All relevant flows must cross it, all non-relevant flows being within the
boundary.
b) Measurements at the boundary must be possible in an easy and accurate
manner.
• Select an appropriate test period depending on the type of process and product.
• Carry out the measurements.
• Calculate the energy and mass flow.
• Verify an energy and mass balance. If the balances are outside acceptable limits, then
repeat the measurements.
• The energy release or use in endothermic and exothermic processes should be taken
into consideration in the energy balance.

Example/ Formula

i) Energy Supplied by Combustion: Q =Fuel consumed x Calorific value

ii) Energy Supplied by Electricity: Q = kWh x 860 kCals

Where, Q = thermal energy flow rate produced by electricity (kJ/h)

iii) Continuity Equation

A1V1 = A2V2
v1 v2

where, ‘V’ is the velocity in m/s , ‘v’ is the specific volume in m3/kg and ‘A’ is the cross
sectional area of the pipe in m2.

iv) Heat addition/rejection of a fluid = mCp∆T

where, m is the mass in kg, Cp is the specific heat in kCal/kg, ∆T is the difference in
temperature in k.

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Example-1: Heat Balance in a Boiler

A heat balance is an attempt to balance the total energy entering a system (e.g boiler)
against that leaving the system in different forms. The Figure 4.11 illustrates the heat
balance and different losses occurring while generating steam.
73.8 % Heat in Steam

12.7 Dry Flue Gas Loss

8.1 %
Heat loss due to hydrogen in fuel
100 % 1.7 %
Heat loss due to moisture in fuel
Steam Boiler
Fuel 0.3 % Heat loss due to moisture in air

2.4 Heat loss due to unburnts in residue

1.0 % Heat loss due to radiation &
other unaccounted loss
Figure 4.11

Example-2: Mass Balance in a Cement Plant

The cement process involves gas, liquid and solid flows with heat and mass transfer,
combustion of fuel, reactions of clinker compounds and undesired chemical reactions that
include sulphur, chlorine, and Alkalies.

A typical balance is shown in the figure 4.12 (Source: Based on figure from Austrian BAT proposal 1996,
Cembureau for Mass balance for production of 1 Kg cement)

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 4. Material and Energy Balance

Figure 4.12

4.6 Case Study

M & E balance for yarn dyeing process Grey Yarn

A schematic balance is shown in Figure

4.13 Dyes and chemicals
Water
Condensate
Steam Yarn Dyeing
Water
Process Description: Wound grey yarn Electrical energy

in spindles is placed in a fixture in a yarn-

dyeing machine. They are then subject to
Effluent
a variety of processes as shown in the Dyed Yarn

table below. After these processes, yarn is

removed from the yarn-dyeing machine Figure 4.13 Material & Energy Balance
and taken to a centrifuge for removal of
major moisture. Once again the yarn is put back into the yarn-dyeing machine where it is
dried by hot air heated by steam through a radiator. The air is supplied by a set of two roots
blowers.

The complete Material & Energy balance is provided in the Table 4.1. Major inputs have
been measured and quantified. A notable feature of this balance is that the cycle times for
various processes have also been listed. This parameter could play a key role in determining
energy saving measures.

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 4. Material and Energy Balance

Table 4.1 Yarn Dyeing Material and Energy Balance (Batch size – 200 kg)
Process Operation Time Measured Measured T Actual Theoretical Measured
Step (Cycle time, In Cold Water Hot Water (oC) Steam Steam Wastewater
minutes) Min (litre) (litre) (kg) (kg) (litre)
1 Scouring Filling water 10
(120’) Chemical addition 30
Raise to 100oC 15 - 2000 100 295 260 1865
Circulation 60
Drain 5
2 Hot Wash Filling water 10
(45’) Raise to 85oC 15
- 2000 85 288 200 1902
Circulation 15
Drain 5
3 Cold Wash Filling water 10
(30’) Circulation 15 2000 - - - 1987
Drain 5
4 Neutralising Filling water 10
(30’) Circulation 15 2000 - - - 1991
Drain 5
5 Cold Wash Filling water 10
(30’) Circulation 15 2000 - - - 1990
Drain 5
6 Dyeing Filling water 10
(215’) Auxiliaries dozing 15
Levelling agent 15
Salt dozing 5 - 2000 90 247 222 1989
Circulation 20
Dyes Dozing 30
Raise to 90oC 25
7 Hot Wash Filling water 10
(45’) Raise to 85oC 15
- 2000 85 219 200 1993
Circulation 15
Drain 5
8 Cold Wash Filling water 10
(30’) Circulation 15 2000 - - - 1996
Drain 5
9 Neutralising Filling water 10
(30’) Circulation 15 2000 - - - 1995
Drain 5
10 Cold Wash Filling water 10
(30’) Circulation 15 2000 - - - 1997
Drain 5
11 Soaping Filling water 10
(45’) Raise to 90oC 15
- 2000 90 253 222 1997
Circulation 15
Drain 5
12 Hot Wash Filling water 10
(45’) Raise to 85oC 15
- 2000 85 221 200 1993
Circulation 15
Drain 5
13 Cold Wash Filling water 10
(30’) Circulation 15 2000 - - - 1994
Drain 5
14 Fixing Filling water 10
(30’) Circulation 15 2000 - - - 1996
Drain 5
15 Finishing Filling water 10
(30’) Circulation 15 2000 - - - 1996
Drain 5
Total 785 18000 12000 1523 1304 29681
16 Centrifuging
- - - - - - -
(20’)
17 Drying
- - - 198 162 -
(420’) -

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 4. Material and Energy Balance

Specific consumption for dyeing:

Batch size - 200 kg
Cold water consumption - 18000 litre
Hot water consumption - 12000 litre
Total water consumption - 30000 litre
Steam Consumption - 1523 kg
Specific cold water consumption - 90-litre/kg yarn
Specific hot water consumption - 60-litre/kg yarn
Specific total water consumption - 150-litre/kg yarn
Specific steam Consumption - 7.6 kg/kg yarn

Specific Steam consumption for drying:

Steam Requirement for drying - 198 kg/batch
Specific steam consumption for drying - 0.99 kg/kg yarn
Specific electrical energy consumption:
Specific electrical energy consumption - 1.99 kWh/kg yarn
Specific wastewater discharge:
Wastewater discharge - 29681 litre
Specific wastewater discharge - 148 kg/kg yarn

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QUESTIONS

1. Draw a typical input output diagram for a process and indicate the various
energy inputs?
2. What is the purpose of material and energy balance?
3. How Sankey diagram is useful for energy analysis ?
4. Draw a process flow chart for any product manufacture?
5. List down the various guidelines required for material and energy balance?
6. A material balance is based on
(a) Mass (b) Volume (c) Concentration (d) Temperature
7. Biscuits are to be baked in a continuous oven. The inlet moisture content is
25%. The outlet moisture is 1%. The production is 2 tonnes /hour on a dry
basis. Make a material balance and find out how much quantity of moisture is
removed per hour?
8. A furnace is loaded with materials at 5 T/hr. The scale losses are 2%. Find
out the material output?
9. In a heat exchanger, inlet and outlet temperatures of cooling water are 28oC &
33 oC. The cooling water circulation is 200 litres/hr. The process fluid enters
the heat exchangers at 60 oC and leaves at 45 oC. Find out the flow rate of the
process fluid?
(Cp of process fluid =0.95)
10. Steam output of boiler is measured by measuring feed water. The tank level
reading from 8.00 a.m. to 8.00 p.m. was 600 m3. Continuous blow down was
given at 1% of the boiler feed rate during the above period. Find out the
average actual steam delivered per hour?
11. The following are the cooling water requirements for a process industry:
Heat exchanger 1: 300 m3 /hr. at 3 kg/cm2
Heat exchanger 2: 150 m3 /hr. at 2.5 kg/cm2
Heat exchanger 3: 200 m3 /hr. at 1 kg/cm2
Find out the total cooling water requirement per hour for the plant?
(all heat exchangers are in parallel)
12. In a dryer, the condensate was measured to be 80 kg/hr. The flash steam was
calculated to be 12 kg/hr. Find out the actual steam consumption of the dryer?

REFERENCES

1. Energy audit reports of National Productivity Council

2. Energy Management Handbook, John Wiley and Sons - Wayne C. Turner

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