CHAPTER 1 .

MATERIAL BALANCE

1.1 Material Balance Across Reactor

There are two reactions occur

First Reaction

CaT + H2SO4 T.A. + CaSO4

Mol. Wt.(Kg/Kmole) 188 98 150 136

Second Reaction

Ca(OH)2 + H2SO4 CaSO4 + 2 H2O

Mol. Wt.(Kg/Kmole) 74 98 136 2 (18)

1.1.1 Material Balance Across First Reaction

Plant Capacity = 1890 kg/batch

New Capacity = 40% Extra = 1.4*1890

= 2650 kg/batch

1 Moles TA is Produced by 1 mole of CaT and 1 mole of H2SO4

So, mole of TA = 2650/150 = 17.66 kmole TA

2650 kg TA need = 17.66*188

= 3320.08 kg CaT

H2SO4 need = 17.66*98

= 1730.68 kg H2SO4

100 kg CaT Contains = 72 kg CaT 4H2O = 72*(188/260) = 52.061 kg CaT

= 8 kg CaO (lime)

= 20 kg moisture

So, Actual Raw Material Required = 6377.28 kg CaT

And, 6377.29 kg Contains  512.18 kg Ca(OH)2

 H2SO4 Required = 1730.68/0.7 (70% w/w)

= 2472.4 kg

Also, 56 kg CaO & 98 kg H2SO4 Produce 136 kg CaSO4

510.18 kg CaO Required  892.81 kg H2SO4

70% H2SO4 Required  1275.45 kg

Total Amount of H2SO4 Required = 2472.4 + 1275.45

= 3747.85 kg H2SO4

20% Excess H2SO4 is added for better reaction

So, Actual Amount of H2SO4 Required = 4551.85 kg

Material to be Charged

CaT 6377.28 kg

Spent H2SO4 4551.85 kg

1.1.1Material balance sheet of Decomposition Reactor-901

1.1.2 Material Balance of First Reaction

CaT (6377.29 kg) = 3320.08 kg CaT(Anhy.)

+ 512.18 kg Lime

+ 2545.03 kg H2O

Spent H2SO4 = 3186.3 kg H2SO4

+ 1365.55 kg H2O

Reacted H2SO4 = 17.66*98

= 1730.68 kg

Formed TA = 17.66*150

= 2650 kg

Formed CaSO4 = 17.66*136

= 2437.08 kg

3.1.1 Material Balance of 2nd Reaction

Reacted,

Ca(OH)2 = 512.18/74

= 6.92 mole

H2SO4 = 6.92 * 98

= 678.16 kg

Formed,

CaSO4 = 136*6.92 = 941.12 kg

H2O = 2*6.92*18 = 249.12 kg

Table 1-1 Summary of Reactor Material Balance

Chemical Input (kg) Output (kg)

CaT (Anhy.) 3320.08 0
3186.3 777.46
H2SO4
512.18 0
Ca(OH)2 H2O
TA 3913.48 4161.7
 0 3342.88
10932.04 10932.04

1.3Material Balance Sheet of Dissolution Reactor – 907

Output = H2O in Dil. ML + H2O in wet CaSO4 +H2O with Washi

ML

= (0.7049 * 4378.75) + (0.1525 * 1954.49) + (0.93 * 161

= 4888.31 Kg

1.4 Material Balance of Ion Exchange

Reaction

L2ABT + H+ Resin L2AB Resin + T.A.

Charged
L2ABT : 722 Kg. (98.0% L2ABT)
 S/Off : 4667 Ltr (9 to 10% T.A.)

Formed,

Product ML : 3080 Ltr

S/Off : 4667 Ltr (Recycle)

Void : 2040 Ltr

1.5 Material Balance Sheet of Evaporator – 905 A

For Reaction

Theoretically,

Moles of L2ABT Reacted = (725 * 0.98)/257

= 2.7646 Kmole

T.A. Formed = 2.7646 * 150

 = 414.69 Kg

Practically,

Output = T.A. in P. ML

= 3080 * 0.1346

= 414.69 Kg

1.6 Material Balance of Evaporator R- 905

1.6.1.1 Feed

Dil. ML = 9438.9 Ltr (Sp.gr. =1.13)

= 9438.9 * 1.13

= 10665.96 Kg

Product ML = 1540 Ltr (Sp.gr. =1.078)

= 1540 * 1.078

= 1660.12 Kg

1.6.1.2 Product

Evaporated Water = 8110.44 Ltr

Thick Liquor = 2868.46 Ltr (Sp.ga. = 1.47)

= 2868.46 * 1.47

= 4216.64 Kg

1.6.2 Overall Material Balance

Output = Water Evaporated + Concentrated Soln

= 8110.44 + 4216.64
 = 12327.08 Kg

Input = Dil. ML + Product ML

= (9438.9 * 1.13) + (1540 * 1.078)

= 12327 Kg

1.6.2 Material Balance Over Tartaric Acid

Input = T.A. in Dil. ML + T.A. in Product ML

= (10665.96 * 0.26) + (1660.12 * 0.1222)

= 2976.10 Kg

Output = T.A. in Conc. Solution

= (0.7058 * 4216.64)

= 2976.10 Kg

1.7 Material Balance Sheet of Centrifuge: F-903 A

1.7.1 Material Balance of H2O

Input = Water in Dil. ML + Water in P. ML

= (0.73 * 10665.96) + (0.778 * 1660.12)

= 9244.29 Kg

Output = Water is Evaporated + Water in Conc. Soln

= 8110.44 + (4216.64 * 0.2689)

= 9244.29 Kg

1.7.2 Material Balance of H2SO4

Input = H2SO4 in Dil. ML

 = (0.01 * 10665.96) Kg

= 106.65 Kg

Output = H2SO4 in Conc. Solution

= (0.0253 * 4216.64)

= 106.65 Kg

1.7.3 Material Balance of Centrifuge

Feed,

Crystalline Solution = 2868.46 Ltr (Sp.gr. = 1.47)

= 4216.64 Kg

Washing Water = 50 Ltr

Product

ML1 = 2823.8 Ltr (Sp.gr. = 1.213)

= 2823.8 * 1.213

= 3016.36 Kg

Wet T.A. = 1204.7 Kg

1.7.4 Overall Material Balance

Input = Crystalline Solution + Washing Water

= 4216.64 Kg + 50 Kg

= 4266.64 Kg
1.7.5 Material Balance Over Tartaric Acid

Input = T.A in Crystalline Solution

= (0.7058 * 4216.64)

= 2976.1 Kg

Output = T.A in ML1 + T.A. in wet T.A.

= (0.5955 * 3061.66) + (0.9565 * 1204.7)

= 2776.1 Kg

1.7.6 Material Balance Over H2O

Input = H2O in Crystalline Soln + H2O with

Washi Water

= (0.2689 * 4216.64) Kg + 50 Kg

= 1183.85 Kg

Output = H2O in ML1 + H2O in wet T.A.

= (0.371 * 3016.66) + (0.04 * 1204.7)

= 1183.85 Kg H2O

1.7.7Material Balance over H2SO4

Input = H2SO4 in Crystalline Solution

= (0.0253 * 4216.64) Kg

= 106.6 Kg H2SO4

Output = H2SO4 in ML1 + H2SO4 in wet T.A.

= (0.0335 * 3061.36) + (0.0035 * 1204.7)

=106.6 Kg H2SO4

1.8 Material Balance Sheet of Dryer

1.8.1 Material Balance Over Dryer

Feed,

Wet T.A. = 1204.7 Kg

Product,

Dry T.A. = 1162.54 Kg Dry T.A.

Moisture Evaporate = 42.16 Kg Moisture

1.8.2 Overall Material Balance

Input = 1204.7 Kg Wet T.A.

Output = Moisture + Dry T.A.

= (42.16 + 1162.54) Kg

= 1204.7 Kg
1.8.3Material Balance Over H2O

Input = H2O in wet T.A.

= (0.04 * 1204.7) Kg

= 4.216 Kg

Output = H2O in Dry T.A. + Evaporated Water

= (1162.54 * 0.0052) + 42.16

= 48.188 Kg

1.8.4 Material Balance Over H2SO4

Input = H2SO4 in wet T.A.

= (0.0035 * 1204.7) Kg

= 4.216 Kg

Output = H2SO4 in Dry T.A.

= (0.0036 * 1162.5355) Kg

= 4.216 Kg

1.8.5 Material Balance Over T.A.

Input = T.A. in wet T.A.

= (0.9565 * 1204.7) Kg
= 1152.3 Kg

Output = T.A. in Dry T.A.

= (0.9912 * 1162.54) Kg

= 1152.3 Kg
CHAPTER 2. ENERGY BALANCE
2.1 Introduction

Energy balance requires knowledge of thermodynamics. The heat duty on process side and utility side
is matched in order to calculate the load on the utilities. Proper values of heat capacities, latent heat of
vaporization, latent heat of condensations etc. at their respective temperatures are needed to be
incorporated in the calculation.

Specific Heat Kcal/Kmole*K

Ca(OH)2 21.4

T.A. 43.05

CaSO4.2H2O 46.8

CaSO4 23.83

PURE H2SO4 0.335

69% H2SO4 32.8996

H2 O 18

Calcium Tartrate 37.6

∆H Kcal/mole
 ∆H◦ f (TA) 1588.35

∆H◦ f (CaT) 1366.51

∆H◦ f (H2SO4) -194.548

∆H◦ f (CaSO4.2H2O) -979.33

∆H◦ f (CaSO4) -479.33

∆H◦ f (Ca(OH)2) -235.58

2.2 Heat Balance of Reactor

Heat of Reaction Cal for 1st Reaction

∆H r (CaT) = mole of reactant (Kmole)* C p (Kcal/Kmole) * ∆T (K)

(In Kcal)

= 16.77*37.6*(35-25)

= 3135.84

∆H r (Ca(OH)2) = 6.92*21.4*(35-25)

= 695.5

∆H r (H2SO4) = 16.77*32.8996*(35-25) + 6.92*32.8996*(35-25)

= 3813.06364

∆H r = 7644.40364

For Product,

∆H p (TA) = 16.77*43.05*(75-25)

= 17951.85

∆H p (H2SO4) = 16.77*23.83*(75-25) + 6.92*23.83*(75-25)

= 13809.485

∆Hp (H2O) = 2*6.92*18*(75-25)

= 5850
 ∆Hp = 37611.335

Standard Heat of Reactio

∆H◦ = ∆H◦ product - ∆H◦ reactant

= -2942.12378

∆H (75◦C) = ∆Hp - ∆Hr + ∆H◦

= 27024.80758

2.3 Heat balance of Evaporator

Pressure 9 to 10 Kg/cm2 or 882 to 980 KPa at that Pressure

Temperature of steam 174.56 ◦C to 179.07◦C.

Steam is used in varying pressure 3.5 Kg/cm2, saturation temperature of steam at pressure is
138.206 ◦C

Inlet T1s = 170 ◦C = 443 K

Outlet T2s = 138.206 ◦C = 411.206 K

So,

m s* λ s @3.5 kg/cm2 + m s C p ∆T = m f * C p, f (Tsat @160 mmHg – 32) + m w *λ w @160 mmHg

where,

ms = mass of steam used

λs = latent heat of vapor at 3.5 Kg/cm2
= 2149.525 KJ/Kg
Cps = Specific Heat of Steam at Function of temperature
= 32.24 + 0.1923* 10-2 T + 1.055*10-5 T2 – 3.595*10-9 T3
∆T = T2s – T1s
mf = mass of total feed to evaporate
C p,f = Specific Heat of fluid
= 0.287 Kcal/Kg*K
mw = evaporated water
Tsat @160 mmH = Temperature of saturation = 61.35 ◦C
 λ w @160 mmH = latent Heat of water
= 2355.075 KJ/Kg
= 592.86 Kcal/Kg
So,

Heat gained by T.A. ML = 12327 Kg * (0.287 Kcal/Kg*K) * (61.35 – 32)

+ 8110.441 Kg * 592.89 Kcal/Kg
= 4912434.64 Kcal
Heat lost by steam = m ∫s [2149.525 + 411.206
𝐶𝑝 𝑑𝑇
*
443

0.1923∗10−2𝑇2 1.055∗10(−5)𝑇3 𝑇4 411.206

= [ 32.24T + 2 + 3 + 3.595*10-9 ] 443
4

= 1025.03 +26.1130 + 61.2157 + 8.9175

= 1103.44 KJ/Kg
So,
= m s [ 2149.525 + 1103.44]
m s * 3252.966 = 4912434.6 Kcal *4.184
KJ/Kcal m s = 6318.4264
For 9 hour = 702.04738 Kg/hr

2.4 Heat Balance of Crystallization

Cycle Time = 3 hr

Heat Lost by Concentration Liquid ML = Heat Gained by Cooling

Water M* Cp*∆Tml = m*Cp*∆Tml
4233.6*700 Cal/Kg ᵒC*(61.33 – 45) = m* 1000 Cal/Kg ᵒC*(32
- 26) m = 8065.714 kg

2.5Heat Balance of Dryer

2.5.1 Heat Balance Over Mixing Nozzles

Air ρ at 30ᵒC = 1.2786

kg/m3 Air ρ at 85ᵒC =

1.0823 kg/m3

So,

m* Cp *∆Tair = m* Cp *∆Thot air

600 *1.2786 *0.25 (T – 30) = 1.0823 *900 *0.25 *(85 – 0)
T = 61.67 ᵒC

2.5.2 Heat Balance Over Radiator

Steam Pressure =7
kg/cm3 Saturation Temperature =
164.16 ᵒC Latent Heat = 206738
kJ/kg
Steam Flow Rate = 100 kg/hr
 Cp of Steam = 1.933 kJ/kg

Heat Lost by Radiator = m* λ + m *Cp *(170 – 164.16)

= 2067.8 *100 +100*1.933 (5.84)
= 207908.872 kg/hr
Here, 25% Radiation Loss;

Actual Amount of Heat loss by air in Radiation

= 0.75 *207908.872

= 155931.654

= (1500 *1.16) (0.25 *4.184) (T –

61.67) So, T = 147.34 ᵒC

Also, 30% air Leaking;

Heat Liberated by hot air in Dryer

= m *(0.25 *4.184) (147.34 – 85)

= 1050*(0.25 *4.184) (147.34 – 85)

= 68517.1147 kg/hr

Moisture Remove from the Dryer = 42.1645/3 kg/hr

= 14.05 kg/hr
Heat Required to remove Moisture from Wet TA

= 14.05 *4.184 (100.35) + 14.05 *2257

= 35534.627 kg/hr

So, Total Heat loss = 68517.1147 – 35534.627

= 32982.48 kg/hr