CHME 201:

Intro. to Chem. Eng. I

Chapter 4: Material
Balances
Part 2: Sections 4.3d-4.5
 4.3d Degrees of Freedom
Analysis (df)
Degrees of freedom analysis is a procedure used to know if you have
enough information to solve the problem.

ndf = nunknowns – nindep.eqn’s

• if ndf = 0
Problem can be solved (determined)
System Equations
• if ndf > 0 Material balances,
Energy balances,
Unknowns > knowns (underspecified) Process specifications, e.g. m1 = 0.4 m2
Physical props & laws, eg. r = m/V
• if ndf < 0 Physical constraints , eg. S xi = 1
overspecified (no solution)

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 Example
Humid air Condenser Dry air
ρH20 is given (n4) O2
(n0) O2
In the condenser, (n5) N2
95% of H2O in the inlet (n1) N2 (n6) H2O
air is condensed.
(n2) H2O
(n3) H2O
225 L/h
7 unknowns n0 ➔ n6 , 7 equations needed
• 3 independent material balance
• n3 = ρ.V
• n0/n1 = 21/79 Draw and label flowchart
• n3 = 0.95 n2
Express what the problem is
asking for in terms of the
➢ One more equation is needed
labeled variables on the chart
➢ Volume is not conserved!
➢ Use consistent units (mole, kg)
➢ Do not make mole balances in reactive processes.
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 Example 4.3-5
A liquid mixture containing 45.0 wt% benzene (B) and 55.0 wt% toluene (T) is fed to a
distillation column. The overhead product stream contains 95.0 mole% benzene and the
bottom product stream contains 8.0% of the benzene fed to the column. The volumetric flow
rate of the feed stream is 2000 L/h and the specific gravity of the feed mixture is 0.872.
Determine the mass flow rate of the overhead product stream and the mass flow rate and
composition (mass fractions) of the bottom product stream. Molecular weights of benzene
and toluene are 78.11 and 92.13, respectively.
SOLUTION
m2 (kg/h)
◼ Draw and label the flow chart. xB2 (kg B/kg)
1-xB2 (kg T/kg)
2000 L/h
m1 (kg/h)
0.45 kg B/kg m3 (kg/h) (contains 8% of B in feed)
0.55 kg T/kg xB3 (kg B/kg)
1-xB3 (kg T/kg)

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 Example 4.3-5

1. basis is given as a
volumetric quantity

2. Draw flowchart and fill in all variable values, including the

basis. Label unknown stream variables and process specification.
 Example 4.3-5
3. Write expressions for quantities requested in the problem statement
 2 =m
m  1 −m
3

 3 =m
m  B3 + m
 T3

xB = m  3 ; x T = 1 − xB
 B3 m
 Example 4.3-5
5. Perform degree of freedom analysis

x B 2 = (kg B / kg )
(1 − x B 2 ) = (kg T / kg )

4 unknowns
-2 material balances
-1 density relationship
-1 process specification
0 degrees of freedom
 6. Write system equations v. total mass balance (check)
7. Solve m 1 =m
 2 +m
 B3 + m
 T3
i. volumetric flow conversion
1744 kgh = 1744 kgh
m ( )
 1 = (2000 hL ) 0.872 kgL = 1744 kgh

x B 2 = 0.942
(1 − x B 2 ) = 0.058
ii. benzene split fraction
 B3 = (0.08 )(0.45)m
m  1 = 62.8 kghB

ii. benzene balance iv. toluene balance

(0.45 )m 1 = m 2 x B 2 + m B 3 (0.55 )m 1 = m 2 (1 − x B 2 ) + m T 3
m 2 = 766 kgh B m T 3 = 915 kgh T
8. Calculate requested (if any) quantities: All quantities are already
calculated in previous step

=766 kg/h
x B 2 = 0.942
=0.94
(1 − x B 2 ) = 0.058
2
=1744 kg/h

=62.8 kg B/h
 3 = 62.8 kghB + 915 kghT = 978 kgh
m
=915 kg T/h
x B 3 = m B 3 m 3 = 62.8 kgh B 978 kgh = 0.064 kgkgB
xT 3 = 1 − 0.064 = 0.936 kgkgT
 Self Test

Which one of the following choices is the correct balance on A.

a. (0.3)(m1)+m2=(x)(400)
b. m1+m2=400
c. (0.2)(m1)=(0.1)(400)
d. (0.5)(m1)=(0.9-x)(400)

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 Self Test

Which one of the following choices is the correct balance on C.

a. (0.3)(m1)+m2=(x)(400)
b. m1+m2=400
c. (0.2)(m1)=(0.1)(400)
d. (0.5)(m1)=(0.9-x)(400)

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 Self Test

Which one of the following choices is the correct balance on B.

a. (0.3)(m1)+m2=(x)(400)
b. m1+m2=400
c. (0.2)(m1)=(0.1)(400)
d. (0.5)(m1) =(0.9-x)(400)

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 Self Test

Which one of the following choices is the correct total balance.

a. (0.3)(m1)+m2=(x)(400)
b. m1+m2=400
c. (0.2)(m1)=(0.1)(400)
d. (0.5)(m1) =(0.9-x)(400)

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 4.4 Balances on Multiple
Unit Processes
Objectives
Demonstrate material balance on a multiple unit physical process.

# of independent systems = # of operations (including mixers and splitters) (4 in the above

process)

More systems can be formed by combining two or more of the four operations such as the
overall system which includes all (as also included in the sketch). However, as the above
equation states, only 4 systems can be used independently.

And as discussed earlier,

# of independent equations = # of components in each system

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 Example 4.4-1

A labeled flowchart of a continuous steady-state two-unit

process is shown below. Calculate the unknown flow
rates and compositions of streams 1, 2 and 3.

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

Solution
Basis: Given flow rates.
The systems about which balances might be written are shown on the following
representation of the flowchart.

6 unknowns → 6 equations needed

3 independent systems, 2 independent balance in each system

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Back to Mixing Point

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 Example 4.4 – 2: Extraction-Distillation Process

In a pilot–plant study, for every 100 kg of acetone–water fed to the first extraction stage, 100 kg of MIBK is
fed to the first stage and 75 kg is fed to the second stage. The extract from the first stage is found to contain
27.5 wt% acetone. (All percentages in the remainder of this paragraph are weight percent.) The second-stage
raffinate has a mass of 43.1 kg and contains 5.3% acetone, 1.6% MIBK, and 93.1% water, and the second-
stage extract contains 9.0% acetone, 88.0% MIBK, and 3.0% water. The overhead product from the
distillation column contains 2.0% MIBK, 1.0% water, and the balance acetone. Determine all unknowns (if
possible).

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Note: the first mixer and splitter are combined to yield the first extractor
while the second mixer and splitter are combined to give the second
extractor

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 Simultaneously solve total mass
and acetone balances to determine
m1 and m3 (m1 =145 kg ; m3 =86.8
kg)
Solve MIBK balance to determine
xM1 (=0.675)

Note: the first mixer and splitter are combined to yield the first extractor
while the second mixer and splitter are combined to give the second extractor
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Perform component mass balances
around the first extractor to
determine mA2 (=10.1 kg), mM2
(=2.3 kg), and mW2 (=42.6 kg).

Note: You can also obtain the same

balance using the second extractor

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Perform component mass balances
around the mixing point to
determine mA4 (=47.7 kg), mM4 (=
174 kg) and mW4 (=9.9 kg).

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Balances around dist. Column:
ndf = 4 unknowns (mA6, mM6,
mW6, and m5) – 3 balances = 1

Underspecified. Cannot be
solved

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 Total mass balance:
ndf = 4 unknowns (mA6, mM6, mW6,
and m5) – 3 balances = 1

underspecified

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 4.5 Recycle and Bypass
It is rare that a chemical reaction A → B proceeds to completion in a reactor. Its
efficiency is never 100. Some A in the product !
To find a way to send the “A” back to feed, you need a seperation and recycle
equipment, this would decrease the cost of purchasing more A.

In a recycle stream, a fraction of the products or unconsumed reactants

in the product stream in the case of a chemical process are sent back to
the beginning of the process Recycle

Feed Process Product

Mixer Splitter

In a bypass stream, a fraction of the feed to a process unit is diverted

around the unit and combined with the output stream from the unit
Bypass

Feed Process Product

Splitter Mixer

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4.5 Recycle and Bypass

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 Example 4.5 - 1
Feed: Fresh air with 4 mole% H2O(v) is “cooled” and “dehumidified” to a
water content of 1.7 mole% H2O.
Fresh air is combined with a recycle stream of dehumidified air.
The blended stream entering unit contains 2.3 mole% H2O. In the air
conditioner some of the water is removed as liquid.
Take 100 mole of dehumidified air delivered to the room, calculate moles
of feed, water condensed, dehumidified air recycled.

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Labeled sketch and assumed basis

Overall system: 2 variables (n1, n3)

2 balance equations (two species)
Degrees of freedom: 2 – 2 = 0
n1, n3 are determined by solving these equations

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Labeled sketch and assumed basis

Mixing Point : 2 variables (n2, n5)

2 balance equations (two species)
Degrees of freedom: 2 – 2 = 0
n2, n5 are determined by solving these equations
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Labeled sketch and assumed basis

Cooler : 2 variables (n2, n4)

2 balance equations (two species)
Degrees of freedom: 2 – 2 = 0
n2, n4 are determined by solving these equations
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Labeled sketch and assumed basis

Splitting points: 2 variables (n4, n5)

1 balance equation (all streams have same xi)
Degrees of freedom: 2-1 = 1

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 Recycling Example: Balances on an Air
Conditioner (Cont.)
◼ Overall: ndf = 2 variables (n1, n3) – 2 balances = 0 To find the 5 unknowns, solve
◼ Mixer: ndf = 2 variables (n2, n5) – 2 balances = 0 overall balances followed by
mixing and air condenser
◼ Cooler: ndf = 2 variables (n2, n4) – 2 balances = 0 balances. There is no need to
◼ Splitter: ndf = 2 variables (n4, n5) – 1 balances = 1 solve the splitter balances.

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 Recycling Example: Balances on an Air
Conditioner (Cont.)
◼ Splitter
ndf = 2 variables (n4, n5) – 1 balances = 1
◼ only 1 independent balance can be written on the splitter because
the streams entering/leaving have the same composition.
(0.983 )n4 = (0.983 )n5 + (0.983 )(100 )  n4 = n5 + 100
(0.017 )n4 = (0.017 )n5 + (0.017 )(100 )  n4 = n5 + 100

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 Recycling Example: Balances on an Air
Conditioner (Cont.)
◼ overall dry air balance (0.960 ) n1 = (0.983 )(100 )  n1 = 102 .4mol
◼ overall mole balance n1 = n3 + (100 )  n3 = 2.4 mol H 2O condensed

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 Recycling Example: Balances on an Air
Conditioner (Cont.)
◼ Overall mole balance on the mixer: n1 + n5 = n2
◼ Water balance on the mixer: (0.04 )n + (0.017 )n = (0.023 )n
1 5 2

◼ solved simultaneously: n2 = 392 .5 mol ; n5 = 290 mol

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 Recycling Example: Balances on an Air
Conditioner (Cont.)
◼ Overall mole balance on air condense:
n4 = n2 − n3 = 392 .5 − 2.4 = 390 .1 mol

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 Take Home Exercise
Example 4.5-2
The flowchart of a steady-state process to recover crystalline potassium chromate (K2CrO4) from an
aqueous solution of this salt is shown below
4500 kg/h of a solution that is one-third K2CrO4 by mass is joined by a recycle stream containing 36.4 wt%
K2CrO4 and the combined stream is fed into an evaporator. The concentrated stream leaving the
evaporator contains 49.4 wt% K2CrO4; this stream is fed into a crystallizer in which it is cooled (causing
crystals of K2CrO4 to settle) and then filtered. The filter cake consists of K2CrO4 cystals and a solution that
contains 36.4 wt% K2CrO4, the crystals account for 95% of the total mass of the filter cake. The solution
that passes through the filter, also 36.4 wt% K2CrO4, is the recycle stream.
Calculate the rate of evaporation, the rate of production of crystalline K2CrO4, the feed rates that the
evaporator and the crystallizer must be designed to handle, and the recycle ratio that is the ratio of mass
of recycle to mass of fresh feed

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