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Material Balances for Non-reactive Process
Introduction
Elementary Principles of Chemical Processes,
by Richard M. Felder and Ronald W. Rousseau
by
MOHD FADHIL MAJNIS
Department of Chemical
& Petroleum Engineering
CHAPTER 3
Learning Outcome
Define the law of material balance and the general equation
of material balance.
Briefly and clearly explain in your own words the meaning
of the following terms:
Batch, semi-batch, continuous, transient and steady state
processes.
By the given process description, able to:
Draw and label the full flowchart
Choose a convenient basis of calculation
Definition “Materials Balance analysis (MB)
is a systematic reconstruction of the way in which a chemical
element, a compound or material passes through a natural
cycle and/or its economical benefits. An analysis of the
material flow, usually is based on the origin of a physical
balance.”
Open vs. closed systems System:
Arbitrary portion/whole process that is considered for analysis
Limits of the system can be drawn as the system boundary
Boiling system
Overall system
Reactor system
Distillation system
Distilla
tion
A, B
C
Re
acto
r
A
B
A + B C
Chemical process system
System boundary
Open vs. closed systems
Closed system Material neither enters nor leaves i.e. no material crosses the system boundary Changes take place inside the system No mass exchange occurs with the surroundings
Open system Material crosses the system boundary
1000 kg H2O
System boundary
Closed system
1000 kg H2O
Open system
100 kg/min 100 kg/min
Process classification
• Feed is charge to the process and product is removed when the process is completed
• No mass is fed or removed from the process during the operation
• Used for small scale production
• Operate in unsteady state
• Example: rice cooking, polymerization
Batch
• Input and output flow continuously through the duration of the process
• Operate in steady state
• Used for large scale production
• Example: hydro power generation, distillation
Continuous
• Neither batch nor continuous
• During the process a part of reactant can be fed or a part of product can be removed.
Semibatch
Distillation
Batch
Continuous
Semibatch
Some daily operations
Processes Batch Continuous Semi-batch
Cookies baking √
Cloth washing √
Water storage √
Process of growing √
The flowing river √
Water filling into bottle √
Toilet flushing √
Balloon filling √
Water boiling in open flask √
By nature, batch & semi-batch processes are unsteady-state operations (why?)
Continuous processes may be either:
Steady-state, e.g. hydroelectricity
Transient, e.g. process start-up, shut down
Type of process operation
Steady state
- All the variables (i.e. temperatures, pressure, volume, flow rate, etc) DO NOT change with time
- Minor fluctuation can be acceptable
Unsteady state or transient
- Process variable DO change with time
because it would not be
possible to maintain all
process variables
constant with time
Steady-state vs. transient System
boundary
1000 kg H2O
Transient
100 kg/min 50 kg/min
1000 kg H2O
Steady state
100 kg/min 100 kg/min
Back to daily operations
Processes Steady-state Transient
Cookies baking (b) √
Clothes washing (b) √
Water storage (b) √ √
Process of growing (c) √
The flowing river (c) √ √
Water filling into bottle (sb) √
Toilet flushing (sb) √
Balloon filling (sb) √
Water boiling in open flask (sb) √
Test Yourself
Define type and operation of process given below
A balloon is filled with air at steady rate of 2 g/min
A bottle of milk is taken from the refrigerator and left on the kitchen
Water is boiled in open flask
Answer
Semibatch and unsteady state
Batch and unsteady state
Semibatch and unsteady state
Balances Law of Conservation of Mass states:
Mass can neither be created nor destroyed.
“So, we should be able to account for all the mass entering and leaving a
given system.” This is known as a material balance or mass
balance.
Material Balance -- A quantitative description of all materials that
enters, leaves, and accumulates in a system.
In its simplest form for balance equation:
Input
(enter
through
system
boundaries
+ Generation
(produced
within the
system)
-
Output
(leaves
through
system
boundaries
Consumption
(consumed
within system)
Accumulation
(buildup within
system) - =
input generation output consumption accumulation
Differential balances • balances that indicate what is happening in a system at an instant
time. • balance equation is a rate (rate of input, rate of generation, etc.)
and has units of the balanced quantity unit divided by a time unit (people/yr, g SO2/s).
• usually applied to a continuous process.
Integral balances • Balances that describe what happens between two instants of time. • balance equation is an amount of the balanced quantity and has the
corresponding unit (people, g SO2). • usually applied to a batch process, with the two instants of time
being the moment after the input takes place and the moment before the product is withdrawn.
Differential & Integral Balances
Simplified Rule for Material Balance
If the balanced quantity is TOTAL MASS, set generation = 0 and consumption = 0. Mass can neither be created nor destroyed.
If the balanced substances is a NONREACTIVE SPECIES (neither a reactant nor a product), set generation = 0 and consumption = 0.
If a system is at STEADY STATE, set accumulation = 0, regardless of what is being balanced.
Balances on Continuous Steady State Process
Steady state: accumulation = 0
IF balance on NONREACTIVE species or total mass; gen. = 0,
cons. = 0, balance equation become
input generation output consumption 0
input output
Integral Balances on Batch Process Ammonia is produced from nitrogen and hydrogen in a batch reactor. At time t =
0 there are n0 mol of NH3 in the reactor, and at a later time tf the reaction terminates and the contents of the reactor, which include nfammonia, are withdrawn. Between t0 and tf no ammonia enters or leaves through the reactor boundaries.
From GMBE: (no component enters or leaves the reactor during operation, input=0; output=0)
Generation – Consumption = Accumulation
For batch reactor:
Accumulation = Initial input – Final output
Final GMBE for batch process
Initial input + Generation = Final output – Consumption
Solving Material Balance
In material balances problems, equations involving
input and output stream variables are derived.
Solving the equations is simple, but deriving them
from a description of process is considered tricky.
Hence, procedure to derive a set of equations that
can be solved for unknown variables will be
outlined.
Strategy in Solving Material Balances
1 • Choose as basis of calculation
2
• Draw a flowchart and fill in all known variables values, including the basis of calculation. Then label unknown stream variables on the chart.
3 • Express what the problem statement asks you to determine in terms of the labeled variables.
4
• If you are given mixed mass and mole units for a stream (such as a total mass flow rate and component mole fractions or vice versa), convert all quantities to one basis.
5 • Do the degree-of-freedom analysis.
6
• Solve the equations (if DOF=0).
• Calculate the quantities requested in the problem statement if they have not already been calculated.
7
• If a stream quantity or flow rate ng was given in the problem statement and another value nc was either chosen as a basis or calculated for this stream, scale the balanced process by the ratio ng/nc to obtain the final result.
Basis of Calculation
Balanced process can always be scaled.
Mean that material balance calculation can be performed on the basis of
any convenient set of stream amount or flow rate and the results can
afterward be scaled to any desired extent.
A basis of calculation is an amount (mass or moles) OR flow rate (mass or
molar) of one stream or stream component in a process. All unknown
variables are determined to be consistent with the basis.
if the amount or flow rate of a stream is given – use it as a basis for
calculation
If NO stream amount or flow rate are known, choose an arbitrary convenient
value ( i.e. 100 kg, 100 kmol/h) on the stream with KNOWN composition. If
mass fraction is known, choose total mass or mass flow rate as basis. If mole
fraction is known, choose a total moles or molar flow rate as basis
Strategy in Solving Material Balances
1 • Choose as basis of calculation
2
• Draw a flowchart and fill in all known variables values, including the basis of calculation. Then label unknown stream variables on the chart.
3 • Express what the problem statement asks you to determine in terms of the labeled variables.
4
• If you are given mixed mass and mole units for a stream (such as a total mass flow rate and component mole fractions or vice versa), convert all quantities to one basis.
5 • Do the degree-of-freedom analysis.
6
• Solve the equations (if DOF=0).
• Calculate the quantities requested in the problem statement if they have not already been calculated.
7
• If a stream quantity or flow rate ng was given in the problem statement and another value nc was either chosen as a basis or calculated for this stream, scale the balanced process by the ratio ng/nc to obtain the final result.
Flowcharts
A flowchart is drawn using boxes or other symbols to represent the
process units and lines with arrows to represent inputs and outputs
It must be fully labeled with values of known and unknown process
variables at the locations of the streams
Fresh feed
100 mols C3H8
P1 mols C3H8
P2 mols C3H6
P3 mols H2
product
Q1 mols C3H8
Q2 mols C3H6
Q3 mols H2
Qr1 mols C3H8
Qr2 mols C3H6
100 + Qr1 mols C3H8
Qr2 mols C3H6
Reactor separator
Flowcharts Labeling
Write the values and units of all known stream variables at the
locations of the streams on the flowchart.
For example, a stream containing 21 mole% O2 and 79% N2 at
320˚C and 1.4 atm flowing at a rate of 400 mol/h might be
labeled as:
400 mol/h
0.21 mol O2/mol
0.79 mol N2/mol
T = 320˚C, P = 1.4 atm
2 Ways to Label Process Stream
60 kmol N2/min
40 kmol O2/min
0.6 kmol N2/kmol
0.4 kmol O2/kmol
100 kmol/min
3.0 lbm CH4
4.0 lbm C2H4
3.0 lbm C2H6
0.3 lbm CH4/lbm
0.4 lbm C2H4/lbm
0.3 lbm C2H6/lbm
10 lbm
total amount or flow rate of the
stream with the fractions of each
component
amount or flow rate for
each component
Flowcharts Labeling
Assign algebraic symbols with units to unknown stream variables [such
as m (kg solution/min), x (lbm N2/lbm), and n (kmol C3H8)]
mol/h
0.21 mol O2/mol
0.79 mol N2/mol
T = 320˚C, P = 1.4 atm
n
400 mol/h
y mol O2/mol
(1-y) mol N2/mol
T = 320˚C, P = 1.4 atm
Consistent on Symbol Notation !!!
gasin fraction moles y
liquidin moles)or (massfraction component x
rate flow volumeV
volumeV
rate flowmolar n
moles n
rate flow mass m
mass m
Flowcharts Labeling
Try to reduce the number of unknown by using any relationship
information given
If that the mass of stream 1 is half that of stream 2, label the masses
of these streams as m and 2m rather than m1 and m2.
If you know that mass fraction of nitrogen is 3 times than oxygen,
label mass fractions as yg O2/g and 3yg N2/g rather than y1 and y2.
When labeling component mass fraction or mole fraction, the
last fraction must be 1 minus the sum of the others
Balance are not written on volumetric qualities
If volumetric flow rate of a stream is given, you still need to label
the mass or molar flow rate of this stream
Class Exercise
Two methanol-water mixture are contained in
separate flask. The first mixture contains 40wt%
methanol and the second flask contains 70wt%
methanol. If 200g of the first mixture combined with
150g of the second, what are the mass and
composition of the product.
Solution
Mixing
200 g
150 g
m g 0.40 g MeOH/g
0.60 g H2O/g
0.70 g MeOH/g
0.30 g H2O/g
x g MeOH/g
(1-x) g H2O/g
How many unit operation?
How many input stream?
How many outlet stream?
How many component?
Any reaction involve?
Any relationship information given?
What being asking?
etc….
Two methanol-water mixture are
contained in separate flask. The first
mixture contains 40wt% methanol
and the second flask contains 70wt%
methanol. If 200g of the first
mixture combined with 150g of the
second, what are the mass and
composition of the product.
Solution
Balance on TOTAL MASS (Input=Output)
200 g + 150 g = m g
m g= 350 g
Balance on MeOH (Input=Output)
x= 0.529 gMeOH/g
(1-0.529) g H2O/g = 0.471 g H2O/g
200 g 0.40 gMeOH +
150 g 0.70 gMeOH =
350 g x g MeOH
g g g
GMBE for BATCH process and NONREACTIVE;
Initial INPUT = Final OUTPUT
Class Exercise
An experiment on the growth rate of certain organism requires an environment of humid air enriched in oxygen. Three input streams are fed into an evaporation chamber to produce an output stream with the desired composition.
A: Liquid water fed at rate of 20 cm3/min
B: Air (21% O2 and 79% N2)
C: Pure O2 with a molar flow rate one-fifth 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 the flowchart of the process.
Solution
Evaporation
20 cm3 H2O (l)/min
mol H2O/min 2n
mol O2/min 1200.0 n
mol air/min 1n
mol/min 3n
0.21 mol O2 /mol
0.79 mol N2 /mol
0.015 mol H2O/mol
y mol O2 /mol
(0.985-y) mol N2/mol
A
B
C
Try This. Distillation column produce ethyl alcohol
Desired product at the top of distillation column
Waste at the bottom of distillation column
Given data
The fresh feed to distillation column is at 1000 kg/hr with 10
wt% of ethyl alcohol and water at 90 wt%
The mass flow rate for top product is at the ratio of 1 of 10
compared with the fresh feed
The composition % of top column is at 60 wt% of ethyl alcohol
Draw and label the flowchart of the process.