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1. Objectives
a. To recall importance of material balance in process industries
b. To familiarize terms of conservation of mass
c. To acquire knowledge on Mass balancing of process operations
2. Topic Learning Outcomes
After the completion of the class the students will able to:
6. Discussion
Law of conservation of mass
A material balance of an industrial process is an exact accounting of all the materials that
enter, leave, accumulate or are depleted in the course of a given time interval of operation. The
material balance is does an expression of the law of conservation of mass in accounting terms.
The overall material balance under steady state conditions is discussed in this unit. This unit
covers various operations like crystallization, extraction, drying, etc., Material balance assists in
the planning and design of processes, in the economic evaluation of the proposed and existing
processes, in the process control and in the process optimization. In the chemical process
industries, it is possible to produce a given end product from different raw materials. For an
appropriate choice of a process, it is very essential to compute the materials requirement for
these different routes. A properly listed material balance enables one to estimate to estimate the
material requirement for an existing process or for a process which is being planned. Material
balance can also assist in the simulation of processes based onm which certain financial
decisions can be made. Thus the material balance can be used in the hourly and daily operating
decisions to be made for running the process efficiently and economically.
In an industrial process, material balance provides an exact accounting of all the materials
that enter and leave and of the changes in the inventory of the materials in the course of a given
= Accumulation of material
within the system
01. If no chemical reaction is involved, nothing is gained by establishing material balances for
the chemical elements present. In such processes, material balances should be based on the
chemical compounds rather than on the elements, or on components of fixed composition even if
not pure chemical compounds.
02. If chemical reactions occur, it becomes necessary to develop material balances based on
chemical elements, or on radicals, compounds, or substances that are not altered, decomposed, or
formed in the process.
03. For processes wherein no chemical reactions occur, use of weight units such as grams or
pounds is preferable. For processes in which chemical reactions occur, it is desirable to utilize
the gram-mole or pound mole, or the gram-atom or pound-atom.
04. The number of unknown quantities to be calculated cannot exceed the number of
independent material balances available; otherwise, the problem of indeterminate.
05. If the number of independent material-balance equations exceeds the number of unknown
weights that are to be computed, it becomes a matter of judgment to determine which of the
equations should be selected to solve the problem. If all the analytical data used in setting up the
equations were perfect, it would be immaterial which equations were selected for use. However,
analytical data are never free from error, and a certain amount of discretion is necessary in order
06. Recognition of the maximum number of truly independent equations is important. Any
material-balance equation that can be derived from other equations written for the process cannot
be regarded as an additional independent equation.
07. If any two or more substances exist in fixed ratio with respect to one another in each stream
where they appear, only one independent material balance equations may be written with respect
to these substances. Although a balance may be written for any one substance in question, it is
generally best to combine the substances appearing in constant ratio into a single group and
develop a single equation for this combined group.
08. A substance that appears in but one incoming stream and one outgoing stream serves as a
reference for computations and is termed a tie substance. Knowledge of the percentage of a tie
substance in two streams establishes the relationship between the weights of the streams so that,
if one is known, the other can be calculated.
09. Material balances of processes involving chemical reaction is fall into two general classes:
(a)The compositions and weights of the various streams entering the process are known. It is
required to calculate the compositions and weights of the streams leaving the process for a
specified degree of completion of the reaction.
(b)The compositions and weights of the entering streams are partially known. It is required to
calculate the compositions and weights of all entering and leaving streams and to determine the
degree of completion of the reaction.
Draw a flowchart
Choose basis of calculations
Label unknown stream variables on the flowchart
Convert known stream volumes or volumetric flow rates to mass or molar basis
using densities or gas laws
Convert all mass and molar unit quantities to one basis
49 48.6
(a) % saturation = x
51 51.4
= 91.0%
Hence x = 81 kg
81
C) % yield = = 16.5%
490
Water = 870 kg
K2Cr2Or = 130 kg
Water remaining after concentration = 870 - 640 = 230 kg
230
= x 0.390 = 0.090 kg.mole or 0.090 x 294 = 26.4 kg
1000
103.6
% yield = = 79.7
130
03. An aqueous solution of sodium surface is saturated at 32.5 oC. Calculate the temperature to
which this solution must be cooled in order to crystallize 60% of the solute as Na 2SO4
10H2O.
Basis: 1000 kg of initial solution.
Mol.wt .ofNa 2 SO 4
Weight fraction of Na2SO4 in 10 H2O crystal =
Mol. wt. of Na 2 SO 4 10 H 2O
162.2
% FeCl2 in FeCl3 6H2O = = 60.0%
162.2 108
05. A solution of sodium sulfate in water is saturated at a temperature of 40 oC. Calculate the
weight of crystals and the percentage yield obtained by cooling 100 kg of this solution to a
temperature of 5oC.
Basis: 100 kg of original solution, saturated at 40oC
142
% Na2SO4 in Na2SO4 10H2O crystals = = 44.1%
142 180
06. The waste acid from a nitrating process contains 23% HNO 2 57% H2SO4 and 20% H2O by
weight. This acid is to be concentrated to contain 27% HNO 3 and 60% H2SO4 by the
addition of concentrated sulfuric acid containing 93% H2SO4 and concentrated nitric acid
containing 90% HNO3. Calculate the weights of waste and concentrated acids that must be
combined to obtain 1000 kg of the desired mixture.
Basis: 1000 kg of final mixture.
H2SO4 Balance
0.57 x + 0.93 y = 1000 x 0.60 = 600 (2)
HNO3 Balance
These results may be verified by a material balance of the water in the process:
Since the final solution contains 13% H2O, this result verifies the calculations.
8. Mind Map
04. A solution of ferric chloride in water contains 15 g-moles of FeCl2r 1000 grams of water.
(a) Calculate the composition of the resulting crystals in percentage of each hydrate formed
when this solution is cooled to 0oC. (b) Calculate the percentage of eutectic crystals
present in the total crystal mass.
05. In the manufacture of soda-ash by the LeBlanc process, sodium sulfate is heated with
06. A contract is drawn up for the purchase of paper containing 5% moisture at a price of Rs.50
per kg. It is provided that, if the moisture content varies from 5%, the price per pound shall
be proportionately adjusted in order to keep the price of the bone dry paper constant. In
addition, if the moisture content exceeds 5%, the purchaser shall deduct from the price paid
to the manufacturer the freight charges incurred as a result of the excess moisture. If the
freight rate is Rs.5 per kg, calculate the price to be paid for 3 tons of paper containing 8%
moisture.
07. A laundry can purchase soap containing 30% of water at a price of $6 per 100 lb of f.o.b.
the factory. The same manufacturer offers a soap containing 5% of water. If the freight rate
is 60 cents per 100 lb, what is the maximum price that the laundry should pay the
manufacturer for the soap containing 5% water ?
08. The spent acid from a nitrating process contains 33% H 2SO4, 36% HNO3 AND 31% H2O by
weight. This acid is to be strengthened by the addition of concentrated sulfuric acid
containing 95% H2SO4 and concentrated nitric acid containing 78% HNO3. The
strengthened mixed acid is to contain 40% H2SO4 and 43% HNO3. Calculate the quantities of