CHAPTER NO 3

MATERIAL BALANCE

1
 Chapter No.3 3 Material Balance

3.1. Material Balance around Dryer:

F3 938.68kg/h
F1 1000 kg/h
Solids 97.20%
Solids 91.24%
Water 2.80%
Water 8.76%
DRYER

F2 61.32kg/h
Solids 0%
Water 100%

Basis: 1000 kg/h of biomass feed

Let the efficiency of dryer be 70%

So the feed F2 (moisture outlet) is;

F2 = (F1) (% of water) (dryer efficiency)

= (1000) (8.76%) (70%)

F2 =61.32 kg/hr

49
 Chapter No.3 3 Material Balance

So, applying overall balance on Dryer

F1 =F2 + F3

F3 =F1 – F2

=1000 – 61.32

= 938.63 kg/h

Applying component balance;

Water balance:

(x1) (F1) = (x2) (F2) + (x3) (F3)

(0.0876)(1000) = (1) (61.32) + (x3) (938.6)

X3 = 0.028

Outlet
Inlet (Biomass) Outlet (Moisture)
(Biomass)
Streams F1 F2 F3
Flow rates (kg/h) 1000 61.32 938.68
C 36.66 - 39.06
H 4.37 - 4.66
O 31.68 - 33.74
N 0.23 - 0.25
S 0.04 - 0.04
H2O 8.76 - 2.8
Ash 18.26 19.45

50
 Chapter No.3 3 Material Balance

3.2. Balance around Gasifier:

Basis: 938.68 kg of feed

F4 247.24 kg/h
(Air) %
O2 23
N2 77

F
F7 1318.914 kg/h
(Syngas) %
CO 33.031
3 938.68 kg/h
(Biomass) % 23.316
CO2
C 39.06
H2 4.66 H2 23.316
O2 33.74 14.5725
N2
N2 0.25
S 0.04 H 2S 0.0291
H2O 2.8
Ash 2.8
Ash 19.45

F5 279.05 kg/h F6 182.57 kg/h

(Steam) % (Ash) %
Water 100 Ash 100

Applying component mass balance:

C Balance:

(0.3906)(938.68) = (ωco) (F7) + (ωCO) (F7)

366.65 = (ωCO + ωC02) F7........................ (1)

51
 Chapter No.3 3 Material Balance

H2 balance:

(0.0466 + 0.028)(938.68) + (1) (F5) = (ωH2 + ωH2S) (F7)

70.03 + F5 = (ωH2 + ωH2S) (F7).................(2)

O2 Balance:

(0.3374 + 0.014) (938.68) + (0.23) (F4) + (1/2) F5 = (1/2 ωCO + ωCO2) (F7)

329.85 + 0.23F4 + 0.5F5 = (0.5ωC0 + ωCO2) (F7)…..............(3)

N2 Balance:

(0.0025)(938.68) + (0.770 (F4) = (N2) (F7)

2.35+0.77F4 = ( N2 ) (F7)…..................................................(4)

S-balance:

(0.04/100) × (938.68) = (H2S) (F7)

0.375 = (H2S) (F7)…...........................................................(5)

Ash Balance:

(0.1945) × (938.68) = (1) (F6)

F6 = 182.57kg/ h ash

Chemical Reaction

2.03C + 1.03 H2O + 0.5 O2 2.03CO + 1.03H2

Air Required:
0.3906×938.68 kg/h C 1 kgmol/h C 0.5 kgmol/h O2
12 kg/h C 2.03 kgmol/h C

O2 required = 7.53 kgmol O2

52
 Chapter No.3 3 Material Balance

Air required = Moles of O2 + Moles of N2

= 7.53 + 1

= 8.53kgmol air

F4 = 247.24 kg/h air

Steam Required:
0.3906×938.68 kg/h C 1 kgmol/h C 1.03 kgmol/h H2 O 1 kgmol/h H2O
12 kg/h C 2.03kgmol/h C 1 kgmol/h H2O

F5= 279.05 kg/h steam

Applying overall material Balance

Mass in = Mass out

F3 + F 4 + F 5 = F 6 + F 7

F7 = F 3 + F 4 + F 5 - F 6

938.68 + 247.24 + 279.05 - 182.57

F7 = 1282.4 kg/h syn gas

Put value of F7 in equation 5;

0.375 = (H2S) (1282.4)

H2S = 0.03

Put value of F7 & F4 in equation 4;

2.35 + 0.77(247.24) = (N2) (1282.4)

N2 = 0.15

53
 Chapter No.3 3 Material Balance

Put value of F5 H2S & F7 in equation 2;

H2 = 0.24

As we know that

ωCO + ωCO2 + ωN2 + ωH2S + ωH2 = 1

ωCO + ωCO2 + 0.15 + 0.03 + 0.24 = 1

ωCO + ωCO2 = 0.58
OR

ωCO = 0.58 - ωCO2................................................................ (6)

Putting values of ωCO, F4, F5 and F6 in equation (6)

329.85 + 0.23(247.24) + 0.5(279.05) = (0.5(0.58 - ωCO2) + ωCO2) (1282.4)

0.41 = 0 29 – 0.5ωCO2 + ωCO2

ωCO2 = 0.24

Put the value of ὠCO2 in equation (6)

ωCO = 0.58 – 0.24

ωCO = 0.34

From literature, 20% of Ash goes into syngas. So F7 will be:

Amount of gas coming out of gasifier = F7 + 20%Ash

=1282.4 + (20%) (18 2.57)

F7 = 1318.914 kg/h

54
 Chapter No.3 3 Material Balance

INLET OUTLET

Stream F9 F4 F5 F6 F7

Flow rates 938.68 247.24 (kg/h) 279.05 (kg/h) 146.06 1318.914

(kg/h) (kg/h) (kg/h)

Component

C 39.06 - - - -

H2 4.66 - - - 23.34

N2 0.25 77 - - 14.58

O2 33.74 23 - - -

S 0.04 - - - -

Ash 19.45 - - 100 2.77

H2O 2.8 100 - -

CO - - - - 33.06

CO2 - - - - 23.34

H2S - - - - 2.92

55
 Chapter No.3 3 Material Balance

3.3. Material Balance around Cyclone Separator:

Syngas in Cyclone Syngas Out

F11
F9
Separator Solids 0.56%
Solids 2.80%
Gas 97.20% Gas 99.44%

Solids
F12

Flow rate of syngas in = F9 = 1318.914 kg/h

Flow rate of syngas out = F11 =? Kg/h

Flow rate of Solids outlet = F12 =?

Kg/h Assume,

Efficiency of Cyclone separator =80 % = 0.8

so, the flow rate of outlet solids is,

F12 = (Efficiency of Separator) × (Flow rate of Syngas in) × (%age solids in

syngas)

F12 = 0.8 × 1318.914 × 0.028

F12 = 29.54 kg/h

So, for syngas outlet,

F11 = F9 – F12

F11 = 1318.914 – 29.54

F11 = 1289.37 kg/h

56
 Chapter No.3 3 Material Balance

INLET OUTLET

Stream F9 F12 F11

Flow rates 1318.914 kg/h 29.54 kg/h 1289.37 kg/h

Component

H2 23.34 - 23.834

N2 14.58 - 14.935

Ash 2.77 100 0.572

CO 33.06 - 33.858

CO2 23.34 - 23.834

H2S 2.92 - 2.967

57
 Chapter No.3 3 Material Balance

3.4. Material Balance around Separator:

Syngas in Syngas Out

F11
Separator F14
Solids 0.572% Solids 0%
Gas 99.428% Gas 100%

Solids
F13

It is now considered that the scrubber will remove remaining solids present in the
syngas.

Solids present in Syngas = 0.572% of F11 = 7.38 kg/hr

Amount of syngas = F11 = 1289.37 kg/hr

Solids removed = F13 =7.38 kg/hr

Amount of cleaned syngas = F12 = 1282 kg/hr

58
 Chapter No.3 3 Material Balance

INLET OUTLET

Stream F11 F13 F14

Flow rates 1289.37 kg/hr 7.38 kg/hr 1282 kg/hr

Component

H2 23.834 - 24

N2 14.935 - 15

Ash 0.572 100 0

CO 33.858 - 34

CO2 23.834 - 24

H2S 2.967 - 3

59
CHAPTER NO 4

ENERGY BALANCE

60
 Chapter No.4 Energy Balance

4.1. Energy Balance around Dryer:

Calorific value of biomass in F3 =32660 KJ/kg

Specific heat of air at T01= CP01 =1KJ/kg

Specific heat of air at T02= CPA =1KJ/kg

Specific heat of water at T2 = CPW =4.18 KJ/kg

HEAT IN

1) By Biomass

Q1 = F1 × C.V

= 1000 × 16885.7/3600

= 4690.47 KW

2) Air

Q01 = F01 × CP01 × ∆TF

=F01 × 1 × (343-298)

Q1 = 45F01 kW

HEAT OUT

1) By F2

Q2 = F2 × CP2 × ∆TF2

CP2 = (CPA + CPW)/2

= 2.59 KJ/kg-k

Q2 = (F1 + 61.32/3600) (2.59) (303 – 298)

Q2 = 12.95 (F1 + 0.017)

61
 Chapter No.4 Energy Balance

2) By F3

Q3 = F3 × CV

= (938.68/3600) × 32660

= 8515 KW

F1 CALCULATION

Total heat in = Total heat out

4690.47 + 45F01 = 12.95 (F01 + 0.017) +8515

F01 = 119.34 kg/s

F01 = 429613 kg/h

Then,

F02 = 429674.42 kg/h

Q1 = 5370.3 kW

Q2 = 1545.67 kW

HEAT LOSSES = (Q1 + Q2) – (Q3 + Q4)

= 0.1 KW

62
 Chapter No.4 Energy Balance

4.2. Energy Balance around Gasifier:

Total Energy In
Total Energy In = Energy in Biomass + Energy in Air + Energy in Steam

4.2.1. Energy in Biomass:

Mass flow-rate of Biomass = F3 = 938.68 kg/h

Temperature of Biomass = T3 = 50°C = 323K

Reference temperature of Biomass = Tr = 25°C = 298K

Specific heat capacity of Biomass = Cp = 1.926 kJ/kg-K

Energy entering in gasifier from Biomass = F3 × Cp × (T3-Tr)

Energy entering in gasifier from Biomass = 938.68 × 1.926 × (313-298)

Energy entering in gasifier from Biomass = 45197.44 kJ/h

Energy entering in gasifier from Biomass = 45197.44/3600

Energy entering in gasifier from Biomass = 12.55 kW

4.2.2. Energy in Air:

Mass flow-rate of Air = F4 = 247.24 kg/h

Temperature of Air = T4 = 304.8°C = 577.8K

Reference temperature of Air = Tr = 25°C = 298K

Specific heat capacity of Air = Cp = 1.073 kJ/kg-K

Energy entering in gasifier from Air = F4 × Cp × (T4-Tr)

Energy entering in gasifier from Air = 247.24 × 1.073 × (577.8-298)

Energy entering in gasifier from Air = 74227.73 kJ/h

63
 Chapter No.4 Energy Balance

Energy entering in gasifier from Air = 74227.73 /3600

Energy entering in gasifier from Air = 20.61 kW

4.2.3. Energy in Steam:

Mass flow-rate of Steam = F5 = 279.05 kg/h

Temperature of Steam = T5 = 400°C = 673K

Reference temperature of Steam = Tr = 25°C = 298K

Specific heat capacity of Steam = Cp = 2.083 kJ/kg-K

Latent Heat of Vaporization = λ = 2350 kJ/kg

Energy entering in gasifier from Steam = F5 × [Cp × (T5-Tr) + λ]

Energy entering in gasifier from Steam = 279.05 × [2.083 × (673-298) + 2350]

Energy entering in gasifier from Steam = 873740.4 kJ/h

Energy entering in gasifier from Steam = 873740.4/3600

Energy entering in gasifier from Steam = 242.71 kW

Total Energy In = Energy in Biomass + Energy in Air + Energy in Steam

= 12.55 + 20.61 + 242.71

Total Energy In = 275.87 kW

Total Energy Generated

Total Energy Generated = F3 × Cp × (T7 – T3)

Total Energy Generated = 938.68 × 1.926 × (1073 – 323)

Total Energy Generated = 1355923.26 kJ/h

Total Energy Generated = 1355923.26/3600

64
 Chapter No.4 Energy Balance

Total Energy Generated = 376.65 kW

Total Energy Out

Total Energy Out = Energy in Ash + Energy in Flue Gas
4.2.4. Energy in Ash:
Mass flow-rate of Ash = F6 = 146.06 kg/h

Temperature of Ash = T6 = 800°C = 1073K

Reference temperature of Ash = Tr = 25°C = 298K

Specific heat capacity of Ash = Cp = 0.514 kJ/kg-K

Energy leaving gasifier with Ash = F6 × Cp × (T6-Tr)

Energy leaving gasifier with Ash = 146.06 × 0.514 × (1073-298)

Energy leaving gasifier with Ash = 58183 kJ/h

Energy leaving gasifier with Ash = 58183/3600

Energy leaving gasifier with Ash = 16.16 kW

4.2.5. Energy in Syngas:

Mass flow-rate of Syngas = F7 = 1318.914 kg/h

Temperature of Ash = T7 = 800°C = 1073K

Reference temperature of Ash = Tr = 25°C = 298K

Specific heat capacity of Ash = Cp = 2.22 kJ/kg-K

Energy leaving gasifier with Ash = F7 × Cp × (T7-Tr)

Energy leaving gasifier with Ash = 1318.914 × 2.22 × (1073-298)

Energy leaving gasifier with Ash = 2269191.537 kJ/h

65
 Chapter No.4 Energy Balance

Energy leaving gasifier with Ash = 2269191.537/3600

Energy leaving gasifier with Ash = 630.33 kW

Total Energy Out = Energy in Ash + Energy in Syngas

= 16.16 + 630.33

Total Energy Out = 646.49 kW

4.2.6. Overall Energy Balance:

Energy Loss = Total Energy in – Total Energy Out + Total Energy Generated

Energy Loss = 275.87 – 646.49 + 376.65

Energy Loss = 6.03 kW

66
 Chapter No.4 Energy Balance

4.3. Energy Balance around Heat Exchanger:

F9 (Water In)

F7 (Syngas In) F8 (Syngas Out)

F10 (Water Out)

4.3.1. For Syngas:

Flow rate of syngas in = F7 = 1318.914 kg/h

Temperature of syngas in = T7 = 800°C = 1073K

Flow rate of syngas out = F8 = 1318.914 kg/h

Temperature of syngas out = T8 = 500°C = 773K

Specific heat capacity of syngas = Cps = 2.22 kJ/kg-K

4.3.2. For Water:

Flow rate of water in = F9 = x kg/h

Temperature of water in = T9 = 25°C = 298K

Flow rate of water out = F10 = x kg/h

Temperature of water out = T10 = 98.55°C = 371.55 K

67
 Chapter No.4 Energy Balance

Specific heat capacity of water = Cpw = 4.18 kJ/kg-K

Applying energy balance on heat exchanger

Energy in (Gas) + Energy in (Water) = Energy out (Gas) + Energy out (Water)

In mathematical form,

(F7×Cps×T7) + (F9×Cpw×T9) = (F8×Cps×T8) + (F10×Cpw×T10)

As F7 = F8 = 1318.914 kg/h and

F9 = F10 = x kg/h

So the equation can be written as

(F7×Cps×T7) + (F9×Cpw×T9) = (F7×Cps×T8) + (F9×Cpw×T10)

Or

F7 × Cps × (T7 – T8) = F9 ×[Cpw × (T10 – T9)]

Putting values,

1318.914 × 2.22 × (1073 – 773) = x × [4.18 × (371.55 – 298)]

x = 2857.141 kg/h

So,

F9 = 2857.141 kg/h

F10 = 2857.141 kg/h

68
 Chapter No.4 Energy Balance

So, heat in gas,

Qs = F7 × Cps × (T7 – T8)

Qs = 1318.914 × 2.22 × (1073 – 773)

Qs = 878396.724 kJ/h

Qs = 878396.724/3600

Qs = 244 kW

So, heat in gas,

Qw = F9 × [Cpw × (T10 – T9)]

Qw = 2857.141 × [4.18 × (371.55 – 298)]

Qw = 878396.57 kJ/h

Qw = 878396.57/3600

Qw = 244 kW

Energy Balance Around Heat Exchanger

Energy In
Stream Flow rate Cp (kJ/kg-K) T(K) Q = F × Cp × (T-Tr)
(kg/hr)
Syngas 1318.914 2.22 1073 630.33
Water 2857.141 4.18 298 0
Total Energy In = 630.33 kW
Energy Out
Stream Flow rate Cp (kJ/kg-K) T(K) Q = F × Cp × (T-Tr)
(kg/hr)
Syngas 1318.914 2.22 773 386.33
Water 2857.141 4.18 371.55 244
Total Energy Out = 630.33 kW

69
References:
Books:

1. David M. Himmelblau, “Basic Principles and Calculations in Chemical

Engineering”, 6th Edition, Prentice Hall PTR, 1996.

2. Coulson, J.M., and Richardson, J.F., “Chemical Engineering”, 4th Edition,

Volume 6, Butterworth Heminann, 1991.

3. D. Q. Kern, “Process Heat Transfer”, Mc-Graw Hill, 2000.

4. Levenspiel, O., “Chemical Reaction Engineering”, 3rd Edition, John Wiley

and Sons Inc., 1999.

5. Coulson, J.M., and Richardson, J.F., “Chemical Engineering”, 4th Edition,

Volume 1, Butterworth Heminann, 1991.

6. Coulson, J.M., and Richardson, J.F., “Chemical Engineering”, 4th Edition,

Volume 2, Butterworth Heminann, 1991.

7. Mc-Cabe, W.L., Smith, J.C., & Harriot, P., “Unit Operations of Chemical

Engineering”, 5th Edition, Mc-Graw Hill, Inc., 1993.

8. J. M. Smith, “Introduction to Chemical Engineering Thermodynamics”,

6th Edition, Mc-Graw Hill.

9. Perry, R.H and D.W.Green, “Perry`s Chemical Engineering Handbook”,

7th Edition, Mc-Graw Hill New York, 1997.

145
 10.George Stephanopoulos, “Chemical Process Control”.

11.Carlos A.Smith, Armando B. Corripio, “Principles and Practice of

Automatic Process Control”.

Soft-wares Used

1. MS- WORD 2010

2. MS- EXCEL 2010

3. MS-VISIO 2010

Websites Used:
1. http://www.undeerc.org/Equipment/Gasification-and-Gas-Cleanup-

Systems/Fluid-Bed-Gasifier.aspx

2. http://www.scribd.com/doc/3085035/Chemical-Analysis-of-Rice-Husk-Ash

3. http://www.knowledgebank.irri.org/rkb/rice-milling/byproducts-and-their-

utilization/rice-husk.html

4. http://en.wikipedia.org/wiki/Cyclonic_separation

5. http://en.wikipedia.org/wiki/Gasification

6. www.nrel.gov/docs/fy13osti/57085.pdf

7. http://www.matche.com/EquipCost/

146
8. http://www.netl.doe.gov/technologies/coalpower/cctc/cctdp/project_briefs/ta

mpa/tampaedemo.html

9. http://www.pres.org.pk/category/reaepakistan/energy-scenario/

10.http://www.bqpes.com/gasification-tech-types.php

11.http://maecourses.ucsd.edu/mae198/content/gasifier.shtml

12.http://manipursfac.com/an-attractive-alternative-electricity-from-rice-husk/

144
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