ABEN 4510 - FOOD PROCESS

ENGINEERING

MATERIAL AND ENERGY

BALANCE

May A. Cabral, MSc, ABE

Instructor

1
 TOPIC OUTLINE

• INTRODUCTION TO MASS AND ENERGY

BALANCE
• ANALYSIS AND COMPUTATION
 LEARNING OUTCOME

 Discuss the principles and concepts of mass and

energy balance
 Compute the mass balance of a system
I. INTRODUCTION TO MASS
AND ENERGY BALANCE
 Introduction

Material (mass and energy) balance

− Useful tool in the analysis of many
engineering problems
− Described the quantities of materials
in the unit operations in food
processing
− Governed with the law of conversation
of mass
 Introduction

Mass and energy balance

− Useful tool the formulation of the product, design
process, estimation of the cost and calculation of
the process efficiency
− process of tracking down the input material to a
process and the output from the process and the
accumulated amount of the product.
− selection and sizing of process equipment, the
required quantity of formulation, and the
information on energy inflow, outflow and conversion
can be determine and calculated
− engineer can gain the idea on where the loss or
conversion of energy takes place and find out means
to resolve the problem in the system
 Introduction

Mass and energy balance

− considered as the fundamental control of processing
particularly in the yield of the products

Exploratory stage
of product

Material balance

− Planning
− Testing − Changes in the
− Checking system
− Refine
− Maintain
 System and
Boundary

• mass (solid and liquid) balances is based

on the fact that in a given system under a
steady state condition, the total mass
entering a system is equal to the total
mass that leaves the system - Carpio
(2010)
• steady state condition of the system or
body happens when there is neither
accumulation nor decay of mass within the
confine of its boundary
 System and
Boundary
• System- any region prescribe in a
space or a finite quantity of
material enclosed by a boundary
(Singh and Heldman,2009)
• Boundary
– confinement of a given system
and it can be real such as
wall of the tanks or it can be
an imaginary surface that
encloses the systems.
Figure 1. A system containing a tank
– stationary or movable
with a discharge pipe and valve
(Source: Singh and Heldman, 2009)
• Surroundings- everything outside
the boundary
 System
1.Close system the boundary of any
system is impervious to flow of
mass which means that it doesn’t
exchange mass with its
surroundings.
− may exchange heat and work with
its surroundings that may result
in change in energy, volume or
other properties of the system,
but the mass remains constant
2.Open System
− also known as control volume is
considered when there is both
heat and mass that can flow into
and out of a system boundary
A close and open system (control volume) showing the
mass inlet and exit (Source: Singh and Heldman, 2009)
(control surface).
 Systems
1.Isolated system
− when mass, heat, or work does not exchange
with its surroundings
− no effect on its surroundings
2. Adiabatic System
− either closed or an open system
− when there is no exchange of heat that takes
place with the surroundings
3. Isothermal system
− happens when a process occurs at a constant
temperature often with an exchange of heat
with surrounding
 System Property

 State Properties
− refer to the physical condition of the
working substance such as temperature,
pressure, density, specific volume,
specific gravity or relative density
 Transport Properties
− refer to the measurement of diffusion
within the working medium resulting from
the molecular activity like viscosities,
thermal conductivities
 System Property

 Intensive Properties
− size independent such as
temperature, pressure and density
 Extensive Properties
− depends on the size or extent of the
system such as mass, volume and
total energy
 Law of Conservation
of Mass
• Mass can be neither created nor destroyed,
however, its composition can be altered from
one form to another.
– Even in the case of chemical reaction, the
reactant mass composition and the product before
and after the reaction may be different, but the
mass of the system remains unchanged
Rate of mass Rate of mass Rate of mass
entering through the exiting through accumulation
-- =
boundary of a system the boundary of within the system
the system

Inflow = Outflow + Accumulation

 Law of Conservation
of Mass
INFLOW OUTFLOW ACCUMULATION

 no accumulation
then the inflow is
 formation equal to outflow
of material  depletion of
and the process is
by chemical =
material + at steady state
through  there is
reaction or accumulation within
microbial chemical and the system, it is
growth biological an unsteady state,
reactions then the quantity
processes and concentration
of the components
in the system could
be change with the
time and process
 Steps in Material
Balancing
According to Singh and Heldman(2009), the following steps should
be advantageous in conducting a material balance.
a)Collect all known data on mass and composition of all inlet and
exit streams from the statement of the problem.
b)Draw a block diagram, indicating the process, with inlet and
exit streams properly identified. Draw the system boundary.
c) Write all available data on the block diagram.
d)Select a suitable basis (such as mass or time) for calculations.
The selection of basis depends on the convenience of
computations.
e)Write the material balances in terms of the selected basis for
calculating unknowns. For each unknown, an independent material
balance is required.
f) Solve material balances to determine the unknowns
ANALYSIS AND
COMPUTATION
 Mass Balance
• In any unit
operation in food
processing, the
nature of the system
as whole can be
represented through a
diagram (Figure 4).
• The mass and energy
that going into the
system must be
balance with the mass
and energy coming out
as stated in the law
of conservation of
mass. Figure 4. Mass and energy balance ( Source: Earle, R.L. and M.D.
Earle, 1966)
 Mass Balance
• The law of conservation of mass leads to material
balance which can be written using the equation
below:

𝑀𝑎𝑠𝑠 𝑖𝑛 = 𝑚𝑎𝑠𝑠 𝑜𝑢𝑡 + 𝑚𝑎𝑠𝑠 𝑠𝑡𝑜𝑟𝑒𝑑

𝑅𝑎𝑤 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 = 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 + 𝑤𝑎𝑠𝑡𝑒𝑠 + 𝑠𝑡𝑜𝑟𝑒𝑑 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠

 Mass Balance

෍ 𝑚𝑅 = ෍ 𝑚𝑃 + ෍ 𝑚𝑊 + ෍ 𝑚𝑆

෍ 𝑚𝑅 = 𝑚𝑅1 + 𝑚𝑅2 + 𝑚𝑅3 + ⋯ . = 𝑇𝑜𝑡𝑎𝑙 𝑅𝑎𝑤 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠

෍ 𝑚𝑃 = 𝑚𝑃1 + 𝑚𝑃2 + 𝑚𝑃3 + ⋯ . = 𝑇𝑜𝑡𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑠

෍ 𝑚𝑊 = 𝑚𝑊1 + 𝑚𝑊2 + 𝑚𝑊3 + ⋯ . = 𝑇𝑜𝑡𝑎𝑙 𝑊𝑎𝑠𝑡𝑒 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠

෍ 𝑚𝑆 = 𝑚𝑆1 + 𝑚𝑆2 + 𝑚𝑆3 + ⋯ . . = 𝑇𝑜𝑡𝑎𝑙 𝑆𝑡𝑜𝑟𝑒𝑑 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠

 Mass Balance
• If there is unknown losses, it still need to be
identified and the material balance will be as follow:

𝑅𝑎𝑤 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 = 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 + 𝑤𝑎𝑠𝑡𝑒𝑠 + 𝑠𝑡𝑜𝑟𝑒𝑑 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 + 𝑙𝑜𝑠𝑠𝑒𝑠𝑠

෍ 𝑚𝑅 = ෍ 𝑚𝑃 + ෍ 𝑚𝑊 + ෍ 𝑚𝑆 + ෍ 𝑚𝐿
 Energy Balance
•As mass is conserve, so is the energy is conserved too in
food processing operations.

•The energy coming into a unit operation can be balance

with the energy coming out and energy stored. This can be
written with the equation below:

𝐸𝑛𝑒𝑟𝑔𝑦 𝑖𝑛 = 𝐸𝑛𝑒𝑟𝑔𝑦 𝑜𝑢𝑡 + 𝐸𝑛𝑒𝑟𝑔𝑦 𝑠𝑡𝑜𝑟𝑒𝑑

 Energy Balance
෍ 𝐸𝑅 = ෍ 𝐸𝑃 + ෍ 𝐸𝑊 + ෍ 𝐸𝐿 + ෍ 𝐸𝑆

෍ 𝐸𝑅 = 𝐸𝑅1 + 𝐸𝑅2 + 𝐸𝑅3 + ⋯ . = 𝑇𝑜𝑡𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦 𝐸𝑛𝑡𝑒𝑟𝑖𝑛𝑔

෍ 𝐸𝑃 = 𝐸𝑃1 + 𝐸𝑃2 + 𝐸𝑃3 + ⋯ . = 𝑇𝑜𝑡𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦 𝐿𝑒𝑎𝑣𝑖𝑛𝑔 𝑤𝑖𝑡ℎ 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑠

෍ 𝐸𝑊 = 𝐸𝑊1 + 𝐸𝑊2 + 𝐸𝑊3 + ⋯ . = 𝑇𝑜𝑡𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦 𝐿𝑒𝑎𝑣𝑖𝑛𝑔 𝑤𝑖𝑡ℎ 𝑊𝑎𝑠𝑡𝑒 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠

෍ 𝐸𝐿 = 𝐸𝐿1 + 𝐸𝐿2 + 𝐸𝐿3 + ⋯ . = 𝑇𝑜𝑡𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦 𝐿𝑜𝑠𝑡 𝑡𝑜 𝑆𝑢𝑟𝑟𝑜𝑢𝑛𝑑𝑖𝑛𝑔𝑠

෍ 𝐸𝑆 = 𝐸𝑆1 + 𝐸𝑆2 + 𝐸𝑆3 + ⋯ . = 𝑇𝑜𝑡𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦 𝑆𝑡𝑜𝑟𝑒𝑑

 Energy Balance
• The overall energy balance equation for a system with H = enthalpy, J/kg
one inlet and one outlet can be mathematically 𝒗𝒎 = average velocity, m/s
written as (Yanniotis, 2008): 𝜶 = correction coefficient (for
circular pipe 𝛼 =1/2 for
𝑉𝑚1 2 𝑉𝑚2 2 𝑑 𝑚𝐸 laminar flow, 𝛼 = 1 for
𝐻1 + + 𝑧1 𝑔 𝑚ሶ 1 − 𝐻2 + + 𝑧2 𝑔 𝑚ሶ 2 + 𝑞 − 𝑊𝑠 = turbulent flow
2𝛼 2𝛼 𝑑𝑡
z = relative heigh from
reference plane, m
m = mass of the system , kg
• Moreover, the overall energy balance equation for a
𝒎ሶ =mass flow rate, kg/s
system at a steady state with more than two streams
q= heat transferred across the
can be written as (Yanniotis, 2008):: boundary
𝑾𝒔 =shaft work done by or to
𝑉𝑚 2
෍ 𝐻1 + + 𝑧𝑔 𝑚ሶ = 𝑞 − 𝑊𝑠 the sytem (positive if work
2𝛼 is done by the system), W
E = total energy per unit mass
of fluid in the system, J/kg
t = time, s
 Energy Balance

• In most of the cases, the overall energy

balance ends up as an enthalpy balance because
the terms of kinetic and potential energy are
negligible compared to the enthalpy term, the
system is assumed adiabatic (Q=0) and there is
no shaft work (Ws =0). Then

෍ 𝑚𝐻
ሶ =0
 Illustrative
Problems
1. How much dry sugar must be added in 100 kg of aqueous
sugar solution in order to increase its concentration from 20%
to 50%?
Assumption: Dry sugar is composed of 100 % sugar
Process diagram
 Overall mass balance:

100 + S2 = S3 (eq 1)

 Soluble solids mass balance:

0.2 (100kg) + S2 = 0.5 (S3) (eq. 2)

 Solving equation 1 and 2 simultaneously,

(0.2*100kg) + S2 = (0.5)(100kg + S2)

20 + S2 = 50kg + 0.5S2

𝑆2 = 30/0.5 = 60 kg

∴ 𝑆3 = 100𝑘𝑔 + 𝑆2 = 100𝑘𝑔 + 60𝑘𝑔 = 𝟏𝟔𝟎 𝒌𝒈

 Conclusion: 60 kg of dry sugar per 100 kg of feed must be added to

increase its concentration from 20% to 50 %.
2. Fresh orange juice with 12% soluble solids
content is concentrated to 60% in a multiple
effect evaporator. To improve the quality of
the final product the concentrated juice is
mixed with an amount of fresh juice (cut
back) so that the concentration of the mixture
is 42%. Calculate how much water per hour
must be evaporated in the evaporator, how
much fresh juice per hour must be added
back and how much final product will be
produced if the inlet feed flow rate is 10, 000
kg/h fresh juice. Assume steady state.
  Assumption: steady state

 Overall mass balance in Envelop I:

10,000kg/h = W + X (eq 1)
 Soluble solids mass balance in Envelop I:
0.12 * 10,000kg/h = 0.60X (eq. 2)
 Overall mass balance in Envelop II:
X+F=Y (eq 3)
 Soluble solids mass balance in Envelop II:

0.6 X + 0.12F =0.42Y (eq. 4)

 From equation 2 find X, then substituting X in equation 1 and find

W. Solve equation simultaneously.

 From eq 2

0.12(10,000kg/h) =0.6X

X= 2000 kg/h

 From eq 1, substituting the value of X

W= 10,000kg/h -2,000kg/h

W= 8,000kg/h

 From equation 3, substituting the value of X

2000 kg/h + F =Y (eq. 5)

 From eq 4 and 5, substituting value of X and solving simultaneously

0.6X + 0.12F=0.42Y

0.6 (2000 kg/h) + 0.12F = 0.42 (2000kg/h + F)

1200 kg/h + 0.12F = 840kg/h + 0.42 F

1200−840 𝑘𝑔/ℎ
𝐹=
(0.42−0.12)

F= 1200 kg/h

 Substituting the value of F to eq 5

Y= 2000 kg/h + 1200 kg/h

Y = 3200 kg/h

 Therefore: 8000 kg/h of water will be evaporated, 1200 kg/h of fresh

juice will be added back and 3200 kg/h of concentrated orange juice
with 42% soluble solids will be produced.
3. 1000 kg/h of a fruit juice with 10% solid is freeze-concentrate to
40% solids. The dilute juice is fed to a freezer wherein the ice
crystals are formed and then the slush is separated in a centrifugal
separator into ice crystals and concentrated juice. An amount of
500 kg/h liquid is recycled from the separator to the freezer.
Calculate the amount of ice that is removed in the separator and
the amount of concentrated juice produce. Assume steady state.

 Assumption: Steady state

 Overall mass balance:
1000kg/h = I + J (eq 1)
 Soluble solids mass balance:
0.1 (1000kg/h) = 0.40 J (eq. 2)
 From Equation 2, we solve for J and then substituting J from equation 1,
we solve for I. Then
 From equation 2,
(0.1∗1000𝑘𝑔/ℎ)
𝐽= =250kg/h
0.4
 Substituting the value of J to equation 1, then
I= 1000kg/h – J
I = 1000 kg/h – 250 kg/h
I= 750 kg/h
 Note: Notice that the recycle stream does not affect the result, Only the
streams that cut the envelope take part in the mass balance.
4. 10000 kg/h milk is heated in a heat exchanger from 45°C to 72°C. Water is used as a
heating medium. It enters the heat exchanger at 90°C and leaves at 75°C. Calculate
the mass flow rate of the heating medium, if the heat losses to the environment are
equal to 1 kW. The heat capacity of water is given equal to 4.2kJ/kg°C and that of
milk is 3.9kJ/kg°C.

 Assumptions:
 The terms of kinetic and potential energy in the energy balance equation are
negligible.
 A pump is not included in the system (Ws= 0)
 The heat capacity of the liquid stream does not change significantly with
temperature
 The system is at steady state.
 Energy balance equation:
𝑅𝑎𝑡𝑒 𝑜𝑓 𝑒𝑛𝑒𝑟𝑔𝑦 𝑖𝑛𝑝𝑢𝑡 = 𝑚ሶ 𝑤𝑖𝑛 𝐻𝑤𝑖𝑛 + 𝑚ሶ 𝑚𝑖𝑛 𝐻𝑚𝑖𝑛
𝑅𝑎𝑡𝑒 𝑜𝑓 𝑒𝑛𝑒𝑟𝑔𝑦 𝑜𝑢𝑡𝑝𝑢𝑡 = 𝑚ሶ 𝑤𝑜𝑢𝑡 𝐻𝑤𝑜𝑢𝑡 + 𝑚ሶ 𝑚𝑜𝑢𝑡 𝐻𝑜𝑢𝑡 + 𝑞
 At steady state:
𝑚ሶ 𝑤𝑖𝑛 𝐻𝑤𝑖𝑛 + 𝑚ሶ 𝑚𝑖𝑛 𝐻𝑚𝑖𝑛 = 𝑚ሶ 𝑤𝑜𝑢𝑡 𝐻𝑤𝑜𝑢𝑡 + 𝑚ሶ 𝑚𝑜𝑢𝑡 𝐻𝑜𝑢𝑡 + 𝑞
 Calculating the known terms:
 Enthalpy of water stream is :
4.2kJ 378𝑘𝐽
Input: 𝐻𝑤𝑖𝑛 = 𝑐𝑝 𝑇 = − °C 90 °C =
kg 𝑘𝑔

Output: 𝐻𝑤𝑜𝑢𝑡 = 𝑐𝑝 𝑇 = 4.2kJ/kg − °C 75 °C = 315𝑘𝐽/𝑘𝑔

 Enthalpy of milk stream
Input: 𝐻𝑚𝑖𝑛 = 𝑐𝑝 𝑇 = 3.9kJ/kg − °C (45°C ) = 175.5 𝑘𝐽/𝑘𝑔
Output: 𝐻𝑚𝑜𝑢𝑡 = 𝑐𝑝 𝑇 = 3.9kJ/kg − °C 72 °C = 280.8𝑘𝐽/𝑘𝑔
 Substituting the values above and taking into consideration that
𝑚ሶ 𝑤𝑖𝑛 = 𝑚ሶ 𝑤𝑜𝑢𝑡 = 𝑚ሶ 𝑤 𝑎𝑛𝑑 𝑚ሶ 𝑚𝑖𝑛 = 𝑚ሶ 𝑚𝑜𝑢𝑡

Then,
𝑚ሶ 𝑤𝑖𝑛 𝐻𝑤𝑖𝑛 + 𝑚ሶ 𝑚𝑖𝑛 𝐻𝑚𝑖𝑛 = 𝑚ሶ 𝑤𝑜𝑢𝑡 𝐻𝑤𝑜𝑢𝑡 + 𝑚ሶ 𝑚𝑜𝑢𝑡 𝐻𝑜𝑢𝑡 + 𝑞

𝑚ሶ 𝑤 (378𝑘𝐽/𝑘𝑔) + 1000(175.5𝑘𝐽/𝑘𝑔)
= 𝑚ሶ 𝑤 (315𝑘𝐽/𝑘𝑔) + (1000)(280.8𝑘𝐽/𝑘𝑔) + (1𝑘𝐽/𝑠)(3600𝑠/ℎ)

𝑚ሶ 𝑤 = 1728.6𝑘𝑔/ℎ
 QUIZ
1. In a jam making process, fruits with 14%
solids are mixed with sugar in proportion of
1: 1.22 (fruit: sugar). The mixture is then
placed in an evaporator to remove the
moisture and to obtain the final product
(jam) with 67% solids. Per kg of fruit, how
much jam is produced? How much water is
removed?
2. The dried vegetable containing 7% moisture
(wet basis) was conveyed to a water
spraying chamber. If the moisture content of
the vegetable is required to raised to 35%
(wet basis), find the amount of water
sprayed to the vegetable.
 References

• Carpio, 2000. E.V. Engineering for Food Technologist. UPLB Publishing Center.

• Singh R. P and Heldman, D.R.. 2009. Introduction to Food Engineering Fourth Edition. Elsevier Inc.
Retrieved at http://www.ucarecdn.com/fb7332e8-c35a-47b0-9805-051fa171f8fa/.

• Park, S.H, Lamsal, B. P and Balasubramaniam.2014. Principles of Food Processing. Ohio State
University, USA. Retrieved at https://www.academia.edu/35933662/Principles_of_Food_Processing

• Yanniotis S.. 2008. Solving Problems in Food Engineering. Springer. Retrieved at

https://link.springer.com/book/10.1007/978-0-387-73514-6

• Earle, R.L. and M.D. Earle. 1966. Unit Operations in Food Processing. Retrieve at
https://nzifst.org.nz/resources/unitoperations/matlenerg.htm

• Mass and Energy Balance. Retrieved athttps://www.cpp.edu/~tknguyen/che302/Notes/chap4-1.pdf

• Alshanableh, F. 2012. Lecture Notes. Material and Energy Balance. Retrieved at

http://old.staff.neu.edu.tr/~filiz/file/FDE201/FDE%20201%20-%20Lecture%20Notes.pdf
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