Material and Energy

Balance
Purpose of material and energy balance

• To Assess the input, conversion efficiency, output

and losses
• To quantify all material, energy and waste streams
in a process or a system
• To find out the difference between
calculated/designed values and measured/actual
values thereby making it possible to identify
previously unknown losses and emissions
• Powerful tool for establishing basis for
improvement and potential savings
 Sankey Diagram and its Use

• Useful tool to represent input and output energy flow in any energy equipment or
system
• Visual impact on input and output losses to enable energy managers to focus on
solutions
 Flow charts

Inputs of the process could include raw materials, water, steam, electricity
Process Steps should be sequentially classified
Wastes / by products could include solids, water, chemicals, energy
Output of the process is the final product produced in the plant.
 Facility as an Energy System

Raw material

Energy Facility Production Facility

100%
Energy
Transformer
Input
DG Set
Boilers
Chillers
Water Supplies

100%
Heat
Output

Product
 Energy use in plant

• Electrical energy which is usually purchased as

HT is converted into LT supply for end use.
• Some plants generate their own electricity using
DG sets or in captive power plants.
• Fuels such as furnace oil, coal are purchased
and then converted into steam or electricity.
• Boiler and Steam Supply System for heating
demand
• Cooling tower and Cooling water supply System
for cooling demand
• Air Compressors and Compressed air supply
System for compressed air needs
Boiler Plant System
Cooling Tower & Cooling Water Supply System
Compressed Air System
Guidelines for material and energy balance
• While splitting up the total system, choose, simple discrete sub-systems.
• Choose material and energy balance envelope such that, the number of
streams entering and leaving, is the smallest possible.

• The measurement units may include, time factor or production linkages.

• Consider a full batch as the reference in case of batch operations.
• It is important to include start-up and cleaning operation consumptions (of
material and energy resources (M&E).

• Calculate the gas volumes at standard conditions.

• In case of shutdown losses, averaging over long periods may be necessary.

• Highlight losses and emissions (M&E) at part load operations if prevalent.

• For each stream, where applicable, indicate energy quality (pressure,

temperature, enthalpy, Kcal/hr, Kw, Amps, Volts etc.).
Example/ Formula
i) Energy Supplied by Combustion: Q =Fuel consumed x Calorific value
 
ii) Energy Supplied by Electricity: Q = kWh x 860 kCals
Where, Q = thermal energy flow rate produced by electricity (kJ/h)
 
iii) Continuity Equation
 
A1V1 = A2V2
v1 v2
 
where, ‘V’ is the velocity in m/s , ‘v’ is the specific volume in m 3/kg and
‘A’ is the cross sectional area of the pipe in m2.
 
iv) Heat addition/rejection of a fluid = mCp diffTemp

where, m is the mass in kg, Cp is the specific heat in kCal/kg, DiffTemp is

the difference in temperature in k
 M & E Calculation Procedure
• Clearly identify the problem to be studied.
• Define a boundary that encloses the entire system or sub-system to be analysed.
Entering and leaving mass and energy flows must be measured at the boundary.
• The boundary must be chosen in such a way that:
• All relevant flows must cross it, all non-relevant flows being within
the boundary.
• Measurements at the boundary must be possible in an easy and
accurate manner.
• Select an appropriate test period depending on the type of process and product.
• Carry out the measurements.
• Calculate the energy and mass flow.
• Verify an energy and mass balance. If the balances are outside acceptable limits,
then repeat the measurements.
• The energy release or use in endothermic and exothermic processes should be
taken into consideration in the energy balance
Example:Heat Balance in a Boiler
 
73.8 % Heat in Steam

12.7 %
Heat
Dry Flueloss
Gasdue to dry flue gas
Loss

8.1 %
Heat loss due to hydrogen in fuel
Steam Boiler 1.7 % flue gas
100 %
Heat loss due to moisture in fuel

Fuel 0.3 %
Heat loss due to moisture in air

2.4 % Heat loss due to unburnts in residue

1.0 % Heat loss due to radiation &

other unaccounted loss
Mass Balance in a Cement Plant