MEB Chapter 3.1

ADDIS ABABA UNIVERSITY
ADDIS ABABA INSTITUTE OF TECHNOLOGY

SCHOOL OF CHEMICAL AND BIOENGINEERING
Introduction to Chemical Engineering (ChEg

2101)
CHAPTER THREE
MATERIAL BALANCES
1
3. INTRODUCTION
What is Material & Energy Balances (MEB) ?
 Material and Energy balances are the foundation of Chemical

Engineering.
 Known as the ‘accountancy’ of Chemical Engineering.
 MEB tells how much material and energy has gone in, how much has
been used and how much has been wasted.
 MEB is the application of the law of conservation of mass: Matter is

neither created nor destroyed and also apply the law that energy is neither
created nor destroyed - simply converted into another form of energy.
INTRODUCTION
What is Material & Energy Balances (MEB) ?
 Matter flow through a control volume and may be reacted to form another
species, but, no matter is lost or gained.
 Conversion between different forms of energy: heat, work, kinetic energy,

potential energy, internal energy, and enthalpy.
 The ideas that matter and energy cannot be lost nor gained can be
extrapolated into the basic form of the equation:
Accumulation = Input - Output + Generation - Consumption

INTRODUCTION…
Why MEB?
 To find out how much material and energy are going in and how
much are going out. (WHY? Remember task of a chemical
engineer….)
 To improve efficiency in use of material and energy.
 To increase profit by maximizing useful products
 Waste minimization
3.1. Revision on process classifications
Distinguish the following processes :

• Batch
• Semi-batch
• Continuous
• Steady-State (SS)
• Unsteady-State (Transient)
Batch Process
Batch
“The feed is charged (fed) into a vessel at the

beginning of the process and the vessel contents
are removed sometime later. No mass crosses the
system boundaries between the time the feed is
charged and the time the product is removed.”
Felder and Rousseau (2000), p.84.
Continuous Process
Continuous Process
“The inputs and outputs flow continuously

throughout the duration of the process.”
Semi-batch Process
Semi-batch
“Any process that is NEITHER Batch NOR

Continuous.”
Comparison
Batch Continuous Semi-batch
• Rapidly add • Pump a mixture of • Allow the contents
reactants to a liquids into a of a pressurized gas
tank& remove distillation column container to escape
the products & at a constant rate & to the atmosphere.
unconsumed steadily withdraw • Slowly blend several
reactants some product streams liquids in a tank
time later from from which nothing
when the the top & bottom of is being withdrawn.
system has the column.
come to
equilibrium.
Steady-State & Transient Processes
If the values of all the variables in a process (i.e., all pressures,

temperatures, volumes, flow rates) do not change with time, except
possibly for minor fluctuations, about constant mean values, the
process is said to be operating at steady-state. If any of the process
variables change with time, transient or unsteady-state operation
is said to exist.
By their nature, batch and semi-batch processes are unsteady-
state operations, whereas continuous processes may be either
steady-state or transient.
Classify the following processes as batch,
continuous, or semi-batch , and transient or
steady-state
• A balloon is filled with air at a steady rate of 2

g/min.
• A bottle of milk if taken from the refrigerator
and left on the kitchen table.
• Water is boiled in an open flask.
3.2. The General Material Balance Equation
and Its Forms
Unit Operation
Input - Output + Generation - Consumption = Accumulation
IN: Enters through system boundaries. Remarks

OUT: Leaves through system • If SS, Acc. = 0
boundaries.
Gen: •For non reactive
Produced within system. SS processes,
Cons:
Consumed within system.
Acc: IN =
Build-up within system. OUT
The General Material Balance Equation and Its Forms…
General Balance
GEN
OUT
IN ACC.
CONS
Equation
Definition:
 A system: in general terms a system is any portion of a
process that can be enclosed within a hypothetical box
(called system boundary). It may be the entire process,
an interconnected combination of some of the process
units, a single unit, or a point at which two or more
process streams come together or one stream splits
into branches. The inputs and outputs to a system are
the process streams that intersect the system boundary.
FEED-2 SYSTEM BOUNDARY

A
C E
B
FEED-1
D PRODUCT-3
PROCESS-1 PROCESS-2
PRODUCT-1 PRODUCT-2 FEED-3
Exercise:
Identify other system boundaries apart from A, B, C, D
& E from the above diagram.
Example:Consider the population of Ethiopia over one year ,

Other
North Nations
America
Arab
ary countries
nd
ou
B
t e m
s
Sy
Population Growth = People Entering - People Leaving
+ People Born - People Die

Material Balance Approaches

Two Ways to Approach:
1.Total Mass Balance Plus N-1 Components
2. N Components (Molecular Components)
Mass Balance
Simplifications of the General Material Balance Equation

The following rules may be used to simplify the material balance
equation:
If the balanced quantity is total mass, set generation = 0 and
consumption = O. Except in nuclear reactions, mass can neither be
created nor destroyed.
If the balanced substance is a nonreactive species (neither a reactant
nor a product), set generation = 0 and consumption = O .
If a system is at steady state, set accumulation = 0, regardless of what is
being balanced. By definition, in a steady-state system nothing can
change with time, including the amount of the balanced quantity.
 If the system does not change with time (at steady state), then
net accumulation is ZERO.
0
Accumulation = Input - Output
+ Generation - Consumption
The generation & consumption terms are the consequences of

chemical reaction. If there is no reaction, the generation and
consumption terms are ZERO.
Accumulation = Input - Output

Forms of the General Balance Equation
Differential Form
• All the terms are rates. Indicate what is happening in a system at an instant
of time.
• The best choice is for a continuous process.
Example: The figure describes a mixing tank problem. The operation is at

continuous steady state. Find all flows and compositions.
F2 40 Ibm/hr C
F1 F3
100 Ibm/hr 150 Ibm/hr
Mixing
50wt% A 75% A
50wt% B 25% B
F4 Product
F2 40 Ibm/hr C
Solution: F1 F3
100 Ibm/hr Mixing 150 Ibm/hr
50wt% A 75% A
50wt% B 25% C
F4 Product
Start with general balance equation & simplify: A steady state

process – accumulation is zero. Mixing process/no reaction –
generation & consumption is zero.
Total balance: Input = Output
F1 + F2 + F3 = F4
F4 = 100 + 40 + 150 = 290 Ib/hr
F2 40 Ibm/hr C
F1 F3
100 Ibm/hr 150 Ibm/hr
Mixing 75% A
50wt% A
50wt% B 25% C
F4 Product
x-A, x-B, x-C
To determine the composition, again start with the general balance & simplify
- steady state & no reaction - no generation & consumption: INPUT =
OUTPUT
- -- -
Balance for A: F1xA + F2xA + F3xA = F4xA
-
(100)(0.5)+(40)(0)+(150)(0.75) = (290)xA
-
(50 + 112.5)- / 290 = xA
x = 0.56 Ibm A/Ibm product
F2 40 Ib/hr C
F1 F3
100 Ib/hr Mixing 150 Ib/hr
50wt% A 75% A
50wt% B F4 Product 25% C
-- -
xA, xB, xC
Similarly for B: Similarly for C:
- - - - - - - -
F1xC + F2xC + F3xC = F4xC
F1xB + F2xB + F3xB = F4xB
- (100)(0)+(40)(1)+(150)(0.25) = (290)x-
(100)(0.5)+(40)(0)+(150)(0) = (290)xB - C
- 77.5 / 290 = xC
50
- / 290 = x B -
xB = 0.17 Ibm B/Ibm product xC= 0.27 Ibm C/Ibm product
Check: x-A + x-B + x-C = 0.56 + 0.17 + 0.27 = 1.0

Integral Form
• Using total amounts of the balanced quantity as
terms.
• Describes what happens between two instants
of time – hence applied to batch and semi-
batch processes.
3.3. GENERAL MATERIAL BALANCE PROCEDURE
1. Draw the Flow Diagram (Flow Chart)
•Identify the units (unit operations)
•Identify the input/output streams to that
particular unit(s) – Label them.
•Write down flow conditions at each
stream - flow rates, mass/mole
fractions, temp, pressure

3.3. GENERAL MATERIAL BALANCE PROCEDURE…
2. Scale up/down the flow chart
• Before we proceed with the problem solving procedure, one

important thing to highlight regarding the flowchart is the ability
to be scaled up and/or down.
• Scaling up or scaling down the flowchart requires a balanced

system.
• Only the masses, moles and flow rates can be scaled up or

scaled down (NOT THE FRACTIONS)
3.3 GENERAL MATERIAL BALANCE PROCEDURE…
2. Scale up/down the flow chart…

1 kg C6H6
2 kg
0.5 kgC6H6/ kg
1 kg C7H8 0.5 kgC7H8/ kg
Scale up x
300
300 kg C6H6
600 kg
0.5 kgC6H6/ kg
300kg C7H8 0.5 kgC7H8/ kg
Replace kg
with Ibm
300 Ibm C6H6/h
600 Ibm/h
0.5 Ibm C6H6/Ibm
300 Ibm C7H8/h 0.5 Ibm C7H8/Ibm
3.1 GENERAL MATERIAL BALANCE PROCEDURE…
3. Choose a basis for calculation
• Usually an amount (moles or mass) or flow rates (molar or mass)

of a stream or component in the process.
• All unknown variables must then be consistent with this basis.
• Early in the solution of most balance problems, must choose a

“basis of calculation” - a reference you choose for the calculations
you plan to make.
4. Express the problem statement
• Put in terms of a labeled variable
5. Put all in one unit
• Amounts as well as compositions
6. Degree of Freedom (DoF) Analysis
•Is the procedure of determining whether there is enough

information to solve a given problem:
DoF = No. of Independent Variables/Unknowns
-
No. of Independent Equations
 If DoF = 0, fully specified and the equation can be solved.
 If DoF > 0, more unknowns than the equations, under

specified.
 If DoF < 0, more independent equations, over specified

6. Degree of Freedom (DoF) Analysis…
Equations are independent when there is no equation that can be

obtained by linear combination of others in the set.
Example: Solve the systems of equation:

i. x + 2y + z = 1 ii. x + 2y + z = 1
2y + 4z = 10 2x + y – z = 2
y + 2z = 5 y + 2z = 5
Could not be solved – under specified Can be solved
7. Solve the Problem (Do the Algebra)

3.4 Material Balances on Non Reactive
Processes
3.4.1 Balances on Single-Unit Non Reactive Processes
Example 1: Material Balances on Distillation Column
A liquid mixture of benzene (B) and toluene (T) containing 55% B by mass is
fed continuously to a distillation column with a feed rate of 100 kg/h. A product
stream leaving the top of the column (overhead product) contains 85% B and
a bottom product stream contains 10.6% B by mass.
Determine the mass flow rate of the overhead product stream and the mass
flow rate of the bottom product stream.
Solution:
(1) Draw the boxes and arrows: Write all known stream variables at
the streams on the chart. Assign algebraic symbols to unknown
stream variables.

mV kg/h
0.850 kg B/kg
0.150 kg T/kg
100 kg/h
DISTILLATION
COLUMN
0.550 kg B/kg

0.450 kg T/kg mL kg/h
0.106 kg B/kg
0.894 kg T/kg
(2) Scaling-up/down: No need to to scale-up/down.

(3) Basis of calculation:
 quantity of some thing (stream component) which we fix and make all
other calculations based on it.
 Use the amount or flow rate given in process statement (e.g.100 kg or
1000 kg/h).
 If not given, assume one. In the example given, the given feed stream
flow rate 100 kg/h is used as the basis of calculation.
(4) Problems:
 express what the problem asks you to determine.
 Based on the questions, we need to determine
. mass. flow rate for top &
bottom product streams; mV and mL (in our chart) respectively.
(5) Conversion of units:

 For consistency and convenience in the calculation.
(6) Perform Degree-of-Freedom (DoF) Analysis
DoF = V – E DoF must be zero to be solved
V=2 m V & m L
 Material Balance for B and T,
E=2
 material balance for overall and B, or overall and T
DoF = Unknowns - Independent Equation

= 2-2
= 0 (the problem is solvable)
Write the general balance equation:
(Remember: Input + Gen. - Output - Consumption = Acc.)
Continuous/SS: Acc. = 0
Input = output
Non-reactive: Gen. = 0, Cons. = 0

mV kg/h
0.850 kg B/kg Total balance:
0.150 kg T/kg
100 kg/h = m V + m L A
100 kg/h
DC
0.550 kg B/kg

mL kg/h Benzene balance:
0.450 kg T/kg
0.106 kg B/kg 100 (0.550) kg B
0.894 kg T/kg h
 + 0.106 m B
= 0.850 mV L
(7) Do the Algebra
Solve equations A and B simultaneously:
The results are: m V = 59.7 kg/h


mL = 40.3 kg/h
Example 2: (Problem 4-20 Felder and Rousseau)
Wet air containing 4.0 mole% water vapor is passed through a column of
calcium chloride pellets. The pellets adsorb 97.0% of the water and none of the
other constituents of the air. The column packing was initially dry and had a
mass of 3.40 kg. Following 5.0 hours of operation, the pellets are reweighed and
found to have a mass of 3.54 kg.
a)Calculate the molar flow rate (mol/h) of the feed gas and mole fraction of
water vapor in the product gas.
b)The mole fraction of water in the product gas is monitored and found to have
the value calculated in part (a) for the first 10 hours of operation, but then
begin to increase. What is the most likely cause of the increase? If the process
continues to run, what will the mole fraction of water in the product gas
eventually be?
Solution:
(a) Calculate the molar flow rate (mol/h) of the feed gas and mole fraction of
n 1 (mol / h) n 2 (mol / h)
Unit Op. x mol H2O / mol
0.040 mol H2O / mol
0.960 mol DA / mol
CaCl2 (1 - x) mol DA / mol
Note n 3 (mol H 2O adsorbed / h)

DA = Dry Air 97.0% of H2O in feed
Solution…
Overall Mole Balance
n 1  n 2  n 3 1
Component Mole Balance

H2O : 0.040n 1  x  n 2  n 3 2
DA : 0.960n 1  (1  x)  n 2 3
Solution…
calcium chloride pellets. The pellets adsorb 97.0% of the water and none of
the other constituents of the air. The column packing was initially dry and
had a mass of 3.40 kg. Following 5.0 hours of operation, the pellets are
reweighed and found to have a mass of 3.54 kg.
Problem ! We need 2 additional

4 unknowns : n 1 , n 2 , n 3 , x information!
2 independent equations H2O adsorption rate & 97%
H2O adsorption
Degree of Freedom ?
DoF = Unks.  IE  Under-specified
=4–2
DoF = + 2  Over-specified
Solution…
Wet air containing 4.0 mole% water vapor is passed through a column of calcium chloride pellets.
The pellets adsorb 97.0% of the water and none of the other constituents of the air. The column
packing was initially dry and had a mass of 3.40 kg. Following 5.0 hours of operation, the pellets are
reweighed and found to have a mass of 3.54 kg.
(a) Calculate the molar flow rate (mol/h) of the feed gas and mole fraction of water vapor in the
product gas.
H2O Adsorption Rate (3.54  3.40) kg 1 mol H 2O

n 3    1.56 mol H 2O / h
5h 0.0180 kg H 2O
97% H2O (of the input stream) adsorbed 0.97(0.040n 1 )  1.56  n 1  40.1 mol / h
O/All Balance : n 1  n 2  n 3  n 2  40.1  1.56  38.54 mol / h
H2O Balance : 0.040n  x  n  n

1 2 3  x  1.2 x 10 5 mol H 2O / mol
Note : We can also employ DA balance to calculate x.

Solution…
b) The mole fraction of water in the product gas is

monitored and found to have the value calculated in (a)
for the first 10 hours of operation, but then begin to
increase. What is the most likely cause of the
increase? If the process continues to run, what will the
mole fraction of water in the product gas eventually
be?
 Calcium chloride pellets must have reached
saturation.
 Mole fraction of water vapor reaches 4.0%.
3.4.2 Material Balances On Multiple-unit Non Reactive
Processes
 Industrial chemical processes involve more than one

unit operation.
 Most processes consist of a number of interconnected

unit processes. Streams will split and/or combine.
3.4.2 Material Balances On Multiple-unit Non Reactive Processes
Determining a full set of flows and compositions will usually

require writing balances around various groups of equipment.
How many system boundaries exist in this process?

FEED 2
PRODUCT 1
FEED 1 COMPONENT
SPLITTER
CATALYTIC REACTOR
PRODUCT 2
Identify as many other system boundaries as possible from the

above diagram!
 How many unit operations are there in the

above process?
Ans: There are three unit operations.
 For the previous process, how many number of

independent equations can be written for the
whole process if the number of components is
N?
Ans: 3*N
Example1: Non-reactive Multiple Unit
Problem 4-29: A liquid mixture containing 30.0 mole% benzene (B),

25.0% toluene (T) and the balance Xylene (X) is fed to a distillation
column. The bottoms product containing 98.0 mole% X and no B, and
96.0% of the X in the feed is recovered in this stream. The overhead
product is fed to a second column. The overhead product from the
second column contains 97.0 % of the B in the feed to this column.
The composition of this stream is 94.0 mole% of B and the balance
T.
Problem 4-29:…
Draw and label flowchart. Do the degree-

of-freedom analysis to prove that for an
assumed basis of calculation, molar flow
rate and compositions of all process
streams can be calculated from the given
information.
Solution:
Draw and label flowchart. Do the degree-of-freedom analysis to prove that for
an assumed basis of calculation, molar flow rate and compositions of all
process streams can be calculated from the given information.
100 mol/h n 2X(mol/h) n 4 (mol/h)

XB5 (mol B/mol)
B2 (mol B/mol)
0.300 mol B/mol XT2 (mol T/mol) XT5 (mol T/mol)

0.940 mol B/mol
Column Column
0.250 mol T/mol 1 0.060 mol T/mol
1 - XB2 -XT2 (mol X/mol) 1 - XB52-XT5 (mol X/mol)
0.450 mol X/mol
n 3 (mol/h)
n 5 (mol/h)
0.020 mol T/mol
0.980 mol X/mol
Solution…
Draw and label flowchart. Do the degree-of-freedom analysis to prove that for an assumed
basis of calculation, molar flow rate and compositions of all process streams can be calculated
from the given information.
DoF Column 1 Column 1
4 unknowns 96% X Recovery: 0.960(0.450)(100)  0.980n 3 (1)
- 3 Independent eqn Total mole balance: 100  n 2  n 3 (2)
- 1 Recovery of X B Balance: 0.300 (100 ) xB 2 n 2 (3)
0 DoF T Balance:  2  0.020 n 3
0.250 (100 )  xT 2 n (4)
Column 2
DoF Column 2
97% B Recovery: x n
0.970 B 2 2  0.940 4 n (5)
4 unknowns
Total mole balance: n 2  n 4  n 5 (6)
- 3 Independent eqn
- 1 Recovery of B
B Balance: xB 2 n 2  0.940 n 2  xB 5 n 5 (7)
0 DoF T Balance: xT 2 n 2  0.060n 4  xT 5 n 5 (8)

Solution…
Solving all the balances, obtain these results:
3
n  44.1 mol/h n 4  30.95 mol/h
n 2  55.9 mol/h n 5  24.96 mol/h
xB 2  0.536 mol B/h xB 5  0.036 mol B/h
xT 2  0.431 mol T/h xT 5  0.892 mol T/h

3.4.3 Material Balances on Non Reactive Processes
Involving Recycle and Bypass
RECYCLE
One of the common processing configurations is the
material recycle structure.
RECYCLE
FEED PROCESS OUTPUT

MIX SPLIT
Often asked to calculate the recycle ratio - divide mass

flow of recycle stream by mass flow of the "fresh feed“.
3.4.3 Material Balances on Non Reactive Processes
Involving Recycle and Bypass…
Some Importance of Recycling:
• Recovery of catalyst. E.g., Fermentation process

• Dilution of a process stream. E.g., Filtration process
• Control of a process variable. E.g., Exothermic
reaction process
• Circulation of a working fluid. E.g., Refrigeration
process
3.4.3 Material Balances on Non Reactive Processes Involving
Recycle and Bypass…
Some Importance of Recycling…
• Recovering and reusing unconsumed reactant and energy

saving.
E.g., See the diagram below: A B
Some Importance of Recycling…
• Drying operation
(diagram to be inserted)
BYPASS
A procedure that has several features in common
with recycle is bypass, in which a fraction of the feed
to a process unit is diverted around the unit and
combined with the output stream from the unit.
BYPASS
FEED PROCESS OUTPUT

SPLIT MIX
 One use of bypass is to obtain precise control of the output stream,

as when a small wet air stream bypasses a drier so that the output
humidity can be regulated as well as to manipulate the process
conditions (T & P).
 Bypass and recycle calculations are approached in exactly the

same manner; the flowchart is drawn and labelled, and overall
balances and balances around the process unit or the stream mixing
point following the process unit are used to determine unknown
variables.
Example of bypass process: Solve problems 4.32 & 4.33 from the
textbook.
Recycle & Bypass– The Difference
Note:
IN PROCESS-1 OUT
At splitting,
components’
composition “Mixing
“Splitting Bypass
s remain the Points”
Points”
same. The
ONLY OUT PROCESS-2 IN
difference is
the mass
flow rate. Recycle
EXAMPLE 1: Recycle
Fresh air containing 4.00 mole% water vapour is to be

cooled and dehumified to a water content of 1.70 mole%
H2O. A stream of fresh air is combined with a recycle
stream of previously dehumidified air and passed through
the cooler. The blended stream entering the unit contains
2.30 mole% H2O. In the air conditioner, some of the water
in the feed stream is condensed and removed as liquid. A
fraction of the dehumidified air leaving the cooler is
recycled and the remainder is delivered to a room.
Taking 100 mol of dehumidified air delivered to the room

as a basis of calculation, calculate the moles of fresh feed,
moles of water condensed, and moles of dehumidified air
recycled.
SOLUTION: Recycle
1. Draw the flowchart. Write all known stream variables at
the streams on the chart. Assign algebraic symbols to
unknown stream variables.
SOLUTION: Recycle
n 5 (mol) 0.983 mol DA/mol

0.017 mol W(l)/mol
n1 (mol) n 2 (mol) AIR

n 4 (mol) 100 mol
0.960 mol DA/mol 0.977 mol DA/mol COND. 0.983 mol DA/mol 0.983 mol DA/mol
0.040 mol W(v)/mol 0.023 mol W(v)/mol 0.017 mol W(v)/mol 0.017 mol W(v)/mol
n 3 [mol W(l)]
59
SOLUTION: Recycle
2) Scaling up/down: No need to do so.

3) Basis of calculation: Quantity of some thing (stream component)
which we fix and make all other calculations based on it.
Given that the amount of dehumidified air delivered to room is 100
mol, BASIS OF CALCULATION is 100 mol.
4) Problems: Express what the problem asks you to determine.
We need to determine the n1, n3, and n5.
5) Conversion of units: For consistency and convenience in the
calculation.
No conversion unit is required
SOLUTION: Recycle
First identify & separate into different system boundaries.
• Overall:
unknowns = 2 (n1, n3)
(-) indep. eqn. = 2 (species DA & W)
= 0 DOF (solvable)
• Mixing: unknowns = 3 (n1, n2, n5)

(-) indep. eqn. = 2 (species DA & W)
= 1 DOF
SOLUTION: Recycle
First identify & separate into different system boundaries...
• Air conditioner: unknowns = 2 (n2, n4)

(-) indep. eqn. = 2 (species DA &
W)
= 0 DOF (solvable)
• Splitter: unknowns = 2 (n2, n4)
(-) indep. eqn. = 1 (CHECK WHY)
= 1 DOF
SOLUTION: Recycle
(7) Write system equation and do the algebra
Overall DA Balance (Fewest Unknown):

0.960n1 = 0.983 (100)
n1 = 102.4 mol fresh feed

Overall Total Balance:
n1 = 100 + n3
n = 2.4 mol H O condensed

SOLUTION: Recycle
(7) Write system equation and do the algebra…
Mixing Total Balance: Mixing Water Balance:

n1 = n5 + n2 0.04n1 + 0.017 n5 = 0.023n2
102.4 = n5 + n2 ….. (1) 4.096 + 0.017n5 = 0.023n2…. (2)
Solving (1) & (2) simultaneously:

n2 = 392.5 mol
n5 = 290 mol recycle

SOLUTION: Recycle
RESULTS:
n1 = 102.4 mol fresh feed
n3 = 2.4 mol H2O condensed
n5 = 290 mol recycle

EXAMPLE 2: Recycle
Forty-five hundred kilograms per hour of a solution that is one-

third K2CrO4 by mass is joined by a recycle stream containing
36.4% K2CrO4, and the combined stream is fed into an

evaporator. The concentrated stream leaving the evaporator
contains 49.4% K2CrO4; this stream is fed into a crystallizer in
which it is cooled (causing crystals of K2CrO4 to come out of

solution) and then filtered.
EXAMPLE 2: Recycle (continued)
The filter cake consists of K2CrO4 crystals and a solution that
contains 36.4% K2CrO4 by mass; the crystals accounts for 95% of

the total mass of the filter cake. The solution that passes through
the filter, also 36.4% K2CrO4 is the recycle stream.
Calculate the rate of evaporation, the rate of production of

crystalline K2CrO4 , the feed rates that the evaporator and the
crystallizer must be designed to handle, and the recycle ratio.
Solution: Recycle
1. Draw the flowchart
m 2 (kg W / h)
m 4  0.95(m 4  m 5 )
Fresh Feed Filter Cake
4500 kg / h m 1 (kg / h) m 3 (kg / h) Crystallizer m 4 (kg K / h)
Evaporator
0.333 kg K / kg x1 kg K / kg 0.494 kg K / kg and Filter m 5 (kg / h)
0.667 kg W / kg (1-x1) kg W / kg 0.506 kg W / kg
0.364 kg K / kg
0.636 kg W / kg
m 6 (kg / h) Filtrate (recycle)

0.364 kg K / kg
0.636 kg W / kg
Solution: Recycle
(2) Scaling up/down : No need to do so.
(3) Basis of calculation: Quantity of some thing (stream
component) which we fix and make all other calculations
based on it. BASIS OF CALCULATION IS 4500 kg/h of
fresh feed.
(4) Problems: Express what the problem asks you to determine.
• • • • •
Need to determine the the m1 , m2 , m3 , m4 and ratio m6/4500.
(5) Conversion of units: For consistency and convenience in the
calculation. No conversion unit is required.
Solution: Recycle
(6) Perform Degree-of-freedom (DOF) Analysis
First identify & separate into different system boundaries:
• • •
• overall: unknowns = 3 (m2 , m4 , m5)
(-) indep. eqn. = 2• (2 species)
•
(-) add. info. = 1 (m4 = 95% total filter cake)
= 0 DOF (solvable)
  
Add. info.: solids constitute 95% by mass of m 4  0.95( m 4  m 5 )

 
the filter cake. This gives the equation (1): m 5  0.05263 m 4  1
Solution: Recycle
(7) Write system equation and do the algebra.
Overall K Balance:
 
(0.333)(4500)kg K/h  m 4  0.364 m 5
Solve simultaneously with (1)

m 4  1470 kg K//h

m 5  77.5 kg entrained solution/h
Solution: Recycle
  
Overall Total 4500 kg/h  m 2  m 4  m 5
Balance: 
m 2  2950 kg Water evaporated per hour.
Crystallizer Total Balance: Crystallizer Water Balance:

    .  
m3  m 4  m5  m6 0.506 m3  0.636 m 5  0.636 m 6
 
m 3  1550  m 6  2   .
m 3  97.4  1.257 m 6  3

m 3  7200 kg/h fed to crystallizer
Solve (2) & (3) 
m 6  5650 kg/h
Solution: Recycle
(7) Write system equation and do the algebra.
 
Mixing Total 4500 kg/h  m 6  m1
Balance: 
m1  10150 kg/h feed to evaporator
Solve for the quantities required in the problem statement.

m1  10150 kg/h feed to evaporator

m 2  2950 kg/h water evaporated

m 3  7200kg /h fed to crystallizer

m 4  1470kg /h K crystals

m6
 1.26kg recycle/kg fresh feed
4500
END OF PRESENTATION ON
NON REACTIVE PROCESS
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ADDIS ABABA UNIVERSITY

ADDIS ABABA INSTITUTE OF TECHNOLOGY

Introduction to Chemical Engineering (ChEg

 Material and Energy balances are the foundation of Chemical

 MEB is the application of the law of conservation of mass: Matter is

 Conversion between different forms of energy: heat, work, kinetic energy,

Accumulation = Input - Output + Generation - Consumption

 To increase profit by maximizing useful products

Distinguish the following processes :

“The feed is charged (fed) into a vessel at the

“The inputs and outputs flow continuously

“Any process that is NEITHER Batch NOR

If the values of all the variables in a process (i.e., all pressures,

• A balloon is filled with air at a steady rate of 2

Input - Output + Generation - Consumption = Accumulation

IN: Enters through system boundaries. Remarks

FEED-2 SYSTEM BOUNDARY

PRODUCT-1 PRODUCT-2 FEED-3

Example:Consider the population of Ethiopia over one year ,

Population Growth = People Entering - People Leaving

+ People Born - People Die

Material Balance Approaches

Simplifications of the General Material Balance Equation

The generation & consumption terms are the consequences of

Accumulation = Input - Output

Example: The figure describes a mixing tank problem. The operation is at

Start with general balance equation & simplify: A steady state

Check: x-A + x-B + x-C = 0.56 + 0.17 + 0.27 = 1.0

1. Draw the Flow Diagram (Flow Chart)

•Identify the units (unit operations)

•Identify the input/output streams to that

particular unit(s) – Label them.

•Write down flow conditions at each

stream - flow rates, mass/mole

fractions, temp, pressure

• Before we proceed with the problem solving procedure, one

• Scaling up or scaling down the flowchart requires a balanced

• Only the masses, moles and flow rates can be scaled up or

2. Scale up/down the flow chart…

3. Choose a basis for calculation

• Usually an amount (moles or mass) or flow rates (molar or mass)

• All unknown variables must then be consistent with this basis.

• Early in the solution of most balance problems, must choose a

6. Degree of Freedom (DoF) Analysis

•Is the procedure of determining whether there is enough

 If DoF = 0, fully specified and the equation can be solved.

 If DoF > 0, more unknowns than the equations, under

 If DoF < 0, more independent equations, over specified

6. Degree of Freedom (DoF) Analysis…

Equations are independent when there is no equation that can be

Example: Solve the systems of equation:

7. Solve the Problem (Do the Algebra)

Example 1: Material Balances on Distillation Column

(2) Scaling-up/down: No need to to scale-up/down.

(5) Conversion of units:

DoF = V – E DoF must be zero to be solved

DoF = Unknowns - Independent Equation