Mass Balance

Objectives of this chapter

Process Classification
Drawing Process Diagram
Writing Material Balance Equation
Understanding about the flowchart scaling
and basis of calculation
Perform Degree of Freedom
Solving equations with unknowns variables
Solving problems involving recycle.
 Process Classification
• Feed is charge to the process and product is
removed when the process is completed
• No mass is fed or removed from the process
during the operation

Batch
• Used for small scale production
• Operate in unsteady state
• Example: rapidly add reactants to a tank and
remove the products and unconsumed
reactant sometime later when the system has
come to equilibrium

• Input and output is continuously red and

remove from the process

Continuou
• Operate in steady state
• Used for large scale production
• Pump a mixture of liq into a distillation
s column at a constant rate and steadilty
withdraw products streams from the top and
bottom column
 Conditions of process
•Process variable do not
Steady state change with time

Unsteady •Process variable change

state/Transi with time
ent
 Test Yourself
Define type and operation of process given
below
 A bottle of milk is taken from the
refrigerator and left on the kitchen
 Carbon monoxide and steam are fed into a
tubular reactor at a steady rate and react to
form CO2 and H2. Products and unused
reactants are withdrawn at the other end.
1) Suppose methane is a component of both the input and
output streams
of a continuous process unit but the mass flow rates of
methane in both
streams are measured and found to be different.

2) There are four possible explanations for the observed

difference?
•Methane is leaking from the unit
•Methane is either being consumed as a reactant or being
generated as a
product within the unit
•Methane is accumulating in the unit ñ possibly adsorbing on
the walls
•The measurements are wrong
inpu generati consumptio accum
output
t on n ulation

1) Input : Enters through system

boundaries
2) Output : Leaves through system
boundaries
3) Generation : Produced within the
system
4) Consumption : Consumed within
system
 Differential & Integral Balances
Differential balances
• balances that indicate what is happening in a system at
an instant time.
• balance equation is a rate (rate of input, rate of
generation, etc.) and has units of the balanced quantity
unit divided by a time unit (people/yr, g SO2/s).
• usually applied to a continuous process.

Integral balances
• Balances that describe what happens between two
instants of time.
• balance equation is an amount of the balanced quantity
and has the corresponding unit (people, g SO2).
• usually applied to a batch process, with the two instants
of time being the moment after the input takes place and
the moment before the product is withdrawn.
Simplified Rule for Material Balance
If the balanced quantity is TOTAL MASS, set
generation = 0 and consumption = 0. Mass
can neither be created nor destroyed.

If the balanced substances is a

NONREACTIVE SPECIES (neither a
reactant nor a product), set generation = 0
and consumption = 0.

If a system is at STEADY STATE, set

accumulation = 0, regardless of what is being
balanced.
 Balances on Continuous Steady State Process
Steady state: accumulation = 0

inpu generati consumptio

output 0
t on n

IF balance on NONREACTIVE species or total

mass; gen. = 0, cons. = 0, balance equation
become
input output
 Integral Balances on Batch Process
 Ammonia is produced from nitrogen and hydrogen in a
batch reactor. At time t = 0 there are n0 mol of NH3 in the
reactor, and at a later time tf the reaction terminates and
the contents of the reactor, which include nfammonia, are
withdrawn. Between t0 and tf no ammonia enters or leaves
through the reactor boundaries.

Initial
Final GMBE input process
for batch + Generation = Final output –
Consumption

Whereby:

Accumulation = Generation – Consumption

Accumulation = Initial input – Final output
 Rules for Labeling Flowchart (1)
Write the values and units of all known
stream variables at the locations of the
streams on the flowchart.
For example, a stream containing 21 mole%
O2 and 79% N2 at 320˚C and 1.4 atm flowing
at a rate of 400 mol/h might be labeled as:
400 mol/h

0.21 mol O2/mol

0.79 mol N2/mol
T = 320˚C, P = 1.4 atm
 Rules for Labeling Flowchart (2)
The information can be given in two ways:

total amount or flow

amount or flow rate rate of the stream with
for each component the fractions of each
component
100 kmol/min

60 kmol N2/min 0.6 kmol N2/kmol

40 kmol O2/min 0.4 kmol O2/kmol

10 lbm
3.0 lbm CH4
4.0 lbm C2H4 0.3 lbm CH4/lbm
3.0 lbm C2H6 0.4 lbm C2H4/lbm
0.3 lbm C2H6/lbm
 Rules for Labeling Flowchart (3)
 Assign algebraic symbols to unknown stream variables
(such as Q kg solution/min, x kg N2/kg, n kmol C3H8,
etc.) and write these variable names and their associated
units on the chart .
Consistent on Symbol Notation !!!
N (mol/h)
m mass
0.21 mol O2/mol m mass flow rate
0.79 mol N2/mol n moles
T = 320˚C, P= 1.4
atm n molar flow rate
400 mol/h V  volume
V volume flow rate
x (mol O2/mol) x component fraction (mass or moles) in liquid
1-x (mol N2/mol) y moles fraction in gas
T = 320˚C, P= 1.4
atm
Rules for Labeling Flowchart (4)
Try to reduce the number of unknown by using any
relationship information given
 If that the mass of stream 1 is half that of stream 2,
label the masses of these streams as m and 2m rather
than m1 and m2.
 If you know that mass fraction of nitrogen is 3 times
than oxygen, label mass fractions as yg O2/g and 3yg
N2/g rather than y1 and y2.
When labeling component mass fraction or mole
fraction, the last fraction must be 1 minus the sum of
the others
Balance are not written on volumetric qualities
 If volumetric flow rate of a stream is given, you still
need to label the mass or molar flow rate of this stream
 Class Exercise-Batch Process
Two methanol-water mixture are contained in
separate flask. The first mixture contains 40wt
% methanol and the second flask contains 70wt
% methanol. If 200g of the first mixture
combined with 150g of the second, what are
the mass and composition of the product.
 Class Exercise
An experiment on the growth rate of certain
organism requires an environment of humid air
enriched in oxygen. Three input streams are fed
into an evaporation chamber to produce an output
stream with the desired composition.

A: Liquid water fed at rate of 20 cm3/min

B: Air (21% O2 and 79% N2)
C: Pure O2 with a molar flow rate one-fifth of the
molar flow rate of stream B

The output gas is analyzed and is found to contain

1.5 mole% water. Draw and label the flowchart of
the process, and calculate all unknown stream
variables.
 Flowchart Scaling

The process is balanced, since material balances on both system

components C6H6 and C7H8 are satisfied [1 kg in = (2 x 0.5) kg out
in both cases].

Masses (but not the mass fractions) of all streams could be

multiplied by a common factor and the process remain balanced.

This procedure of multiplication is referred as scaling the

flowchart
1) scaling up - final stream quantities are larger than original
quantities
2) scaling down - if they are smaller
Mass
Massorormol
mol
fractions
fractionswill
will
not
notchange
change
with
withscaling
scaling
 Exercise
A 60-40 mixture (by moles) of A and B is
separated into two fractions. A flowchart of
the process is shown. It is desired to
achieve the same separation with a
continuous feed of 1250 lb-moles/h. Scale
50 mol
the flowchart accordingly.
0.95 mol A
0.05 mol B
100
mol
0.6 mol A
0.4 mol B

12.5 mol A
37.5 mol B
 Basis of Calculation
 A basis of calculation is an amount (mass or moles) OR flow
rate (mass or molar) of one stream or stream component in
a process. All unknown variables are determined to be
consistent with the basis.
 if the amount or flow rate of a stream is given – use it as a
basis for calculation
 If NO stream amount or flow rate are known, choose an
arbitrary convenient value ( i.e. 100 kg, 100 kmol/h) on
the stream with KNOWN composition. If mass fraction is
known, choose total mass or mass flow rate as basis. If
mole fraction is known, choose a total moles or molar flow
rate as basis
 For rule of thumbs for process with no reaction :
 mass is normally use with liquid
 Class Exercise
An aqueous solution of sodium hydroxide
contains 20% NaOH by mass. It is desired to
produce an 8% NaOH solution by diluting a
stream of the 20% solution with a stream of
pure water. Calculate the ratios (liter H2O/kg
feed solution) and (kg products solution/kg
feed solution)
100 m2 (kg)
kg
0.2 kg 0.08 kg NaOH/kg
NaOH/kg 0.92 kg H2O/kg
0.8 kg H2O/kg
m1 (kg H2O)
V1 (L H2O)
 Strategy in Solving Problems
• Choose as basis of calculation - 100kg
1

• Draw and label the flowchart

2

• Express what the problem statement asks you to determine in terms of the
labeled variables.- V1/100 (liter H2O/kg feed solution) and m2/100 (kg
3 product solution/kg feed solution)

• Count unknown variables and equations relating them –1) unknown (m1, m2,
V1) 2) equations-2 balance materials (NaOH, water) + density of liquid water
4

• Outline the solution procedure.

5
 Problem 4.8

c) 50 large eggs/min, 0.22 broken eggs/eggs

Next Lecture
Strategy in Solving Material Balances
• Choose as basis of calculation
1

• Draw a flowchart and fill in all known variables values, including the basis of
2 calculation. Then label unknown stream variables on the chart.

• Express what the problem statement asks you to determine in terms of the
3 labeled variables.

• If you are given mixed mass and mole units for a stream (such as a total mass
flow rate and component mole fractions or vice versa), convert all quantities to
4 one basis.

• Do the degree-of-freedom analysis.

5
• Solve the equations (if DOF=0).
• Calculate the quantities requested in the problem statement if they have not
6 already been calculated.
• If a stream quantity or flow rate ng was given in the problem statement and
another value nc was either chosen as a basis or calculated for this stream, scale
7 the balanced process by the ratio ng/nc to obtain the final result.
DEGREE-OF-FREEDOM
 Degree-of-Freedom
 Degree-of-freedom analysis – to see whether
there is enough information to solve a given
problem for a properly drawn and labeled
flowchart before doing any material balance
calculation
 Procedure to perform a degree-of-freedom
analysis:
a) draw and completely label a flowchart
b) count the unknown variables on the chart
(nunknowns)
c) count the independent equations (nindep. eq.)
n df= n unknowns - n indep. eq .
d) Find number of degree-of-freedom (n )
df
 Degree-of-Freedom
 Three possibilities number of degree-of-freedom
(ndf)
1. If ndf = 0
 the problem can in principle be solved.
2. If ndf> 0
 there are more unknowns than independent
equations relating to them
 at least n additional variable values must be
df
specified before remaining variable values
can be determined.
 Either relations have been overlooked or the
problem is underspecified.
3. If ndf< 0
 there are more independent equations than
unknowns.
 Either the flowchart is incompletely labeled or
the problem is overspecified with redundant
 6 Sources of Equation for Balance
1. Material balances.
 For a nonreactive process, number of independent equation
can be written is not more than number of molecules species
(nms) of the process
 If benzene and toluene is involve in stream, we can write
balance on benzene, toluene, total mass, atomic carbon and
etc., but only TWO INDEPENDENT balance equation exist
2. An energy balance.
 If the amount of energy exchanged between the system and
its surroundings is specified or if it is one of the unknown
process variables, an energy balance provides a relationship
between inlet and outlet material flows and temperatures.
3. Process specifications
 The problem statement may specify how several process are
related.
 i.e: Outlet flow rate is two times than flow rate stream 1 or
etc.
 6 Sources of Equation for Balance
4. Physical properties and laws
 Two of the unknown variables may be the mass and volume
of a stream material, in which case a tabulated specific
gravity for liquids and solids or an equation of state for
gases would provide an equation relating the variables.

5. Physical constraints
 For example, if the mole fractions of the three components
of a stream labeled xA, xB, and xC, then the relation among
these variables is xA + xB + xC = 1.
 Instead label as xc, the last fraction should be 1-xA-xB

6. Stoichiometric relations
 If chemical reactions occur in a system, stoichiometric
equation provide a relationship between the quantities of
reactant and the product
 Exercise for DOF
A stream of humid air enters a condenser in which 95%
of the water vapor in the air is condensed. The flow rate
of the condensate (the liquid leaving the condenser) is
measured and found to be 225L/h. Dry air may be taken
to contain 21 mole% oxygen, with the balance nitrogen.
The entering air contains 10 mole % water. Calculate the
flow rate of the gas stream leaving the condenser.
 Exercise
A liquid mixture containing 45% benzene and 55% toluene by
mass is fed to distillation column. A product stream leaving the
top of the column contains 95 mole% B and bottom products
stream contain 8% of the benzene fed to the column( meaning
that 92% of the benzene leaves with the overhead products). The
volumetric flow rate of the feed stream is 2000 L/h and the
specific gravity of the feed mixture is 0.872. Determine the mass
flow rate of the overhead products stream and the mass flow rate
and composition (mass fraction) of the bottom products stream.
RECYCLE
 Topic Outcomes
Analyze and solve material balance
problems involving RECYCLE
applications.
 Recycle
Normally in chemical reaction, some of
unreacted reactant also found in the product.
This unreacted reactant can be separated
and recycle back to the reactor
Fresh
Feed Product
Reactor Separator

Recycle Stream
 Purpose of Recycle
1. Recovery of catalyst – catalyst is very expensive

2. Dilution of process stream – typically for slurry

solution

3. Control of process variables – especially for the

reaction that release heat, heat can be reduce
by lowering the feed concentration

4. Circulation of working fluid such as in

refrigerator system
 Conversion for Reactive Process
25 mol A/min
75 mol A/min 100 mol A/min 75 mol B/min Product 75 mol B/min
Reactor Separation
Unit

25 mol A/min

Overall Conversion
Reactant input to Process – reactant output from Process
Reactant input to Process

Single Pass Conversion

Reactant input to Reactor – reactant output from Reactor
Reactant input to Reactor
 Exercise-Recycle
Fresh air containing 4 mole% water vapor is to
be cooled and dehumidified to a water content
of 1.7mole% H2O. A stream of fresh air is
combined with a recycle stream of previously
dehumidified air and passed through the
cooler. The blend stream entering the unit
contains 2.3mole% H2O. In the air conditioner,
some of the water in the feed stream is
condensed and removed as a 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
 Exercise: Recycle vs. Un-recycle
4500 kg/h 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 a
crystal of K2CrO4 to come out of solution) and then filtered. The
filter cake consist of K2CrO4 crystals and solution that contains
36.4% k2CrO4 by mass; the crystals account for 95% of the total
mass of the filter cake. The solution passes through the filter,
also 36.4% K2CrO4 is the recycle stream.
1. Calculate the rate of evaporation, the rate of production
of crystalline K2CrO4, the feed rates that evaporator and
the crystallizer must be designed to handle, and the
recycle ratio (mass of recycle/mass of feed)
2. Suppose that the filtrate were discard instead of being
recycled. Calculate the production rate of crystals.