Material and Energy Balance

Material Balance

In any part of chemical industry, the raw materials enter as a feed and after the chemical or
physical reaction is completed it gives products. Therefore, it must know the amount the entering
and leaving of the process. Then the amount of the process in any factory will be known by
material balance and energy balance.

Material balance is apply based on the law of conservation of mass which states that any matter
can be neither created nor destroyed, but can be converted from one form to another form.

The material balance equation will be:

Input – Output + Generation – Consumption = Accumulation

Where, Input = enters through the system boundaries, Generation = produced within the system.
Output = leaves through the system boundaries; Consumption = consumed with in system.
Accumulation = build up within the system.

The following assumptions are used to simplify the material balance equation:

 If the balance quantity is total mass; generation = 0 and consumption =0, expect in
nuclear reactions.
 If the balanced substance is nonreactive species; generation = 0 and consumption =0.
 For steady state process accumulation will zero.

Therefore, the material balance equation will be; Input = Output

The material balance has used for:

 To calculate the unknown quantity.

 To know the performance of factory.
 Helps to minimize utility production cost.

Material balance is classified in to two types those are: Material balance with chemical reaction
& Material balance without chemical reaction.
But all the material balance in the factory is without chemical reaction

Material Balance for Extraction

Cane + Imbibition water = Draft juice + Bagasse

Bagasse = Cane + Imbibition water - Draft juice

The purpose of draft juice weighing carried out in sugar industries are:

i) To determine the weight of bagasse supplied to boiler plant

ii) To determine the diffuser plant extraction
iii) To determine the boiling house recovery

Diffusion
C J

Where, C = Prepared cane I = Imbibition water added per unit of cane

B = Bagasse to boiler J = Draft juice to process data

f = Mass fraction of fiber in the cane m = Moisture content in bagasse

Data’s taken from literature Assumption

f= 15% [mass fraction of fiber in the cane]

m = 52% [moisture content in bagasse]

I=λƒ

Where λ = Ratio of weight of imbibition’s water to weight of fiber

f - Fiber content per unit of cane

I - quantity of imbibition’s water added per unit of weight of cane

The optimum ratio is obtained at λ = 2

Therefore; I = 2ƒ

ƒ = 0.15 x C but C = 13000 tcd

13000 ton C 1000 Kg C 1 day 1 hr. 1 min.

Day 1 ton 24 hr. 60 min. 60 sec

C = 150.463 Kg c/ sec.

f = 0.15 x 150.463 kg c/ sec. = 25.57 kg c/ sec.

Therefore; I = 2f = 2 x 25.57 kg c/ sec. = 45.14 kg c/sec.

Overall material balance on diffuser

C + J = I + B
But B = ƒ / w = 25.57 Kg c. sec / 0.52 = 49.173 kg c/ sec.

J = C + I - B
J = 150.463 kg c/ sec + 45.14 kg c/ sec - 49.173 kg c/ sec

J = 146.43 kg c/ sec

To find the volumetric flow rate of the juice the juice brix is i.e. Bx = 15° by using the brix we
can find the density of the juice from the table

𝜌j = 1061 Kg/ m3

Q = J / ρ = 0.138 m3 / sec = 496.8 m3/ hr.

Material Balance for clarification

MOL

Draft juice Clarification Clear juice

Mud
From literature for the manufacture of raw sugar by ordinary defecation one should allow for 0.5
– 0.8 Kg of CaO per t.c.

Taking the average value = 650 g CaO

The lime prepared at 10° Bx, say 140g CaO Per liter. Therefore the quantity of milk of lime per
13000 t.c.d is then:

= (13000 t.c.d x 650g CaO) per t.c / 140 g CaO per liter

= 60357.143 l/day = 60.357 m3/day

Draft juice + MOL = Mud juice + Clear juice