CHAPTER III

MASS & ENERGY BALANCE

From the process in chapter II, we can calculate mass and energy balance of
the plant. Mass balance will be evaluated each equipment. From this chapter, we
will know how much fish needed to produce fish oil with our designated capacity
which converts 17, 056 ton fish oil 341,12 kg per day. Then, we will know the
energy needed to generate the process from the beginning until fish oil as main
product and fish meal as by product produced. In this chapter, mass and energy
balance will be calculated each unit and then each operation unit.

3.1 Mass Balance for Each Operation Unit

Firstly, we calculate the mass balance for each operation unit, as follows:

Table x Mass Balance

Operation Unit: Pressing

Mass Balance (kg/day)
Component Output to Output (Fish
Input
Decanter Meal)
Palmitic Acid 2988.86 2988.86 0

Oleic 1644.28 1644.28 0

Stearic 1084.95 1084.95 0

Palmitoleic 988.27 988.27 0

Miristic Acid 624.97 624.97 0

Eicosapentaenoic 132.37 132.37
acid (EPA) 0

Docosahexaenoic 114.94 114.94

acid (DHA) 0

Linolenic 93.81 93.81 0

Lysine 1570.86 0 1570.86

Methionine 1210.98 0 1210.98

1
 PCB 69.93 69.93 0
Dioxine 95.51 95.51 0
Phospholipid 221.73 221.73 0
Pigment 85.28 85.28 0
Triglycerides 65.69 65.69 0
Wax 39.23 39.23 0
Hydrogen 18.76 18.76
Peroxide 0

Ketone 37.86 37.86 0

Lindane 15.18 15.18 0
Water 5952.54 5952.54 0

TOTAL 17,056 14,274.17 2,781.83

TOTAL 17,056 17,056

Table x. Mass Balance

Operation Unit: Decanting

Mass Balance (kg/day)
Input Output Output to
Component
(Stickwater) Carbon
Treatment

Palmitic Acid 2988.86 19.43 2969.43

Oleic 1644.28 8.88 1635.40

Stearic 1084.95 7.70 1077.25

Palmitoleic 988.27 6.72 981.55

Miristic Acid 624.97 2.25 622.72

Eicosapentaenoic 132.37 132.37

0
acid (EPA)

2
Docosahexaenoic 114.94 114.94
0
acid (DHA)

Linolenic 93.81 0 93.81

PCB 69.93 0 69.93

Dioxine 95.51 0 95.51

Phospholipid 221.73 0 221.73

Pigment 85.28 0 85.28

Triglycerides 65.69 0 65.69

Wax 39.23 0 39.23

Hydrogen 18.76 18.76

0
Peroxide

Ketone 37.86 0 37.86

Lindane 15.18 0 15.18

Water 5952.54 5952.54 0

14274.17 5997.52 8276.64

TOTAL
14274.17 14274.17
TOTAL

Table x. Mass Balance

Operation Unit: Carbon Treatment

Mass Balance (kg/day)
Component Input Output to Output to Waste
Degumming
Palmitic Acid 2969.43 2969.43 0

Oleic 1635.40 1635.40 0

Stearic 1077.25 1077.25 0

Palmitoleic 981.55 981.55 0

Miristic Acid 622.72 622.72 0

3
Eicosapentaenoic
132.37 132.37 0
acid (EPA)

Docosahexaenoic
114.94 114.94 0
acid (DHA)

Linolenic 93.81 93.81 0

PCB 69.93 0 69.93

Dioxine 95.51 26.74 68.77

Phospholipid 221.73 221.73 0

Pigment 85.28 85.28 0

Triglycerides 65.69 65.69 0

Wax 39.23 39.23 0

Hydrogen
18.76 18.76 0
Peroxide

Ketone 37.86 37.86 0

Lindane 15.18 15.18 0

TOTAL 8,276.64 8,137.94 138.70

TOTAL 8,276.64 8,276.64

Operation Unit: Acid Degumming

Mass Balance (kg/day)
Component Input Output to Alkali Output to Waste
Refining
Palmitic Acid 2969.43 2969.43 0

Oleic 1635.40 1635.40 0

Stearic 1077.25 1077.25 0

4
 Palmitoleic 981.55 981.55 0

Miristic Acid 622.72 622.72 0

Eicosapentaenoic 132.37 132.37 0

acid (EPA)

Docosahexaenoic 114.94 114.94 0

acid (DHA)

Linolenic 93.81 93.81 0

Dioxine 26.74 26.74 0

Phospholipid 221.73 0 221.73

Pigment 85.28 85.28 0

Triglycerides 65.69 65.69 0

Wax 39.23 39.23 0

Hydrogen 18.76 18.76 0

Peroxide

Ketone 37.86 37.86 0

Lindane 15.18 15.18 0

TOTAL 8,137.94 7,916.22 221.73

TOTAL 8,137.94 8,137.94

Operation Unit: Alkali Refining

5
 Mass Balance
Component Input Output to Water Output to Waste
Washing
Palmitic Acid 2,969.43 2,969.43 0
Oleic 1,635.40 1,635.40 0

Stearic 1,077.25 1,077.25 0

Palmitoleic 981.55 981.55 0

Miristic Acid 622.72 622.72 0

Eicosapentaenoic 132.37 132.37

0
acid (EPA)

Docosahexaenoic 114.94 114.94

0
acid (DHA)

Linolenic 93.81 93.81 0

Dioxine 26.74 26.74 0

Pigment 85.28 85.28 0

Triglycerides 65.69 65.69 0

Wax 39.23 39.23 0

Hydrogen 18.76 18.76

0
Peroxide

Ketone 37.86 37.86 0

Lindane 15.18 15.18 0

Sodium 5500.00 0
5,500
Hydroxide

TOTAL 13,416.22 7,916.22 5,500

TOTAL 13,416.22 13,416.22

6
Transeterification/ Saponification Reaction that occurs in Water Washing stages:
Triglycerides (Esther and Fatty Acids) + 3 NaOH ---> Glycerol + 3 Soap

Operation Unit: Water Washing

Mass Balance
Component Input Output to Output to Waste
Bleaching

Palmitic Acid 2,969.43 0 0

Oleic 1,635.40 0 0

Stearic 1,077.25 0 0

Palmitoleic 981.55 0 0

Miristic Acid 622.72 0 0

Soaps 0 0 3,213.01

Glycerol 0 0 9,631.15

Eicosapentaenoic 132.37 132.37

0
acid (EPA)

Docosahexaenoic 114.94 114.94

0
acid (DHA)

Linolenic 93.81 93.81 0

Dioxine 26.74 26.74 0

Pigment 85.28 85.28 0

Triglycerides 65.69 7.88 0

Wax 39.23 39.23 0

Hydrogen 18.76 18.76

0
Peroxide

Ketone 37.86 37.86 0

Lindane 15.18 15.18 0

Water 2,500 0.00 2,500

TOTAL 10,416.22 572.06 9,844.15

TOTAL 10,416.22 10,416.22

7
 Operation Unit: Bleaching
Mass Balance
Component Input Output to Output to Waste
Winterization
Eicosapentaenoic 132.37 132.37 0
acid (EPA)
Docosahexaenoic 114.94 114.94
0
acid (DHA)

Linolenic 93.81 93.81 0

Dioxine 26.74 26.74 0

Bleaching Earth 127.92 0 127.92

Pigment 85.28 0 85.28

Triglycerides 7.88 7.88 0

Wax 39.23 39.23 0

Hydrogen 18.76 18.76

0
Peroxide

Ketone 37.86 37.86 0

Lindane 15.18 15.18 0

699.98 486.78 213.20

TOTAL
699.98 699.98
TOTAL

8
 Operation Unit: Winterization
Mass Balance
Component Input Output to Output to Waste
Deodorization
Eicosapentaenoic 132.37 132.37
0
acid (EPA)

Docosahexaenoic 114.94 114.94

0
acid (DHA)

Linolenic 93.81 93.81 0

Dioxine 26.74 26.74 0

Triglycerides 7.88 0 7.88

Wax 39.23 0 39.23

Hydrogen 18.76 18.76

0
Peroxide

Ketone 37.86 37.86 0

Lindane 15.18 15.18 0

TOTAL 486.78 439.67 47.11

486.78 486.78
TOTAL

Operation Unit: Deodorization

Mass Balance
Component Input Output to Output to Waste
Packaging
Eicosapentaenoic 132.37 132.37 0
acid (EPA)

9
 Docosahexaenoic 114.94 114.94
0
acid (DHA)

Linolenic 93.81 93.81 0

Dioxine 26.74 0 26.74

Hydrogen 18.76 0 18.76

Peroxide

Ketone 37.86 0 37.86

Lindane 15.18 0 15.18

TOTAL 439.67 341.12 98.55

TOTAL 439.67 439.67

3.2 Overall Mass Balance

After the mass balance of each operation unit has been calculated, we also
calculate th overall mass balance, as follows:

Table x. Overall Mass Balance

Mass In
Mass Out (kg/day)
(kg/day)
Component
Feed Fish Oil Fish Meal Waste

Palmitic Acid 2988.86 0 343.72 4187.15

Oleic 1644.28 0 151.93 2680.30

Stearic 1084.95 0 100.90 1375.12

Palmitoleic 988.27 0 121.56 1229.85

Miristic Acid 624.97 0 75.62 871.82

Eicosapentaenoic acid 132.37
132.37 0 0
(EPA)
Docosahexaenoic acid 114.94
114.94 0 0
(DHA)
Linolenic 93.81 93.81 0 0

10
 Lysine 1570.86 0 1570.86 0

Methionine 1210.98 0 1210.98 0

PCB 69.93 0 0 187.62

95.51
Dioxine 0 0 443.46

Phospholipid 221.73 0 221.73 0

Pigment 85.28 0 0 85.28

Triglycerides 65.69 0 0 472.45

Wax 39.23 0 0 209.79

Hydrogen Peroxide 18.76 0 0 187.62

Ketone 37.86 0 0 208.08

Lindane 15.18 0 0 151.8

Water 5952.54 0 0 2804

TOTAL (kg/day) 17056.00 341.12 3797.29 12917.59

TOTAL (kg/day) 17,056 17,056

Source: Private Data

After the mass balance is calculated, mass efficiency of the process should also
be calculated. We calculate the mass efficiency of fish oil production with the
following formula:

 Mass efficiency of main product (fish oil):

𝑝𝑢𝑟𝑒 𝑓𝑖𝑠ℎ 𝑜𝑖𝑙 341.12

% 𝑚𝑎𝑠𝑠 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦𝑓𝑖𝑠ℎ 𝑜𝑖𝑙 = 𝑥 100% = 𝑘𝑔 𝑥100% = 2%
𝑟𝑎𝑤 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 17,056

 Mass efficiency of by product (fish meal)

𝑓𝑖𝑠ℎ 𝑚𝑒𝑎𝑙 3797.29

% 𝑚𝑎𝑠𝑠 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦𝑓𝑖𝑠ℎ 𝑚𝑒𝑎𝑙 = 𝑥 100% = 𝑘𝑔 𝑥100%
𝑟𝑎𝑤 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 17,056
= 22,26%

 Hence, the overall mass efficiency of products is 24,26%

11
 % 𝑚𝑎𝑠𝑠 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = 24,26%

3.3 Energy Required per Operation Unit

The energy balance is determined for the system that have temperature change,
because it is where the energy flows to the system. The energy balance for each
operation unit will be listed as follows:

Operation Unit: Cooking

Cp Tout (oC) Q (kJ)
Component m (kg) Tin (oC)
(kJ/kg.oC)
Palmitic Acid 0.463 2988.86 15.5 90 103096.2
Oleic 2.884 1644.28 15.5 90 353286.7

Stearic 2.359 1084.95 15.5 90 190675.1

Palmitoleic 2.72 988.27 15.5 90 200263

Miristic Acid 0.432 624.97 15.5 90 20114.03

Eicosapentaenoic
0.75 132.37 15.5 90 7396.174
acid (EPA)

Docosahexaenoic
0.87 114.94 15.5 90 7449.836
acid (DHA)

Linolenic 1.916 93.81 15.5 90 13390.63

Lysine 1.668 1570.86 15.5 90 195204.2

Methionine 1.823 1210.98 15.5 90 164466.9

PCB 0.396 69.93 15.5 90 2063.063

Dioxine 0.98 95.51 15.5 90 6973.448

Phospholipid 2.87 221.73 15.5 90 47408.77

Pigment 0.53 85.28 15.5 90 3367.281

Triglycerides 2.23 65.69 15.5 90 10912.85

Wax 3.43 39.23 15.5 90 10024.33

Hydrogen
2.629 18.76 15.5 90 3674.656
Peroxide

Ketone 2.297 37.86 15.5 90 6479.589

12
 Lindane 0.73 15.18 15.5 90 825.5556

Water 5.861 5952.54 15.5 90 2599146

QTotal (kJ) 3,946,218

Operation Unit: Drying

Cp Tout (oC) Q (kJ)
Component m (kg) Tin (oC)
(kJ/kg.oC)
Palmitic Acid 0.463 2988.86
60 90 103096.2
Oleic 2.884 1644.28 60 90 353286.7

Stearic 2.359 1084.95 60 90 190675.1

Palmitoleic 2.72 988.27 60 90 200263

Miristic Acid 0.432 624.97 60 90 20114.03

Lysine 1.668 1570.86 60 90

78605.71
Methionine 1.823 1210.98 60 90 66228.28

60 90 1046636
Water
5.861 5952.54

1,193,631
QTotal (kJ)

Operation Unit: Carbon Treatment

Cp o
Component m (kg) Tin (oC) Tout ( C) Q (kJ)
(kJ/kg.oC)
Palmitic Acid 0.463 2969.43 60 90 13748.47
Oleic 2.884 1635.40 60 90 47164.96

Stearic 2.359 1077.25 60 90 25412.25

Palmitoleic 2.720 981.55 60 90 26698.15

Miristic Acid 0.432 622.72 60 90 2690.15

13
Eicosapentaenoi 0.750 132.37 60 90 992.78
c acid (EPA)
Docosahexaenoi 60 90
c acid (DHA) 0.870 114.94 999.98

Linolenic 1.916 93.81 60 90 1797.40

PCB 0.396 69.93 90 276.92

60
Dioxine 0.980 95.51 60 90 936.03

Phospholipid 2.870 221.73 60 90 6363.59

Pigment 0.530 85.28 60 90 451.98

Triglycerides 2.230 65.69 60 90 1464.81

Wax 3.430 39.23 60 90 1345.55

Hydrogen 60 90
Peroxide 2.629 18.76 493.24

Ketone 2.297 37.86 60 90 869.74

Lindane 0.730 15.18 90 110.81

60
131,816.8
QTotal (kJ)
4

Operation Unit: Heating (Bleaching Stage)

Cp o
Component o m (kg) Tin (oC) Tout ( C) Q (kJ)
(kJ/kg. C)
Eicosapentaenoic
acid (EPA) 0.75 132.37 90 105 1489.16
Docosahexaenoic 90 105
acid (DHA) 0.87 114.94 1499.97

Linolenic 1.92 93.81 90 105 2696.10

Dioxine 0.98 90 105

26.74 393.13
Bleaching Earth 0.37 127.92 90 105 709.96

Pigment 0.53 85.28 90 105 677.98

Triglycerides 2.23 7.88 90 105 263.67

14
 Wax 3.43 39.23 90 105 2018.32

Hydrogen 90 105
Peroxide 2.63 18.76 739.86

Ketone 2.30 37.86 90 105 1304.62

Lindane 0.73 15.18 90 105 166.22

QTotal (kJ)
11,958.98

Operation Unit: Centrifugation

Cp Tout (oC) - Tin (oC)
Component m (kg) Q (kJ)
(kJ/kg.oC)
Soaps 0.56 1838.01 10 28.65
Glycerol 1.63 5506.15 10 89750.17

Eicosapentaenoic 10
acid (EPA) 0.75 132.37 992.78

Docosahexaenoi 10
c acid (DHA) 0.87 114.94 999.98

Linolenic 1.92 93.81 10 1797.40

Dioxine 0.98 26.74 10 262.09

Pigment 0.53 85.28 10 451.98

Triglycerides 2.23 65.69 10 1464.81

Wax 3.43 39.23 10 1345.55

Hydrogen 10
Peroxide 2.63 18.76 493.24

Ketone 2.30 37.86 10 869.74

Lindane 0.73 15.18 10 110.81

Water 5.86 2500.00 10 146525.00

QTotal (kJ)
245,092.2

15
 Operation Unit: Distillation
Cp Tout (oC) - Tin (oC)
Component m (kg) Q (kJ)
(kJ/kg.oC)
Eicosapentaenoic
acid (EPA) 0.75 132.37 200 19855.50
Docosahexaenoic 200
acid (DHA) 0.87 114.94 19999.56

200
Linolenic
1.92 93.81 35947.99

Dioxine 0.98 26.74 200 5241.79

Hydrogen 200
Peroxide 2.63 18.76 9864.85

Ketone 2.30 37.86 200 17394.87

Lindane 0.73 15.18 200 2216.26

QTotal (kJ) 110,520.

8

Operation Unit: Winterization

Cp Tout (oC) - Tin (oC)
Component m (kg) Q (kJ)
(kJ/kg.oC)
Eicosapentaenoic
acid (EPA) 0.75 132.37 105 10424.14
Docosahexaenoic 105
acid (DHA) 0.87 114.94 10499.77

105
Linolenic
1.916 93.81 18872.7

Dioxine 0.98 26.74 105 2751.938

Triglycerides 2.23 7.88 105 1845.663

Wax 3.43 39.23 105 14128.25

16
 Hydrogen 105
Peroxide 2.629 18.76 5179.046

Ketone 2.297 37.86 105 9132.306

Lindane 0.73 15.18 105 1163.535

QTotal (kJ) 73,997.34

Operation Unit: Alkali Refining

In Mass (kg) Cp (kJ/kg.oC) Q (kJ)

65.69
Triglyceride
2.23 1464.812
NaOH 19090.5
5500 0.3471
Sum 58.736.31
Out Mass (kg) Cp (kJ/kg.oC) Q (kJ)
Glycerol 5506.145 1.63 89750.17
Soaps 1838.009 10292.85
0.56
Sum 120628.7
Total (Out-In) 61,892.41

3.4 Energy Required for Component Stream

Component’s Energy
Cp Tout (oC) Q (kJ)
Component m (kg) Tin (oC)
(kJ/kg.oC)
0.463 2988.86 90 and
Palmitic Acid
15.5 105 121466.75
2.884 1644.28 15.5 90 and
Oleic
105 417845.71

2.359 1084.95 15.5 90 and

Stearic
105 225495.68

17
 2.72 988.27 15.5 90 and
Palmitoleic
105 235624.91

0.432 624.97 15.5 90 and

Miristic Acid
105 23673.81

Eicosapentaenoic 0.75 132.37 15.5 200

acid (EPA) 18316.70

Docosahexaenoic 0.87 114.94 15.5 200

acid (DHA) 18449.59

Linolenic 1.916 93.81 15.5 200 33162.02

Lysine 1.668 1570.86 15.5 90 195204.19

Methionine 1.823 1210.98 15.5 90 164466.89

PCB 0.396 69.93 15.5 70 1509.22

Dioxine 0.98 95.51 15.5 70 5101.38

Phospholipid 2.87 221.73 15.5 90 47408.77

Pigment 85.28 15.5 105

0.53 4045.26
Triglycerides 2.23 65.69 15.5 200 27025.78

Wax 3.43 39.23 15.5 200 24825.36

Hydrogen 15.5 200

Peroxide 2.629 18.76 9100.32

Ketone 37.86 15.5 200 16046.77

2.297
Lindane 0.73 15.18 15.5 200 2044.50

Water 5.861 5952.54 15.5 100 2948024.20

QTotal (kJ) 4,538,837.82

3.5 Overall Energy Balance

After calculating the energy required from the component stream and also
energy derived from each operation unit, we have to calculate the overall
energy balance, as follows:

𝐸𝑛𝑒𝑟𝑔𝑦 𝐵𝑎𝑙𝑎𝑛𝑐𝑒

18
 = −𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑈𝑛𝑖𝑡 ′ 𝑠 𝐸𝑛𝑒𝑟𝑔𝑦 + 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑆𝑡𝑟𝑒𝑎𝑚′ 𝑠 𝐸𝑛𝑒𝑟𝑔𝑦

Energy Balance Q (kJ)

Component Stream’s
Energy (A) 5,775,127.095
Operation Unit’s Energy (B) 4,538,837.818

Total (A-B) 1,236,289.28

EXECUTIVE SUMMARY

Fish oil, derived from the tissue of oily fish species, is widely adopted in
numerous human and animal nutrition applications as a food and feed supplement
due to its high content of essential long chain omega 3 fatty acid, such as EPA and
DHA and linelonic acid which are essential nutrients for both humans and animals.
Additionally, the popularity of omega 3 fish oil in various applications, such as
supplements and functional food and pharmaceutical, also boosted its market.
In Indonesia. there are various types of fish that can be used to produce fish
oil, such as kembung. lemuru. tongkol. kakap. tuna etc. One of the most potential
species for fish oil production in Indonesia is kembung/long jawed mackerel fish
(Rastrelliger Sp.). We chose this specific fish due to the consideration of huge
amount of production in 2013 which was 938,991 ton and also the fact that the
higher content of omega-3 or other essential fatty acid compared to other common
feedstock of fish oil, such as salmon and tuna.
The production capacity of a plant could be determined by market analysis
that had been made. Market analysis indicated any opportunities that could be taken
by the new manufacturers to invest in fish oil industry. Opportunities could be
maximized among the competition with other manufacturers, both the existing
manufacturers and new manufacturers. Moreover, we knew that fish oil still had
been a imported commodity in Indonesia and the stakeholeders of fish oil plant
commonly came from foreign countries. By considering the supply and demand of
kembung fish and fish oil in Indonesia, we proposed to produce 341.12 kg of fish

19
oil everyday that was derived from 17,056 kg of fresh long jawed mackerel
(Rastrelliger Sp) fish.
Plant location would be projected to be in Gresik since we considered the
affordable distibution cost to our targeted market, particularly in Java region.
Regarding the process selection, we chose to have 5 main stages before the final
product would be packaged and distributed, which included cooking, pressing,
decanting, polishing and drying.
In addition. we also calculated the mass and energy balance in daily basis.
We obtained that the mass balance efficiency of the process was 24,26%, energy
required for each operation unit was 4,538,838 kiloJoule and energy required for
component stream was 5,775,127 kiloJoule.

REFERENCES

https://examine.com/supplements/fish-oil/

http://ilmukelautan.trunojoyo.ac.id/wp-
content/uploads/2016/08/8_Prosiding_semnaskel_2016.pdf

http://spo.nmfs.noaa.gov/Circulars/CIRC276.pdf

http://www.iffo.net/system/files/Chemical%20composition%20and%20stability%
20of%20fish%20oil%201992-1_1.pdf

http://www.fao.org/docrep/x5738e/x5738e05.htm

https://static1.squarespace.com/static/53296b1be4b0f59c2976d2c8/t/554b718ce4b
09bf8cbb829ae/1431007628437/Fish+Oil+Technical+Document.pdf

https://www.bps.go.id/linkTabelStatis/view/id/1019

https://www.researchgate.net/publication/228086444_Extraction_Processing_and
_Stabilization_of_Health-Promoting_Fish_Oils

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