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MATERIAL BALANCE
A process design starts with the development of a process flow sheet or process
flow diagram. For the development of such a diagram, material and energy balance
calculations are necessary. These balances follow the laws of conservation of mass and
energy which states that the total mass of various components involved remains constant
during and unit operation or unit process. Thus, for any unit operations or unit process,
For steady state operations where accumulation is constant or nil, the above equation
becomes:
INPUT = OUTPUT
During material balance some of the assumptions play a vital role which we have
considered wherever it is necessary.
Assumptions:
1. 80% conversion
2. 10% excees Ca(OH)2
3. 400 kg of water added to fermenter
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Molasses reacted = molasses fed x conversion
= 1000 x 0.80
= 800 kg reacted
= 1000 – 800
= 200 kg unreacted
= 1000 x 74
180
= 1.1 x 411.11
= 411.11 x 0 .80
= 328.88 kg reacted
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Ca(OH)2 unreacted = Ca(OH)2 fed - Ca(OH)2 reacted
=452.22 - 328.88
=123.33 kg unreacted
= 160 kg of water.
= 400 + 160
= 560 kg of water.
Lactobacillus bacteria are also added to the fermenter.Its amount per one
batch is 100 Kg and its growth depends upon the temperature and acidity of water.
After the fermentation, the remaining bacteria go with the cake.
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M o l a s (1s e0 s0 k0 g)
(4 5 .22 2 2k g)
M o l a s s(2e0s0k g)
C a(O H)2 C a(O H)2 (1 2 .33 3K G)
FERM EN T ER C a l c i u m L (9 a c6 t.88a9tk eg)
W a t (5e r6 0k g)
W a t (4e r0 0k g)
Assumption :
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Water out = Water in – 2 % loss of Water
= 548.80 kg of Water
M o l a s s e(2s 0 0 k g)
C a(O H)2 (1 2 3.3 3 K G) CAKE
C a l c i u m L a c t(9 a t6e8.8 9 k g) F IL T E R
M o l a s s e(2s0 0k g)
W a t e(5 r 6 0 k g)
C a(O H)2 (1 2 3.3 3 k g)
C a l c i u m l a c t(1
a t9.3
e 7 k g)
W a t e(1 r 1.2 k g)
F IL T R A T E
C a l c i u m l a c t(9a t4e9.5 1 k g)
W a t e (5r 4 8.8 k g)
Assumption:
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1. 95 % conversion of Calcium Lactate
= 949.51 x 0.95
= 949.51 – 902.03
= 744.79 kg
kg of H2SO4 = 949.51 x 98
218
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= 426.81 kg H2SO4 fed
= 405.50 kg.
= 21.33 kg
= 902.03 x 136
218
H 2S O4
(4 2 6.8 1 K G)
C a l c i u m L a c t(4a 7.4
t e 7 K G)
A C ID U L A T IO N H 2S O4 (2 1.3 3 K G)
L a c t i c a c(7i d4 4.7 9 k g)
C a l c i u m l a c t(9a 4t e9.5 1 k g) TANK C aS O 4 (5 6 2.7 3 k g)
W a t e(5 r 4 8.8 k g) W a t e(5 r 4 8.8 k g)
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Material in kg per Material out kg per
Components day day
CaSO4 0 562.73
Total 1925.12 1925.12
Assumption :
= 737.34 kg
= 21.11 kg
= 47.00 kg
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= 543.31 kg
= 576.36 kg.
C a l c i u m L a c(4t 7a.4t7eK G)
H2 S O4 (2 1.3 3K G) CAKE
L a c t i c a(7c i4d4.7 9k g) F IL T E R C a S 4O(5 6 2.7 3 K G)
C a S 4O(5 6 2.7 3k g) L a c t i c a(7.4
c i d4 k g)
W a t e(5r 4 8.8 k g) H2 S O4 (0.2 1 3k g)
C a l c i u m l a c(0.4
t a 7t keg)
W a t e(5.4
r 8k g)
F IL T R A T E
L a c t i c a(7c i3d7.3 4k g)
H2 S O4 (2 1.1 1k g)
C a l c i u m l a c(4t 7a.0t0ek g)
W a t e(5r 4 3.3 1k g)
Assumption:
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1. 5% adsorption of water
2. 90 % adsorption of calcium lactate
3. 85% adsorption of H2SO4
= 47 – 0.9 x 47
= 4.7 kg
= 42.3 kg
= 3.16 kg.
= 17.95 kg
= 737.34 kg
= 516.14 kg.
= 27.17 kg
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F IL T R A T E CARBON C a l c i u m L a(4.7 c t ka g)t e
L a c t i c a(7c3i .7d3 4k g) CO LU M N H2 S O4 (3.1 6 k g)
L a c t i c a(7c3i .7d3 4k g)
H2 S O4 (2 1.1 1k g)
C a l c i u m l a(4c 7t.0a0tkeg) W a t (5e r1 .61 4k g)
W a t e(5r4 .33 1k g)
M A T E R IA L A D S O R B E D
W a t e(2r7.1 6k g)
H2S O4 (1 7.9 4 k g)
C a l c i u m l a(4c 2t.3a kt eg)
Assumption:
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Lactic acid out = lactic acid in - 2 % loss of Lactic acid
= 722.59 kg
= 4.465 kg
= 3.002 kg
= 438.719 kg
= 77.41 kg
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= 722.59 x 100
807.467
= 89.48 %
W at er(438.71 kg)
Lact i c aci(14.74
d kg)
C al ci um lact at (0.235
e kg)
H 2S O4 (0.158 kg)
C al ci um Lact at (4.7
e kg)
H2 S O4 (3.1 6 kg) E VAP O RAT O R
Lact i c aci(737.34
d kg)
W at er(516.14 kg)
Lact i c aci(722.59
d kg)
C al ci um l act at
(4.46
e kg)
H 2S O4 (3.002 kg)
W at er(77.41 kg)
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