CCB 1064: Professor Saibal Ganguly

Lecture Set 4: Mass Balance without reactions

Professor Dr. Saibal Ganguly
Universiti Teknologi PETRONAS September 2011

CCB 1064: Professor Saibal Ganguly

Lecture Set 4: OBJECTIVES

At the end of the lecture, students should be able to:
Understand what is mass balance Analyze problems for mass balance without reactions Understand mass balance for multiple processes Formulation of mass balances with recycle and purge

CCB 1064: Professor Saibal Ganguly

Classification of Chemical Processes

Chemical process may be classified as: 1. Batch process: The feed is charged into a process unit at the beginning of the process and the output is removed from the process unit at the end of the process. 2. Continuous process: The inputs and outputs flow continuously throughout the duration of the process. 3. Semi batch process: Any process that is neither batch nor continuous.

CCB 1064: Professor Saibal Ganguly

Steady state and Unsteady state processes

If the process variables such as flow rates, temperatures, pressures, volume etc do not change with time, the process is said at STEADY STATE. On the other hand, if the process variables do change with time, the process is said at UNSTEDY STATE or TRANSIENT. By nature, batch and semi-batch process are unsteady state operation, while continuous process is steady state operation.

CCB 1064: Professor Saibal Ganguly

Example 1:
Process A balloon is filled with air at a steady state rate of 2 g/min Water is boiled in an open flask Water is boiled in an closed flask Gasoline from car tank Carbon dioxide and steam are fed into reactor to form carbon dioxide and hydrogen Classification Semi-batch, transient Remark Volume, T, P change with time. Volume, T, P change with time. T & P change with time. Volume change with time All process variables do not change with time.

Semi-batch, transient Batch, transient Semi-batch, transient Continuous, steady state

CCB 1064: Professor Saibal Ganguly

CONSERVATION OF MASS
The law of conservation of mass states that for any process unit(s), mass can neither be created nor destroyed but it can change from one phase to another phase or converted into other forms through reaction process. The law concludes that:

Total mass INPUT = Total mass OUTPUT

[1]

OVERALL MASS BALANCE 6

CCB 1064: Professor Saibal Ganguly COMPONENT MASS BALANCE

Generally, the mass balance equation for any process unit is given as:
Input + Generation - Output - Consumption = Accumulation
Input :: Enters through system boundaries Generation:: Produced within system only for reactive system

[2]

Output:: Leaves through system boundaries Consumption:: Consumed within system only for reactive system Accumulation:: Buildup within system only for transient operation

CCB 1064: Professor Saibal Ganguly Balance on Continuous Steady-State Processes

For continuous steady-state operation for reactive system, the accumulation team is equal to zero. Hence, EQ [2] becomes,

Input + Generation - Output - Consumption = 0 [3]

For continuous steady-state operation for non reactive system, EQ [3] is simplified as,

Input = Output

[4]

CCB 1064: Professor Saibal Ganguly

Balances on Batch Processes

For batch processes, the input and output in Eq [2] is zero, and the equation is simplified as,

Generation - Consumption = Accumulation

For batch processes, accumulation is defined as,

[5]

Final Output - Initial Input = Accumulation

[6]

Hence by equating Eq [5] and [6], for batch processes, the mass balance equation is given as,
Initial Input + Generation = Final Output + Consumption [7]

CCB 1064: Professor Saibal Ganguly

Steps in Solving Material Balance

1.Read and understand the process description ---- type of process unit used and the type of process operation. 2.Draw a flowchart for the process description to represent process unit and to represent inputs and outputs. 3.Write all known stream variables i.e. inputs & outputs, on the flowchart. 4.Assign algebraic symbols to unknown stream variables. 5. Perform degree of freedom analysis. You must have equal number of equations related to unknown process variables (zero degree of freedom). 6.Take basis of calculation. 7.Write mass balance equation for the overall system and for specific component using selected Eq [1] to [7]. 8.Perform mass balance for the process description. Always check the overall mass balance Total Inputs = Total Outputs

CCB 1064: Professor Saibal Ganguly

SEPARATION BY DISTILLATION

11

CCB 1064: Professor Saibal Ganguly

One distillation tray in the column

12

CCB 1064: Professor Saibal Ganguly

The distillation process:
In a distillation column, vapor and liquid flow in countercurrent directions to each other. Liquid is vaporized at the bottom, and vapor is condensed from the top product and withdrawn from the column. A number of trays are placed in the column, or the column is packed with open material, so that the vapor phase contacts the liquid phase, and components are transferred from one phase to the other. As you proceed up the column the temperature decreases, and the net effect is an increase in the more volatile component(s) in the vapor and a decrease in the less volatile components in the liquid. Vapor is withdrawn from the top of the column and liquid from the bottom. Feed to the column usually enters part way up the column.

13

CCB 1064: Professor Saibal Ganguly Example 5:

1000 kg/hr of mixture containing equal parts by mass of methanol and water is distilled. Product streams leave the top and the bottom of the distillation column. The flow rate of the bottom stream is measured and found to be 673 kg/hr and the overhead stream is analyzed and found to contain 96.0 wt% methanol. a. Draw and label a flowchart of the process and do the degree of freedom analysis. b. Calculate the mass and mole fractions of methanol and the molar flow rates of methanol and water in the bottom product stream. c.Suppose the bottom product stream is analyzed and the mole fraction of methanol is found to be significantly higher than the value calculated in part (b), list as many possible reasons for the discrepancy as you can think of.

CCB 1064: Professor Saibal Ganguly Example 6:

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. (a) Draw and label flowchart. Do the degree-of-freedom analysis to prove that for an assumed basis of calculation, molar flowrate and compositions of all process streams can be calculated from the given information. (b) calculate (i) the percentage of the benzene in the process feed (the feed to the first column) that emerges in the overhead product from the second column and (ii) the percentage of toluene in the process feed that emerges in the bottom product from the second column.

CCB 1064: Professor Saibal Ganguly

Solution:

(a) Draw and label flowchart. Do the degree-of-freedom analysis to prove that for an assumed basis of calculation, molar flowrate and compositions of all process streams can be calculated from the given information.

16

CCB 1064: Professor Saibal Ganguly

n2 (mol/h)
100 mol/h

n4 (mol/h)
0.940 mol B/mol 0.060 mol T/mol

XB2 (mol B/mol) 0.450 mol X/mol 0.300 mol B/mol 0.250 mol T/mol XT2 (mol T/mol)
1 - XB2 -XT2 (mol X/mol)

n5 (mol/h) n3 (mol/h)
0.02 mol T/mol 0.980 mol X/mol XB5 (mol B/mol) XT5 (mol T/mol) 1 - XB5 -XT5 (mol X/mol)

CCB 1064: Professor Saibal Ganguly

Column 1 Eqn 1: Eqn 2: Eqn 3: Eqn 4: 96% X Recovery: Total mole balance: B Balance: T Balance:

0.960( 0.450)(100)
100

0.980 3

n2 n3

0.300(100)
0.250(100)

xB 2 n2
0.020 3

xT 2 n2

DoF Column 1: 4 unknowns; 3 Independent eqn 1 Recovery of X Column 2 Eqn 5: Eqn 6: Eqn 7: Eqn 8:

0 DoF

97% B Recovery: Total mole balance: B Balance: T Balance:

0.970 B 2 2

x n

0.940 4

n2 n4

n5
0.940 2

xB 2 n2

xB 5 n5

xT 2 n2

0.060 4

xT 5 n5
0 DoF

DoF Column 2: 4 unknowns; 3 Independent eqn 1 Recovery of X

CCB 1064: Professor Saibal Ganguly

(b) Calculate (i) the percentage of the benzene in the process feed (the feed to the first column) that emerges in the overhead product from the second column and (ii) the percentage of toluene in the process feed that emerges in the bottom product from the second column.

Overall Benzene Recovery:

0.940(30.95) x 100% 97% 0.300(100)

Overall Toluene Recovery:

0.892(24.96) x 100% 89% 0.250(100)

19

CCB 1064: Professor Saibal Ganguly

EVAPORATOR

CCB 1064: Professor Saibal Ganguly

Evaporation as a process operation involves the concentration of one more or solutes by transfer of the solvent from the liquid into the vapor phase. Evaporation also may be simply formation of vapor from a liquid. The heating medium, usually steam, is introduced in the steam chest connected to a set of tubes inside the evaporator body. The steam condenses causing some of the liquid outside of the tubes to vaporize. As a matter of economy, often a multiple series of evaporators are connected so that the vapor from one evaporator is introduced (at a lower pressure) into the steam chest of the next evaporator where it condenses, and so on. Dissolved solids can be deposited on the exterior of the heating tubes (scaling) so that different interior evaporator designs are used to reduce scaling.

21

CCB 1064: Professor Saibal Ganguly

Example 7:
A triple effect evaporator is designed to reduce water from an incoming brine (NaCl + H2O) stream from 25 wt % to 3 wt %. If the evaporator unit is to produce 14,670 lb/hr of NaCl (along with 3 wt % H2O), determine: a. the feed rate of brine in lb/hr. b. the water removed from the brine in each evaporator.
Solution

Steps 1, 2, 3 and 4
This is a steady state problem. Draw the flowchart and analyze

Step 5: It is best to choose 1 hr of operation or an arbitrary

amount of dry salt produced per hour as the basis. We will select Basis: 14,670 lb = 1 hr

CCB 1064: Professor Saibal Ganguly

Step 6: There are 6 unknown stream flows: F, V1, V2, V3, P1, and
P2.

Step 7 and 8
Balances for salt and water and total balance can be written for each unit as a system as well as overall balances (not all of these balances would be independent). We will use the salt and total balances as the simplest ones. Overall balances Total balance : F = V1 + V2 + V3 + 14,670 (1) Salt balance : 0.25 F = 0.97 (14,670) (2) Evaporator I

Total balance : F = V1 + P1 (3) Salt balance : 0.25 F = 0.33 P1 (4) Evaporator II Total balance : P1 = V2 + P2 (5)

CCB 1064: Professor Saibal Ganguly

Salt balance : 0.33 P1 = 0.50 P2 (6) Evaporator III Total balance : P2 = V3 + 14,670 (7) Salt balance : 0.50 P2 = 0.97 (14,670) (8) Any set of 6 independent equations can be used to determine the 6 unknowns. We will use equations (1) to (6) to solve for all of the unknowns.

Step 9
By starting the solution with equation (2), the equations become uncoupled. F = 56,900 lb/hr From equation (4) 0.25 (56,900) = 0.33 P1 P1 = 43,100 lb/hr Sec. 3.5 Material Balances for Multiple Units 5 1 From equation (3) V1 = 13,800 lb/hr

CCB 1064: Professor Saibal Ganguly

From equations (5) and (6) P2 = 28,460 lb/hr ; V2 = 14,700 lb/hr From equation (1) 56,900 = 13,800 + 14,700 + V3 + 14,670 V3 = 13,800 lb/hr

Step 10 Equations (7) and (8) can be used to check the

results. Equation (7) P2 = V3 + P3 28,460 13,800 + 14,670 = 28,470 Equation (8) 0.5 P2 = 0.97 P3 0.5 (28,460) = 0.97 (14,670) 14,230 lb = 14,230 lb

25

CCB 1064: Professor Saibal Ganguly

Example 8:
A crystallizer contains 6420 lb of aqueous solution of anhydrous sodium sulfate (concentration 29.6 wt %) at 104 C. The solution is cooled to 20 to crystallize out the C desired Na2SO4. 10 H2O. The remaining solution ( the mother liquor) is found to contain 16.1 % anhydrous sodium sulfate. What is the weight of this mother liquor.

26

CCB 1064: Professor Saibal Ganguly

End of Lecture Set 4

THANK YOU
27