ENG1002 Lecture Week2-Updated 2019-S2 XS

ENG1002 – Magic and Wizardry
Week 2: Mass Balance
Julie Karel, Materials Science & Engineering

Jonathan Li, Electrical & Computer Systems Engineering
Udo Bach, Chemical Engineering
Amanda Eaton, Learning Skills Advisor, Monash Library
Overview
What will we learn over the next 3 weeks:
Week 1: mass balance without chemical reaction

Week 2: mass balance with chemical reaction
Week 3: energy balance
Overview
What is the aim of our lectures in week 2-4:

• Application of the pre-lecture material
• Some basic repetition of the pre-lecture material
• Some new knowledge and concepts, not covered in the pre-lecture material
• Some real world examples of engineering problems & solutions
• Some background information relevant to humanity’s engineering grand
challenges of this century
Grand Challenges - your answers from week 1
Tuesday Class Wednesday Class

Limited Resources & peak fuel
Fossil Fuel
Climate Change
Climate Change
Overpopulation
Renewable Energy
Plastic Pollution Pollution
Unlimited Needs & Wants Poverty

The 14 Grand Challenges for Engineering in the 21st century
Our to-do list for saving the planet

1. Make solar energy affordable.
2. Provide energy from fusion.
3. Develop carbon sequestration methods.
4. Manage the nitrogen cycle.
5. Provide access to clean water.
6. Restore and improve urban infrastructure.
7. Advance health informatics.
8. Engineer better medicines.
9. Reverse-engineer the brain.
10. Prevent nuclear terror.
11. Secure cyberspace.
12. Enhance virtual reality.
13. Advance personalized learning. Provided to us by:
14. Engineer the tools for scientific discovery. The National Academy of Engineering (USA)
http://engineeringchallenges.org/challenges.aspx
The 14 Grand Challenges for Engineering in the 21st century
Our to-do list for saving the planet

1. Make solar energy affordable.
2. Provide energy from fusion.
3. Develop carbon sequestration methods.
4. Manage the nitrogen cycle. Chemical
5. Provide access to clean water. Engineering
6. Restore and improve urban infrastructure. challenges
7. Advance health informatics.
8. Engineer better medicines.
9. Reverse-engineer the brain.
10. Prevent nuclear terror.
11. Secure cyberspace.
12. Enhance virtual reality.
13. Advance personalized learning. Provided to us by:
14. Engineer the tools for scientific discovery. The National Academy of Engineering (USA)
http://engineeringchallenges.org/challenges.aspx
Chemistry versus Chemical Engineering
What chemists make:
© www.RTI.org
Chemists synthesise new chemical

compounds that can help improve the
world we live in:
• New anti-cancer drugs
chemical plant
• New semiconductors for solar cells
• Biodegradable polymers
• New battery materials
[…]
…. on the gram scale
What chemists make: What chemical engineers make:
© www.RTI.org
Chemists synthesise new chemical

compounds that can help improve the
world we live in:
• New anti-cancer drugs
chemical plant Chemical engineers develop processes to produce
• New semiconductors for solar cells
these materials on a large scale (many tons) to make
• Biodegradable polymers
them available to the global population.
• New battery materials
[…] Sustainability – renewable resources - zero waste production
…. on the gram scale – green chemistry - recycling – energy efficiency - …
Example: Paracetamol (pain killer)
Single dose: 500 mg
Annual production (2014):

Example: Paracetamol (pain killer)
Single dose: 500 mg
Annual production (2014): 150,000 tons

Þ17,000 kg per hour 24/7 throughout the year
Þ(4.8 kg per second!)
ÞRequirement for large scale chemical synthesis facilities and

processes
Chemistry: Chemical Engineering:
m = 5.04 g
n = 0.25 mole
V = 45 ml
chemical plant
© C&EN
Almost exclusively batch processes Often continuous flow processes

m = 5.04 g
n = 0.25 mole
V = 45 ml
No lab coat!
�
chemical plant
© C&EN
Almost exclusively batch processes Often continuous flow processes

m = 5.04 g
n = 0.25 mole
V = 45 ml
© C&EN
Almost exclusively batch processes Typically continuous flow processes

Flow
Think of the process of filling a car up with petrol,….
flow
Fuel hose
Flow (volumetric flow – ‘V-dot’)
Flow of liquid
△V
In a certain time span (△t) a certain volume of liquid (△V)

has run through the pipe
Flow (mass flow – ‘m-dot’)
Flow of liquid
△m
In a certain time span (△t) a certain volume (△V)

Flow of liquid
△m

Flow of liquid
△m

Flow of liquid
△m

Batch processes versus continuous flow processes
Batch process example:
Brewing beer
© beerconnoisseur.com
Monash Student Team: Brewlab (initiated by Chemical Engineering Department)
Monash Student Team: Brewlab (Chemical Engineering Department)
https://www.monashbrewlab.com
https://www.facebook.com/MonashBrewLab/
Batch process example:
Brewing beer
© beerconnoisseur.com © gtreview.com
Batch process example: Continuous flow process example:
Brewing beer Crude oil refinery
© beerconnoisseur.com © gtreview.com
Continuous flow processes – example - crude oil refinery
Distillation
Gasoline, diesel, natural gas
Crude oil Precursors for chemical industry

(i.e. polymers)
Asphalt, paraffin
• Crude oil can contain hundreds of different chemical

compounds
• The first process in an oil refinery plant is a separation
process called ‘distillation’ in which these compounds
are separated according to their boiling point.
• The products yielded by this process (i.e. gasoline,
diesel, natural gas) still represent a mix of different
chemicals – however they all have similar boiling points
© steemkr.com
• No chemical reactions during distillation
Continuous flow processes – example - crude oil refinery
Gasoline, diesel, natural gas
Crude oil Precursors for chemical industry

(i.e. polymers)
Asphalt, paraffin
© steemkr.com
Continuous flow process example:
Crude oil refinery
Distillation Process
Crude oil refinery
Input stream
Output streams
Distillation Process
Crude oil refinery

Mass balance
• In chemical engineering processes are often

run in continuous flow mode.
• Starting materials are continuously feed into
the process, producing a continuous stream
of products, leaving the process
• These processes can run for hours, days,
weeks or months without interruption.
• It is important to keep track of how much
(mass) of a specific material is entering and
leaving the specific processing units at any
given time.
A step-by-step approach
• Total mass balance (single component systems)
• Component mass balance (multi component systems)
• Mass balance with chemical reactions

Law of conservation of mass
Mass can neither be created nor destroyed.

Antoine Lavoisier's 1789
(2 years after the First Fleet
set sails for Australia)

First case scenario: No accumulation

Steady state system:
What comes in must come out


First case scenario: No accumulation

Steady state system:
What comes in must come out

Mass balance in systems without accumulation
Crude oil refinery: No accumulation
Input stream
Output streams
Crude oil refinery: No accumulation !!!

=0

Process Flow diagram
‘System’
Process Flow diagrams
‘System’
Process Flow diagrams
stream 1
stream 2 stream 3
‘System’
stream 4
input streams: stream 1, stream 2

output stream: stream 3, stream 4

Process flow diagram:
gas
gasoline
kerosine
Crude oil Distillation diesel
fuel oil
paraffin

Second case scenario:

Systems in which mass accumulation
is possible
If it hasn’t come out, it’s still in there

Law of conservation of mass overall mass balance

Þ understand your system:

Is there accumulation or not
Example: Systems with accumulation
Pumped storage hydroelectric power station
Power generation
Power storage
Source:
Climatecouncil.org.au
https://environmentvictoria.org.au/2018/04/30/victoria-edge-clean-energy-revolution/
Negative Electricity Prices – example: California
• Electricity prices are driven by

demand and supply
• When more electricity is produced

than consumed the electricity price
can go negative
• Traditionally this occurred at night

when coal and nuclear power
stations keep producing electricity
while there is a low demand
• As we source an increasing
time of the day
amount of electricity from solar
Source: Mark Rothleder – conference slides California ISO
www.eia.gov/conference/2016/pdf/presentations/rothleder.pdf
cells oversupply is now more likely
to occur in the middle of the day
Snowy Hydro 2.0 – the Facts
• Pumped storage hydroelectric power station in the Snowy Mountains
• Price tag: $3.8 billion - $4.5 billion
• First power generation: 2024
• Capacity (generation and storage): source: SBS
2,000 megawatts (max 8,000 MW)

• Jobs: 5,000 direct and indirect jobs over the construction period
• 350,000 MWh large scale storage (2,700 times more than the SA Tesla battery)
system
Exercise
Compose a mass flow diagram and mass balance

equation for the upper reservoir for Snowy Hydro 2.0,
considering mass changes (if appropriate) due to
catchment of precipitation, electricity generation and
storage and drainage from the lower reservoir
Process Flow Diagram and mass balance equation for Snowy Hydro 2.0
upper
reservoir
lower
reservoir
Example: system without accumulation
Water desalination plant
(a 2 component system)
Water supply – Example Cape Town (SA)
Cape-town was running out of water in 2018
‘Day zero’ has been projected to be July 9th
image credit: www.kuhnassociatesllc.com
25/07/18
508 Gl
x
image source: https://www.timeslive.co.za

Source: Climate systems analysis group
Cape Town – Water Crisis
image source: CNN image source: CNN
Images of Cape Town’s largest water catchment (Theewaterskloof Dam)

Drought in Cape Town
Cape Town: drought since 2015 as a result of an el nino weather
pattern and climate change caused by global warming:
Wonthaggi Desalination Plant
image source: www.water.vic.gov.au image source: Herald Sun

Example: Water Desalination Plant
https://www.aquasure.com.au/pipeline-powerline
victoriasdesalinationplant-present.blogspot.com.au
Factsheet:
Announced: 2007 (Melbourne water storage were then at 29% capacity)
Completed: 2012 (Melbourne water storage were then at 81% capacity)
Cost: 4 billion $ ($770 per capita)
Energy Consumption: 3 kWh / kL of drinking water
Capacity: 150 GL/year
The cost to desalinate seawater to drinking water quality is $1.50 - $5.00 /kL compared to
$0.30 – $0.90 /kL for drinking water from dams
Diffusion
• Molecules in liquids and gasses at room
temperature are continuously performing
random movement in all directions of space
(Brownian motion).
• In systems with concentration gradients this
random movement will result in directional
movement along the gradient.
• The end result of this diffusion process is a
homogeneously mixed solution with equal
concentrations everywhere
• This always happens spontaneously. We can
never observe the reverse process in nature.
• Why? => you will learn in your
thermodynamics class in 2nd semester.
Osmosis
Experiment:
• a semitransparent membrane
separates a high concentration
sugar solution and distilled water
• We observe the diffusion of water
concentrated through the membrane into the
salt or sugar
solution
concentrated sugar solution
semipermeable
membrane
distilled water
Osmosis
Water will diffuse into the sugar solution even against an external pressure
(here: the hydrostatic pressure of the sugar solution rising in a tube)
osmotic
pressure
concentrated
salt or sugar
solution
semipermeable
membrane
distilled water
Osmosis
Source: University of Michigan, demo lab

www.youtube.com/watch?v=pCupvFGN4bw
Jelly Bean (Gelatine = polypeptide gel)
H2O
H2O + + -
- +
- - H2O
+ +
-
H2O
H2O
H2O
-
H2O + In pure water -
+ - +
- + -
-
- - H2O
+ + + +
- -
H2O
H2O
+ - + - + - + + - + - + - +
- - -
- - - -
- - -
+ - -
+ + +
+ + + + +
- + + + + - +
+ - + - In salt water + -
+ - + + - -
- - + -
+ - - + +
- - + - - -
+ - + - +
-
- + + - + + -
- + -
+ + +
- + - + - + - +
+ - + - + - + -
Osmosis and reverse osmosis
Osmosis
• Osmosis describes the diffusion process through a semipermeable membrane
• This membrane is permeable for e.g. the solvent molecules (i.e. water) but not for the solutes
(i.e. salt or sugar)
• ‘mixing’ of the 2 solutions with different concentrations can only happen by diffusion of solvent
molecules from the side of lower concentration to the side with higher concentration.
• The driving forces for the mixing process will drive this type of mixing process even against a
moderate external pressure.
Reverse Osmosis
• High external pressures applied to the high-concentration solution can reverse the natural
osmosis process.
• This results in solvent (i,e. water) molecules passing through the membrane from the high
concentration side (i.e. sea water) to the low concentration side (drinking water).
• This effect is applied in modern water desalination plants
source: Green Living
Reverse osmosis – water desalination
sea water
(high pressure) brine
H2O H2O H2O
water
semipermeable
membrane
• Capacity: 150GL/year
• 40 % (mass) of the sea water that enters the plant is extracted as fresh
water. The rest flows back to the sea.
• The salt mass fraction in sea water is 0.035.
Task 1: Draw a process diagram for the desalination process.

Task 2: Write down the overall mass balance equation for the desalination
process.
Task 3: Write down the component mass balance equations.
Task 1: Process Flow Diagram and overall mass balance equation
seawater Desalination drinking water

Plant
brine (seawater concentrate)

Task 1: Process Flow Diagram
Sea Desalination drinking water

Bass Strait Plant
Task 2: Total mass balance

Bass Strait Plant
no accumulation !!!
Task 3: Component Mass balance
Sea
Bass Desalination Plant
Plant
Bass Strait
Strait
= the mass flow of pure salt that comes into the plant with the sea water intake
= the mass flow of pure salt that leaves the plant as fresh water
= the mass flow of pure salt that flows back to the ocean as brine
Sea
Bass Desalination Plant
Plant
Bass Strait
Strait
= the mass flow of water (pure H2O) that comes into the plant with the sea water intake
= the mass flow of water (pure H2O) that leaves the plant as fresh water
= the mass flow of water (pure H2O) that flows back from the plant to the ocean as brine

Bass Strait Plant
no accumulation !!!
No chemical reaction
• 40 % (mass) of the sea water that enters the plan is extracted as fresh water
Task 4: Calculate the average mass flow of fresh water in kg per second.
Task 5: Calculate the overall mass flows and all component mass flows for all the streams in kg per second.
Input stream Output stream Output stream

seawater drinking water brine
Component 1:
Component 2:
Task 4: mass flow of drinking water
• 40 % (mass) of the sea water that enters the plant is extracted as fresh
water
Task 4: calculate the average mass flow of fresh water in kg per second
150 GL/year = 150 109 l/year = 1.5 1011 l/year
= 1.5 1011 l/year / (365 days/year *24h/day * 60 min/h*60 s/min) =
= 4,800 l/sec (about 26 full bathtubs a second!)
= 4,800 kg/sec
Task 5: component mass flow balance
• 40 % (mass) of the sea water that enters the plant is extracted as fresh water
?
?
? ? :
0
• 40 % (mass) of the sea water that enters the plan is extracted as fresh water
:
?
?
? :
?
6,780
6,780 all the salt that is flowing into the plant with the
? seawater must flow out with the brine:
success!
Mass fraction of salt in the brine?
Task 6: What is the mass fraction of
salt in the brine that flows back into the
sea?
Answers:
1) 0.035
2) 0.058
3) 0.070
4) 0.60 flux.qa/XPCZFC
5) none of the above
Task 6: mass fraction of salt in the brine:
:
Example: Blood Dialysis
• The Kidney does an amazing job in removing
waste products such as urea and excess water
from the blood.
• Patients with kidney malfunction typically need to
frequently undergo blood dialysis where blood
(with waste products) is taken from the patient
and pumped through a dialyzer.
• In a dialyzer 2 inverted streams of (1) blood and
(2) a dialysate are separated by a
semipermeable membrane.
• This membrane allows water, ions and small
molecules such as urea to pass from the blood
into the dialysate.
• The membrane is impermeable for red and white
image source: Advin Healthcare
blood cells and large proteins (such as
antibodies) contained in the blood.
Example: Blood Dialysis
image source: Aviva (https://www.aviva.co.uk)
image source: Advin Healthcare
urea
=> see Worksheet Booklet: question 2, week ( a waste product of protein
synthesis in the body)
Mass balance – The word’s challenges today
Global disappearance of glaciers
1850 (simulation) today
Rhone Glacier – Swiss Alps

- https://gletscherg2h.wordpress.com/gletscheralswasserversorgung/
Glacier mass balance
Sublimation is the transition

of a substance directly from
the solid to the gas phase,
without passing through the
image source: http://www.antarcticglaciers.org
liquid phase.
Glacier mass balance
watch: https://www.youtube.com/watch?v=9mhtzkXO5SM
Exercise
•Compose a generic mass flow diagram and mass

balance equation for a glacier, considering mass
changes (if appropriate) due to snowfall onto the glacier,
sublimation of ice from the glacier, melting of ice and
carving
Process Flow Diagram and mass balance equation for a glacier
Glacier
Glacier: seasonable mass balance flow rates
ablation = dissipation/loss
image modified from: http://www.antarcticglaciers.org
Cumulative mass balance
Cumulative glacier mass balance since
1960 in tons per area (m2) of glacier1.
What is the average height loss of the

Patagonian glaciers between 1960 and today?
Answers:
Answer 1: 39 cm
Answer 2: 33 m
Answer 3: 39 m
Answer 4: 3.3 m
36
Answer 5: 36 cm
Answer 6: none of the above

density of ice = 0.92 g/cm3 1
in reference to 1960 glacier area
Cumulative glacier mass balance since
1960 in tons per area (m2) of glacier1.

Answers:
Answer 1: 39 cm
Answer 2: 33 m
Answer 3: 39 m !!!!!!!!!!!!!!!!!!!!!
Answer 4: 3.3 m
- 36
Answer 5: 36 cm
Answer 6: none of the above

density of ice = 0.92 g/cm3 1
in reference to 1960 glacier area

Ice-Sheet Mass Balance
deaccumulation of
ice within the global
ice sheet
accumulation of
deaccumulation of
water in the oceans
ice within the global
ice sheet
Global Warming – Impact on Asia’s Glaciers
Glacier Mass Loss (Asian Glaciers) EOC in %
Glaciers of the high mountains of Asia make a

substantial contribution to the water supply of
millions of people.
If CO2 emissions are not controlled, about 70% of
Asia’s glaciers could be lost by the end of this
century (EOC). This could threaten water
availability and food security for millions of people
Average global temperature change EOC in °C

Questions?
image source: Vinod Chopra Films

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ENG1002 – Magic and Wizardry

Week 2: Mass Balance

Julie Karel, Materials Science & Engineering

What will we learn over the next 3 weeks:

Week 1: mass balance without chemical reaction

What is the aim of our lectures in week 2-4:

Tuesday Class Wednesday Class

Plastic Pollution Pollution

Unlimited Needs & Wants Poverty

Our to-do list for saving the planet

Our to-do list for saving the planet

Chemists synthesise new chemical

Chemists synthesise new chemical

Single dose: 500 mg

Annual production (2014):

Single dose: 500 mg

Annual production (2014): 150,000 tons

ÞRequirement for large scale chemical synthesis facilities and

Almost exclusively batch processes Often continuous flow processes

Almost exclusively batch processes Often continuous flow processes

Almost exclusively batch processes Typically continuous flow processes

Think of the process of filling a car up with petrol,….

In a certain time span (△t) a certain volume of liquid (△V)

In a certain time span (△t) a certain volume (△V)

In a certain time span (△t) a certain volume (△V)

In a certain time span (△t) a certain volume (△V)

In a certain time span (△t) a certain volume (△V)

Batch process example:

Batch process example: Continuous flow process example:

Brewing beer Crude oil refinery

Crude oil Precursors for chemical industry

• Crude oil can contain hundreds of different chemical

Gasoline, diesel, natural gas

Crude oil Precursors for chemical industry

Crude oil refinery

Crude oil refinery

Continuous flow process example:

Crude oil refinery

• In chemical engineering processes are often

• Total mass balance (single component systems)

• Component mass balance (multi component systems)

• Mass balance with chemical reactions

Mass can neither be created nor destroyed.

Mass can neither be created nor destroyed.

First case scenario: No accumulation

What comes in must come out

Mass can neither be created nor destroyed.

First case scenario: No accumulation

What comes in must come out

Crude oil refinery: No accumulation

Crude oil refinery: No accumulation !!!

Crude oil refinery: No accumulation !!!

Crude oil refinery: No accumulation !!!

input streams: stream 1, stream 2

Crude oil refinery: No accumulation !!!

Process flow diagram:

Mass can neither be created nor destroyed.

Second case scenario:

If it hasn’t come out, it’s still in there

Mass can neither be created nor destroyed.

Þ understand your system:

• Electricity prices are driven by

• When more electricity is produced

• Traditionally this occurred at night