Unit 2

Material Balance for Physical Systems

Concept Material Balance
• Chemical or Process plant is required to carry out transformation of raw materials into
desired products effectively and economically.
• Helps to evaluate specific consumptions of materials, evaluate losses of materials, and to
figure out the malfunctioning of processing units.
• A material balance is an accounting of all the material that enters, leaves, accumulates or
depleted in a process or in a process unit in a given time.
• All material balance follows the Law of Conservation of Mass, which states that mass can
neither be created nor destroyed.

• Chemical processes may be classified as batch,

continuous, or semi-batch & as either steady state or
transient.
• Batch Process: The feed is charged into a vessel at the
beginning of process & vessel contents are removed
sometime later.
• No mass crosses the system boundaries between time
feed is charged & time product is removed.
Continuous process: The inputs & outputs flow continuously throughout the duration of
process. e.g., Pump a mixture of liquids into a distillation column at a constant rate & steadily
withdraw product streams from top & bottom of column.
Semi-batch Process: Any batch that is neither batch nor continuous. e.g., Allow contents of
a pressurized gas container to escape to atmosphere; slowly blend several liquids in a tank
from which nothing is being withdraw
Chemical reactions involve conversion of one species to another
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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
 Input = Output + Accumulation
Accumulation refers to a change in mass or moles within the system with respect to time.
For steady state operations/processes wherein the accumulation of the material is constant
Input = Output
An operation/a process is said to occur under steady state when the values of variable (e.g.,
composition, flow rate) of the input and output streams of the operation/process do not
change with respect to time (i.e., variables are time invariant)
The material balance problems are classified in two categories as follows:
1) The material balance problems of processes involving no chemical reactions
2) The material balance problems of processes involving chemical reactions
Further each category is divided into,
1) Steady state operations, and
2) Unsteady state operations

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Distillation
• Separation of components of a liquid mixture by partial vaporization and condensation
based on relative volatility.
• Product from top is called distillate or overhead product.
• Product removed from bottom is called bottom product.

Feed = Distillate + Bottom (on weight or mole balance)

F (kg/h) = D (kg/h) + W (kg/h)
Material Balance of component A
A in feed = A in distillate + A in bottoms

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
𝑥𝐹 ∙ 𝐹 = 𝑥𝐷 ∙ 𝐹 + 𝑥𝑊 ∙ 𝐹
𝑥𝐹 , 𝑥𝐷 , and 𝑥𝑊 are the weight fractions of A in feed, distillate and bottom

Evaporation

• Used in chemical industry for concentration of a weak liquor to produce a thick liquor
by evaporating a portion of solvent by condensing steam.
• It may be carried out in a single or a multiple effect evaporator.
Overall material balance:
Weak liquor = Water evaporated + Crystallized product + Thick liquor
If crystallized product is nil:
Weak liquor = Water evaporated + Thick liquor
Material balance of solids (solute)
Solids (solute) in weak liquor = Solids (solute) in thick liquor
Material balance of water:
Water in weak liquor = Water evaporated + Water in thick liquor
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Drying

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Material Balance of moisture
Moisture removed from solids = Moisture added in air
Initial moisture in wet solids – moisture in dried solids = Moisture in outlet air – Moisture in
inlet air
* The quantity of solids does not change during this operation
Drying operation with recycle air

Material Balance over solids

Solids in wet solids (feed) = Solids in dried products
If F’, R’, and M’ are the quantities of dry air in fresh air, recycle air and mixed air then,
F’ + R’ = M’
Moisture balance in F, R, and M:
Moisture in M = Moisture in F + Moisture in R
Moisture balance at the outlet of dryer
Moisture in P = Moisture in R + Moisture in E
Moisture Balance over Dryer
Moisture added in air = Moisture removed from solids
X2M’ – X1M’ = Moisture removed from solids
Where X2 and X1 are kg moisture/water per kg dry air in the leaving air

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Extraction

Overall Material Balance:

Feed in solution = Extract phase + Raffinate phase
If A is the solute to be extracted, then the material balance of A for fresh solvent is:
A in feed solution = A in extract phase + A in raffinate phase

Material Balance of Solids:

Solids in seed = Solids in meal (if no solids go in given solvent)
Material Balance of Oil:
Oil in seeds = Oil in meal + Oil in solvent (extracted oil)
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Absorption

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Used for recovery/removal of a solute gas component from its mixture with another
component gas (called as inert gases with respect to absorption) with the help of a suitable
liquid solvent in which the solute gas is absorbed.
Material balance of inert gas:
Inert gas in gas entering the tower = Inert gas leaving the tower (i.e., inert gas in lean gas)
Material balance of solute gas (for no solute in solvent):
Solute gas in inlet gas – Solute gas in lean gas (gas leaving the tower) + Solute gas in solvent
leaving the tower
Solute gas removed by absorption = Solute in inlet gas – Solute in lean gas
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Filtration

This operation is carried out in the industry for the separation of solids from a suspension in
a liquid. Wet solids are the product of this operation. e.g., Centrifuge machines, drum-filters.
Overall Material balance
Feed slurry = Wet solids + Filtrate
Material Balance of solids
Solids in slurry = Solids in wet solids product + Solids in filtrate (if any)
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Mixing

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Mixing/blending of liquids may be carried out in a mechanically agitated vessel.
Overall Material Balance
Feed stream 1 + Feed stream 2 + Feed stream 3 = Desired product stream
Suppose feed stream 1 contains components A, B, and C. Product stream contains A, B, and
C. Feed stream 2 contains A and C, and feed stream 3 contains B and C then,

Material Balance of A:
A in feed stream 1 + A in feed stream 2 = A in desired product stream
Material Balance of B:
B in feed stream 1 + B in feed stream 3 = B in desired product stream
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Crystallization

Overall Material balance

Feed solution = Saturated solution + Crystals
Material Balance of solute crystals
Crystals in feed solution = Crystals obtained + Crystals in saturated solution
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Recycle Operations

• The recycling operation with chemical reaction is common in industrial process.

• This is mainly performed to utilize the valuable reactants to their maximum so that the
loss of the reactants is minimized.

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
 • Recycling is returning back a portion of the stream leaving a process unit to the entrance
of the process unit for further processing.
• Recycling operations, commonly encountered in unit operations and unit processes are
performed for
o Maximum utilization of the valuable reactants
o Improvement of the performance of the operation.
o Utilization of heat being lost in the exit stream.
o Better operating conditions of system
o Improvement of the selectivity of a product
o Maintaining process rate at a high value
o Enrichment of the product.

Bypassing
Bypass stream is a stream that skips one or more stages of the process and goes directly to
another downstream stage. Bypass stream is used to control the composition of the final
product at the desired value.

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 1: A feed containing 50% benzene and 50% toluene is fed to a distillation column
at the rate of 500 kg/h. The top product contains 95% benzene and the bottom product
contains 92% toluene by weight.
Calculate
1) the mass flow rate of the top and the bottom products,
2) the percentage recovery of benzene.

Solution: Basis: Feed of 500 kg fed to the distillation column

To solve any mass balance problem, following steps should be followed,

1) Write an appropriate basis based upon the given information
2) Draw the schematic representation showing all the streams information
3) Writing first the overall material balance
4) Writing the material balance over the desired product as given in the problem statement.
These steps will help you to solve the mass balance problem with ease.
Overall Material/Mass balance
F=D+W 1
We know, F = 500 kg/h, therefore equation 1 becomes
500 = D + W 2
Now take the mass balance around benzene,
𝐹. 𝑥𝐹 = 𝐷. 𝑥𝐷 + 𝑊. 𝑥𝑊
We know, in feed, Benzene is 50%, in the top product (i.e., distillate, D) Benzene obtained
is 95% and in bottom product (W) Benzene obtained is 8% as Toluene obtained is 92%,

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
therefore we can write these quantities in terms of mass fractions around benzene as 𝑥𝐹 =
0.5, 𝑥𝐷 = 0.95, and 𝑥𝑊 = 0.08, respectively
Mass balance around Benzene (Component Balance)
𝑭. 𝒙𝑭 = 𝑫𝒙𝑫 + 𝑾𝒙𝑾 3
Substituting the values of 𝑥𝐹 , 𝑥𝐷 , and 𝑥𝑊 , we get
500 × 0.5 = 𝐷 × 0.95 + 𝑊 × 0.08 4
250 = 0.95𝐷 + 0.08𝑊
From equation 2, we can substitute, W = 500 – D, we get
250 = 0.95𝐷 + 0.08(500 − 𝐷)
250 = 0.95𝐷 + 40 − 0.08𝑊
250 − 40 = 0.87𝑊
210 = 0.87𝑊
𝑾 ≈ 𝟐𝟒𝟏. 𝟑𝟖 𝒌𝒈/𝒉
Substitute, the value of W in equation 2, we get
500 = D + 241.38
𝑫 ≈ 𝟐𝟓𝟖. 𝟔𝟐 𝒌𝒈/𝒉
Percentage recovery of Benzene
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐶6 𝐻6 𝑖𝑛 𝑡𝑜𝑝 𝑝𝑟𝑜𝑑𝑢𝑐𝑡
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦 = × 100
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐶6 𝐻6 𝑖𝑛 𝑓𝑒𝑒𝑑
𝐷. 𝑥𝐷
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦 = × 100
𝐹. 𝑥𝐹
241.38 × 0.95
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦 = × 100
500 × 0.5
𝑷𝒆𝒓𝒄𝒆𝒏𝒕𝒂𝒈𝒆 𝑹𝒆𝒄𝒐𝒗𝒆𝒓𝒚 = 𝟗𝟏. 𝟕𝟐%
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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 2: A single effect evaporator is fed with 10000 kg/h of weak liquor containing
15% caustic by weight and is concentrated to get thick liquor containing 40% by weight
caustic (NaOH). Calculate
1) Kg/h of water evaporated and
2) Kg/h of thick liquor obtained.
Solution: Basis: 10000 kg/h of weak liquor

1) Overall Mass balance

𝐹 =𝑃+𝑊
F is feed, P is concentrated liquid, and W is water evaporated
We have, F = 10000 kg/h, thus equation 1 becomes,
10000 = 𝑃 + 𝑊 (1)
2) Take mass balance around caustic i.e., component balance (NaOH)
Caustic will be present only in the feed and concentrated liquor, as no caustic will be
present in water evaporated.
Mass of caustic in feed = Mass of caustic in concentrated liquor
10000 × 0.15 = 𝑃 × 0.40
1500 = 𝑃 × 0.40
𝑃 = 1500/0.40
𝑷 = 𝟑𝟕𝟓𝟎 𝒌𝒈/𝒉
Substitute the value of P in equation 1, we get
10000 = 3750 + 𝑊
𝑾 = 𝟔𝟐𝟓𝟎 𝒌𝒈/𝒉
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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 3: 2000 kg of wet solids containing 70% solids by weight are feed to tray dryer
where it is dried by hot air. The product finally obtained is found to contain 1% moisture
by weight.
Calculate:
1) kg of water removed from wet solids and
2) kg of product removed.
Solution: Basis: 2000 kg of wet solids

F=D+W
F = Feed to the drier i.e., 2000 kg, D is dried solids, and W is water evaporated
Given,
Initial mass of wet solids = 2000 kg
Initial weight fraction of solids = 70% = 0.70
∴ Initial weight fraction of moisture = 30% = 0.30
Final weight fraction of moisture in the product = 1% = 0.01
Final weight fraction of solids in the product = 99% = 0.99
1) Mass of Solids in the Feed
The mass of solids in the initial wet solids is calculated as:
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑𝑠 = 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑒𝑡 𝑠𝑜𝑙𝑖𝑑𝑠 × 𝑊𝑒𝑖𝑔ℎ𝑡 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑𝑠
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑𝑠 = 2000 × 0.7 = 1400 𝑘𝑔
2) Mass of the Final Product
In the final product, this mass of solids remains unchanged. Therefore, the mass of the final
product (P) can be calculated using the final weight fraction of solids
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑𝑠
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑓𝑖𝑛𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 (𝑃) =
𝐹𝐼𝑛𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑𝑠
1400
𝑃= ≈ 1414.14 𝑘𝑔
0.9

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
 3) Mass of Water Removed
The mass of water removed can be found by subtracting the mass of water in the final
product from the initial mass of water in the wet solids.
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑚𝑎𝑠𝑠 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑚𝑎𝑠𝑠 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡
= ×
𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑜𝑓 𝑤𝑒𝑡 𝑠𝑜𝑙𝑖𝑑𝑠 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑚𝑎𝑠𝑠
= 2000 × 0.3 = 600 𝑘𝑔
𝑜𝑓 𝑤𝑎𝑡𝑒𝑟

Final mass of water

𝐹𝑖𝑛𝑎𝑙 𝑚𝑎𝑠𝑠 𝐹𝑖𝑛𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛
= 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑓𝑖𝑛𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 ×
𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
𝐹𝑖𝑛𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 1414.14 × 0.01 ≈ 14.14 𝑘𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑟𝑒𝑚𝑜𝑣𝑒𝑑 = 600 − 14.14 ≈ 585.86 𝑘𝑔
kg of water removed = 585.86 kg
kg of product obtained = 1414.14 kg
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Problem 4: The waste acid from a nitrating process containing 20% NHO3, 55% H2SO4,
25% H2O by weight is to be concentrated by addition of concentrated sulfuric acid
containing 95% H2SO4 and concentrated nitric acid containing 90% HNO3, to get the
desired mixed acid containing 26% HNO3 and 60% H2SO4. Calculate the quantities of
waste and concentrated acids required for 1000 kg of desired mixed acid.

Solution: Basis: 1000 kg of desired product

Let ,
W = mass of waste acid (kg),
S = mass of concentrated H2SO4 required (kg)
N = mass of concentrated HNO3 required (kg)

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
1) Overall mass balance
The sum of all the components (waste acid, concentrated sulfuric acid, and concentrated
nitric acid) should equal the desired mixed acid
W + S + N = 1000 kg (1)
2) HNO3 (Nitric Acid) Balance
The total amount of HNO3 in the waste acid and concentrated nitric acid should equal the
amount in the desired mixed acid
𝑊 × 0.20 + 𝑁 × 0.9 = 1000 × 0.26
0.2𝑊 + 0.9𝑁 = 260 (2)
3) H2SO4 (Sulfuric Acid) Balance
𝑊 × 0.55 + 𝑆 × 0.95 = 1000 × 0.60
0.55𝑊 + 0.95𝑆 = 600 (3)
Solving Eq. (1) and (2)
From equation (1),
N = 1000 – W – S (4)
Substituting the value of N in equation (2)
0.2𝑊 + 0.9(1000 − 𝑊 − 𝑆) = 260
0.2𝑊 + 900 − 0.9𝑊 − 0.9𝑆 = 260
−0.7𝑊 − 0.9𝑆 = −640
0.7𝑊 + 0.9𝑆 = 640 (5)
Now, solve equation (3) and (5) simultaneously, we get
Multiply 0.55𝑊 + 0.95𝑆 = 600 by 0.9
Multiply 0.7𝑊 + 0.9𝑆 = 640 by 0.95
0.495𝑊 + 0.855𝑆 = 540
0.665𝑊 + 0.855𝑆 = 608
Solving simultaneously,
0.17𝑊 = 68
𝑾 = 𝟒𝟎𝟎 𝒌𝒈
Substitute the value of W in eq. (5) we get,
0.7(400) + 0.9𝑆 = 640
0.9𝑆 = 640 − 280
0.9𝑆 = 360

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
 𝑺 = 𝟒𝟎𝟎 𝒌𝒈
Now, substitute the value of S and W in eq. (1), we get
400 + 400 + N = 1000
N = 200 kg
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Problem 5: It is desired to make up 1000 kg solution containing 35% by weight of a
substance 'A' two solution are available, one containing 10 weights % 'A' and other
containing 50 weight % of 'A'. How many kilogram of each solution is required?
Solution: Basis: 1000 kg of desired product.

Overall Material/Mass Balance

𝑆1 + 𝑆2 = 1000 (1)
𝑆1 = 1000 − 𝑆2
Material balance over ‘A’
0.5𝑆1 + 0.1𝑆2 = 1000 × 0.35
0.5𝑆1 + 0.1𝑆2 = 350
0.5(1000 − 𝑆2 ) + 0.1𝑆2 = 350
500 − 0.5𝑆2 + 0.1𝑆2 = 350
500 − 350 = 0.4𝑆2
150 = 0.4𝑆2
𝑺𝟐 = 𝟑𝟕𝟓 𝒌𝒈
Substitute the value of S2 in Eq. (1)
𝑆1 + 375 = 1000
𝑺𝟏 = 𝟔𝟐𝟓 𝒌𝒈
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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 6: 10000 kg/h of solution containing 20% methanol is continuously fed to a
distillation column. Distillate (product) is found to contain 98% methanol and waste
solution from column carries 1% methanol. ALL percentage are by weight:
Calculate
1) The mass flow rate of distillate and bottom product and
2) The percentage loss of methyl alcohol
Solution: Basis: 10000 kg/h of feed solution

Overall mass balance

10000 = 𝐷 + 𝑊 (1)
Methanol balance
𝑀𝑒𝑡ℎ𝑎𝑛𝑜𝑙 𝑀𝑒𝑡ℎ𝑎𝑛𝑜𝑙 𝑖𝑛 𝑀𝑒𝑡ℎ𝑎𝑛𝑜𝑙 𝑖𝑛
= +
𝑖𝑛 𝑓𝑒𝑒𝑑 𝑑𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑒 𝑏𝑜𝑡𝑡𝑜𝑚 𝑝𝑟𝑜𝑑.
0.2 × 10000 = 0.98 × 𝐷 + 0.01 × 𝑊
2000 = 0.98 × 𝐷 + 0.01 × 𝑊 (2)
Substitute the value of D from Eq. (1) as 𝐷 = 10000 − 𝑊 in Eq. (2)
2000 = 0.98 × (1000 − 𝑊) + 0.01 × 𝑊
2000 = 9800 − 0.98𝑊 + 0.01𝑊
7800 = 0.97𝑊
𝑾 = 𝟖𝟎𝟒𝟏. 𝟐𝟑 𝒌𝒈/𝒉
Substituting the value of W in Eq. (1), we get
10000 = 𝐷 + 8041.23
𝑫 = 𝟏𝟗𝟓𝟖. 𝟕𝟔 𝒌𝒈/𝒉
Percentage Loss of methyl alcohol
Methanol in bottom product = 0.01 × W = 0.01 × 8041.23 ≈ 80.41 kg/h
80.41
Percentage Loss = × 100 ≈ 𝟒. 𝟎𝟐%
2000
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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 7: A mixture of phenol and water forms two separate liquid phases, one rich in
phenol and other rich in water, composition of layers is 70% and 90% (by weight) phenol
respectively. If 500 kg of phenol and 700 kg of water are mixed and layer allowed to
separate, what will be the weight of two layers?
Solution: Basis: 500 kg phenol and 700 kg of water

Overall mass balance (OMB)

𝑊 = 𝑊1 + 𝑊2 (1)
Phenol Balance (Component Balance)
500 𝑘𝑔 = 0.70𝑊1 + 0.1𝑊2 (2)
Water Balance (Component Balance)
700 𝑘𝑔 = 0.30𝑊1 + 0.9𝑊2 (3)
Solve the equation simultaneously, multiply Eq. (2) by 9, we get
4500 𝑘𝑔 = 6.30𝑊1 + 0.9𝑊2
700 𝑘𝑔 = 0.30𝑊1 + 0.9𝑊2
3800 = 6.0𝑊1
𝑾𝟏 = 𝟔𝟑𝟑. 𝟑𝟑 𝒌𝒈
Substitute 𝑊1 = 633.33 in Eq. (2), we get
0.7 × 633.33 + 0.1𝑊2 = 500
443.33 + 0.1𝑊2 = 500
0.1𝑊2 = 56.67
𝑾𝟐 = 𝟓𝟔𝟔. 𝟕 𝒌𝒈
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___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 8: Soyabean seeds are extracted with hexane in batch extractor. The flaked seeds
are found to contain 18.6% oil, 69% solids, and 12.4% moisture (by weight). At the end
of the extraction process, cake (meal) is separated from hexane-oil-mixture. The cake is
analysed to contain 0.8% oil, 87.7% solids, and 11.5% moisture (by weight). Find the
percentage recovery of oil.
Solution: Basis: 100 kg of flaked seeds

Material Balance over solids

𝑆𝑜𝑙𝑖𝑑𝑠 𝑖𝑛 𝑠𝑒𝑒𝑑𝑠 = 𝑆𝑜𝑙𝑖𝑑𝑠 𝑖𝑛 𝑐𝑎𝑘𝑒
0.69 × 100 = 0.877𝑥
69 = 0.877𝑥
𝑥 = 78.68 𝑘𝑔
Oil in cake is given as 0.8%
∴ 𝑂𝑖𝑙 𝑖𝑛 𝑐𝑎𝑘𝑒 = 0.008 × 78.68
𝑶𝒊𝒍 𝒊𝒏 𝒄𝒂𝒌𝒆 = 𝟎. 𝟔𝟑 𝒌𝒈
Material balance of oil
Oil in seeds = Oil in cake + Oil recovered
18.6 = 0.63 + Oil recovered
∴ Oil recovered = 18.6 – 0.63 = 17.97 kg
𝑂𝑖𝑙 𝑟𝑒𝑚𝑜𝑣𝑒𝑑
% 𝑹𝒆𝒄𝒐𝒗𝒆𝒓𝒚 𝒐𝒇 𝒐𝒊𝒍 = × 100
𝑂𝑖𝑙 𝑖𝑛 𝑠𝑒𝑒𝑑𝑠
17.97
= × 100 = 𝟗𝟔. 𝟔𝟏%
18.6
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___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 9: Fresh juice contains 15% solids and 85% water by weight and it is to be
concentrated to contain 40% solids by weight. In a single evaporation system, it is found
that volatile constituents of juice escape with water leaving the concentrated juice with
a flat taste. In order to overcome this problem, part of the fresh juice bypasses the
evaporator.

Calculate: a) The fraction of juice that bypass the evaporator.

b) The concentrated juice produced (containing 40% solids) per 100 kg of
fresh juice fed to the process.
Solution: Basis: 100 kg of fresh juice

We use bypassing to maintain the composition/concentration of the final product.

𝒙 → kg of juice fed to the evaporator
𝒚 → kg of juice bypasses the evaporator
𝒛 → kg of juice leaving the evaporator
𝑷 → kg of concentrated juice
𝑥 + 𝑦 = 100 (1)
Material balance of solids over evaporator
0.15𝑥 = 0.55𝑧 (2)
Overall material balance after evaporator
𝑧+𝑦 = 𝑃 (3)
Material balance of solids after evaporator
0.55𝑧 + 0.15𝑦 = 0.4𝑃 (4)
Substitute the values of ‘P’ from Eq. (3) in Eq. (4)

___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
 0.55𝑧 + 0.15𝑦 = 0.4(𝑧 + 𝑦) (5)
From Eq. (1), we have
𝑥 = 100 − 𝑦
From Eq. (2), we have
0.15𝑥 = 0.55𝑧
0.15(100 − 𝑦) = 0.55𝑧
0.15(100 − 𝑦)
𝑧= = 27.27 − 0.2727𝑦
0.55
Put value of ‘z’ in Eq. (5) & solve it for ‘y’,
0.55(27.27 − 0.2727𝑦) + 0.15𝑦 = 0.4𝑦 + 0.4(27.27 − 0.2727𝑦)
14.9985 − 0.149985𝑦 + 0.15𝑦 = 0.4𝑦 + 10.908 − 0.10908𝑦
0.290905𝑦 = 4.0905
𝒚 = 𝟏𝟒. 𝟎𝟔 𝒌𝒈
∵ 𝑥 + 𝑦 = 100
𝑥 = 100 − 14.06 = 85.94 𝑘𝑔
15 − 0.15𝑦 15 − 0.15(14.06)
𝑧= =
0.55 0.55
𝒛 = 𝟐𝟑. 𝟒𝟒 𝒌𝒈
𝑃 = 𝑥 + 𝑦 = 23.44 + 14.06
𝑷 = 𝟑𝟕. 𝟓 𝒌𝒈
Fraction of juice that bypasses evaporator in percent
𝑦 14.06
= 100 × 100 = × 100
100

= 𝟏𝟒. 𝟎𝟔 %
Quantity of concentrated juice obtained finally,
P = 37.5 kg
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___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 10: The NH3 air mixture containing 0.2 kg NH3 per kg air enters into absorption
system where ammonia is absorbed in water. the gas leaving the system is found to contain
0.004 kg NH3 per kg of air. Find the percentage recovery of ammonia.
Solution: Basis: 1 kg of air inlet to absorption system.

0.2
Ammonia in inlet gas to absorption system = × 1 = 0.2 𝑘𝑔
1

Air is inert as far as absorption is concerned.

𝐴𝑖𝑟 𝑖𝑛 𝑔𝑎𝑠 𝑙𝑒𝑎𝑣𝑖𝑛𝑔 𝐴𝑖𝑟 𝑖𝑛
= = 1 𝑘𝑔
𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚 𝑖𝑛𝑙𝑒𝑡 𝑔𝑎𝑠
𝑁𝐻3 𝑖𝑛 𝑔𝑎𝑠 𝑙𝑒𝑎𝑣𝑖𝑛𝑔 0.004
= × 1 = 0.004 𝑘𝑔
𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚 1
Material balance of NH3
NH3 in gas entering = NH3 in gas leaving + NH3 absorbed
0.2 = 0.004 + 𝑁𝐻3 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑
∴ 𝑁𝐻3 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑 = 0.2 − 0.004 = 𝟎. 𝟏𝟗𝟔 𝒌𝒈
𝑁𝐻3 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑
% 𝑟𝑒𝑐𝑜𝑣𝑒𝑟𝑦 𝑁𝐻3 = × 100
𝑁𝐻3 𝑖𝑛 𝑔𝑎𝑠 𝑖𝑛𝑙𝑒𝑡
0.196
% 𝑟𝑒𝑐𝑜𝑣𝑒𝑟𝑦 𝑁𝐻3 = × 100 = 𝟗𝟖 %
0.2
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___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 11: Potatoes are dried from 14% total solid to 95% total solids. What is the
product yield from each 1000 kg of raw potatoes assuming that 8% by weight of the
original potatoes is lost in peeling.
Solution: Basis: Initial mass of raw potatoes = 1000 kg
Initial total solids = 14 %
Final total solids = 93 %
8% weight of the original potatoes is lost in peeling.
1) Calculate the mass of potatoes after peeling
If 8% by weight of the original potatoes is lost during peeling,
Mass after peeling = 1000 × (1 − 0.08) = 1000 × 0.92 = 920 𝑘𝑔
2) Calculate the initial mass of solids in peeling potatoes
The initial mass of solids in the peeled potatoes = 920 × 0.14 = 128.8 𝑘𝑔
3) Calculate the mass of the final product
In final product, the mass of solids remain unchanged, but the percentage of solids has
increased to 93%. Therefore, mass of final product (P) can be calculated as,
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑𝑠
𝑃=
𝐹𝑖𝑛𝑎𝑙 𝑠𝑜𝑙𝑖𝑑𝑠
128.8
𝑃= ≈ 138.49 𝑘𝑔
0.93

Calculate the product yield

𝑃
𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝑌𝑖𝑒𝑙𝑑 =
× 100
1000
138.49
𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝑌𝑖𝑒𝑙𝑑 = × 100
1000
𝑷𝒓𝒐𝒅𝒖𝒄𝒕 𝒀𝒊𝒆𝒍𝒅 = 𝟏𝟑. 𝟖𝟓%
___________________________________________________________________________
Material Balance of Unsteady state operations
Unsteady state operations: Operations during which the values of the variables of the system
changes with time. In many cases operating condition are not steady, so in dealing with such
cases it is important to know the methods involving in setting up and solving mass balance
equation.
In unsteady state operations, input and output parameters (e.g., concentration) change
with respect to time. Purging of a vessel, batch/semi-batch operations (batch distillation)
starting up and shutting down of a continuous process units, etc are examples. In this case mass

___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
balance, calculations are done by considering small time interval Δt and finding the change in
the parameter (variable, e.g., composition) occurring during time interval Δt.
For material balances (for system with chemical reactions)
Mass accumulated = Mass entering – Mass leaving + Mass generated – Mass consumed
Example:
CH4 + 2O2 → CO2 + 2H2O
Input (Reactants): Methane (CH4) and Oxygen (O2)
Output (Products): Carbon dioxide (CO₂) and Water (H₂O)
Generation: Carbon dioxide and water are generated in the reaction.
Consumption: Methane and oxygen are consumed.
Accumulation: Accumulation of CO₂ or unreacted CH₄ and O₂ may occur in a non-steady-state
system.

• 𝑚̇𝑖𝑛 - inlet mass flow rate During the period Δt, the terms in the mass
• 𝑚̇𝑜𝑢𝑡 - outlet mass flow rate balance equation can be written as
• 𝑟̇𝑔 - rate of generation Mass entering = 𝑚̇𝑖𝑛 Δt
• 𝑟̇𝑐 - rate of consumption Mass leaving = 𝑚̇𝑜𝑢𝑡 Δt
• All parameters change with time. Mass generated = 𝑟̇𝑔 Δt
Mass consumed = 𝑟̇𝑐 Δt

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___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 12: A storage tank of demineralised (DM) water has a holding capacity of 1500
m3 up to an overflow point. The DM water having silica as (as SiO2) content of 0.005 mg/l
is flowing into a tank at a rate of 25 l/s. The outflow from the tank to the high pressure
boiler is 25 l/s. With time, the quality of DM water deteriorates and the silica content in
the feed DM water increased to 0.02 mg/l. Assuming that the inflow into and the outflow
from the tank remains constant at 25 l/s, calculate the time required for the silica content
in the storage tank to increase to 0.01 mg/l.
Solution: Basis: 25 l/s inflow of DM water to the tank.

a) At steady state condition of DM water storage tank

b) Unsteady state conditions of DM water storage tank

Total water in tank = 1500 m3 = 1500000 lit
Let ‘c’ be the concentration of silica in tank (in mg/l) at any time ‘t’. Let Δt is the time interval
during which the change in the concentration is observed.
Let Δc be the change in concentration during time interval Δt.
Consider, t = 0, when the silica level in the inflow of DM water increases to 0.02 mg/l.
Silica Balance
𝐼𝑛𝑝𝑢𝑡 𝑜𝑓 𝑠𝑖𝑙𝑖𝑐𝑎 𝑖𝑛𝑡𝑜 𝑡ℎ𝑒 𝑡𝑎𝑛𝑘
= 25 × 0.02 × ∆𝑡 = 0.05∆𝑡
𝑖𝑛 𝑡𝑖𝑚𝑒 𝑖𝑛𝑡𝑒𝑟𝑣𝑎𝑙 ∆𝑡 𝑠𝑒𝑐𝑜𝑛𝑑𝑠
𝑂𝑢𝑡𝑝𝑢𝑡 𝑜𝑓 𝑠𝑖𝑙𝑖𝑐𝑎 𝑓𝑟𝑜𝑚
= 25 × 𝑐 × ∆𝑡 (𝑚𝑔/𝑠)
𝑡ℎ𝑒 𝑡𝑎𝑛𝑘 𝑖𝑛 ∆𝑡 𝑠𝑒𝑐𝑜𝑛𝑑𝑠

___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
 𝐴𝑐𝑐𝑢𝑚𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑠𝑖𝑙𝑖𝑐𝑎
= 1500000 × ∆𝑐 (𝑚𝑔/𝑠)
𝑖𝑛 𝑡ℎ𝑒 𝑡𝑎𝑛𝑘 𝑖𝑛 ∆𝑡 𝑠𝑒𝑐𝑜𝑛𝑑𝑠
𝐼𝑛𝑝𝑢𝑡 − 𝑂𝑢𝑡𝑝𝑢𝑡 = 𝐴𝑐𝑐𝑢𝑚𝑢𝑙𝑎𝑡𝑖𝑜𝑛
0.5∆𝑡 − 25𝑐∆𝑡 = 1500000∆𝑐
∆𝑡(0.5 − 25𝑐) = 1500000∆𝑐
∆𝑡(1 − 50𝑐) = 3000000∆𝑐
Converting into the differential form & integrating
𝑑𝑡(1 − 50𝑐) = 3000000𝑑𝑐
𝑑𝑐
𝑑𝑡 = 3000000 ×
(1 − 50𝑐)
𝑡 𝐶2
𝑑𝑐
∫ 𝑑𝑡 = 3000000 ∫
0 𝐶1 (1 − 50𝑐)
First solving,
𝐶2
𝑑𝑐 1 1 − 50𝐶2
∫ = − 𝑙𝑛 ( )
𝐶1 (1 − 50𝑐) 50 1 − 50𝐶1
Using the property of logarithms,
𝑎 𝑏
𝑙𝑛 ( ) = −𝑙𝑛
𝑏 𝑎
We can write:
1 1 − 50𝐶2 1 1 − 50𝐶1
− 𝑙𝑛 ( )= 𝑙𝑛 ( )
50 1 − 50𝐶1 50 1 − 50𝐶2
So, by inverting the argument of the logarithm (switching 𝐶1 and 𝐶2), the negative sign is
removed.
Now substitute, when t = 0, C1 = 0.005 mg/l,
when t = t, C2 = 0.01 mg/l.
0.01
𝑑𝑐 1 1 − 50 × 0.005 1 0.75 1
∫ = 𝑙𝑛 ( )= 𝑙𝑛 ( )= 𝑙𝑛(1.5)
0.005 (1 − 50𝑐) 50 1 − 50 × 0.01 50 0.5 50
Now, the expression for 𝑡 becomes:
1
𝑡 = 3000000 × 𝑙𝑛(1.5)
50
Simplifying,
𝑡 = 60000 × ln(1.5)
𝑡 = 24327.906 𝑠𝑒𝑐𝑜𝑛𝑑𝑠
𝒕 = 𝟔. 𝟕𝟓𝟕 𝒉

___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 13: A evaporator is fed with 15000 kg/h of a solution containing 10% NaCl, 15%
NaOH and rest water. In the evaporation, water is evaporated and NaCl is precipitated
out as crystals. The thick layer leaving the evaporator contains 45% NaOH, 2% NaCl,
and rest water.
Calculate: a) kg/h of water evaporated, b) kg/h of thick layer.
Solution: Basis: 15000 kg/h of weak solution fed to the evaporator.

Assume x, y, and z be the kg/h of water evaporated, thick layer, and NaCl precipitated as
crystals.
Overall Material Balance
∑𝐼𝑛𝑝𝑢𝑡 𝑠𝑡𝑟𝑒𝑎𝑚 = ∑𝑂𝑢𝑡𝑝𝑢𝑡 𝑠𝑡𝑟𝑒𝑎𝑚
15000 = 𝑥 + 𝑦 + 𝑧
Material balance of NaOH
NaOH in fed solution = NaOH in thick liquor
0.15 × 15000 = 0.45𝑦
𝑦 = 5000 𝑘𝑔/ℎ
Material balance of NaCl
NaCl in fed solution = NaCl in thick liquor + NaCl ppt as crystals
0.10 × 15000 = 0.02 × 5000 + 𝑧
𝑧 = 1400 𝑘𝑔/ℎ
We have, 𝑥 + 𝑦 + 𝑧 = 15000
𝑥 + 5000 + 1400 = 15000
𝑥 = 8600 𝑘𝑔/ℎ
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___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 14: The NH3 air mixture containing 0.2 kg NH3 per kg air enters into absorption
system where ammonia is absorbed in water. The gas leaving the system is found to
contain 0.004 kg NH3 per kg of air. Find percentage recovery of ammonia.
Solution: Basis: 1 kg of air is gas inlet to absorption system

0.2
Ammonia in inlet gas to absorption system = × 1 = 𝟎. 𝟐 𝒌𝒈
1

Air is inert as far as absorption is concerned

∴𝐴𝑖𝑟 𝑡ℎ𝑒
𝑖𝑛 𝑔𝑎𝑠 𝑙𝑒𝑎𝑣𝑖𝑛𝑔
𝑠𝑦𝑠𝑡𝑒𝑚
𝐴𝑖𝑟 𝑖𝑛
= 𝑖𝑛𝑙𝑒𝑡 𝑔𝑎𝑠
= 1 𝑘𝑔

𝑁𝐻3 𝑖𝑛 𝑔𝑎𝑠 𝑙𝑒𝑎𝑣𝑖𝑛𝑔 0.004

= × 1 = 0.004 𝑘𝑔
𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚 1
Material balance of NH3
𝑁𝐻3 𝑖𝑛 𝑔𝑎𝑠 𝑁𝐻3 𝑖𝑛 𝑔𝑎𝑠
= + 𝑁𝐻3 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑
𝑒𝑛𝑡𝑒𝑟𝑖𝑛𝑔 𝑙𝑒𝑎𝑣𝑖𝑛𝑔
𝑁𝐻3 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑 = 0.2 − 0.004 = 𝟎. 𝟏𝟗𝟔 𝒌𝒈
% 𝑟𝑒𝑐𝑜𝑣𝑒𝑟𝑦 𝑁𝐻3 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑
= × 100
𝑜𝑓 𝑁𝐻3 𝑁𝐻3 𝑖𝑛 𝑔𝑎𝑠 𝑖𝑛𝑙𝑒𝑡
% 𝑟𝑒𝑐𝑜𝑣𝑒𝑟𝑦 0.196
= × 100 = 𝟗𝟖%
𝑜𝑓 𝑁𝐻3 0.2
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___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Problem 15: In a textile industry, it is desired to prepare 24% caustic soda solution by
weight. Because of very high heat of dissolution of caustic soda in water, the above
solution is prepared by 2 step process.
First caustic soda is dissolved in the correct quantity of water in a dissolution tank
to prepare 50% (by weight) solution. After dissolution and cooling is complete, this
solution is taken to a dilute tank where some more water is added for producing 24% by
weight caustic soda solution. Assuming no evaporation loss of water in dissolution tank,
calculate the weight ratio of water fed to the dissolution tank to bypass water to dilution
tank.

Solution: Basis: 100 kg of solid caustic soda (NaOH) charged to the dissolution tank

Let 𝑥 be the kg of 50% solution leaving dissolution tan.

Mass balance of caustic soda (solid) over dissolution tank

𝑆𝑜𝑙𝑖𝑑 𝑐𝑎𝑢𝑠𝑡𝑖𝑐 𝑠𝑜𝑑𝑎 𝑆𝑜𝑙𝑖𝑑 𝑐𝑎𝑢𝑠𝑡𝑖𝑐 𝑠𝑜𝑑𝑎 𝑖𝑛
=
𝑐ℎ𝑎𝑟𝑔𝑒𝑑 𝑡𝑜 𝑑𝑖𝑠𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 𝑡𝑎𝑛𝑘 50% 𝑁𝑎𝑂𝐻 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛
100 = 0.5𝑥
𝑥 = 200 𝑘𝑔
Overall mass/material balance over dissolution tank
𝑘𝑔 𝑜𝑓 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 𝑘𝑔 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑁𝑎𝑂𝐻 𝑘𝑔 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑎𝑑𝑑𝑒𝑑
= +
𝑙𝑒𝑎𝑣𝑖𝑛𝑔 𝑡𝑎𝑛𝑘 𝑎𝑑𝑑𝑒𝑑 𝑡𝑜 𝑡𝑎𝑛𝑘 𝑡𝑜 𝑡𝑎𝑛𝑘
∴ 200 = 100 + 𝑘𝑔 𝑜𝑓 𝑡𝑜
𝑤𝑎𝑡𝑒𝑟 𝑎𝑑𝑑𝑒𝑑
𝑡𝑎𝑛𝑘

𝑘𝑔 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑎𝑑𝑑𝑒𝑑
= 100
𝑡𝑜 𝑡𝑎𝑛𝑘 (𝑊1 )
𝑊1 = 100 𝑘𝑔
Let 𝑊2 be the bypass water. let 𝑦 be the kg of 24% of NaOH solution.

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Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade
Material balance of caustic soda over dilution tank
𝑆𝑜𝑙𝑖𝑑 𝑁𝑎𝑂𝐻 𝑖𝑛 𝑆𝑜𝑙𝑖𝑑 𝑁𝑎𝑂𝐻 𝑖𝑛
=
50% 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 25% 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛
100 = 0.24𝑦
𝑦 = 416.66 𝑘𝑔
𝑘𝑔 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
= 416.66 − 100 = 316.66 𝑘𝑔
𝑖𝑛 24% 𝑠𝑜𝑙.
Material Balance of water over dilution tank
𝑘𝑔 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑖𝑛 𝑘𝑔 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑖𝑛 𝑘𝑔 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
= +
24% 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 50% 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 𝑏𝑦𝑝𝑎𝑠𝑠 (𝑊2 )
316.66 = 100 + 𝑊2
𝑊2 = 216.66 𝑘𝑔
𝑊1 100
𝑊𝑒𝑖𝑔ℎ𝑡 𝑟𝑎𝑡𝑖𝑜 = = = 0.4615
𝑊2 216.66
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___________________________________________________________________________
Process Calculation
Chemical Engineering (SE)
Dr. Shailesh Ravi Varade