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4.MaterialandEnergyBalance

4.MATERIALANDENERGYBALANCE
Syllabus
MaterialandEnergybalance:Facilityasanenergysystem,Methodsforpreparing
processflow,Materialandenergybalancediagrams.

Materialquantities,astheypassthroughprocessingoperations,canbedescribedby
materialbalances.Suchbalancesarestatementsontheconservationofmass.Similarly,
energyquantitiescanbedescribedbyenergybalances,whicharestatementsonthe
conservationofenergy.Ifthereisnoaccumulation,whatgoesintoaprocessmustcome
out.Thisistrueforbatchoperation.Itisequallytrueforcontinuousoperationoverany
chosentimeinterval.
Materialandenergybalancesareveryimportantinanindustry.Materialbalancesare
fundamentaltothecontrolofprocessing,particularlyinthecontrolofyieldsofthe
products.Thefirstmaterialbalancesaredeterminedintheexploratorystagesofanew
process,improvedduringpilotplantexperimentswhentheprocessisbeingplannedand
tested,checkedoutwhentheplantiscommissionedandthenrefinedandmaintainedasa
controlinstrumentasproductioncontinues.Whenanychangesoccurintheprocess,the
materialbalancesneedtobedeterminedagain.
Theincreasingcostofenergyhascausedtheindustriestoexaminemeansofreducing
energyconsumptioninprocessing.Energybalancesareusedintheexaminationofthe
variousstagesofaprocess,overthewholeprocessandevenextendingoverthetotal
productionsystemfromtherawmaterialtothefinishedproduct.
Materialandenergybalancescanbesimple,attimestheycanbeverycomplicated,but
thebasicapproachisgeneral.Experienceinworkingwiththesimplersystemssuchas
individualunitoperationswilldevelopthefacilitytoextendthemethodstothemore
complicatedsituations,whichdoarise.Theincreasingavailabilityofcomputershas
meantthatverycomplexmassandenergybalancescanbesetupandmanipulatedquite
readilyandthereforeusedineverydayprocessmanagementtomaximiseproductyields
andminimisecosts.

4.1BasicPrinciples
Iftheunitoperation,whateveritsnatureisseenasawholeitmayberepresented
diagrammaticallyasabox,asshowninFigure.4.1.Themassandenergygoingintothe
boxmustbalancewiththemassandenergycomingout.

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4.MaterialandEnergyBalance

Productsout
mP1 mP2 mP3

Raw
M aterialsin
mR1 mR2 mR3

Wasteproducts
Unit

mW1 mW2 mW3

Operation
StoredMaterials
mS1mS2mS3
StoredEnergy
ES1ES2ES3
Energyin
Heat,Work,

Energyin
products

EP1 EP2 EP3

Energyin
Waste
EW1 EW2 EW3

Chemical,Electrical
ER1ER2ER3

Energylosses
Tosurroundings
EL1EL2EL3

Figure4.1:MassandEnergyBalance

Thelawofconservationofmassleadstowhatiscalledamassoramaterialbalance.
MassIn=MassOut+MassStored
RawMaterials=Products+Wastes+StoredMaterials.
mR=mP +mW+mS
(where(sigma)denotesthesumofallterms).

mR=mR1+mR2+mR3
mP =mP 1+mP 2+mP 3

=TotalRawMaterials
=TotalProducts.

mW =mW1+mW2+mW3=TotalWasteProducts
mS=mS1+mS2+mS3

=TotalStoredProducts.

Iftherearenochemicalchangesoccurringintheplant,thelawofconservationofmass
willapplyalsotoeachcomponent,sothatforcomponentA:
mAinenteringmaterials=mAintheexitmaterials+mAstoredinplant.
Forexample,inaplantthatisproducingsugar,ifthetotalquantityofsugargoinginto
theplantisnotequalledbythetotalofthepurifiedsugarandthesugarinthewaste
liquors,thenthereissomethingwrong.Sugariseitherbeingburned(chemically
changed)oraccumulatingintheplantorelseitisgoingunnoticeddownthedrain
somewhere.Inthiscase:
MA=(mAP +mAW+mAU )
wheremAUistheunknownlossandneedstobeidentified.Sothematerialbalanceis
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now:
RawMaterials=Products+WasteProducts+StoredProducts+Losses
whereLossesaretheunidentifiedmaterials.
Justasmassisconserved,soisenergyconservedinfoodprocessingoperations.The
energycomingintoaunitoperationcanbebalancedwiththeenergycomingoutandthe
energystored.
EnergyIn=EnergyOut+EnergyStored
ER=EP +EW+EL+ES
where
ER=ER1+ER2+ER3+.=TotalEnergyEntering
Ep=EP 1+EP 2+EP 3+.=TotalEnergyLeavingwithProducts
EW=EW1+EW2+EW3+=TotalEnergyLeavingwithWasteMaterials
EL=EL1+EL2+EL3+.=TotalEnergyLosttoSurroundings

ES=ES1+ES2+ES3+.=TotalEnergyStored
Energybalancesareoftencomplicatedbecauseformsofenergycanbeinterconverted,
forexamplemechanicalenergytoheatenergy,butoverallthequantitiesmustbalance.

4.2TheSankeyDiagramanditsUse
TheSankeydiagramisvery
usefultooltorepresentan
entireinputandoutputenergy
flowinanyenergyequipment
orsystemsuchasboiler
generation,firedheaters,
furnacesaftercarryingout
energybalancecalculation.
Thisdiagramrepresents
visuallyvariousoutputsand
lossessothatenergymanagers
canfocusonfinding
improvementsinaprioritized
manner.
Figure4.2:EnergyBalanceforaReheatingFurnace

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Example:TheFigure4.2showsaSankeydiagramforareheatingfurnace.Fromthe
Figure4.2,itisclearthatexhaustfluegaslossesareakeyareaforpriorityattention.
Sincethefurnacesoperateathightemperatures,theexhaustgasesleaveathigh
temperaturesresultinginpoorefficiency.Henceaheatrecoverydevicesuchasair
preheaterhastobenecessarilypartofthesystem.Thelowertheexhausttemperature,
higheristhefurnaceefficiency.

4.3MaterialBalances
Thefirststepistolookatthethreebasiccategories:materialsin,materialsoutand
materialsstored.Thenthematerialsineachcategoryhavetobeconsideredwhetherthey
aretobetreatedasawhole,agrossmassbalance,orwhethervariousconstituentsshould
betreatedseparatelyandifsowhatconstituents.Totakeasimpleexample,itmightbe
totakedrysolidsasopposedtototalmaterialthisreallymeansseparatingthetwo
groupsofconstituents,nonwaterandwater.Morecompletedissectioncanseparateout

chemicaltypessuchasminerals,orchemicalelementssuchascarbon.Thechoiceand
thedetaildependonthereasonsformakingthebalanceandontheinformationthatis
required.Amajorfactorinindustryis,ofcourse,thevalueofthematerialsandso
expensiverawmaterialsaremorelikelytobeconsideredthancheaperones,and
productsthanwastematerials.
BasisandUnits
Havingdecidedwhichconstituentsneedconsideration,thebasisforthecalculationshas
tobedecided.Thismightbesomemassofrawmaterialenteringtheprocessinabatch
system,orsomemassperhourinacontinuousprocess.Itcouldbe:somemassofa
particularpredominantconstituent,forexamplemassbalancesinabakerymightbeall
relatedto100kgofflourenteringorsomeunchangingconstituent,suchasin
combustioncalculationswithairwhereitishelpfultorelateeverythingtotheinert
nitrogencomponentorcarbonaddedinthenutrientsinafermentationsystembecause
theessentialenergyrelationshipsofthegrowingmicroorganismsarerelatedtothe
combinedcarboninthefeedortheessentiallyinertnonoilconstituentsoftheoilseeds
inanoilextractionprocess.Sometimesitisunimportantwhatbasisischosenandin
suchcasesaconvenientquantitysuchasthetotalrawmaterialsintoonebatchorpassed
inperhourtoacontinuousprocessareoftenselected.Havingselectedthebasis,thenthe
unitsmaybechosensuchasmass,orconcentrationswhichcanbebyweightorcanbe
molarifreactionsareimportant.
4.3.1Totalmassandcomposition
Materialbalancescanbebasedontotalmass,massofdrysolids,ormassofparticular
components,forexampleprotein.
Example:Constituentbalance
Skimmilkispreparedbytheremovalofsomeofthefatfromwholemilk.Thisskimmilk
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isfoundtocontain90.5%water,3.5%protein,5.1%carbohydrate,0.1%fatand0.8%
ash.Iftheoriginalmilkcontained4.5%fat,calculateitscompositionassumingthatfat
onlywasremovedtomaketheskimmilkandthattherearenolossesinprocessing.
Basis:100kgofskimmilk.
Thiscontains,therefore,0.1kgoffat.Letthefatwhichwasremovedfromittomake
skimmilkbexkg.
Totaloriginalfat=(x+0.1)kg

Totaloriginalmass=(100+x)kg
andasitisknownthattheoriginalfatcontentwas4.5%so
(x+0.1)/(100+x)=0.045
where=x+0.1=0.045(100+x)
x=4.6kg
Sothecompositionofthewholemilkisthenfat=4.5%,water=90.5/104.6=86.5%,
protein=3.5/104.6=3.3%,carbohydrate=5.1/104.6=4.9%andash=0.8%
Concentrations
Concentrationscanbeexpressedinmanyways:weight/weight(w/w),weight/volume
(w/v),molarconcentration(M),molefraction.Theweight/weightconcentrationisthe
weightofthesolutedividedbythetotalweightofthesolutionandthisisthefractional
formofthepercentagecompositionbyweight.Theweightvolumeconcentrationisthe
weightofsoluteinthetotalvolumeofthesolution.Themolarconcentrationisthe
3
numberofmolecularweightsofthesoluteexpressedinkgin1m
ofthesolution.The
molefractionistheratioofthenumberofmolesofthesolutetothetotalnumberof
molesofallspeciespresentinthesolution.Noticethatinprocessengineering,itisusual
toconsiderkgmolesandinthischapterthetermmolemeansamassofthematerial
equaltoitsmolecularweightinkilograms.Inthischapterpercentagesignifies
percentagebyweight(w/w)unlessotherwisespecified.
Example:Concentrations
Asolutionofcommonsaltinwaterispreparedbyadding20kgofsaltto100kgof
3
water,tomakealiquidofdensity1323kg/m
.Calculatetheconcentrationofsaltinthis
solutionasa(a)weightfraction,(b)weight/volumefraction,(c)molefraction,(d)molal
concentration.
(a)Weightfraction:
20/(100+20)=0.167:%weight/weight=16.7%

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(b)Weight/volume:
Adensityof1323kg/m
solutioncontains

meansthatlm

ofsolutionweighs1323kg,but1323kgofsalt

(20x1323kgofsalt)/(100+20)=220.5kgsalt/m

1m solutioncontains220.5kgsalt.
Weight/volumefraction=220.5/1000=0.2205
Andsoweight/volume=22.1%
c)Molesofwater=100/18=5.56
Molesofsalt=20/58.5=0.34
Molefractionofsalt=0.34/(5.56+0.34)=0.058
d)Themolarconcentration(M)is220.5/58.5=3.77molesinm

Notethatthemolefractioncanbeapproximatedbythe(molesofsalt/molesofwater)as
thenumberofmolesofwateraredominant,thatisthemolefractioniscloseto0.34/
5.56=0.061.Asthesolutionbecomesmoredilute,thisapproximationimprovesand
generallyfordilutesolutionsthemolefractionofsoluteisacloseapproximationtothe
molesofsolute/molesofsolvent.
Insolid/liquidmixturesofallthesemethodscanbeusedbutinsolidmixturesthe
concentrationsarenormallyexpressedassimpleweightfractions.
Withgases,concentrationsareprimarilymeasuredinweightconcentrationsperunit
volume,oraspartialpressures.Thesecanberelatedthroughthegaslaws.Usingthegas
lawintheform:
pV=nRT
wherepisthepressure,Vthevolume,nthenumberofmoles,Ttheabsolutetemperature,
3
andRthegasconstantwhichisequalto0.08206m
atm/moleK,themolar
concentrationofagasisthen
n/V=p/RT
andtheweightconcentrationisthennM/VwhereMisthemolecularweightofthegas.
2

TheSIunitofpressureistheN/m
calledthePascal(Pa).Asthisisofinconvenientsize
formanypurposes,standardatmospheres(atm)areoftenusedaspressureunits,the
5
conversionbeing1atm=1.013x10
Pa,orverynearly1atm=100kPa.
Example:AirComposition
Ifairconsistsof77%byweightofnitrogenand23%byweightofoxygencalculate:
(a)themeanmolecularweightofair,
(b)themolefractionofoxygen,
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(c)theconcentrationofoxygeninmole/m
atmospheresandthetemperatureis25

andkg/m

ifthetotalpressureis1.5

C.

(a)Takingthebasisof100kgofair:itcontains77/28molesofN2and23/32molesofO2
Totalnumberofmoles=2.75+0.72=3.47moles.
Someanmolecularweightofair=100/3.47=28.8
Meanmolecularweightofair=28.8
b)Themolefractionofoxygen=0.72/(2.75+0.72)=0.72/3.47=0.21
Molefractionofoxygen=0.21
(c)Inthegasequation,wherenisthenumberofmolespresent:thevalueofRis0.08206
3
o
m atm/moleKandatatemperatureof25
C=25+273=298K,andwhereV=1m
pV=nRT
andso,1.5x1=nx0.08206x298
3
n=0.061mole/m
weightofair=nxmeanmolecularweight
=0.061x28.8=1.76kg/m

andofthis23%isoxygen,soweightofoxygen=0.23x1.76=0.4kgin1m

Concentrationofoxygen=0.4kg/m
or0.4/32=0.013mole/m

Whenagasisdissolvedinaliquid,themolefractionofthegasintheliquidcanbe
determinedbyfirstcalculatingthenumberofmolesofgasusingthegaslaws,treatingthe
volumeasthevolumeoftheliquid,andthencalculatingthenumberofmolesofliquid
directly.
Example:Gascomposition
Inthecarbonationofasoftdrink,thetotalquantityofcarbondioxiderequiredisthe
o
equivalentof3volumesofgastoonevolumeofwaterat0
Candatmosphericpressure.
Calculate(a)themassfractionand(b)themolefractionoftheCO2inthedrink,ignoring
allcomponentsotherthanCO2andwater.
Basis1m

ofwater=1000kg
3

Volumeofcarbondioxideadded=3m
Fromthegasequation,pV=nRT
1x3=nx0.08206x273
n=0.134mole.
Molecularweightofcarbondioxide=44
Andsoweightofcarbondioxideadded=0.134x44=5.9kg
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(a)Massfractionofcarbondioxideindrink=5.9/(1000+5.9)=5.9x10
(b)Molefractionofcarbondioxideindrink=0.134/(1000/18+0.134)=2.41x10
4.3.2TypesofProcessSituations
Continuousprocesses
Incontinuousprocesses,timealsoentersintoconsiderationandthebalancesarerelated
tounittime.Thusinconsideringacontinuouscentrifugeseparatingwholemilkintoskim
milkandcream,ifthematerialholdupinthecentrifugeisconstantbothinmassandin
composition,thenthequantitiesofthecomponentsenteringandleavinginthedifferent
streamsinunittimeareconstantandamassbalancecanbewrittenonthisbasis.Suchan
analysisassumesthattheprocessisinasteadystate,thatisflowsandquantitiesheldup
invesselsdonotchangewithtime.
Example:Balanceacrossequipmentincontinuouscentrifugingofmilk
If35,000kgofwholemilkcontaining4%fatistobeseparatedina6hourperiodinto
skimmilkwith0.45%fatandcreamwith45%fat,whataretheflowratesofthetwo
outputstreamsfromacontinuouscentrifugewhichaccomplishesthisseparation?
Basis1hour'sflowofwholemilk
Massin
Totalmass=35000/6=5833kg.
Fat=5833x0.04=233kg.
AndsoWaterplussolidsnotfat=5600kg.
Massout
Letthemassofcreambexkgthenitstotalfatcontentis0.45x.Themassofskimmilkis
(5833x)anditstotalfatcontentis0.0045(5833x)
Materialbalanceonfat:
Fatin=Fatout
5833x0.04=0.0045(5833x)+0.45x.andsox=465kg.
Sothattheflowofcreamis465kg/hrandskimmilk(5833465)=5368kg/hr
Thetimeunithastobeconsideredcarefullyincontinuousprocessesasnormallysuch
processesoperatecontinuouslyforonlypartofthetotalfactorytime.Usuallythereare
threeperiods,startup,continuousprocessing(socalledsteadystate)andclosedown,
anditisimportanttodecidewhatmaterialbalanceisbeingstudied.Alsothetime

intervaloverwhichanymeasurementsaretakenmustbelongenoughtoallowforany
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4.MaterialandEnergyBalance

slightperiodicorchancevariation.
Insomeinstancesareactiontakesplaceandthematerialbalanceshavetobeadjusted
accordingly.Chemicalchangescantakeplaceduringaprocess,forexamplebacteriamay
bedestroyedduringheatprocessing,sugarsmaycombinewithaminoacids,fatsmaybe
hydrolysedandtheseaffectdetailsofthematerialbalance.Thetotalmassofthesystem
willremainthesamebuttheconstituentpartsmaychange,forexampleinbrowningthe
sugarsmayreducebutbrowningcompoundswillincrease.
Blending
Anotherclassofsituationswhichariseareblendingproblemsinwhichvarious
ingredientsarecombinedinsuchproportionsastogiveaproductofsomedesired
composition.Complicatedexamples,inwhichanoptimumorbestachievable
compositionmustbesought,needquiteelaboratecalculationmethods,suchaslinear
programming,butsimpleexamplescanbesolvedbystraightforwardmassbalances.
Drying
Insettingupamaterialbalanceforaprocessaseriesofequationscanbewrittenforthe
variousindividualcomponentsandfortheprocessasawhole.Insomecaseswhere
groupsofmaterialsmaintainconstantratios,thentheequationscanincludesuchgroups
ratherthantheirindividualconstituents.Forexampleindryingvegetablesthe
carbohydrates,minerals,proteinsetc.,canbegroupedtogetheras'drysolids',andthen
onlydrysolidsandwaterneedbetaken,throughthematerialbalance.
Example:DryingYield
Potatoesaredriedfrom14%totalsolidsto93%totalsolids.Whatistheproductyield
fromeach1000kgofrawpotatoesassumingthat8%byweightoftheoriginalpotatoesis
lostinpeeling.
Basis1000kgpotatoentering
As8%ofpotatoesarelostinpeeling,potatoestodryingare920kg,solids129kg

Massin(kg)
Potatosolids140kg
Water
860kg

Massout(kg)
Driedproduct
92
Potatosolids140x(92/100)

=129kg
Associatedwater10kg
Totalproduct139kg
Losses
Peelingspotato
Solids11kg
Water69kg
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Waterevaporated781kg
Totallosses
861kg
Total
1000kg
Productyield=139/1000=14%
Oftenitisimportanttobeabletofollowparticularconstituentsoftherawmaterial
throughaprocess.Thisisjustamatterofcalculatingeachconstituent.

4.4EnergyBalances
Energytakesmanyforms,suchasheat,kineticenergy,chemicalenergy,potentialenergy
butbecauseofinterconversionsitisnotalwayseasytoisolateseparateconstituentsof
energybalances.However,undersomecircumstancescertainaspectspredominate.In
manyheatbalancesinwhichotherformsofenergyareinsignificantinsomechemical
situationsmechanicalenergyisinsignificantandinsomemechanicalenergysituations,
asintheflowoffluidsinpipes,thefrictionallossesappearasheatbutthedetailsofthe
heatingneednotbeconsidered.Weareseldomconcernedwithinternalenergies.
Thereforepracticalapplicationsofenergybalancestendtofocusonparticulardominant
aspectsandsoaheatbalance,forexample,canbeausefuldescriptionofimportantcost
andqualityaspectsofprocesssituation.Whenunfamiliarwiththerelativemagnitudesof
thevariousformsofenergyenteringintoaparticularprocessingsituation,itiswiseto
putthemalldown.Thenaftersomepreliminarycalculations,theimportantonesemerge
andotherminoronescanbelumpedtogetherorevenignoredwithoutintroducing
substantialerrors.Withexperience,theobviouslyminoronescanperhapsbeleftout
completelythoughthisalwaysraisesthepossibilityoferror.
Energybalancescanbecalculatedonthebasisofexternalenergyusedperkilogram
ofproduct,orrawmaterialprocessed,orondrysolidsorsomekeycomponent.The
energyconsumedinfoodproductionincludesdirectenergywhichisfuelandelectricity
usedonthefarm,andintransportandinfactories,andinstorage,selling,etc.and
indirectenergywhichisusedtoactuallybuildthemachines,tomakethepackaging,to
producetheelectricityandtheoilandsoon.Fooditselfisamajorenergysource,and
energybalancescanbedeterminedforanimalorhumanfeedingfoodenergyinputcan
bebalancedagainstoutputsinheatandmechanicalenergyandchemicalsynthesis.

IntheSIsystemthereisonlyoneenergyunit,thejoule.However,kilocaloriesarestill
usedbysomenutritionistsandBritishthermalunits(Btu)insomeheatbalancework.
Thetwoapplicationsusedinthischapterareheatbalances,whicharethebasisforheat
transfer,andtheenergybalancesusedinanalysingfluidflow.
HeatBalances
Themostcommonimportantenergyformisheatenergyandtheconservationofthiscan
beillustratedbyconsideringoperationssuchasheatinganddrying.Inthese,enthalpy
(totalheat)isconservedandaswiththemassbalancessoenthalpybalancescanbe
writtenroundthevariousitemsofequipment.orprocessstages,orroundthewhole
plant,anditisassumedthatnoappreciableheatisconvertedtootherformsofenergy
suchaswork.
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Enthalpy(H)isalwaysreferredtosomereferencelevelordatum,sothatthequantities
arerelativetothisdatum.Workingoutenergybalancesisthenjustamatterof
consideringthevariousquantitiesofmaterialsinvolved,theirspecificheats,andtheir
changesintemperatureorstate(asquitefrequentlylatentheatsarisingfromphase
changesareencountered).Figure4.3illustratestheheatbalance.

HeattoSurroundings

HeatfromElectricity
HeatfromfuelCombustion
HeatfromM echanicalSources

HeatoutinProducts
Heat
Stored

HeatoutinWastes

HeatinRawM aterials

HeatBalance

Figure4.3:HeatBalance
Heatisabsorbedorevolvedbysomereactionsinprocessingbutusuallythequantities
aresmallwhencomparedwiththeotherformsofenergyenteringintofoodprocessing
suchassensibleheatandlatentheat.Latentheatistheheatrequiredtochange,at
constanttemperature,thephysicalstateofmaterialsfromsolidtoliquid,liquidtogas,or
solidtogas.Sensibleheatisthatheatwhichwhenaddedorsubtractedfrommaterials
changestheirtemperatureandthuscanbesensed.TheunitsofspecificheatareJ/kgK
andsensibleheatchangeiscalculatedbymultiplyingthemassbythespecificheatby

thechangeintemperature,(mxcx T).TheunitsoflatentheatareJ/kgandtotallatent
heatchangeiscalculatedbymultiplyingthemassofthematerial,whichchangesits
phasebythelatentheat.Havingdeterminedthosefactorsthataresignificantinthe
overallenergybalance,thesimplifiedheatbalancecanthenbeusedwithconfidencein
industrialenergystudies.Suchcalculationscanbequitesimpleandstraightforwardbut
theygiveaquantitativefeelingforthesituationandcanbeofgreatuseindesignof
equipmentandprocess.
Example:Dryerheatbalance
3

Atextiledryerisfoundtoconsume4m
/hrofnaturalgaswithacalorificvalueof800
kJ/mole.Ifthethroughputofthedryeris60kgofwetclothperhour,dryingitfrom55%
moistureto10%moisture,estimatetheoverallthermalefficiencyofthedryertakinginto
accountthelatentheatofevaporationonly.
60kgofwetclothcontains
60x0.55kgwater=33kgmoisture
and60x(10.55)=27kgbonedrycloth.

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Asthefinalproductcontains10%moisture,themoistureintheproductis27/9=3kg
AndsoMoistureremoved/hr=333=30kg/hr
Latentheatofevaporation=2257kJ/K
Heatnecessarytosupply=30x2257=6.8x10

kJ/hr

Assumingthenaturalgastobeatstandardtemperatureandpressureatwhich1mole
occupies22.4litres
Rateofflowofnaturalgas=4m

/hr=(4x1000)/22.4=179moles/hr

Heatavailablefromcombustion=179x800=14.3x10

kJ/hr

Approximatethermalefficiencyofdryer=heatneeded/heatused
=6.8x10

/14.3x10

=48%

Toevaluatethisefficiencymorecompletelyitwouldbenecessarytotakeintoaccount
thesensibleheatofthedryclothandthemoisture,andthechangesintemperatureand
humidityofthecombustionair,whichwouldbecombinedwiththenaturalgas.However,
asthelatentheatofevaporationisthedominanttermtheabovecalculationgivesaquick

estimateandshowshowasimpleenergybalancecangiveusefulinformation.
Similarlyenergybalancescanbecarriedoutoverthermalprocessingoperations,and
indeedanyprocessingoperationsinwhichheatorotherformsofenergyareused.
Example:Autoclaveheatbalanceincanning
Anautoclavecontains1000cansofpeasoup.Itisheatedtoanoveralltemperatureof
o
o
100 C.Ifthecansaretobecooledto40
Cbeforeleavingtheautoclave,howmuch
o
o
coolingwaterisrequiredifitentersat15
Candleavesat35
C?
o

Thespecificheatsofthepeasoupandthecanmetalarerespectively4.1kJ/kg
Cand
o
0.50kJ/kg C.Theweightofeachcanis60ganditcontains0.45kgofpeasoup.Assume
o
4
thattheheatcontentoftheautoclavewallsabove40
Cis1.6x10 kJandthatthereisno
heatlossthroughthewalls.
Letw=theweightofcoolingwaterrequiredandthedatumtemperaturebe40
temperatureofthecansleavingtheautoclave.

C,the

Heatentering
Heatincans=weightofcansxspecificheatxtemperatureabovedatum
3

=1000x0.06x0.50x(10040)kJ=1.8x10

kJ

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Heatincancontents=weightpeasoupxspecificheatxtemperatureabovedatum
=1000x0.45x4.1x(10040)=1.1x10

kJ

Heatinwater=weightofwaterxspecificheatxtemperatureabovedatum
=wx4.186x(1540)
=104.6wkJ.
Heatleaving
Heatincans=1000x0.06x0.50x(4040)(cansleaveatdatumtemperature)=0
Heatincancontents=1000x0.45x4.1x(4040)=0
Heatinwater=wx4.186x(3540)=20.9w

HEATENERGYBALANCEOFCOOLINGPROCESS40

CASDATUMLINE

HeatEntering(kJ)
HeatLeaving(kJ)
Heatincans
1800
Heatincans
0
Heatincancontents110000
Heatincancontents0
Heatinautoclavewall16000
Heatinautoclavewall0
Heatinwater
104.6w
Heatinwater
20.9W
Totalheatentering
127.800104.6wTotalheatleaving
20.9W
Totalheatentering=Totalheatleaving
127800104.6w=20.9w
w=1527kg
Amountofcoolingwaterrequired=1527kg.

OtherFormsofEnergy
Motorpowerisusuallyderived,infactories,fromelectricalenergybutitcanbeproduced
fromsteamenginesorwaterpower.Theelectricalenergyinputcanbemeasuredbya
suitablewattmeter,andthepowerusedinthedriveestimated.Therearealwayslosses
fromthemotorsduetoheating,frictionandwindagethemotorefficiency,whichcan
normallybeobtainedfromthemotormanufacturer,expressestheproportion(usuallyasa
percentage)oftheelectricalinputenergy,whichemergesusefullyatthemotorshaftand
soisavailable.
Whenconsideringmovement,whetheroffluidsinpumping,ofsolidsinsolidshandling,
oroffoodstuffsinmixers.theenergyinputislargelymechanical.Theflowsituationscan
beanalysedbyrecognisingtheconservationoftotalenergywhetherasenergyofmotion,
orpotentialenergysuchaspressureenergy,orenergylostinfriction.Similarly,chemical
energyreleasedincombustioncanbecalculatedfromtheheatsofcombustionofthe
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4.MaterialandEnergyBalance

fuelsandtheirratesofconsumption.Eventuallyenergyemergesintheformofheatand
itsquantitycanbeestimatedbysummingthevarioussources.
EXAMPLERefrigerationload
Itisdesiredtofreeze10,000loavesofbreadeachweighing0.75kgfromaninitialroom
o
o
temperatureof18
Ctoafinaltemperatureof18
C.Thebreadfreezingoperationisto
becarriedoutinanairblastfreezingtunnel.Itisfoundthatthefanmotorsareratedata
totalof80horsepowerandmeasurementssuggestthattheyareoperatingataround90%
oftheirrating,underwhichconditionstheirmanufacturer'sdataclaimsamotor
efficiencyof86%.If1tonofrefrigerationis3.52kW,estimatethemaximum

refrigerationloadimposedbythisfreezinginstallationassuming(a)thatfansandmotors
areallwithinthefreezingtunnelinsulationand(b)thefansbutnottheirmotorsarein
thetunnel.Theheatlossratefromthetunneltotheambientairhasbeenfoundtobe6.3
kW.
Extractionratefromfreezingbread(maximum)=104kW
Fanratedhorsepower

=80

Now0.746kW=1horsepowerandthemotorisoperatingat90%ofrating,
Andso(fan+motor)power=(80x0.9)x0.746=53.7kW
(a)Withmotors+fansintunnel
Heatloadfromfans+motors

=53.7kW

Heatloadfromambient

=6.3kW

Totalheatload

=(104+53.7+6.3)kW=164kW
=46tonsofrefrigeration

(b)Withmotorsoutside,themotorinefficiency=(10.86)doesnotimposealoadon
therefrigeration
Totalheatload

=(104+[0.86x53.7]+6.3)
=156kW
=44.5tonsofrefrigeration

Inpractice,materialandenergybalancesareoftencombinedasthesamestoichiometric
informationisneededforboth.
Summary
1.Materialandenergybalancescanbeworkedoutquantitativelyknowingtheamounts
ofmaterialsenteringintoaprocess,andthenatureoftheprocess.
2.Materialandenergybalancestakethebasicform
Contentofinputs=contentofproducts+wastes/losses+changesinstoredmaterials.

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4.MaterialandEnergyBalance

3.Incontinuousprocesses,atimebalancemustbeestablished.
4.Energyincludesheatenergy(enthalpy),potentialenergy(energyofpressureor
position),kineticenergy,workenergy,chemicalenergy.Itisthesumoverallofthese
thatisconserved.

5.Enthalpybalances,consideringonlyheatareusefulinmanyprocessingsituations.
TheobjectiveofM&Ebalanceistoassesstheinput,conversionefficiency,outputand
losses.AM&Ebalance,usedinconjunctionwithdiagnosis,isapowerfultoolfor
establishingthebasisforimprovementsandpotentialsavings.
.

4.5MethodforPreparingProcessFlowChart
Theidentificationanddrawingupaunitoperation/processisprerequisiteforenergyand
materialbalance.Theprocedurefordrawinguptheprocessflowdiagramsisexplained
below.
Flowchartsareschematicrepresentationoftheproductionprocess,involvingvarious
inputresources,conversionstepsandoutputandrecyclestreams.Theprocessflowmay
beconstructedstepwisei.e.byidentifyingtheinputs/output/wastesateachstageofthe
process,asshownintheFigure4.4.

Inputs

PROCESS
STEP1

Wastes

Wastes
Inputs

PROCESS
STEP2

Output
Figure4.4:ProcessFlowChart

Inputsoftheprocesscouldincluderawmaterials,water,steam,energy(electricity,etc)
ProcessStepsshouldbesequentiallydrawnfromrawmaterialtofinishedproduct.
Intermediatesandanyotherbyproductshouldalsoberepresented.Theoperatingprocess
parameterssuchastemperature,pressure,%concentration,etc.shouldberepresented.

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4.MaterialandEnergyBalance

Theflowrateofvariousstreamsshouldalsoberepresentedinappropriateunitslikem
orkg/h.Incaseofbatchprocessthetotalcycletimeshouldbeincluded.
Wastes/byproductscouldincludesolids,water,chemicals,energyetc.Foreachprocess
steps(unitoperation)aswellasforanentireplant,energyandmassbalancediagram
shouldbedrawn.
Outputoftheprocessisthefinalproductproducedintheplant.
Example:Processflowdiagramrawmaterialtofinishedproduct:Papermakingisa
highenergyconsumingprocess.Atypicalprocessflowwithelectrical&thermalenergy
flowforanintegratedwastepaperbasedmillisgiveninFigure4.5

Trees
UsedPap er
Bark(fuel)

Barking
Electricity

WoodPreparation
Chipping

Steam

Pulping

Electricity

Mechanical

ChemicalPulping

WastePaper

Pulping

Bleaching

Pulping

Steam

BleachPlant

Electricity

BleachPlant

Kneading

ChemicalRecovery
Electricity
Steam

Liquorconcentration
Refiner

Electricity

Steam

EnergyRecovery

Electricity

Fu el

Recausticization
Electricity

Papermaking

Steam

StockPreparation

Electricity

Electricity

Steam

Forming

Pressing

Electricity

Steam

Drying

Electricity

Paper

Figure4.5:ProcessFlowDiagramofPulp&PaperIndustry

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Page17
4.MaterialandEnergyBalance

4.6FacilityasanEnergySystem
Therearevariousenergysystems/utilityservicesprovidestherequiredtypeofsecondary
energysuchassteam,compressedair,chilledwateretctotheproductionfacilityinthe
manufacturingplant.AtypicalplantenergysystemisshowninFigure4.6.Although
variousformsofenergysuchascoal,oil,electricityetcentersthefacilityanddoesits
workorheating,theoutgoingenergyisusuallyintheformoflowtemperatureheat.

Rawmaterial

EnergyFacility/Utility
Energy
Input
(Coal,oil,gas,
electricity)

Transformer
DGSet
Boilers
Chillers
WaterSupplies
Air
compressors

ProductionFacility
Electricity

Heat
Output

Steam
ChilledWater
Water

(WasteStream
Fluegas,
Watervapour,
heatand
emissions)

CompressedAir

EnergyConversion

EnergyUtilisation

Figure4.6:PlantEnergySystem

Product
Theenergyusageintheoverallplantcanbesplitupintovariousformssuchas:
Electricalenergy,whichisusuallypurchasedasHTandconvertedintoLTsupply
forenduse.
SomeplantsgeneratetheirownelectricityusingDGsetsorcaptivepowerplants.
Fuelssuchasfurnaceoil,coalarepurchasedandthenconvertedintosteamor
electricity.
Boilergeneratessteamforheatinganddryingdemand
Coolingtowerandcoolingwatersupplysystemforcoolingdemand
Aircompressorsandcompressedairsupplysystemforcompressedairneeds
Allenergy/utilitysystemcanbeclassifiedintothreeareaslikegeneration,distribution
andutilisationforthesystemapproachandenergyanalysis.
Afewexamplesforenergygeneration,distributionandutilizationareshownbelowfor

boiler,coolingtowerandcompressedairenergysystem.
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4.MaterialandEnergyBalance

BoilerSystem:Boileranditsauxiliariesshouldbeconsideredasasystemforenergy
analyses.EnergymanagercandrawupadiagramasgiveninFigure4.7forenergyand
materialbalanceandanalysis.Thisdiagramincludesmanysubsystemssuchasfuel
supplysystem,combustionairsystem,boilerfeedwatersupplysystem,steamsupplyand
fluegasexhaustsystem.

5Bar,Comp.air/steamfor
Steam

atomisation
HPDos ing

12Bar/190oC

(Phos phate)

3Bar
Fur.Oil

180oC

Tank
4.5KL

Heater/3.5kw
Filterunits

B OILER
30TPH
12B ar

BioGas fromETP

FD

Air

Economis er

160oC

66m

Fan

170oC
75KW
35640m3

Chimney

540mmWC
LPdos ing
125oC

(Oxytreat)

Condens atereturn

Deareator

Condens ate

10m3

tank25m3

Blowdown
tank

8.95KW

4.5KW

36m3/hr

48.1m3/hr

1.5m

21.5m

DM watertank

Drain

250m3
2.8KW
48.1m3/hr

Figure4.7B oilerPlantSystemEnergyFlowDiagram

21.5m

CoolingTower&CoolingWaterSupplySystem:Coolingwaterisoneofthecommon
utilitydemandsinindustry.Acompletediagramcanbedrawnshowingcoolingtower,
pumps,fans,processheatexchangersandreturnlineasgiveninFigure4.8forenergy
auditandanalysis.Alltheenduseofcoolingwaterwithflowquantitiesshouldbe
indicatedinthediagram.
M3/hr
2000

Fan4Nos.x30 kw

VAHP
Condensor

10
Co olin gTower

Pump

InstrumentAirCompressor
Intercooler
Aftercoo ler

5 000 m3/hr
Flo wMeter

ProcessAirCompressor
600

3000m3/hr
370kw
Heavy Blow

2500m3/h r

drain

41.5 m

Coo ler
Hotaircooler

32 oC
170

BrinePlant
Condenser
OilCooler
SolventRecov ery

220

ColumnCondenser
Pro ductCooler

SoftWater
Tan k

1.5

BoilerPlant
FWPu mp
Drain

2 00m3

GlandCooling

40m3/hr

Fermentor
Continuo usBlowd own

Germinator

1 5m3/hr(0.3%)

Prefermentor
38.5

Pump 30kw

Fermento r
Continuo usSteriliser

Iron Corrosion
Test

DGSet
Coo lingTower

Drain,2 m3/hr

Figure4.8CoolingTowerWaterSystem

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4.MaterialandEnergyBalance

CompressedairSystem
Compressedairisaversatileandsafemediaforenergyuseintheplants.Atypical
compressedairgeneration,distributionandutilizationdiagramisgiveninFigure4.9.
Energyanalysisandbestpracticesmeasuresshouldbelistedinallthethreeareas.

GENERATION

DISTRIBUTION

UTILISATION/
ENDUSEAPPLICATIO

Extraction
FilterPress
110kw

Activated

850m 3/hr.

AluminaDrier

Instrumentation
&Controls

110kw
850m 3/hr.

Fermenter
530Nm3/hrfor

er
iv
e rs
c
e

FilterPress

150minutes/day

7Ba

Boiler

AirR

Atomisation
225Nm3/hr

110kw
850m 3/hr.

Vent
Compressor3No.
Twostage,double
acting,reciprocating,
watercoolednon
lubricated,heavyduty

Westfalia

Chilled
WaterHeat

Receiver

5Bars

N2Plant

Exchanger
630Nm 3/hr
Moisture

Air

150Nm 3/hr
N2

N2
Receiver

Drain

Figure4.9InstrumentAirSystem

4.7HowtoCarryoutMaterialandEnergy(M&E)Balance?
MaterialandEnergybalancesareimportant,sincetheymakeitpossibletoidentifyand
quantifypreviouslyunknownlossesandemissions.Thesebalancesarealsousefulfor
monitoringtheimprovementsmadeinanongoingproject,whileevaluatingcostbenefits.
Rawmaterialsandenergyinanymanufacturingactivityarenotonlymajorcost
componentsbutalsomajorsourcesofenvironmentalpollution.Inefficientuseofraw
materialsandenergyinproductionprocessesarereflectedaswastes.
GuidelinesforM&EBalance

(Extraction)

Centrifuge
(Extraction)

Foracomplexproductionstream,itisbettertofirstdrafttheoverallmaterial
andenergybalance.
Whilesplittingupthetotalsystem,choose,simplediscretesubsystems.The
processflowdiagramcouldbeusefulhere.
Choosethematerialandenergybalanceenvelopesuchthat,thenumberof
streamsenteringandleaving,isthesmallestpossible.
Alwayschooserecyclestreams(materialandenergy)withintheenvelope.
Themeasurementunitsmayinclude,timefactororproductionlinkages.
Considerafullbatchasthereferenceincaseofbatchoperations.
Itisimportanttoincludestartupandcleaningoperationconsumptions(of
materialandenergyresources(M&E).

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4.MaterialandEnergyBalance

Calculatethegasvolumesatstandardconditions.
Incaseofshutdownlosses,averagingoverlongperiodsmaybenecessary.
Highlightlossesandemissions(M&E)atpartloadoperationsifprevalent.
Foreachstream,whereapplicable,indicateenergyquality(pressure,
temperature,enthalpy,Kcal/hr,KW,Amps,Voltsetc.).
WhilepreparingM&Ebalances,precisionofanalyticaldata,flowandenergy
measurementshavetobeaccurateespeciallyincaseofshorttimespan
references.

Thematerialandenergy(M&E)balancesalongtheaboveguidelines,arerequiredto
bedevelopedatthevariouslevels.
1.OverallM&Ebalance:Thisinvolvestheinputandoutputstreamsforcomplete
plant.
2.SectionwiseM&Ebalances:Inthesequenceofprocessflow,materialand
energybalancesarerequiredtobemadeforeachsection/department/costcentres.
Thiswouldhelptoprioritizefocusareasforefficiencyimprovement.
3.EquipmentwiseM&Ebalances:M&Ebalances,forkeyequipmentwouldhelp
assessperformanceofequipment,whichwouldinturnhelpidentifyandquantify
energyandmaterialavoidablelosses.
EnergyandMassBalanceCalculationProcedure:
TheEnergyandMassbalanceisacalculationprocedurethatbasicallychecksifdirectly
orindirectlymeasuredenergyandmassflowsareinagreementwiththeenergyandmass
conservationprinciples.
Thisbalanceisoftheutmostimportanceandisanindispensabletoolforaclear
understandingoftheenergyandmasssituationachievedinpractice.
Inordertouseitcorrectly,thefollowingprocedureshouldbeused:

Clearlyidentifytheproblemtobestudied.
Defineaboundarythatenclosestheentiresystemorsubsystemtobeanalysed.
Enteringandleavingmassandenergyflowsmustbemeasuredattheboundary.
Theboundarymustbechoseninsuchawaythat:
a)Allrelevantflowsmustcrossit,allnonrelevantflowsbeingwithinthe
boundary.
b)Measurementsattheboundarymustbepossibleinaneasyandaccurate
manner.
Selectanappropriatetestperioddependingonthetypeofprocessandproduct.
Carryoutthemeasurements.
Calculatetheenergyandmassflow.
Verifyanenergyandmassbalance.Ifthebalancesareoutsideacceptablelimits,
thenrepeatthemeasurements.
Theenergyreleaseoruseinendothermicandexothermicprocessesshouldbe
takenintoconsiderationintheenergybalance.

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4.MaterialandEnergyBalance

Example/Formula
i)EnergySuppliedbyCombustion:Q=FuelconsumedxGrossCalorificvalue
ii)EnergySuppliedbyElectricity:Q=kWhx860kCals
Where,Q=thermalenergyflowrateproducedbyelectricity(kCals/hr)
iii)ContinuityEquation
A1 V1=A2 V2
v1
v2
Where,V1andV2arethevelocityinm/s,v1 andv2 thespecificvolumeinm
2
Aisthecrosssectionalareaofthepipeinm
.
iv)Heataddition/rejectionofafluid=mCp T
where,misthemassinkg,CpisthespecificheatinkCal/kg.C,Tisthedifferencein
temperatureink.
Example1:HeatBalanceinaBoiler
Aheatbalanceisanattempttobalancethetotalenergyenteringasystem(e.gboiler)
againstthatleavingthesystemindifferentforms.TheFigure4.10illustratestheheat
balanceanddifferentlossesoccurringwhilegeneratingsteam.

73.8%HeatinSteam

/kgand

12.7%
8.1%

100%

Steam
Boiler

1.7%
0.3%

Fuel

2.4%
1.0%
Figure4.10

DryFlueGasLoss
Heatlossduetohydrogeninfuel
Heatlossduetomoistureinfuel
Heatlossduetomoistureinair
Heatlossduetounburntsinresidue
Heatlossduetoradiation&
otherunaccountedloss

Example2:MassBalanceinaCementPlant
Thecementprocessinvolvesgas,liquidandsolidflowswithheatandmasstransfer,
combustionoffuel,reactionsofclinkercompoundsandundesiredchemicalreactionsthat
includesulphur,chlorine,andAlkalies.
Atypicalbalanceisshowninthefigure4.11(Source:BasedonfigurefromAustrian
BATproposal1996,CembureauforMassbalanceforproductionof1Kgcement)

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4.MaterialandEnergyBalance

Figure4.11

Example3:MassBalanceCalculation
Thisproblemillustrateshowamassbalancecalculationcanbeusedtochecktheresults
ofanairpollutionmonitoringstudy.Afabricfilter(bagfilter)isusedtoremovethedust
fromtheinletgasstreamsothatoutletgasstreammeetstherequiredemissionstandards
incement,fertilizerandotherchemicalindustries.
Duringanairpollutionmonitoringstudy,theinletgasstreamtoabagfilteris1,69,920
3
3
m /hrandthedustloadingis4577mg/m
.Theoutletgasstreamfromthebagfilteris
3
3
1,85,040m /hrandthedustloadingis57mg/m
.
Whatisthemaximumquantityofashthatwillhavetoberemovedperhourfromthebag
filterhopperbasedonthesetestresults?

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4.MaterialandEnergyBalance

Figure4.12ConservationofMatter

Solution:
Basedondustbalance,
Mass(in)=Mass(out)
Inletgasstreamdust=outletgasstreamdust+HopperAsh
1.Calculatetheinletandoutletdustquantitiesinkgperhour
3

Inletdustquantity=169920(m
/hr)x4577(mg/m
=777.7kg/hr
Outletdustquantity=185040(m
=10.6kg/hr

/hr)x57(mg/m

)x1/1000000(kg/mg)

)x1/1000000(kg/mg)

2.Calculatethequantityofashthatwillhavetoremovedfromthehopperperhour
Hopperash=InletgasdustquantityOutletgasdustquantity
=777.7kg/hr10.6kg/hr
=767.1kg/hr

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Example4:MaterialRequirementforProcessOperations
Ascrubberisusedtoremovethefinematerialordustfromtheinletgasstreamwithaspray
ofliquid(typicallywater)sothatoutletgasstreammeetstherequiredprocessoremission
standards.

HowmuchwatermustbecontinuallyaddedtowetscrubbershowninFigurebelowinorder
tokeeptheunitrunning?Eachofthestreamsisidentifiedbyanumberlocatedinadiamond
symbol.Stream1istherecirculationliquidflowstreambacktothescrubberanditis4.54
3
m /hr.Theliquidbeingwithdrawfortreatmentanddisposal(stream4)is0.454kgm

/hr.

Assumethatinletgasstream(number2)iscompletelydryandtheoutletstream(number6)
has272.16kg/hrofmoistureevaporatedinthescrubber.Thewaterbeingaddedtothe
scrubberisstreamnumber5.

Figure4.13ExampleofMaterialBalance

Solution:
Step1.Conductamaterialbalancearoundthescrubber.
1.ForStream6,convertfromkg/hrtom
conversionfactorbelowappliesonlytopurewater.
Stream6=272.16kg/hrxm

/hrtokeepunitsconsistent.The

/1000kg

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4.MaterialandEnergyBalance

=0.272m /hr
2.SetupthematerialbalanceequationandsolveforStream3.
InputScrubber

=OutputScrubber

Stream1+Stream2=Stream3+Stream6
3

4.54m /hr+0=ym
Stream3=ym

/hr+0.272m

/hr=4.27m

/hr

/hr

Step2.Conductamaterialbalancearoundtherecirculationtank.SolveforStream5.
InputTank

=OutputTank

Stream3+Stream5=Stream1+Stream4
3

4.25m /hr+xm

/hr=4.54m

Stream5=xm

/hr+0.454m

/hr

/hr=5m3/hr4.27m

/hr

=0.73m /hr
Ifitistocalculateonlythemakeupwaterat5,
Stream5=Stream4+Stream6
=0.454+0.272
=0.73m3/hr
OneofthekeystepsinsolvingExample4wasdrawingasimplesketchofthesystem.Thisis
absolutelynecessarysothatitispossibletoconductthematerialbalances.Drawingsarea
valuablefirststepwhensolvingawidevarietyofproblems,evenonesthatappearssimple.
Thedrawingisaveryusefulwaytosummarizewhatweknowandwhatweneedtoknow.It
helpsvisualizethesolution.Iftheprobleminvolvesdimensionalquantities(suchasstream
flowquantities),thedimensionsshouldbeincludedonthesketch.Theyserveasremindersof
theneedtoconvertthedataintoconsistentunits.

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4.MaterialandEnergyBalance

QUESTIONS

1.
2.
3.
4.
5.
6.
7.

8.
9.

10.

11.

12.

Drawatypicalinputoutputdiagramforaprocessandindicatethevarious
energyinputs.
Whatisthepurposeofmaterialandenergybalance?
HowSankeydiagramisusefulforenergyanalysis?
Drawaprocessflowchartforanyproductmanufacture.
Listdownthevariousguidelinesrequiredformaterialandenergybalance.
Amaterialbalanceisbasedon
(a)Mass(b)Volume(c)Concentration(d)Temperature
Biscuitsaretobebakedinacontinuousoven.Theinletmoisturecontentis
25%.Theoutletmoistureis1%.Theproductionis2tonnes/houronadry
basis.Makeamaterialbalanceandfindouthowmuchquantityofmoistureis
removedperhour.
Afurnaceisloadedwithmaterialsat5T/hr.Thescalelossesare2%.Find
outthematerialoutput?
o
Inaheatexchanger,inletandoutlettemperaturesofcoolingwaterare28
C&
o
33 C.Thecoolingwatercirculationis200litres/hr.Theprocessfluidenters
o
o
theheatexchangersat60
Candleavesat45
C.Findouttheflowrateofthe
processfluid?
(Cpofprocessfluid=0.95)
Steamoutputofboilerismeasuredbymeasuringfeedwater.Thetanklevel
3
readingfrom8.00a.m.to8.00p.m.was600m
.Continuousblowdownwas
givenat1%oftheboilerfeedrateduringtheaboveperiod.Findoutthe
averageactualsteamdeliveredperhour?
Thefollowingarethecoolingwaterrequirementsforaprocessindustry:
3
2
Heatexchanger1:300m
/hr.at3kg/cm
3
2
Heatexchanger2:150m
/hr.at2.5kg/cm
3
2
Heatexchanger3:200m
/hr.at1kg/cm
Findoutthetotalcoolingwaterrequirementperhourfortheplant?
(allheatexchangersareinparallel)
Inadryer,thecondensatewasmeasuredtobe80kg/hr.Theflashsteamwas
calculatedtobe12kg/hr.Findouttheactualsteamconsumptionofthedryer?

REFERENCES
1.EnergyauditreportsofNationalProductivityCouncil
2.EnergyManagementHandbook,JohnWileyandSonsWayneC.Turner
3.UnitOperationsinFoodProcessing,R.L.Earle,NZIFST

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