MASS BALANCE

DICTATE

EVA FATHUL KARAMAH

CHEMICAL ENGINEERING DEPARTMENT

UNIVERSITY OF INDONESIA
2007
 Units And Dimensions

Add the following:

a. 1 foot + 3 seconds =
b. 1 horsepower + 300 watts =
c. 1 foot x 3 seconds =

what is your conclusion?

- You can add, subtract, or equate numerical quantities only if dimensions of the of the quantities
are the same. And only after the units are transformed to be the same.
- You can multiply or divide unlike units or dimensions. But you cannot cancel or merge units
unless they are identical.

SO,
DIMENSIONS are our basic concept of measurement in term of physical quantity, such as length, mass,
time, temperature, and so on.
UNITS are the means of expressing the dimensions, such as feet and centimeters for length, or
kilograms and pounds for mass.

Table 1. SI Units
Physical Quantity Name of Unit Symbol Definition

Basic S1 Units
Length meter m
Mass kilogram kg
Time second s
Temperature kelvin K
Amount of substance mole mol

Derived S1 Units
Energy joule J kg ⋅ m2 ⋅ s-2
Force newton N kg ⋅ m ⋅ s-2 → J ⋅ m-1
Power watt W kg ⋅ m2 ⋅ s-3 → J ⋅ s-1
Density kilogram per cubic meter kg ⋅ m-3
Velocity meter per second m ⋅ s-1
Acceleration meter per second squared m ⋅ s-2
Pressure newton per square meter, N ⋅ m-2, Pa
pascal
Heat capacity joule per (kilogram.kelvin) J ⋅ kg-1 ⋅ K-1

Alternative Units
Time minute, hour, day, year min, h, d, y
Temperature degree Celcius OC

Volume liter (dm3) L

Mass ton (Mg), gram t, g
Table 2. American Engineering SystemUnits
 Physical Quantity Name of Unit Symbol
Basic Units
Length feet ft
Mass pound (mass) lbm
Force pound (force) lbf
Time second, hour s, hr
Temperature degree Rankine OR

Derived Units
Energy British thermal unit, foot pound (force) Btu, (ft)(lbf)
Power horsepower hp
Density pound (mass) per cubic feet lbm/ft3
Velocity feet per second ft/s
Acceleration feet per second squared ft/s2
Pressure pound (force) per square inch, pascal lbf/in.2
Heat capacity Btu per pound (mass) per degree F Btu/(lbm)(OF)

MOLE UNIT

Mole: certain numbers of molecules, atoms, electrons, or other spesified types of particles.
amount of a substance that contains as many elementary entities as there are atoms in 0.012 kg
of carbon 12. (=6.02 x 1023 molecules, in SI; non standard: poundmole = 6.02 x 1023 x 453.6
molecules; kilomole, kmol=1000 moles)

mass in g
g mol =
molecular weight

mass in lb
lb mol =
molecular weight
mass in g = (mol wt) (g mol)
mass in lb = (mol wt) (lb mol)

DENSITY

Density: ratio of mass per unit volume

Density of liquids and solids do not change significantly at ordinary conditions with pressure, but they do
change with temperature. Density varies with composition.

SPECIFIC GRAVITY

Specific Gravity: ratio of a substance of interest to that of a reference substance. Dimensionless.

Reference substance for liquids and solids is normally water. While for gas frequently is air, but may be
other gases.
State the temperature at which each density is chosen.

20o → temp of solution

sp gr = 0.73
4o → temp of reference substance
Specific gravity in the petroleum industry: oAPI
141.5
o
API = − 131.5
60o
sp gr o
60
o
60 141.5
sp gr o = o
60 API + 131.5

Example 1. Application of Specific Gravity

In the production of a drug having a molecular weight of 192, the exit stream from the reactor
flows at the rate of 10.3 L/min. The drug concentration is 41.2% (in water), and the specific gravity
of the solution is 1.025. Calculate the concentration of the drug (in kg/L) in the exit stream, and
the flowrate of the drug in kg mol/min.

Solution

Basis: 1.00 kg solution

Reactor 0.412 kg drug

0.588 kg water
s.g. = 1.025
10.3 L/min

Density of the solution = 1.025 x 1 g/cm3 = 1.025 g/cm3

The amount of drug in the solution

0.412 kg drug g soln 1 kg 103 cm3
= 1.025 = 0.422 kg drug/L soln
1.00 kg soln cm3 1000 g 1L

To get the flowrate, we take a different basis

Basis: 1 minute ≡ 10.3 L solution
Molar flowrate of the drug
0.422 kg drug 1 kg mol drug
= 10.3 L soln/min = 0.0226 kg mol/min
1L soln 192 kg drug

SPECIFIC VOLUME

The inverse of the density, that is, the volume per unit mass of unit amount of material.

MOLE FRACTION AND MASS (WEIGHT) FRACTION

MOLE FRACTION: the moles of a particular substance divided by the total number of moles present.
 moles of A
mole fraction of A =
total moles

MASS (WEIGHT) FRACTION: the mass (weight) of a substance divided by the total mass (weight) of al
the substances present.

mass (weight) of A
mass (weight) fraction of A =
total mass (weight)

Mole percent and weight percent are the respective fractions times 100.
The composition of gases will be presumed to be given in mole percent or fraction unless specifically
stated otherwise.
The analysis of liquids and solids will be assumed to be weight percent or fraction unless specifically
stated otherwise.

CONCENTRATION

Concentration: the quantity of some solute per specified amount of solvent, or solution, in a mixture of
two or more components.
Can be expressed as:
1. Mass per unit volume (lbm of solute/ft3, g of solute/L, lbm of solute/bbl, kg of solute/m3)
2. Moles per unit volume (lb mol of solute/ft3, g mol of solute/L, g mol of solute/cm3)
3. Part per million (ppm); parts per billion (ppb) – for extremely dilute solutions. Ppm is equivalent
to a weight fraction for solid and liquids; it is a mol fraction for gases.
4. Molarity (g mol/L) and normality (equivalents/L)

Example 2. Use of ppm

The current OSHA 8 hour limit for HCN in air is 10.0 ppm. A lethal dose of HCN in air is 300
mg/kg of air at room temperature. How many mg HCN/kg air is the 10.0 ppm? What fraction of the
lethal dose is 10.0 ppm?

Solution
Basis: 1 kg mol of the air/HCN mixture

10.0 g mol HCN 10.0 g mol HCN

10.0 ppm = =
10 gmol (air + HCN)
6
106 gmol air
Amount of HCN (in mg) per kg of air
10.0 g mol HCN 27.03 g HCN 1 g mol air 1000 mg HCN 1000 g air
= = 9.32 mg HCN/kg air
106 g mol air 1 g mol HCN 29 g air 1 g HCN 1 kg air

Lethal dose = 300 mg/kg of air

10.0 ppm = 9.32 mg/kg of air
 10.0 ppm 9.32
= = 0.031
lethal dose 300

BASIS

The basis is the reference chosen for the calculations i any particular problems. A proper choice of basis
frequently makes the problem much easier to solve.
For selecting a suitable basis, ask yourself the following questions:
1. What do I have to start with?
2. What answer is called for?
3. What is the most convinient basis to use?

Example 3. Choosing a basis

Most processes for producing high-energy-content gas or gasoline from coal include some type of
gasification step to make hydrogen or synthesis gas. Pressure gasification is preferred because of
its greater yoeld of methane and higher rate of gasification.
Given that a 50.0-kg test run of gas averages 10.0% H2, 40.0% CH4, 30.0% CO, and 20.0% CO2.
What is the average molecular weight of the gas?

Solution
Basis: 100 kg mol of gas

Component percent = kg mol Mol. Weight kg

CO2 20.0 44.0 880
CO 30.0 28.0 840
CH4 40.0 16.04 642
H2 10.0 2.02 20
Total 100.0 2382

2382 kg
Average molecular weight = = 23.8 kg/kg mol
100 kg mol

TEMPERATURE

Temperature scale: Celcius (oC), Kelvin (oK), Fahrenheit (oF), Rankine (oR)

To K = To C + 273
To R = To F + 460
To F − 32 = To C × 1.8

Δ oC = Δ oK
Δ oF = Δ oR

ΔoC
= 1. 8 or Δ oC = 1.8Δ o F
Δ oF
ΔoK
= 1. 8 or Δ oK = 1.8Δ o R
ΔoR

PRESSURE

CHEMICAL EQUATION AND STOICHIMETRY

Chemical equation provides both qualitative and quantitative informations essential for the calculation of
the combining moles of materials involved in a chemical process.
Stoichiometry: quantitative relationship between reactants and products.
Stoichiometric ratios: ratios obtained from the numerical coefficients in the chemical equation.

Example 4. Stoichiometry
A limestone analysis:
CaCO3 92.89%
MgCO3 5.41%
Insoluble 1.70%

a. How many kilograms of calcium oxide can be made from 5 tons of this limestone?
b. How many kilograms of CO2 can be recovered per kilogram of limestone?
c. How many kilograms of limestone are needed to make 1 ton of lime?

Solution:
Draw a process diagram

CO2

limestone

CaO
MgO lime
heat
Insoluble

Lime includes all the impurities present in the limestone that remain after the CO2 has been driven
off.
Chemical reactions involved:

CaCO3 → CaO + CO2 (1)

MgCO3 → MgO + CO2 (2)

Additional data:

CaCO3 MgCO3 CaO MgO CO2

Mol. Wt. 100.1 84.32 56.08 40.32 44.0

Basis: 100 kg of limestone

 Limestone Products
Component kg = percent kg mol Solid kg CO2
Component
CaCO3 92.89 0.9280 CaO 52.04 40.83
MgCO3 5.41 0.0642 MgO 2.59 2.82
Insoluble 1.70 Insoluble 1.70
Total 100.00 0.9920 56.33 43.65

The quantities of products are calculated from the chemical equation.

CaO produced → rxn (1):
1 kgmol CaCO 3 1 kg mol CaO 56.08 kg CaO
= 92.89 kg CaCO 3 = 52.04 kg
100.1 kg CaCO 3 1 kg mol CaCO 3 1 kg mol CaO

MgO produced → rxn (2):

1 kgmol MgCO 3 1 kg mol MgO 40.32 kg MgO
= 5.41 kg MgCO 3 = 2.59 kg
84.32 kg MgCO 3 1 kg mol MgCO 3 1 kg mol MgO

CO2 is produced from reaction (1) and reaction (2):

1 kgmol CaCO 3 1 kg mol CO 2 44.0 kg CO 2
rxn (1): 92.89 kg CaCO 3 = 40.83 kg
100.1 kg CaCO 3 1 kg mol CaCO 3 1 kg mol CO 2
1 kgmol MgCO 3 1 kg mol CO 2 44.0 kg CO 2
rxn (2): 5.41 kg MgCO 3 = 2.82 kg
84.32 kg MgCO 3 1 kg mol MgCO 3 1 kg mol CO 2
Total CO2 produced = (40.83 + 2.82) kg = 43.65 kg

Total mass product = 100 kg = amount of limestone entering the process.

Calculate the quantities originally asked for:

a. CaO produced from 5 tons of limestone
52.04 kg CaO 1000 kg
= 5 tons limestone = 2602 kg
100 kg limestone 1 ton

b. CO2 recovered per kilogram of limestone

43.65 kg CO 2
= = 0.437 kg
100 kg limestone

c. Limestone required to make 1 ton of lime

100 kg limestone 1000 kg
= = 1775.25 kg limestone
56.33 kg lime 1 ton
In industrial reactors, exact stoichiometric amounts of material used is rarely find. To make a desired
reaction take place or to use up a costly reactant, excess reactants are nearly always used. This excess
material comes out together with, or perhaps separately from , the product – and sometimes can be
used again.
Some new definitions must be understood:
1. Limiting reactant: reactant that is present in the smallest stoichiometric amount or reactant that
would first disappear if the reaction were to proceed according to the chemical equation to
completion.
Determination: calculate the mole ratio(s) of the reactants in actual feed and compare each ratio
with the corresponding ratio of the coefficients in the chemical equation.

2. Excess reactant: reactant present in excess of the limiting reactant.

Percent excess: based on the amount of any excess reactant above the amount required to react
with the limiting reactant according to the chemical reaction.

moles in excess
% excess = × 100
moles required to react with limiting reactant

moles in excess = total available moles – moles required to react with the limiting reactant

Excess air: the amount of air available to react that is in excess of the air theoretically required to
completely burn.
Even if only part of the limiting reactant actually reacts, the required and excess quantities
are based on the entire amount of the limiting reactant as if it had reacted completely.

3. Conversion: the fraction of the feed or some key material in the feed that is converted into
products.

moles (mass) of feed (or a compound in the feed) that react

% conversion =
moles (mass) of feed (or a compound in the feed) introduced

Degree of completion: fraction of the limiting reactant converted into products.

4. Selectivity: ratio of the moles of a particular (usually the desired) product produced to the moles of
another (usually undesired or by-) product produced in a set of reactions.

5. Yield: mass or moles of final product divided by the mass or moles of initial or key reactant either
fed or consumed. → for a single reactant and product
If more than one product and more than one reactant are involved, the reactant upon ehich the yield
is to be based must be clearly stated.

Yield and Selectivity : measures the degree to which a desired reaction proceeds relative to competing
alternative (undesirable) reactions.

Example 5. Incomplete reaction

Antimony is obtained by heating pulverized stibnite (Sb2S3) with scrap iron and drawing off the
molten antimony from the bottom of reaction vessel.

Sb2S3 + 3Fe → 2Sb + 3FeS

 Suppose that 0.600 kg of stibnite and 0.250 kg of iron turnings is heated together to give 0.200 kg
of Sb metal. Determine:
a. The limiting reactant
b. The percentage of excess reactant
c. The degree of completion (fraction)
d. The percent conversion
e. The yield

Solution:
Process diagram:

1.77 g mol Sb2S3

FeS
4.48 g mol Fe REACTOR

1.64 g mol Sb

The g mol is calculated from molecular weight data:

Component kg mol.wt. g mol

Sb2S3 0.600 339.7 1.77
Fe 0.250 55.85 4.48
Sb 0.200 121.8 1.64
FeS 87.91

Sb 2 S 3
a. Examine ratio of
Fe

actual/available stoichiometric
Sb 2 S 3 1.77/4.48 = 0.40 1/3 = 0.33
Fe

actual > stoichiometric → Sb2S3 : excess reactant, Fe : limiting reactant.

Sb2S3 required to react with limiting reactant = 4.48/3 g mol = 1.49 g mol.

b. Percentage of excess reactant:

1.77 - 1.49
% excess = × 100 = 18.8% excess Sb 2 S 3
1.49
c. Not all of limiting reactant reacts. The amount of Fe actually does react is computed from the
amount of Sb produced:
 3 g mol Fe
1.64 g mol Sb = 2.46 g mol Fe
2 gmol Sb

2.46
degree of completion = = 0.55
4.48

d. Conversion → refres to Sb2S3.

1 g mol Sb 2 S 3
The amount of Sb2S3 actually react = 1.64 g mol Sb = 0.82 g mol Sb2S3
2 g mol Sb
0.82
% conversion of Sb2S3 to Sb = × 100 = 46.3%
1.77

kg of Sb formed 0.200 kg Sb 1 kg Sb 0.33 kg Sb

e. Yield: = = =
kg of Sb 2 S 3 introduced 0.600 kg Sb 2 S 3 3 kg Sb 2 S 3 kg Sb 2 S 3

EXERCISES:

1. Write balanced equations for the following reaction:

a. C9H18 and oxygen to form carbon dioxide and water
b. FeS2 and oxygen to form Fe2O3 and sulfur dioxide

2. The electrolytic manufacture of chlorine gas from a sodium chloride solution is carried out by the
following reaction:

2NaCl + 2H2O → 2NaOH + H2 + Cl2

How many kilograms of Cl2 can one produce from 10 m3 of a brine soluiton containing 5% by weight
of sodium chloride? The specific gravity of the solution relative to water at 4OC is 1.07.

3. Calcium oxide (CaO) is formed by decomposing limestone (pure CaCO3). In one kiln the reaction
goes to 70% completion.
a. What is the composition of solid product withdrawn from the kiln?
b. What is the yield in terms of pounds of CO2 produced per pound of limestone charged?
 MATERIAL BALANCE
Material balance → application of the conservation law for mass: “matter is neither created nor
destroyed”.

To make a material balance of a process, first specify the system and outline its boundaries.
A Process: one or a series of actions or operations or treatments that result in an end [product].
System: any arbitrary portion or whole of a process set out specifically for analysis.
Open (Flow) System: system in which material is transferred across the system boundary, that is, enters
the system, leaves the system, or both.
Closed (batch) system: system in which there is no such transfer during the time interval of interest.

Concept of material balance:

⎧accumulation⎫ ⎧input through⎫ ⎧output through⎫ ⎧generation ⎫ ⎧consumption⎫

⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪
⎨within ⎬ = ⎨system ⎬ − ⎨system ⎬ + ⎨within ⎬ − ⎨within ⎬ (1)
⎪the system ⎪ ⎪boundaries ⎪ ⎪boundaries ⎪ ⎪the system⎪ ⎪the system ⎪
⎩ ⎭ ⎩ ⎭ ⎩ ⎭ ⎩ ⎭ ⎩ ⎭

Accumulation: a change in mass or moles (plus or minus) within the system with respect to time
Transfer through system boundaries: inputs to and outputs of the system
Generation and consumption within the system: related to product and reactant of the reaction in the
system

Steady-state: the values of the variables within the system do not change with time, accumulation is
zero
Unsteady-state: the values of the variables within the system change with time

Flow in Flow in Flow in Flow in

positive accumulation

Flow out Flow out Flow out Flow out

 negative accumulation

If the system is steady state and there is no reaction occurs, eq. (1) becomes:

⎧mass/mole input ⎫ ⎧mass/mole output ⎫

⎪ ⎪ ⎪ ⎪
⎨through the ⎬ = ⎨through the ⎬ (2)
⎪system boundaries⎪ ⎪system boundaries⎪
⎩ ⎭ ⎩ ⎭

Example 1. Total Mass Balance

A thickener in a waste disposal unit of a plant removes water from wet sewage sludge as shown
in figure E.1. How many kilograms of water leave the thickener per 100 kg of wet sludge that
enter the thickener? The process is in steady state.

100 kg 70 kg
Thickener
wet sludge dehydrated sludge

water = ?

Fig. E.1.

Solution:

Basis: 100 kg wet sludge

The system is the thickener (open system), no accumulation, generation or consumption occurs.
The total mass balance is:

in = out
100 kg = 70 kg + kg of water

So the amount of water is (100 – 70) kg = 30 kg

ANALYSIS OF MATERIAL BALANCE PROBLEMS

Total mass (mole) balance: balance of total mass (mole) all component in or out of the system
Component mass balance: balance of a specific component in a system
Expressing flows of component as variables for a single component in a mixture:
1. mass (molar) flow, mi (ni), i = specific component
2. product of measure of concentration times the flow, xiF, xi is the mass (mole) fraction of
component i in F, and F is the total mass (molar) flow

In any mixture of N components, N stream variables exist, either N values of mi aor ni, namely (N – 1)
values of xi, plus the stream flow itself, F. Because ∑ x i = 1 .

Strategy for analyzing material balance problems:

1. Read the problem and clarify what is to be accomplished.
2. Draw a sketch of the process; define the system by a boundary.
3. Label with symbols the flow of each stream and the associated compositions and other
information that is unknown.
4. Put all the known values of compositions and stream flows on the figure by each stream;
calculate additional compositions and flows from the given data as necessary. Or, at least
initially identify the known parameters in some fashion.
5. Select a basis.
6. Make a list by symbols for each of the unknown values of the stream flows and compositions, or
at least mark them distinctly in some fashion, and count them.
7. Write down tha names of an appropriate set of balances to solve; write the balances down with
type of balance listed by each one.
8. Count the number of independent balances that can be written; ascertain that a unique solution
is possible. If not, look for mare information or check your assumptions.
9. Solve the equations. Each calculation must be made on a consistent basis.
10. Check your answer by introducing them, or some of them, into any redundant material
balances.
SOLVING MATERIAL BALANCE PROBLEMS THAT DO NOT INVOLVE CHEMICAL REACTIONS

Without any reactions in the system, the balance equations will be:

⎧accumulation⎫ ⎧input through⎫ ⎧output through⎫

⎪ ⎪ ⎪ ⎪ ⎪ ⎪
⎨within ⎬ = ⎨system ⎬ − ⎨system ⎬
⎪the system ⎪ ⎪boundaries ⎪ ⎪boundaries ⎪
⎩ ⎭ ⎩ ⎭ ⎩ ⎭

Example 2. Membrane Separation

Membrane technology can be used in the separation of nitrogen and oxygen from air. Figure E.2
illustrates a nanoporous membrane for such ???
What is the composition of the waste stream if the stream amounts to 80% of the inputs?

High-pressure Membrane Low-pressure

side side

21% O2 O2 25%

Input Output

79% N2 N2 75%

O2 N2
Waste Stream

Fig. E2a

The process is steady state and without chemical reaction, so eq. (2) is used to solve the
problem. The system is the membrane. Let x O2 be the mole fraction of oxygen, and x N2 be the
mole fraction of nitrogen, and let nO2 and n N2 be the respective moles.

F (g mol) MEMBRANE P (g mol)

x . x .
O2 0.21 W (g mol) O2 0.25
N2 0.79 N2 0.75

x n .
O2 xO2 nO2
N2 xN2 nN2

Fig. E2b
 Step 1, 2, 3 and 4. All of the data and symbols have been placed in Fig. E2b

Step 5. Pick a convenient basis.

Basis: 100 mol F.
Then we know, W = 0.80 (100) = 80 mol
Step 6. Three unknown exist: P, x O2 , and x N 2 or P, nO2 , and n N 2
Step 7. Two independent balances are the oxygen and nitrogen balances. The third independent
balance is x O2 + x N 2 = 1.00; or n N 2 + nO2 = 80.
Step 8 and 9. The component balances are:
In Out In Out
O2: 0.21(100) = 0.25P + x O2 (80) or 0.21(100) = 0.25P + nO2
N2: 0.79(100) = 0.75P + x N 2 (80) or 0.79(100) = 0.75P + n N 2
1.00 = x O2 + x N 2 n O2 + n N 2 = 80
The solution of these equations is x O2 = 0.20, x N2 = 0.80, and P = 20 mol.
A simpler calculation involves the use of the total balance and one component balance
F = P + W or 100 = P + 80, → P = 20

Step 10. Check. Use the total balance as a check on the solution.
F=P+W
?
100 = 20 + 80

Example 3. Continous Distillation

A novice manufaturer of alcohol for gasohol is having a bit of difficulty with a distillation column.
The operation is shown in Fig. E3. Technicians think too much alcohol is lost in the bottoms
(waste). Calculate the composition of the bottoms and the mass of the alcohol lost in the bottoms.

Vapor Heat cooling

System Exchanger water
Boundary
Reflux Distillate (product) P
60% EtOH
40% H2O
Distillation Wt = 1/10 feed
1000 kg Feed, F
10% EtOH Column
90% H2O
Bottoms (waste) B
Heat EtOH ?
H2O ?

Fig. E3

Solution
 Assume the system is steady state, no reaction occurs. So, In = Out
Let x designate the mass fraction.

Basis: F = 1000 kg of feed

Given: P = 1/10 of F → P = 0.1(1000) = 100 kg

The remaining unknowns: xEtOH,B , xH2O,B , and B. unique
Two components: two independent component mass balances solution
xEtOH,B + xH2O,B = 1

Total mass balance: F = P + B

B = 1000 – 100 = 900 kg

Component balances:
kg feed in - kg distillate out = kg bottoms out %
EtOH balance: 0.10(1000) - 0.60(100) = 40 4.4
H2O balance: 0.90(1000) - 0.40(100) = 860 95.6
900 100.0

Check: Use the total balance to calculate B, and EtOH component balance to calculate mEtOH,B as
40 kg → mass H2O in B = 900 – 40 = 860 kg

Example 4. Mixing

Dilute sulfuric acid has to be added to dry charged batteries at service stations to activate a
battery. You are ask to prepare a batch of new 10.63% acid as follow. A tank of old weak battery
acid (H2SO4) solution contains 12.43% H2SO4 ( the remainder is pure water). If 200 kg of 77.7%
H2SO4 is added to the tank, and the final solution is to be 18.63% H2SO4, how many kilograms of
battery acid have been made? See Figure E4.

200 kg Added Solution, A

H2SO4 77.7% system

H2O 22.3%

H2SO4 18.63%
H2O 81.37%
H2SO4 12.43%
Final Solution, P kg
H2O 87.57%

Original Solution, F kg

Fig. E4

Solution

No reaction. Assume steady state → in = out

Basis: 200 kg A
 Total balance: A + F = P
200 + F = P (1)

H2SO4 balance:
200(0.777) + F(0.1243) = P(0.1863) (2)
Substitute (1) to (2)
200(0.777) + F(0.1243) = (200 + F)(0.1863)
155.4 + 0.1243F = 37.26 + 0.1863F
118.14 = 0.062F
F = 1905.5 kg

Use eq. (1) to find P

P = (200 + 1905.5) kg = 2105.5 kg

Example 5. Crystallization

A tank holds 10,000 kg of a saturated solution of Na2CO3 at 30OC. You want to crystallize from
this solution 3000 kg of Na2CO3 . 10H2O without any accompanying water. To what temperature
must the solution be cooled?

Solution

No reaction. Unsteady state.

Difficulties: information about composition of the solutions and solid precipitate.
Calculation of final concentration of Na2CO3 → corresponding temperature from handbook
containing solubility data.

Diagram of the process:

System Boundary System Boundary

10,000 kg

Na2CO3 Na2CO3
Saturated Saturated
Solution Solution
H2O H2O T=?
30OC

Initial State Final State

Na2CO3 . H2O
3000 kg

Crystals Removed

Fig. E5a
Component of the system: Na2CO3 and H2O.

Find the compositions of the streams for each solution and solid crystals of Na2CO3 . 10H2O
Use solubility data for Na2CO3 as a function of temperature:

Solubility
Temp (OC)
(g Na2CO3/100 g H2O)
0 7
10 12.5
20 21.5
30 38.8

Because the initial solution is saturated at 30OC, we can calculate the composition of the initial
solution:
38.8 g Na 2 CO 3
= 0.280 mass fraction Na 2 CO 3
38.8 g Na 2 CO 3 + 100 g H 2 O

Calculate the composition of the crystals.

For 1 gmol Na2CO3 . 10H2O
Comp. mol mol. wt. mass mass fr.
Na2CO3 1 106 106 0.371
H2O 10 18 180 0.629
Total 286 1.000

Select a basis.
Basis: 10,000 kg of saturated solution at 30OC.

Enter the known data to process diagram:

System Boundary System Boundary

10,000 kg P = ? kg
Na2CO3 0.280 Na2CO3 mNa2CO3
H2O 0.720 H2O mH2O

Initial State Final State

3,000 kg
Na2CO3 0.371
H2O 0.629

Crystals Removed

Fig. E5b

System: unsteady state, transport in = 0, so

 accumulation = -out

two components → two independent mass balance eq.

three unknowns: m Na2CO 3 , mH2O , P
third independent balance eq. : m Na2CO 3 + mH2O = P
→ unique solution

The total and component balances (only 2 are independent)

Accumulation in Tank
Final - Initial = Transport out
Na2CO3 m Na2CO - 10,000(0.280) = -3,000(0.371)
3
H2O m H2 O - 10,000(0.720) = -3,000(0.629)
Total P - 10,000 = -3,000

The solution for the unknowns:

Component kg
m Na2CO 3 1687
m H2 O 5313
P (total) 7000

Check on total: 7,000 + 3,000 = 10,000

To find the temperature of the final solution, calculate the composition of the final solution in terms
of grams of Na2CO3 /100 grams of H2O
1,687 g Na 2 CO 3 31.8 g Na 2 CO 3
=
5,313 g H 2 O 100 g H 2 O

By linear interpolation, the temperature to which the solution must be cooled is:
38.8 − 31.8 O
30O C −
38.8 − 21.5
( )
10 C = 26O C

PROBLEMS

1. A cereal product containing 55% water is made at the rate of 500 kg/hr. You need to dry the
product so that it contains only 30% water. How much water has to be evaporated per hour?
2. To prepare a solution of 50.0% sulfuric acid, a dilute waste acid containing 28.0% H2SO4 is
fortified with a purchased acid containing 96.0% H2SO4 . How many kilograms of the purchased
acid must be bought for each 100 kg of dilute acid?
3. An aqueous etching solution containing 8.8% KI is to be prepared to etch gold in printed circuit
boards. The desired solution is to be formed by combining a strong solution (12% KI and 3% I2
in H2O) with a weak solution (2.5% KI and 0.625% I2 in H2O)
a. What should be the value of R, the ratio of the weights of the strong to the weak
solution, to make up the desired etching solution? What will be the concentration of I2 in
the final solution?
 b. Note that you cannot independently vary the concentration of both KI and I2 in the final
mixture simply by varying the value of R. Derive a relationship between the weight
fraction of KI and the weight fraction of I2 in the mixture to illustrate this point.
4.
SOLVING MATERIAL BALANCE PROBLEMS INVOLVING CHEMICAL REACTIONS

The balance equation applied:

⎧accumulation⎫ ⎧input through⎫ ⎧output through⎫ ⎧generation ⎫ ⎧consumption⎫

⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪ ⎪
⎨within ⎬ = ⎨system ⎬ − ⎨system ⎬ + ⎨within ⎬ − ⎨within ⎬
⎪the system ⎪ ⎪boundaries ⎪ ⎪boundaries ⎪ ⎪the system⎪ ⎪the system ⎪
⎩ ⎭ ⎩ ⎭ ⎩ ⎭ ⎩ ⎭ ⎩ ⎭

Generation and consumption terms can come into play in making component mole balance. Often, in
component and total balances, the moles will not necessarily balance unless the generation and
consumption terms are taken into account.

Example of material balance with chemical reactions : combustion problems.

Special terms in combustion problems:
1. Flue or stack gas: All the gases resulting from a combustion process including the water vapor,
sometimes known as wet basis.
2. Orsat analysis or dry basis: All the gases resulting from a combustion process not including the
water vapor.
3. Theoretical air (theoretical oxygen): the amount of air (oxygen) required to be brought into the
process for complete combustion. Sometimes this quantity is called the required air (or oxygen).
4. Excess air (or excess oxygen): the amount of air (or oxygen) in excess of that required for
complete combustion. The calculated amount of excess air does not depend on how much
material is actually burned but what can be burned. Even if only partial combustion takes place,
the excess air (or oxygen) is computed as if the process of combustion produced only CO2.