LECTURE 9 MATERIAL BALANCE PROBLEMS INVOLVING MULTIPLE UNITS

9.1 Introduction

Welcome to lecture 9. If you have driven past an industrial plant, power station, or waste
disposal facility, you must have noticed how complex the equipment is. Such plants involve a
large number of interconnected processing units. Based on what you have learned in previous
lessons you are now prepared to solve problems involving an entire plant.
In this lecture we are going to discuss how to treat and solve material balance problems for
systems of serially coupled units. You will be pleased to learn that principles employed in
previous lessons still apply. All you have to do is apply them to individual subsystems and/or to
the overall system.

9.2 Lecture Objectives

By the end of this lecture you will be able to:

1. write a set of independent material balances for a complex process involving more than
one unit
2. solve problems involving several connected units by applying the 10-step strategy

9.3 Main concepts

To formulate material balances for a complex process we are going to use a process
flowdiagram. From a previous course “Introduction to Unit Operations” you know that a
flowdiagram is a graphical representation of a process and describes it in sufficient detail. Look
at the Figure 9.1 which illustrates a serial combination of mixing and splitting stages.
4

3 5
B
1 A C 6

2 7

Figure 9.1(a). A serial mixing and splitting in a system without reaction. Streams 1 plus 2 mix to
form stream3, and stream 5 is split into streams 6 and 7.
In a mixer (point A), two or more entering streams of different compositions are combined. In a
splitter (point C), two or more streams exit, all of which have the same composition. You need
to differentiate between a splitter and a separator, in which the exit streams can be of different
compositions. An example of a separator is a distillation column.

Question

How many material balances can you formulate for the three units A, B and C process shown in
Figure 9.1(a) above?

Let us show the boundaries for all the material balances that can be made on the process in
Figure 9.1(a).

3 5

1
6

I 7
2

Figure 9.1(b). The dashed line I designates the boundary for overall material balances made on
the process in Figure 9.1(a).
4

3 5

1
6

III IV
II I
Ii 7
2

Figure 9.1(c). Dashed lines II, III and IV designate the boundaries for material balances around
each of the individual units comprising the overall process.
 4

3 5

1 6

V
2 7

Figure 9.1(d). The dashed line V designates the boundary for material balances around a system
comprised of the mixing point plus the unit portrayed by the box.

3 5

6
1

VI
2 7

Figure 9.1(e). The dashed line VI designates the boundary for material balances about a system
comprised of the unit portrayed by the box plus the splitter.

4
5
3

1 6

VII
2
7

Figure 9.1(f). The dashed line VII designates the boundary for material balances about a system
comprised of the mixer plus the splitter.
You can conclude that you can make material balances on seven different systems. How many
independent material balance equations can be written for the process? You can write an
independent material balance equation for each component present in each unit or subsystem
except for splitters. For splitters, only one independent mass balance equation can be written
regardless of the number of components present in the streams.
A subsystem with zero degrees of freedom is a good starting point. Frequently, the best way
to start is to make material balances for the overall process.

Example 9.1
The system shown below is open and steady state. No reaction takes place. The arrows designate
flows.

2 4 6

1 I II III 8
3 5

7
The composition of each stream is as follows (with units suppressed):
1. Pure A
2. Pure B
3. Aand B, concentrations known: ωA = 0.800, ωB = 0.200
4. Pure C
5. A, B, and C, concentrations known; ωA = 0.571, ωB = 0.143, ωC = 0.286
6. Pure D
7. A and D, concentrations known; ωA = 0.714, ωD = 0.286
8. B and C, concentrations known; ωB = 0.333, ωC = 0.667

What is the maximum number of independent mass balances that can be generated to solve this
problem? Write down the possible equations. Do they form a unique set?

Solution:

Select each of the three units as a system. With respect to the material balances for the individual
units, you can make 9 species (component) equations as follows for the three units (ignoring any
total balances for the 3 units, plus overall species and total balance, plus balances for
combinations of units):
Number of component balances
At unit I, two components are involved 2
At unit II, three components are involved 3
 At unit III, four components are involved 4
Total: 9
However, not all of the balances are independent. In the following list, all of the known
concentrations have been inserted, and F represents the stream flow designasted by the
superrscript.

Subsystem I :

A: F1(1.00) + F2(0) = F3 (0.800) (a)

Balances
B: F1(0) + F2(1.00) = F3 (0.20) (b)

Subsystem II:
A: F3(0.800) + F4(0) = F5 (0.571) (c)
Balances
B: F3(0.200) + F4(0) = F5 (0.143) (d)

C: F3(0) + F4(1.00) = F5 (0.286) (e)

Subsystem III:
A: F5(0.571) + F6(0) = F7 (0.714) + F8(0) (f)

Balances B: F5(0.143) + F6(0) = F7 (0) + F8(0.333) (g)

C: F5(0.286) + F6(0) = F7 (0) + F8(0.667) (h)

D: F5(0) + F6(1.00) = F7 (0.286) + F8(0) (i)

If you take as a basis F1 = 100, seven values of Fi are unknown, hence only seven independent
equations need to be written. Can you recognize by inspection that among the entire set of 9
equations two are redundant, and hence a unique solution can be obtained using 7 independent
equations?
If you solved the 9 equations sequentially starting with Eq. (a) and ending with Eq. (i), along
the way you would notice that Eq. (d) is redundant with Eq. (c) and Eq. (h) is redundant with Eq.
(g). The redundancy of Eq. (c) and (d) becomes apparent if you recall that the sum of the mass
fractions in a stream is unity, hence an implicit relation exists between Eq. (c) and (d) so that
they are not independent. Why are Eq.(g) and (h) not independent?
If you inspect the set of Eq.s (a) through (i) in order to solve them, you will find that each
one can be solved for one variable. Look at the following list:
 Equation Determines Equation Determines
(a) F3 (e) F4
(b) F2 (f) F7
(c) F5 (g) F8
(d) F5 (h) F8
(i) F6

Take note

In calculating the degrees of freedom for problems involving multiple units, you must be careful
to write only independent material balances and not miss any essential unknowns.

Table 9.1is a simplified checklist to help keep in mind possible unknowns and equations for a
process.

Table 9.1. Checklist of variables and equations to consider in a degree-of -freedom analysis
Variables:

Flow variables:
Species (or total flow) entering and leaving for each subsystem
Species (or total flow) entering and leaving the overall system

Reaction variables:
Extents of reaction (if any) for each subsystem
Equations:

Basis for each subsystem or the overall system

Material balances (species or element):
For each species or element (or their total) in each subsystem
For each species or element (or their total) in the overall system

Specifications (for each subsystem and overall):

Specified compositions
Specified flow rates
Specified flow ratios
Specified conversions or extent of reaction
Splitter restrictions
Implicit equations (sum of mole or mass fractions)
9.4 Worked examples
Next we look at some examples of making and solving material balances for systems composed
of multiple units.

Example 9.2
A liquid mixture containing 30.0 mole% benzene (B), 25% toluene (T), and the balance xylene
(X) is fed to a distillation column. The bottoms product contains 98.0 mole % X and no B, and
96.0% of the X in the feed is recovered in this stream. The overhead product is fed to a second
column. The overhead product from the second column contains 97.0% of the B in the feed to
this column. The composition of this stream is 94.0 mole% B and the balance T.

100 mol/h n2 (mol/h) n4 (mol/h)

0.300 mol B/mol xB2 (mol B/mol) 0.940 mol X/mol

0.250 mol T/mol xT2 (mol T/mol) 0.060 mol T/mol
0.450 mol X/mol 1- xB2- xB2 (mol X/mol)
n5 (mol/h)
xB5 (mol B/mol)
n3 (mol/h)
xT5 (mol T/mol)
0.020 mol T/mol
1- xB5 - xT5 (mol X/mol)
0.980 mol X/mol

i. Draw and label a flowchart of this process and conduct the degree-of-freedom analysis to
prove that for an assumed basis of calculation, molar flow rates and compositions of all
process streams can be calculated from the given information.
ii. Write in order the equations you would solve to calculate unknown process variables.
iii. In each equation circle the variable(s) for which you would solve.
iv. Calculate the overall benzene and toluene recovery.

Solution:
i. All the data have been put on the flowdiagram. The basis is 100 mol/h fresh feed.

The degree-of-freedom analysis:

Column 1: Column 2:
4 unknowns (n2, n3, xB2 , xT2 ) 4 unknowns ( n4, n5, xB5, xT5)
-3 balances -3 balances
-1 recovery of X in bot. (96%) -1 recovery of B in top. (97%)
0 degrees of freedom 0 degrees of freedom
ii. and iii Column 1:
96% X recovery: 0.96(0.450)(100) = 0.98 n3 (1)
Total mole balance: 100 = n2 + n3 (2)
 B balance: 0.300(100) = xB2n2 (3)
T balance: 0.250(100) = xT2n2 + 0.020n3 (4)

Column 2:
97% B recovery: 0.97 xB2n2 = 0.940 n4 (5)
Total mole balance: n2 = n4 + n5 (6)
B balance: xB2n2 = 0.940n4 + xB5n5 (7)

T balance: xT2n2 = 0,060 n4 + xT5n5 (8)

The answers are:

(1) ⇒ n3 = 44.1 mol/h (2) ⇒ n2 = 55.9 mol/h

(3) ⇒ xB2 = 0.536 mol B/mol (4) ⇒ xT2 = 0.431 mol T/mol

(5) ⇒ n4 = 30.95 mol/h (6) ⇒ n5 = 24.96 mol/h

(7) ⇒ xB5 = 0.036 mol B/mol (8) ⇒ xT5 = 0.892 mol T/mol

0.940(30.95)
iv. Overall benzene recovery: 100%  97%
0.300(100)

0.892(24.96)
Overall toluene recovery: 100%  89%
0.250(100)

Example 9.3

You are asked to design an acetone recovery system having the flowdiagram given below. All
the concentrations of both gases and liquids are specified in weight percent. Calculate mass flow
rates A, F, W, B, and D. Given that G = 1400 kg/hr.
 D Distillate
Air A Condenser ❸
W Acetone 0.99
Water 100% Air 0.995 Water 0.01
Water 0.005 1.00
1.00
Absorber Distillation
column column

❶ ❷
B Bottom
Acetone 0.04
Water 0.96
1400 kg/hr G
1.00
entering gas F
Air 0.95 Acetone 0.19
Acetone 0.03 Water 0.81
Water 0.02 1.00
1.00

Solution:
This is an open, steady-state process without reaction. Three subsystems exist.

Pick 1 hour as a basis so that G = 1400 kg.

The mass balances for Unit 1 (Absorber Column):

In Out
Air: 1400(0.95) = A(0.995) (a)
Acetone: 1400(0.03) = F(0.19) (b)
Water: 1400(0.02) + W(1.0) = F(0.81) + A(0.005) (c)
Solve equations (a), (b), and (c) to get
A = 1336.7 kg/hr
F = 221.05 kg/hr
W = 157.7 kg/hr
(Check) Use the total balance (Absorber Column)
G+W = A+F
1400 1336.7
 157.7 221.05

1557.7 ≅ 1557.1

The mass balances for the combined Units 2 plus 3 (Distillation column & Condenser) are:

Acetone: 221.05(0.19) = D(0.99) + B(0.04) (d)

Water: 221.05(0.81) = D(0.01) + B(0.96) (e)

Take note

We have combined Units 2 (Distillation column) and 3 (Condenser) because the top stream
leaving the Distillation column and entering the Condenser has no information at all.

Solve Eq.s (d) and (e) simultaneously to get:

D = 34.91 kg/hr

B =186.1 kghr

(Check) Use the total balance (Distillation & Condenser)

F=D+B or 221.05 ≅ 34.91 + 186.1 = 221.01

Question

What other mass balances could be written for the system and substituted for any one of the
Equations (a) through (e)?

Typical balances would be the overall balances:

In Out
Air: G(0.95) = A(0.995) (f)

Acetone: G(0.03) = D(0.99) + B(0.04) (g)

Water: G(0.02) = A(0.005) + D(0.01) + B(0.96) (h)

Total: G +W = A+D+B (i)

Equations (f) through (i) do not add any extra information to the problem; the degrees of freedom
are still zero. But any of the equations can be substituted for one of equations (a) through (e) as
long as you make sure that the resulting set of equations is independent.
Example 9.4
A triple effect evaporator is designed to reduce water from an incoming brine (NaCl + H2O)
stream from 75 wt % to 3 wt %. If the evaporator unit is to produce 14,670 lb/hr of NaCl (along
with 3 wt% H2O), determine:
a) The feed rate of brine in lb/hr.
b) The water removed from the brine in each evaporator.
The data are shown in the accompanying figure.

Solution:
Steps 1, 2, 3 and 4 This is a steady state problem. The data has been placed on the figure.
V1 mass fr V2 mass fr V3 mass fr
Brine F H2O 1.00 H2O 1.00 H2O 1.00
lb/hr
I II III
mass fr
NaCl 0.25
H2O 0.75

P1 P2
P3 14,670 lb/hr
mass fr mass fr mass fr
NaCl 0.33 NaCl 0.50 NaCl 0.97
H2O 0.67 H2O 0.50 H2O 0.03

Step 5: It is best to choose 1 hour of operation as the basis. We will select

Basis: 14,670 lb = 1 hr

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

Step 7 and 8 Balances for salt and water and total balance can be written for each unit as a
system as well as overall balances (not all of these balances would be independent). We will use
the salt and total balances as the simplest ones.

Overall balances
Total balance: F = V1 + V2 + V3 + 14,670 (1)
Salt balance: 0.25F = 0.97(14,670) (2)

Evaporator I
Total balance: F = V1 + P1 (3)
Salt balance: 0.25F = 0.33P1 (4)

Evaporator II
 Total balance: P1 = V2 + P2 (5)
Salt balance: 0.33P1 = 0.50P2 (6)

Evaporator III
Total balance: P2 = V3 + 14,670 (7)
Salt balance: 0.50P2 = 0.97(14,670) (8)

Any set of 6 independent equations can be used to determine the 6 unknowns. We will use
equations (1) to (6) to solve for all of the unknowns.

Step 9 By starting the solution with equation (2), the equations become uncoupled:
F = 56,900 lb/hr

From equation (4): 0.25 (56,900) = 0.33 P1

P1 = 43,100 lb/hr/hr

From equation (3): V1 = 13,800 lb

From equations (5) and (6): P2 = 28,460 lb/hr; V2 = 14,700 lb/hr

From equation (1): 56,900 = 13,800 + 14,700 + V3 + 14,670

V3 = 13,800 lb/hr

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

Equation (7): P2 = V3 + P3

28,460 ≅ 13,800 +14,670 = 28,470

Equation (8): 0.5 P2 = 0.97 P3

0.5(28,460) = 0.97(14,670)

14,230 lb = 14,230 lb