TOPIC 3 Part 2:

MATERIAL BALANCES
FOR NON-REACTIVE
SYSTEMS
Credit to:
CHE471 CPPI DR SITI WAHIDA & PM Dr JUN & DR NORLIZA
 LECTURE OUTLINE

4.7 BALANCE IN MULTI-UNIT

PROCESS

4.8 BALANCE INVOLVING TIE

COMPONENT

4.9 RECYCLE AND BYPASS

(REF: Chapter 4 of
the Textbook)
CHE471 CPPI 2
4.7 BALANCE IN MULTI-
UNIT PROCESS
 4.7 BALANCE IN MULTI-UNIT PROCESS

• Material Balance Calculation:

Industrial chemical processes involved more than one unit operation
• System : portion of a process that can be enclosed within a boundary
Ø Entire process
Ø Interconnected combination of some of the process units
Ø A single unit
Ø A point at which two or more process streams come together or split into branches

PRODUCT 1
FEED 2

COMPONENT
FEED 1 SPLITTER
MIXER
CATALYTIC
REACTOR

PRODUCT 2 4
 4.7 BALANCE IN MULTI-UNIT PROCESS

System of Multiple-Unit Processes

• How many system boundaries exist in this process?

FEED 2
PRODUCT 1

FEED 1 COMPONENT
SPLITTER

CATALYTIC
REACTOR

PRODUCT 2

5
 4.7 BALANCE IN MULTI-UNIT PROCESS

A flowchart for a two – unit process is shown in Figure 4.4-1 (textbook). Five
boundaries drawn about portions of process define systems on which balances
may be written.

Feed 2 A Boundary A encloses the entire

process. Balance on this system
C E
are referred to as overall balances.
B D
Boundary B encloses a feed
Feed 1 Unit 1 Unit 2 Product 3 stream mixing points.

Boundary C encloses Unit 1

Boundary D encloses a stream
splitting point

Product 1 Product 2 Feed 3 Boundary E encloses Unit 2

Figure 4.4-1, Felder 6

 4.7 BALANCE IN MULTI-UNIT PROCESS

Example
A labeled flow chart of continuous steady – state two – unit process is shown below. Each stream
contains two components, A and B, in different proportions. Three streams whose flow rates
and/or compositions are not known are labeled 1, 2, and 3. Calculate the unknown flow rates 1,
2 and 3.

40.0 kg/h 30.0 kg/h

0.90 kg A/kg 0.60 kg A/kg
0.10 kg B/kg 0.40 kg B/kg

100.0 kg/h 1 2 3
Unit 1 Unit 2
0.50 kg A/kg
0.50 kg B/kg

30.0 kg/h
0.30 kg A/kg
0.70 kg B/kg 7
 40.0 kg/h 30.0 kg/h
0.90 kg A/kg 0.60 kg A/kg
0.10 kg B/kg 0.40 kg B/kg

Analyze the information

100.0 kg/h 1 x 2 3
Unit 1 Unit 2
0.50 kg A/kg
0.50 kg B/kg

30.0 kg/h
0.30 kg A/kg
0.70 kg B/kg

Overall material balance: 1 unknown – (3)

Process unit 1: 1 unknown – (1)
Mixing point x: 2 unknown – (1,2)
Process unit 2: 2 unknown – (2,3) 8
 Important: Solve equation with least unknown

Total material balance: 1 unknown – (3)

40.0 kg/h 30.0 kg/h
100 + 30 = 40 + 30 + m3 0.90 kg A/kg 0.60 kg A/kg
kg 0.10 kg B/kg 0.40 kg B/kg
m3 = 60.0
h

Process unit 1: 1 unknown – (1) 100.0 kg/h x

1 2 3
Unit 1 Unit 2
kg 0.50 kg A/kg
100 = 40 + m1 m1 = 60.0 0.50 kg B/kg
h
30.0 kg/h
Mixing unit : 1 unknown – (2) 0.30 kg A/kg
0.70 kg B/kg

m1 + 30 = m2
kg
m2 = 60 + 30 = 90
h

9
 4.7 BALANCE IN MULTI-UNIT PROCESS

Problem 4.29

A liquid mixture containing 30.0 mole% benzene (B), 25.0% toluene (T) and the balance xylene (X)
is fed to a distillation column. The bottoms product containing 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% of B and the balance T.
(a) Draw and label flowchart. Do the degree-of-freedom analysis to prove that for an assumed
basis of calculation, molar flowrate and compositions of all process streams can be calculated
from the given information.
(b) calculate (i) the percentage of the benzene in the process feed (the feed to the first column)
that emerges in the overhead product from the second column and (ii) the percentage of toluene
in the process feed that emerges in the bottom product from the second column.

10
 4.7 BALANCE IN MULTI-UNIT PROCESS

Solution
(a) Draw and label flowchart.
(b) Do the degree-of-freedom analysis to prove that for an assumed basis of calculation, molar flowrate
and compositions of all process streams can be calculated from the given information.

100 mol/h n!2 (mol/h) n!4 (mol/h)

Column Column
0.300 mol B/mol 1 XB2 (mol B/mol) 2 0.940 mol B/mol
0.250 mol T/mol XT2 (mol T/mol) 0.060 mol T/mol
0.450 mol X/mol 1 - XB2 -XT2 (mol X/mol)

XB5 (mol B/mol)

n!3 (mol/h) 0.020 mol T/mol n!5 (mol/h) XT5 (mol T/mol)
0.980 mol X/mol
1 - XB5 -XT5 (mol X/mol)

11
 4.7 BALANCE IN MULTI-UNIT PROCESS
Cont..Solution

100 mol/h n!2 (mol/h) n!4 (mol/h)

Column Column
0.300 mol B/mol 1 XB2 (mol B/mol) 2 0.940 mol B/mol
0.250 mol T/mol XT2 (mol T/mol) 0.060 mol T/mol
0.450 mol X/mol 1 - XB2 -XT2 (mol X/mol)

XB5 (mol B/mol)

n!3 (mol/h) 0.020 mol T/mol n!5 (mol/h) XT5 (mol T/mol)
0.980 mol X/mol
1 - XB5 -XT5 (mol X/mol)

DoF Column 1 DoF Column 2

4 unknowns 4 unknowns
- 3 Independent eqn - 3 Independent eqn
- 1 Recovery of X - 1 Recovery of X
0 DoF 0 DoF

Column 1 Column 2

0.960(0.450)(100) = 0.980n!3 97% B Recovery:

0.970 xB 2 n!2 = 0.940n!4 (5)
96% X Recovery: (1) n!2 = n!4 + n!5
Total mole balance: 0.300(100) = xB 2 n!2 (2) Total mole balance: (6)
B Balance: (7)
B Balance: 100 = n!2 + n!3 (3) xB 2n!2 = 0.940n!2 + xB5n!5
T Balance: (4) T Balance:
0.250(100) = xT 2 n!2 + 0.020n!3 xT 2n!2 = 0.060n!4 + xT 5n!5 (8)
 4.7 BALANCE IN MULTI-UNIT PROCESS
Cont..Solution
(c) Calculate:

(i) the percentage of the benzene in the process feed (the feed to the first column) that emerges in the overhead
product from the second column and

(ii) the percentage of toluene in the process feed that emerges in the bottom product from the second column.

Solving all the balances and obtain these results:

Overall Benzene Recovery:
n!3 = 44.1 mol/h n!4 = 30.95 mol/h
n!2 = 55.9 mol/h 0.940(30.95)
n!5 = 24.96 mol/h x 100% = 97%
0.300(100)
xB 2 = 0.536 mol B/h xB5 = 0.036 mol B/h

xT 2 = 0.431 mol T/h xT 5 = 0.892 mol T/h Overall Toluene Recovery:

0.892( 24.96)
x 100% = 89%
0.250(100)
EXERCISE in CLASS: EXERCISE#1
Flash distillation is used to separate some component in the hydrocarbon mixture. A hydrocarbon mixture
containing 35.0 mole% pentane (A), 15.0 mole% hexane (B) and balance octane (C) is fed to a flash distillation
column. The bottoms product contains 97.0 mole% C and no A, and 96.0% of the C in the feed is recovered in
the bottom stream. The overhead product is fed to a second column. The overhead product from the second
column contains 97.0 mol% of the A in the second column feed. The composition of overhead product stream is
92.0 mole% A and the balance B. Based on 100 mol/h of distillation column feed, calculate:

i) The molar flow rate and the composition of first column overhead product
(10 marks)
ii) The molar flow rate and the composition of second column bottom product
(6 marks)

Solution:
First: Analyse the info given

Feed: 0.35 mol A/mol, 0.15 mol B/mol, 0.50 mol C/mol Bottom unit 1: 0.97 mol C/mol, 0.03 mol B/mol
F = 100 mol/h Amount C = 0.96 x (C at Feed)

Overhead product unit 2: 0.92 mol A/mol, 0.08 mol B/mol

Amount A = 0.97 x (A at Feed unit 2) 14
Basis of calculation: 100 mol/h of feed
Process flow chart:

Overhead product, m3

0.92 mol A/mol

0.08 mol B/mol
A=0.97(xm2)
Overhead product, m2
2
x mol A/mol
y mol B/mol
(1-x-y) mol C/mol
100 mol/h Bottom product, m4
1
0.35 mol A/mol v mol A/mol
0.15 mol B/mol w mol B/mol
0.50 mol C/mol (1-v-w) mol C/mol
Bottom product, m1

0.97 mol C/mol

0.03 mol B/mol
C=0.96(0.50x100)
15
EXERCISE 1 CONT.. Overhead product, m3

0.92 mol A/mol

Write system equation and outline a solution procedure 0.08 mol B/mol
A=0.97(xm2)
Overhead product, m2

Amount of C = 0.96 ´ (0.50 ´ 100 )

2
Unit 1: Bottom product: x mol A/mol
y mol B/mol
0.97 ´ m1 = 48 100 mol/h
(1-x-y) mol C/mol
Bottom product, m4
1
48 mol
m1 = = 49.485
0.35 mol A/mol v mol A/mol
0.15 mol B/mol w mol B/mol
0.97 h 0.50 mol C/mol (1-v-w) mol C/mol
Bottom product, m1

Unit 2: Overhead product – required to find x and m1 0.97 mol C/mol

0.03 mol B/mol
C=0.96(0.50x100)

Analyze the material balance for:

Solve for composition at overhead product unit 1
1) Total material balance:
2) Material balance for component (Unit 1):
Overall M/B: 2 unk. (m3, m4)
Unit 1: 1 unk. (m2) A: 1 unk. (x)

Unit 2: 3 unk. (m2, m3, m4) B: 1 unk. (y)

C: 2 unk (x, y)
From total material balance for Unit 1: From material balance for A & B at unit 1:
100 = m1 + m2
mol 0.35 ´100 = x ´ 50.515 0.15 ´100 = y ´ 50.515 + 0.03 ´ 49.485
m2 = 100 - 49.485 = 50.515
h 35 15 - 1.48455
x= = 0.693 y= = 0.268
50.515 50.515 16
EXERCISE 1 CONT.. Overhead product, m3

0.92 mol A/mol

0.08 mol B/mol
A=0.97(xm2)
Unit 2: Overhead product – required to find x and m1 Overhead product, m2
2
x mol A/mol

Amount of A = 0.97 ´ ( xm2 )

y mol B/mol
(1-x-y) mol C/mol
100 mol/h Bottom product, m4
1

0.92 ´ m3 = 0.97 ´ 0.693 ´ 50.515

0.35 mol A/mol v mol A/mol
0.15 mol B/mol w mol B/mol
0.50 mol C/mol (1-v-w) mol C/mol
Bottom product, m1

mol
m3 = 36.909 0.97 mol C/mol
0.03 mol B/mol

h C=0.96(0.50x100)

Solve for mass & composition at overhead product unit 2 From material balance for A at unit 2:
0.693 ´ 50.515 = 0.92 ´ 36.909 + v ´13.606
3) Material balance Unit 2:
v=
(0.693 ´ 50.515) - (0.92 ´ 36.909) = 0.077
Total M/Balance: 1 unk. (m4) 13.606
Component A: 2 unk. (m4, v) From material balance for B at unit 2:
Component B: 2 unk. (m4, w) 0.268 ´ 50.515 = 0.08 ´ 36.909 + w ´13.606
Component C: 3 unk. (m4, v, w) w=
(0.268 ´ 50.515) - (0.08 ´ 36.909) = 0.778
13.606
From total material balance at unit 2:
Final Answer: Molar flow rates & compositions
50.515 = 36.909 + m4 mol mol
m2 = 50.515 m4 = 13.606
mol 1st column h 2nd column h
m4 = 50.515 - 36.909 = 13.606 (overhead) x A = 0.693 mol A/mol (overhead) x A = 0.077 mol A/mol
h xB = 0.268 mol B/mol xB = 0.778 mol B/mol
xC = 0.039 mol C/mol xC = 0.145 mol 17
C/mol
4.8 BALANCE INVOLVING TIE
COMPONENT
 4.7 BALANCE INVOLVING TIE COMPONENT

Tie component/element
• A material or component that goes directly from one stream into another without changing in
any respect or having like material added to it or lost from it
• Having constant mass through out the process
• Slightly easier to solve the calculation

EXAMPLE #1 EXAMPLE #2

Composition 100 kg H2O

W=? 100%H2O

F=? P=?
F=? P=? Wet fish cake Dryer Dry fish cake
Composition Composition 80%w/w H2O 40% w/w H2O
50% EtOH 91% EtOH
50% H2O 9%H2O 20% w/w BDC 60%w/w BDC

19
4.9 BYPASS AND RECYCLE
 4.7 BYPASS AND RECYCLE

The difference between

o Bypass and Recycle.
- able to distinguish mixing vs. splitting points.
o Material balances involving the abovementioned processes.

Note: INPUT OUTPUT Splitting

§ At bypass,
“Splitting “Mixing Point
the
components Points” Points”
mass Bypass Mixing
“Mixing “Splitting Point
fractions
Points” Points”
remain the
same.
INPUT OUTPUT See example 4.5-2
§ The ONLY
difference is
the mass flow
rate. Recycle
21
 4.7 BYPASS AND RECYCLE
Problem 4.32
Fresh orange juice contains 12.0 wt% solids and the balance water, and concentrated orange juice contains 42.0
wt% solids. Initially a single evaporation process was used for the concentration, but volatile constituents of the
juice escaped with the water, leaving the concentrate with a flat taste. The current process overcomes the
problem by bypassing the evaporator with a fraction of fresh juice. The juice that enters the evaporator is
concentrated to 58 wt% solids, and the evaporator product stream is mixed with the bypassed fresh juice to
achieve the desired final concentration.
Draw and label the flowchart. Perform the degrees of freedom analyses. Calculate the amount of product (42%
concentrate) produced per 100 kg fresh juice fed to the process and the fraction of the feed that bypasses the
evaporator.

Step 1. Draw and label

the flowchart

22
 4.7 BYPASS AND RECYCLE
Cont..Problem 4.32

Step 2. Choose a basis of calculation: Given 100 kg fresh juice.

Step 3a. Perform the DoF analysis on overall process system.

Degrees of Freedom
2 Unks. (m3, m5)
- 2 IE’s

0 DoF
Overall Process

Balances

Overall : 100 = m3 + m5
S : (0.12)(100) = 0 + 0.42m5
W : (0.88)(100) = m3 + 0.58m5
23
 4.7 BYPASS AND RECYCLE
Cont..Problem 4.32
Step 3b. Perform the DoF analysis (Continuation) on Bypass.

Balances Degrees of Freedom

m3 (kg W)
Overall : 100 = m1 + m2 2 Unks. (m1, m2)
100 kg m1 m4 m5
0.12 kg S / kg 0.12 kg S / kg
Evaporator 0.58 kg S / kg 0.42 kg S / kg
- 1 IE’s

Bypass
0.88 kg W / kg 0.88 kg W / kg 0.42 kg W / kg 0.58 kg W / kg S : (0.12)(100) = 0.12m1 + 0.12m2
m2
0.12 kg S / kg W : (0.88)(100) = 0.88m1 + 0.88m2 1 DoF
0.88 kg W / kg

Step 3c. Perform the DoF analysis (Continuation) on Evaporator.

m3 (kg W)
Balances Degrees of Freedom
Overall : m1 = m3 + m4 3 Unks. (m1, m3, m4)

Evaporator
100 kg m1 m4 m5
Evaporator - 2 IE’s
0.12 kg S / kg 0.12 kg S / kg 0.58 kg S / kg 0.42 kg S / kg
0.88 kg W / kg 0.88 kg W / kg 0.42 kg W / kg 0.58 kg W / kg
S : 0.12m1 = 0.58m4
1 DoF
m2
W : 0.88m1 = 0.42m4 + m3
0.12 kg S / kg
0.88 kg W / kg
 4.7 BYPASS AND RECYCLE
Cont..Problem 4.32
Step 3c. Perform the DoF analysis (Continuation) on Mixing Point.

Balances Degrees of Freedom

m3 (kg W)
3 Unks. (m2, m4, m5)

Mixing Point
Overall : m4 + m2 = m5
100 kg m1 m4 m5 - 2 IE’s
Evaporator
0.12 kg S / kg
0.88 kg W / kg
0.12 kg S / kg
0.88 kg W / kg
0.58 kg S / kg
0.42 kg W / kg
0.42 kg S / kg
0.58 kg W / kg
S : 0.12m2 + 0.58m4 = 0.42m5
m2 1 DoF
0.12 kg S / kg
W : 0.88m2 = 0.42m4 + 0.58m5
0.88 kg W / kg

Step 4a. Do the algebra. Solve Let’s start with the Overall Process because DoF = 0
the balance equations.
Recall the material balances for overall process
Calculate the amount of
product (42% concentrate) Overall: 100 = m3 + m5 1 From (2) : m5 = 28.6 kg
produced per 100 kg fresh juice Amount of product
fed to the process and the S: (0.12)(100) = 0.42m5 2
fraction of the feed that bypasses W: (0.88)(100) = m3 + 0.58m5 From (1) : m3 = 71.4 kg
3
the evaporator.
 4.7 BYPASS AND RECYCLE
Cont..Problem 4.32
Step 4b. Do the algebra. Solve the balance equations (Continuation). Include
the new values that we have obtained.

DoF (updated)
71.4 (kg W) 2 unknowns (m2, m4)
- 2 IE’s
100 kg m1 m4 28.6 kg
0 DoF Known m5 = 28.60 kg
Evaporator
0.12 kg S / kg 0.12 kg S / kg 0.58 kg S / kg 0.42 kg S / kg Solve for m4 = 18.65 kg
0.88 kg W / kg 0.88 kg W / kg 0.42 kg W / kg 0.58 kg W / kg Balances on mixing point
m2 = 9.95 kg
m2 Overall : m4 + m2 = m5
0.12 kg S / kg S : 0.12m2 + 0.58m4 = 0.42m5
0.88 kg W / kg
W: 0.88m2 + 0.42m4 = 0.58m5

Step 4c. Do the algebra.

71.4 (kg W)
The bypass fraction
Calculate the amount of product 100 kg m1 18.65 kg 28.6 kg
(42% concentrate) produced per Evaporator m2 9.95
100 kg fresh juice fed to the
0.12 kg S / kg
0.88 kg W / kg
0.12 kg S / kg
0.88 kg W / kg
0.58 kg S / kg
0.42 kg W / kg
0.42 kg S / kg
0.58 kg W / kg = =
process and the fraction of the 100 100
9.95 kg
feed that bypasses the
0.12 kg S / kg
= 0.0995
evaporator 0.88 kg W / kg
 4.7 BYPASS AND RECYCLE
Exercise in class
4500 kg/h of a solution that is 1/3 K2Cr2O7 (C) by mass is joined by a recycle stream containing 36.4% C, and the
combined stream is fed into an evaporator. The concentrated stream leaving the evaporator contains 49.4% C;
this stream is fed into a crystallizer in which it is cooled (causing crystals of C to come out of solution) and then
filtered. The filter cake consists of C crystals and a solution that contains 36.4% C by mass; the crystals account
for 95% of the total mass of the filter cake. The solution that pass through the filter, also 36.4%, in the recycle
stream.

1) Calculate the rate of evaporation, the rate of production of crystalline C, the feed rates that the evaporator
and the crystallizer must be designed to handle, and the recycle ratio (mass of recycle)/(mass of fresh feed)

2) Suppose that the filtrate were discarded instead of being recycled. Calculate the production rate of crystals.
What are the benefits and costs of recycling?

ATTEMPT: Problem 4.36

 ATTEMPT THESE QUESTIONS

Past Year EQs:

• Q3 DEC 2016
• Q3 JULY 2017
• Q3 JUNE 2019

Problems in Chapter 4 (Textbook) for Mutliple Unit Balances

(Non-reactive processes)
END OF TOPIC 3: PART 2