Mass Balances

Design of Process Plants: Ammonia Production

Conservation of mass principle

Batch/Continuous/Semi-batch/Steady state/Transient Processes

General problem solving strategy

Mass balance problem solving approach

Examples of mass balance problems

A mixing problem (two streams in, one stream out)
Distillation column problems
A condenser (one stream in, 2 streams out)
A dryer
A membrane system
1
 Design of Process Plants
A chemist has discovered in the laboratory that substances A and B will produce
product C at a temperature T and a pressure P.

Applying this knowledge in industry is the job of engineers. They would design a
process for the production C from A and B by considering technical feasibility in
addition to economic and environmental constraints.

As the first step, let’s imagine a simple process that is shown below.

2
 Design of Process Plants
Engineer will consider several factors (some of which summarized in the next slide) to
produce a more realistic process design as shown below:

3
 Design of Process Plants
Some factors to consider during the design stage include:
1. There are raw materials (A and B) in the output of the reactor, because
chemical reactions are often associated with some reversibility and products (C)
can be converted back to A and B. Usually unwanted chemical reactions occur in
the reactor, and they produce by-products (D)
3. Depending on the chemical reactions, the reactor may require cooling or
heating. A heat exchanger can be employed for this purpose.
5. To prevent environmental pollution and conserve energy and raw materials,
post-processing method /separation processes are necessary.
6. Catalysts can improve the conversion rate of the raw materials to the
products.
7. Nitrogen is used to provide the necessary pressure.

The design of each component in a process requires specialized training. Design of

chemical reactors requires knowledge of the kinetics and reactor design. Heat
exchanger design is a subject in a heat transfer course.

A critical step for all these processes is the analysis of mass and energy balances
4
 Design of Process Plants
Before we delve into mass and energy balances let us attempt to design a plant for the
production of ammonia.

𝐍𝟐 + 𝟑𝐇𝟐 ⇌ 𝟐𝐍𝐇𝟑

5
Design of Process Plants

6
 Design of Process Plants

Is there another way of producing Hydrogen?

Can we perhaps use methane?

7
Design of Process Plants

8
Design of Process Plants

9
Design of Process Plants

10
Conservation of mass principle

11
 Conservation of mass principle

The above equation is general and applies to all mass balance problems.
The last two terms, which pertain to generation and consumption of material, are
generally included in material balances only for chemical components when
chemical reaction occurs in the system.

12
 Conservation of mass principle
To begin our discussion of the material balance equation, let’s consider a system
composed of a single component for which there are no chemical reactions occurring.
Then, the general equation, with the absence of reaction, reduces to

13
 Conservation of mass principle
Closed System:

Open System

14
 Steady state and Transient Processes

Steady state: If all variables in a process (temperature, pressure,

volume, flow rate) do not change in time (except possibly for minor
fluctuations about constant mean values), the process is said to be
operating at steady state conditions.

Transient: If any of the process variables change with time, transient or

unsteady state operation is said to exist.

15
 Steady state and Transient Processes
Steady State:

Consider the system on the left at time = t

What happens after 50 minutes, i.e.at time = t+50

Accumulation = Input – Output = 0

Input = Output

16
 Steady state and Transient Processes
Transient (Unsteady State)

Consider the system on the left at time = t

What happens after 50 minutes, i.e.at time = t+50

Accumulation = In – Out = 500 kg

17
 Batch, Continuous and Semi-batch Processes
Batch process: No mass crosses the boundaries between the time the feed is charged
into the vessel and the time the mixing is complete (i.e. between time 0 and time t).

The initial state of a mixing process (t=0). Final state of the mixing process (t=t).

18
 Batch, Continuous and Semi-batch Processes
Continuous process: Inputs and outputs flow continuously across and
throughout the duration of the process.

19
 Batch, Continuous and Semi-batch Processes

Semi-batch process: Any process that is neither batch nor continuous!

The initial state of a Mass flows into the Final state of the
mixing process (t=0). vessel over a certain mixing process. No
Vessel is empty period from time t=0 mass enters or leaves
to t = 1 hour
20
Batch/Continuous/Semi-batch and Steady State vs Transient Processes

Classify the following processes as batch, continuous, or semi-batch, and transient or

steady state.

A balloon is filled with air at a steady rate of 2 g/min. (Semi-batch, transient)

A bottle of milk is taken from the refrigerator and left on the (Batch, transient)
kitchen table.

Water is boiled in an open flask. (Semibatch, transient)

CO and H2O are fed into a tubular reactor at a steady rate and
react to form CO2 and H2. Products/unused reactants are
withdrawn at the other end. The reactor contains air when the
process is started up. The composition and flow rate of the
entering reactant stream are also independent of time.
Classify the process (a) initially (Continuous, transient)

and (b) after a long period of time has elapsed. (Continuous, steady state)
21
 General Problem Solving Approach/Strategy

Almost every engineering problem-solving technique involves five broad steps:

Describe the problem

Identify pertinent known and unknown facts
Identify the scientific principles needed for solution

Manipulate the numbers

Evaluate the result

22
 Mass balance problem example (simple)

Estimate the volume water in the lake as of January 1st 2010

23
 Mass balance problem example (simple)

Lake Area = 3 km2

Average annual rain fall = 750 mm Accumulation = In – Out
Average flow into lake= 32,000 m3/h
Average flow out of lake= 750,000 m3/day
Average annual evaporation rate = 0.05 g/m2.s

24
 Problem Solving Approach for Mass Balance Problems
The previous 5 steps can be expanded into the following 10 steps:

1. Read the problem thoroughly. Understand what is required for the answer.
2. Draw a sketch or flow sheet of the problem and specify system boundary.
3. Write down the known and label unknown stream variables.
4. Determine what additional data, if any, are needed. Find them. Be sure to indicate the
source and applicability of anything you bring from outside.
5. Choose a calculation basis.
6. Determine the number of unknowns.
7. Determine the number of independent equations and perform a degrees of freedom
analysis. Can the problem be solved as is, or is more information needed?
8. Write the required equations: Material Balances Equations, Specifications, Physical
Properties, etc.
9. Solve the equations for the unknowns. Use a solution strategy. Solve the equations
in a planned order. Often, this allows sequential rather than simultaneous solution.
10. Check the solution. Does it make sense?
25
 Degrees of Freedom
The number of degrees of freedom (ND) is calculated using the number of unknowns (NU) and
the number of independent equations (NE):

ND = NU – NE
When you calculate the number of degrees of freedom (ND), you can ascertain what the
“solvability” of a problem is. Three outcomes may occur:

26
 Degrees of Freedom

Underspecified NU > NE > 0 Exactly specified; NU = NE

(not enough equations) (enough equations)

Over specified; NU < NE < 0 Over specified; NU < NE < 0

(more than enough equations) (more than enough equations) 27
 Two component mass balance problems
Example Problem: Mixer
A continuous mixer mixes a concentrated NaOH aqueous solution with a very dilute
NaOH aqueous solution to produce a moderately concentrated aqueous solution of
NaOH. Determine the composition and flow rate of the product if the flow rate of the
concentrated NaOH solution is 1000 kg/hr, with a mass fraction of 0.5 of NaOH and the
rest is water while the very dilute NaOH aqueous solution flows into the mixer at a
rate of 9,000 kg/hr and contains a mass fraction of 0.05 of NaOH. Draw a sketch of the
process and put the data and unknown variables on the sketch with appropriate labels.
Use the proposed strategy to solve the problem.

28
Problem Solving Approach for Mass Balance Problems

1. Read the problem thoroughly. Understand what is required

for the answer.

2. Draw a sketch or flow sheet of the problem and specify

system boundary.

29
 Example Problem: Mixer

very dilute NaOH flow rate of the

aqueous solution flows concentrated NaOH solution
into the mixer at a rate of is 1000 kg/hr, with a mass
9,000 kg/hr and contains fraction of 0.5 of NaOH and
a mass fraction of 0.05 of the rest is water
NaOH.

How many components

do we have?
Steady state or transient?
Batch or continuous? There are two components:
H2O and NaOH
Steady state and continuous

Determine the composition and flow

rate of the product
30
 Example Problem: Mixer
How many known
3. Write down the known
variables do we have?
and label unknown
stream variables
very dilute NaOH aqueous
solution flows into the mixer
flow rate of the concentrated
at a rate of 9,000 kg/hr and
NaOH solution is 1000 kg/hr,
contains a mass fraction of
with a mass fraction of 0.5 of
0.05 of NaOH.
NaOH and the rest is water

Determine the composition and flow

Are all the known variables
rate of the product
shown? 31
 Problem Solving Approach for Mass Balance Problems

4. Determine what additional data, if any, are needed. Find them.

Be sure to indicate the source and applicability of anything you
bring from outside.

5. Choose a calculation basis. For this problem we can choose 1

hour of operation as our basis
More on basis later

6. Determine the number of unknowns variables.

32
 Example Problem: Mixer

How many unknown

variables do we have?

There are three: Product

flow rate, xNaOH and xH2O

How many independent mass xNaOH

balance equations do we have? xH2O
33
 Problem Solving Approach for Mass Balance Problems

7. Determine the number of independent equations and perform a

degrees of freedom analysis. Can the problem be solved as is, or is
more information needed?

8. Write the required equations: Material Balances Equations,

Specifications, Physical Properties, etc.

34
 Example Problem: Mixer
How many independent mass
balance equations do we have? Do we have another
independent equation?
There are two: one for each
component or one overall Yes, the sum of the mass
plus one component fractions for the product
stream: xNaOH + xH2O =1

xNaOH
xH2O
35
 Example Problem: Mixer
What are the degrees
of freedom (ND)?
Since the number of
unknown variables and the
number of equations are
equal; Therefore, ND=0

P
Equations:
Overall MB: P = 1000+9000
xNaOH
NaOH MB: 0.05*9000 +0.5*1000 =xNaOH *P
xH2O
Mass Fraction ∑: xNaOH + xH2O =1 36
 Problem Solving Approach for Mass Balance Problems

9. Solve the equations for the unknowns. Use a solution strategy.

Solve the equations in a planned order. Often, this allows
sequential rather than simultaneous solution.

37
 Example Problem: Mixer

Equations:
From Overall MB: P = 10,000
From NaOH MB: xNaOH = 0.095
From Mass Fraction ∑ : xH2O =0.905 38
Problem Solving Approach for Mass Balance Problems

10. Check the solution. Does it make sense?

39
 Example Problem: Mixer

Use the “redundant” component mass

balance equation (i.e. for water) to check:
0.95*9000 + 0.5*1000 = 0.905*10,000 40
 Example Problem: Mixer

Can we perform a mole

balance?
Will the number of moles
going in equal the number of
moles going out?
Is this assumption always
valid?

Mole Basis
F1 F2 P
NaoH 11.25 12.50 23.75
H2O 475.00 27.78 502.78
486.25 40.28 526.53 41
 Process Units (No Reaction)
There are several unit operations that are used in chemical engineering processes. The
focus is on typical operations involving the transfer of mass through physical/
mechanical routes (mixing, evaporation, humidification, drying, distillation, absorption
(stripping), etc.)

Mixer (Blender)
The mixing process has the following
characteristics: There are two or
more entering streams, and only one
exit stream resulting from the
blending of the incoming streams.
The streams can be in any phase,
that is, gas, liquid, or solid.

42
 Process Units (No Reaction)
Distillation Column
Distillation is a method of separating chemical substances based on differences in their
volatilities. In the distillation column, more volatile components are in the distillate, while less
volatile components are in the bottoms. Separation is accomplished by boiling. Perfect
separation is not possible

43
 Process Units (No Reaction)
Dryer (Direct Heating)
Drying is a mass transfer process resulting
in the removal of moisture by evaporation
from a solid, semisolid, or liquid to
produce a solid state. To achieve this
operation, the dryer is supplied with a
source of heat. Vapor is produced in the
process.

Filter
Filtration is a technique used either to
remove impurities from a liquid or to
isolate a solid from a fluid. Filtration is
commonly a mechanical or a physical
operation that is used for the separation
of solids from fluids (liquids or gases) by
interposing a medium through which only
the fluid can pass.

44
 Process Units (No Reaction)
Evaporator
The process of evaporation is used in the
different branches of the industry for food or
chemicals processes or in desalination, in which
an increase in the concentration of the solutions
is required or in the case of desalination where
pure vapour is required.

Absorber (Stripper)
In gas absorption, a soluble component is
absorbed by contact with a liquid phase
in which the component is soluble. An
absorber is often called a scrubber . This
system is used for absorbing impurities
from a gas stream of certain components
such as hydrogen sulfide, carbon dioxide,
and ammonia, using a suitable solvent.

45
 Process Units (No Reaction)
Dehumidification
A dehumidifier s a device that reduces the
level of humidity in air or a gas stream. It has
the following characteristics: Feed stream
contains a condensable component and a
noncondensable component, and the
condensate is a liquid with the condensable
component only, such as water in air

Humidification
A humidifier is a device that increases the
amount of moisture in indoor air or a
stream of air. It operates by allowing
water to evaporate from a pan or a
wetted surface, or by circulating air
through an air-washer compartment that
contains moisture. Humidifier processes
have the following characteristics: Feed
gas is not saturated, liquid is evaporated
in the process unit, and exit product may
46
or may not be saturated
 Process Units (No Reaction)
Flash Separator
Flash separator splits a liquid feed into
vapor- and liquid-phase products.
Vaporization is caused by reducing the
pressure or by heating. Vapor and liquid
streams are in equilibrium

Divider (Splitter)
A splitter is used to divide the flow rate in
a certain stream into two or more
streams with different flow rates. The
composition of streams F1, F2, and F3 is
the same since no operation is taking
place between inlet and exit streams.

47
 Example Problem: Distillation (Example 1)
A mixture containing 10% ethanol and 90% water by weight is fed continuously into a
distillation column at a rate of 1000 kg/hr. The distillation column produces a “top”
stream known as distillate and a “bottom” stream known as condensate. The distillate
contains 60% ethanol by weight and is produced at a rate one tenth of the feed. Draw
and label a block diagram (flowsheet) of the process. Determine the degrees of
freedom. Calculate all unknown stream flow rates and compositions.
Top product

Steady state or transient?

Batch or continuous?
Steady state and continuous
Feed
How many components, Nc, do we have?
There are 2 components: water and ethanol

How many streams, Ns, do we have?

There are 3 streams: Feed, Top and Bottom

Bottom Product 48
 Example Problem: Distillation (Example 1)
A mixture containing 10% ethanol and 90% water by weight is fed continuously into a
distillation column at a rate of 1000 kg/hr. The distillation column produces a “top”
stream known as distillate and a “bottom” stream known as condensate. The distillate
contains 60% ethanol by weight and is produced at a rate one tenth of the feed. Draw
and label a block diagram (flowsheet) of the process. Determine the degrees of
freedom. Calculate all unknown stream flow rates and compositions.
Top: 𝑻 kg/hr
(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑻
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑻

How many variables do we have?

Feed: 𝑭 kg/hr
(Nc+1)*Ns = (2+1)*3 = Nine
(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑭
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑭
How many of these variables are
known/given/calculated immediately?

Bottom: 𝑩 kg/hr
(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑩
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑩 49
 Example Problem: Distillation (Example 1)
A mixture containing 10% ethanol and 90% water by weight is fed continuously into a
distillation column at a rate of 1000 kg/hr. The distillation column produces a “top”
stream known as distillate and a “bottom” stream known as condensate. The distillate
contains 60% ethanol by weight and is produced at a rate one tenth of the feed. Draw
and label a block diagram (flowsheet) of the process. Determine the degrees of
freedom. Calculate all unknown stream flow rates and compositions.
Top: 𝑻 kg/hr
(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑻 = 𝟎. 𝟔
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑻 = 𝟎. 𝟒

4 are given, one can be calculated

𝑭 = 1000 kg/hr immediately; i.e. five (5)
(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑭 = 𝟎. 𝟏 Let us take 𝑭, i.e. 1000 kg/hr as our basis
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑭 = 𝟎. 𝟗
How many unknown variables?

Bottom: 𝑩 kg/hr
(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑩
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑩 50
 Example Problem: Distillation (Example 1)
A mixture containing 10% ethanol and 90% water by weight is fed continuously into a
distillation column at a rate of 1000 kg/hr. The distillation column produces a “top”
stream known as distillate and a “bottom” stream known as condensate. The distillate
contains 60% ethanol by weight and is produced at a rate one tenth of the feed. Draw
and label a block diagram (flowsheet) of the process. Determine the degrees of
freedom. Calculate all unknown stream flow rates and compositions.
Top: 𝑻 kg/hr
(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑻 = 𝟎. 𝟔
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑻 = 𝟎. 𝟒

There are 4 unknown variables

𝑭 = 1000 kg/hr How many independent mass balance

(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑭 = 𝟎. 𝟏 equations are there?
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑭 = 𝟎. 𝟗

Bottom: 𝑩 kg/hr
(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑩
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑩 51
 Example Problem: Distillation (Example 1)
A mixture containing 10% ethanol and 90% water by weight is fed continuously into a
distillation column at a rate of 1000 kg/hr. The distillation column produces a “top”
stream known as distillate and a “bottom” stream known as condensate. The distillate
contains 60% ethanol by weight and is produced at a rate one tenth of the feed. Draw
and label a block diagram (flowsheet) of the process. Determine the degrees of
freedom. Calculate all unknown stream flow rates and compositions.
Top: 𝑻 kg/hr
(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑻 = 𝟎. 𝟔
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑻 = 𝟎. 𝟒
There are 2 independent mass balance
equations
𝑭 = 1000 kg/hr
Are there any additional equations/
(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑭 = 𝟎. 𝟏
specifications?
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑭 = 𝟎. 𝟗

Bottom: 𝑩 kg/hr
(𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑩
(𝒙𝑾𝒂𝒕𝒆𝒓 )𝑩 52
 Example Problem: Distillation (Example 1)
A mixture containing 10% ethanol and 90% water by weight is fed continuously into a
distillation column at a rate of 1000 kg/hr. The distillation column produces a “top”
stream known as distillate and a “bottom” stream known as condensate. The distillate
contains 60% ethanol by weight and is produced at a rate one tenth of the feed. Draw
and label a block diagram (flowsheet) of the process. Determine the degrees of
freedom. Calculate all unknown stream flow rates and compositions.

Number of unknowns = 4 (𝑻, 𝑩, (𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑩 , (𝒙𝑾𝒂𝒕𝒆𝒓 )𝑩 )

Number of Equations = 4:
2 independent balances (one overall and a single component or two component)
1 specification/equation: 𝑻 = (1/10)* 𝑭
1 fraction summation for the bottoms; i.e. 𝒙𝑩 = 𝟏. 𝟎 ; (𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑩 + (𝒙𝑾𝒂𝒕𝒆𝒓 )𝑩 = 𝟏. 𝟎

Therefore the degrees of freedom = 0

53
 Example Problem: Distillation (Example 1)
A mixture containing 10% ethanol and 90% water by weight is fed continuously into a
distillation column at a rate of 1000 kg/hr. The distillation column produces a “top”
stream known as distillate and a “bottom” stream known as condensate. The distillate
contains 60% ethanol by weight and is produced at a rate one tenth of the feed. Draw
and label a block diagram (flowsheet) of the process. Determine the degrees of
freedom. Calculate all unknown stream flow rates and compositions.

Overall Mass balance: 𝑭= 𝑻+𝑩 ; 1000 = 𝑻 + 𝑩 (1)

Component Balance (ethanol): 0.1*1000 = 𝟎. 𝟔 ∗ 𝑻 + (𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑩 ∗ 𝑩 (2)
1 specification/equation: 𝑻 = (1/10)* 𝑭 ; 𝑻 = (1/10)*1000 (3)
1 fraction summation: (𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑩 + (𝒙𝑾𝒂𝒕𝒆𝒓 )𝑩 = 𝟏. 𝟎 (4)

From (3) 𝑻 =100

From (1) 𝑩 = 900
from (2) (𝒙𝑬𝒕𝒉𝒂𝒏𝒐𝒍 )𝑩 = 0.044
From (4) (𝒙𝑾𝒂𝒕𝒆𝒓 )𝑩 = 𝟎. 𝟗𝟓𝟔

54
 Example Problem: Distillation (Example 1)
A mixture containing 10% ethanol and 90% water by weight is fed continuously into a
distillation column at a rate of 1000 kg/hr. The distillation column produces a “top”
stream known as distillate and a “bottom” stream known as condensate. The distillate
contains 60% ethanol by weight and is produced at a rate one tenth of the feed. Draw
and label a block diagram (flowsheet) of the process. Determine the degrees of
freedom. Calculate all unknown stream flow rates and compositions.

Check your answer: use the water balance

0.9*1000 = 0.4*100 +0.956*900

55
 Some points to remember

All material balance calculations are variations on a single theme:

Given values of some input and output stream variables (e.g. flowrates,
compositions), derive and solve equations for the others

Number of variables (total known and unknown) = (Nc+1)*Ns

The maximum number of independent mass balance equations that can be derived
by writing balances on a nonreactive system equals the number of chemical
species (components) in the input and output streams

Write balances first that involve the fewest number of unknown variables

56
 Some points to remember

Basis of calculation – is an amount or flow rate of one of the process streams on a mass
or mole basis

If a stream amount or flow rate is given in the problem statement, use this as
the basis of calculation (usually)

If no stream amounts or flow rates are known, you can assume one, preferably
a stream of known composition
– if mass fractions are known, choose a total mass or mass flow rate of
that stream (e.g., 100 kg or 100 kg/h) as a basis
– if mole fractions are known, choose a total number of moles or a
molar flow rate

57
 Some points to remember

Sources of Equations

Sources of equations that relate unknown process variables include:

1. Material balances – for a nonreactive process, usually but not always, the
maximum number of independent equations that can be written equals the
number of chemical species in the process

2. Process constraints/specifications– given in the problem statement

3. Physical constraints – e.g., mass or mole fractions must add to 1 (usually

taken care of when setting up the flow diagram)

58
 Example Problem: Distillation (Example 2)
The feed to a distillation column contains 36% benzene by weight, the remainder
being Toluene. The overhead distillate (top) is to contain 52% benzene by weight while
the bottom stream is to contain 5% benzene by weight. Calculate the percentage of
the benzene feed that is contained in the top distillate, the percentage of the total
feed that leaves as top distillate and the flow rate of the bottom distillate.

Top product

Steady state or transient?

Batch or continuous?
Steady state and continuous
Feed
How many components, Nc, do we have?
There are 2 components: benzene and toluene

How many streams, Ns, do we have?

There are 3 streams: Feed, Top and Bottom

Bottom Product 59
 Example Problem: Distillation (Example 2)
The feed to a distillation column contains 36% benzene by weight, the remainder
being Toluene. The overhead distillate (top) is to contain 52% benzene by weight while
the bottom stream is to contain 5% benzene by weight. Calculate the percentage of
the benzene feed that is contained in the top distillate, the percentage of the total
feed that leaves as top distillate and the flow rate of the bottom distillate.

Top: 𝑻 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑻
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑻

How many variables do we have?

Feed: 𝑭 kg/hr
(Nc+1)*Ns = (2+1)*3 = Nine
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑭
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑭
How many of these variables are
known/given/calculated immediately?

Bottom: 𝑩 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑩
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑩 60
 Example Problem: Distillation (Example 2)
The feed to a distillation column contains 36% benzene by weight, the remainder
being Toluene. The overhead distillate (top) is to contain 52% benzene by weight while
the bottom stream is to contain 5% benzene by weight. Calculate the percentage of
the benzene feed that is contained in the top distillate, the percentage of the total
feed that leaves as top distillate and the flow rate of the bottom distillate.

Top: 𝑻 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑻
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑻

3 are given, 3 can be calculated

Feed: 𝑭 kg/hr immediately; i.e. six (6) are known
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑭
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑭 How many unknown variables?

Bottom: 𝑩 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑩
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑩 61
 Example Problem: Distillation (Example 2)
The feed to a distillation column contains 36% benzene by weight, the remainder
being Toluene. The overhead distillate (top) is to contain 52% benzene by weight while
the bottom stream is to contain 5% benzene by weight. Calculate the percentage of
the benzene feed that is contained in the top distillate, the percentage of the total
feed that leaves as top distillate and the flow rate of the bottom distillate.

Top: 𝑻 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑻 =0.52
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑻 =0.48

There are 3 unknown variables

Feed: 𝑭 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑭 =0.36 How many independent mass balance
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑭 =0.64 equations are there?

Bottom: 𝑩 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑩 =0.05
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑩 =0.95 62
 Example Problem: Distillation (Example 2)
The feed to a distillation column contains 36% benzene by weight, the remainder
being Toluene. The overhead distillate (top) is to contain 52% benzene by weight while
the bottom stream is to contain 5% benzene by weight. Calculate the percentage of
the benzene feed that is contained in the top distillate, the percentage of the total
feed that leaves as top distillate and the flow rate of the bottom distillate.

Top: 𝑻 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑻 =0.52
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑻 =0.48

There are 2 independent mass balance

equations
Feed: 𝑭 kg/hr
Are there any additional equations/
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑭 =0.36
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑭 =0.64 specifications?
No there are none

Bottom: 𝑩 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑩 =0.05
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑩 =0.95 63
 Example Problem: Distillation (Example 2)
The feed to a distillation column contains 36% benzene by weight, the remainder
being Toluene. The overhead distillate (top) is to contain 52% benzene by weight while
the bottom stream is to contain 5% benzene by weight. Calculate the percentage of
the benzene feed that is contained in the top distillate, the percentage of the total
feed that leaves as top distillate and the flow rate of the bottom distillate.

Top: 𝑻 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑻 =0.52
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑻 =0.48

Based on the above, the degrees of

freedom ND will be equal to: ?
Feed: 𝑭 kg/hr ND = NU - NE = 3 – 2 = 1,
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑭 =0.36 i.e. underspecified
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑭 =0.64
Is there anything else we have not
considered ?

Bottom: 𝑩 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑩 =0.05
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑩 =0.95 64
 Example Problem: Distillation (Example 2)
The feed to a distillation column contains 36% benzene by weight, the remainder
being Toluene. The overhead distillate (top) is to contain 52% benzene by weight while
the bottom stream is to contain 5% benzene by weight. Calculate the percentage of
the benzene feed that is contained in the top distillate, the percentage of the total
feed that leaves as top distillate and the flow rate of the bottom distillate.

Top: 𝑻 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑻 =0.52
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑻 =0.48

Yes: A Basis
What shall we choose?
Feed: 𝑭 kg/hr Assume 𝑭= 100 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑭 =0.36 Overall 100 = 𝑻 + 𝑩
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑭 =0.64 Benzene 0.36*100=0.52* 𝑻 +0.05* 𝑩

Bottom: 𝑩 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑩 =0.05
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑩 =0.95 65
 Example Problem: Distillation (Example 2)
The feed to a distillation column contains 36% benzene by weight, the remainder
being Toluene. The overhead distillate (top) is to contain 52% benzene by weight while
the bottom stream is to contain 5% benzene by weight. Calculate the percentage of
the benzene feed that is contained in the top distillate, the percentage of the total
feed that leaves as top distillate and the flow rate of the bottom distillate.

Top: 𝑻 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑻 =0.52
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑻 =0.48

𝑻 = 66 kg/hr ; 𝑩 = 34 kg/hr
% Benzene in top distillate= 95.3%
Feed: 𝑭 kg/hr
% 𝑻/𝑭 = 66%
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑭 =0.36
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑭 =0.64

Bottom: 𝑩 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑩 =0.05
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑩 =0.95 66
 Example Problem: Distillation (Example 2)
The feed to a distillation column contains 36% benzene by weight, the remainder
being Toluene. The overhead distillate (top) is to contain 52% benzene by weight while
the bottom stream is to contain 5% benzene by weight. Calculate the percentage of
the benzene feed that is contained in the top distillate, the percentage of the total
feed that leaves as top distillate and the flow rate of the bottom distillate.

Top: 𝑻 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑻 =0.52
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑻 =0.48

What if we choose a different value

for the basis; i.e. 𝑭= 200 kg/hr
Feed: 𝑭 kg/hr
Try it
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑭 =0.36
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑭 =0.64 𝑻 = 131.9 kg/hr ; 𝑩 = 68.1 kg/hr
% Benzene in top distillate= 95.3%
% 𝑻/𝑭 = 66%
Bottom: 𝑩 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑩 =0.05
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑩 =0.95 67
 Example Problem: Distillation (Example 2)
The feed to a distillation column contains 36% benzene by weight, the remainder
being Toluene. The overhead distillate (top) is to contain 52% benzene by weight while
the bottom stream is to contain 5% benzene by weight. Calculate the percentage of
the benzene feed that is contained in the top distillate, the percentage of the total
feed that leaves as top distillate and the flow rate of the bottom distillate.

Top: 𝑻 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑻 =0.52
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑻 =0.48

What if we choose a different basis;

say bottoms flow; i.e. 𝑩= 100 kg/hr
Feed: 𝑭 kg/hr
Try it
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑭 =0.36
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑭 =0.64 𝑻 = 193.8 kg/hr ; 𝑭 = 293.8 kg/hr
% Benzene in top distillate= 95.3%
% 𝑻/𝑭 = 66%
Bottom: 𝑩 kg/hr
(𝒙𝑩𝒆𝒏𝒛𝒆𝒏𝒆 )𝑩 =0.05
(𝒙𝑻𝒐𝒍𝒖𝒆𝒏𝒆 )𝑩 =0.95 68
 Example Problem: Distillation (Example 3)
A continuous distillation column is to be used to separate a 3‐component mixture of
acetic acid (AA), water (W) and Benzene (B), and a trial run gave the data below (mass
basis). The data for the benzene in the feed (which consists of AA, W and B) was not
taken because of an instrument malfunction. Perform a degree of freedom analysis,
and, if possible, calculate the benzene flow in the feed in kg/h.
𝑾 kg/hr How many components?
How many unknown variables?
How many independent mass
balance equation?
𝑨 kg/hr

𝑩 kg/hr

69
 Example Problem: Distillation (Example 3)
A continuous distillation column is to be used to separate a 3‐component mixture of
acetic acid (AA), water (W) and Benzene (B), and a trial run gave the data below (mass
basis). The data for the benzene in the feed (which consists of AA, W and B) was not
taken because of an instrument malfunction. Perform a degree of freedom analysis,
and, if possible, calculate the benzene flow in the feed in kg/h.

How many components? 3 components: AA, W and B

How many unknown variables? 3 flow rate of top stream, flowrate of B and flow
rate of aqueous solution
How many independent mass balance equation? 3, one for each component or one
overall and 2 component balances
Therefore degrees of Freedom = 0

70
 Example Problem: Distillation (Example 3)
A continuous distillation column is to be used to separate a 3‐component mixture of
acetic acid (AA), water (W) and Benzene (B), and a trial run gave the data below (mass
basis). The data for the benzene in the feed (which consists of AA, W and B) was not
taken because of an instrument malfunction. Perform a degree of freedom analysis,
and, if possible, calculate the benzene flow in the feed in kg/h.
𝑾 kg/hr

𝑨 kg/hr
For AA: 0.8* 𝑨 = 0.109* 𝑾 +350
For W: 0.2* 𝑨 = 0.217* 𝑾
For B: 𝑩 = 0.674* 𝑾

𝑾 = 461.13 kg/hr
𝑩 kg/hr
𝑨 = 500.33 kg/hr
𝑩 = 310.80 kg/hr
Use overall balance to check: 500.33 + 310.8 = 461.13 + 350
71
 Example Problem: Distillation (Example 4)
A novice manufacturer of ethyl alcohol (ethanol) for gasohol is having a bit of a
difficulty with a distillation column. The process is shown below. It appears that
too much alcohol is lost in the bottoms (waste). Calculate the composition of the
alcohol lost in the bottoms and the mass of alcohol lost in the bottoms based on
the data shown in the figure below that was collected during 1 hour of operation.
How many components?
How many unknown variables?
How many independent mass balance equation?

72
 Example Problem: Distillation (Example 4)
A novice manufacturer of ethyl alcohol (ethanol) for gasohol is having a bit of a
difficulty with a distillation column. The process is shown below. It appears that
too much alcohol is lost in the bottoms (waste). Calculate the composition of the
alcohol lost in the bottoms and the mass of alcohol lost in the bottoms based on
the data shown in the figure below that was collected during 1 hour of operation.
There are 2 components, 4 unknown variables and Are there any additional equations/
2 independent mass balance equation specifications?

Yes, there are two

73
 Example Problem: Distillation (Example 4)
A novice manufacturer of ethyl alcohol (ethanol) for gasohol is having a bit of a
difficulty with a distillation column. The process is shown below. It appears that
too much alcohol is lost in the bottoms (waste). Calculate the composition of the
alcohol lost in the bottoms and the mass of alcohol lost in the bottoms based on
the data shown in the figure below that was collected during 1 hour of operation.

This is almost identical to the

first example we did earlier. IN
fact the answers are exactly the
same! The answers are also in
the book.

74
 Example Problem: Condenser
A stream of humid air enters a condenser in which 95% of the water vapour in the air is
condensed. The flow rate of the condensate (the liquid leaving the condenser) is measured and
found to be 225 L/h. Dry air may be taken to contain 21% oxygen, with the balance nitrogen.
Sketch the process on a simple block diagram (flow sheet).
How many variables are there? List them on the sketch.
What are the known (specified) variables, equations, relationships given?
What are the degrees of freedom? Can you determine whether the problem is underspecified,
over specified or exactly specified?
If the problem is exactly specified, calculate the values for all the unknown variables.

75
 Example Problem: Condenser (Continued)

𝒏𝟏 𝒏𝟑

(𝒙𝑵𝟐 )𝒏𝟏 (𝒙𝑵𝟐 )𝒏𝟑

(𝒙𝑶𝟐 )𝒏𝟏 (𝒙𝑶𝟐 )𝒏𝟑
(𝒙𝑯𝟐 𝑶 )𝒏𝟏 (𝒙𝑯𝟐 𝑶 )𝒏𝟑

𝒏𝟐 (𝑥𝑁2 )𝑛2 = 0
(𝑥𝑂2 )𝑛2 = 0
(𝑥𝐻2 𝑂 )𝑛2 = 1.0

A stream of humid air enters a condenser in which 95% of the water vapour in the air is
condensed. The flow rate of the condensate (the liquid leaving the condenser) is measured and
found to be 225 L/h. Dry air may be taken to contain 21% oxygen, with the balance nitrogen.
Sketch the process on a simple block diagram (flow sheet).
How many variables are there? List them on the sketch.
What are the known (specified) variables, equations, relationships given?

76
 Example Problem: Condenser (Continued)

𝒏𝟏 𝒏𝟑

(𝒙𝑵𝟐 )𝒏𝟏 (𝒙𝑵𝟐 )𝒏𝟑

(𝒙𝑶𝟐 )𝒏𝟏 (𝒙𝑶𝟐 )𝒏𝟑
(𝒙𝑯𝟐 𝑶 )𝒏𝟏 (𝒙𝑯𝟐 𝑶 )𝒏𝟑

𝒏𝟐 (𝑥𝑁2 )𝑛2 = 0
(𝑥𝑂2 )𝑛2 = 0
(𝑥𝐻2 𝑂 )𝑛2 = 1.0
There are 9 unknown variables: (shown in red above)
6 mole fractions: 3 (N2, O2 and H2O) in feed and 3 (N2, O2 and H2O) in dry air product
3 molar flow rates, 𝑛1 , 𝑛2 , 𝑛3

There are 3 independent material/mass balance equations: 1 each of N2, O2 and H2O
There are 2 mole fraction summations (1 for 𝑛1 and 1 for 𝑛3 )
There are 3 other relationships/specifications that are given :
The relationship between the volumetric and molar flow rate of the condensate (density)
95% of the water in the feed is condensed
The amount of oxygen in dry air
This gives a total of 8 equations/relations/specifications.
77
The degrees of freedom are equal to one. The problem is therefore underspecified.
 Example Problem: Condenser (Continued)
Suppose now that we had been given an additional piece of information-for example, that the
entering air contains 10.0 mole % water. This leads to 9 equations/relations/specifications.
Therefore, the degrees of freedom will now be equal to zero and the problem can be solved.

From this piece of information, and the specification that dry air contains 21% (by mole) oxygen
we can determine the mole fractions in the feed stream:
(𝑥𝐻2 𝑂 )𝑛1 = 0.1 , (𝑥𝑂2 )𝑛1 = 0.9 ∗ 0.21 = 0.189, (𝑥𝑁2 )𝑛1 = 1 − 0.189 + 0.1 = 0.711

In view of the above, we are now left with 6 unknown variables:

3 mole fractions: ((𝑥𝑁 )𝑛 , (𝑥𝑂 )𝑛 , (𝑥𝐻 𝑂 )𝑛 ) for product stream 𝑛3 and 3 molar flow rates, 𝑛1 , 𝑛2 , 𝑛3
2 3 2 3 2 3

And 6 equations/relations/specifications:
3 independent material mass balances 1 each of N2, O2 and H2O (or 1 overall and 2 component)
1 mole fraction summation (for n3)
2 relationship/specifications: (a) the volumetric and molar flow rate of the condensate (density)
and (b) 95% of the water in the feed is condensed
Therefore the degrees of freedom are now equal to zero and the equations/specifications/
relations can be derived and used to solve the problem.

78
 Example Problem: Condenser (Continued)
95% of the water vapour
𝒏𝟏 in the air is condensed.
𝒏𝟑 The flow rate of the
(𝒙𝑵𝟐 )𝒏𝟑 condensate (the liquid
(𝒙𝑵𝟐 )𝒏𝟏
(𝒙𝑶𝟐 )𝒏𝟏 (𝒙𝑶𝟐 )𝒏𝟑 leaving the condenser) is
(𝒙𝑯𝟐 𝑶 )𝒏𝟏 (𝒙𝑯𝟐 𝑶 )𝒏𝟑 found to be 225 L/h. Dry
air may be taken to
𝒏𝟐 (𝑥𝑁2 )𝑛2 = 0 contain 21% oxygen, with
(𝑥𝑂2 )𝑛2 = 0
(𝑥𝐻2 𝑂 )𝑛2 = 1.0
the balance nitrogen.
the entering air contains
Mass balance equations/relations/specifications: 10.0 mole % water
Relations/specifications (2 No.)
𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 (𝑉)×𝑑𝑒𝑛𝑠𝑖𝑡𝑦 (𝜌)
Volumetric and molar flow rate: 𝑚𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 (𝑛 ) = 𝑚𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑤𝑒𝑖𝑔ℎ𝑡
(1)
Water specification: 𝑛2 = 0.95 × 0.1 × 𝑛1 (2)

Mass balance (3 No.)

Overall mass balance: 𝑛1 = 𝑛2 + 𝑛3 (3)
N2 mass balance: (𝑥𝑁2 )𝑛1 × 𝑛1 = (𝑥𝑁2 )𝑛3 × 𝑛3 (4)
O2 mass balance: (𝑥𝑂2 )𝑛1 × 𝑛1 = (𝑥𝑂2 )𝑛3 × 𝑛3 (5)

Mole Fraction summation (1 No.)

(𝑥𝑁2 )𝑛3 + (𝑥𝑂2 )𝑛3 + (𝑥𝐻2𝑂 )𝑛3 = 1.0 (6) 79
 Example Problem: Condenser (Continued)

𝒏𝟏 𝒏𝟑

(𝒙𝑵𝟐 )𝒏𝟏 (𝒙𝑵𝟐 )𝒏𝟑

(𝒙𝑶𝟐 )𝒏𝟏 (𝒙𝑶𝟐 )𝒏𝟑
(𝒙𝑯𝟐 𝑶 )𝒏𝟏 (𝒙𝑯𝟐 𝑶 )𝒏𝟑

𝒏𝟐 (𝑥𝑁2 )𝑛2 = 0
(𝑥𝑂2 )𝑛2 = 0
(𝑥𝐻2 𝑂 )𝑛2 = 1.0

Solutions
225 𝐿 1.0 𝑘𝑔 1 𝑚𝑜𝑙
From (1) 𝑛2 = = 12,500 𝑚𝑜𝑙/ℎ𝑟
ℎ𝑟 𝐿 18×10−3 𝑘𝑔

From (2) 𝑛1 = 131,579 𝑚𝑜𝑙/ℎ𝑟 From (3) 𝑛3 = 119,079 𝑚𝑜𝑙/ℎ𝑟

From (4) (𝑥𝑁2 )𝑛3 = 0.786 From (5) (𝑥𝑂2 )𝑛3 = 0.209 From (6) (𝑥𝐻2𝑂 )𝑛3 = 0.005

Check
Use the last “dependent” mass balance equation to check the result
H2O balance (𝑥𝐻2 𝑂 )𝑛1 × 𝑛1 = (𝑥𝐻2 𝑂 )𝑛3 × 𝑛3 + 𝑛2
13,158 = 13,095
80
 Example Problem: Drying
Fish caught by human beings can be turned into fish meal and the fish meal can be
used as feed to produce meat for human beings or used directly as food. Fish protein
concentrate, primarily for aesthetic reasons, is used as a supplementary protein food.
As such it competes with soy and other oilseed proteins.
In processing of the fish, after the oil is extracted, the fish cake is dried in rotary drum
dryers, finely ground, and packed. The resulting standard product contains 65%
protein. In a given batch of fish cake that contains 80% water (the remainder is bone
dry cake, BDC), 100 kg of water is removed in an hour, and it is found that the fish cake
is then 40% water. Calculate the weight of the fish cake originally put in the dryer.

81
 Example Problem: Drying
Fish caught by human beings can be turned into fish meal and the fish meal can be
used as feed to produce meat for human beings or used directly as food. Fish protein
concentrate, primarily for aesthetic reasons, is used as a supplementary protein food.
As such it competes with soy and other oilseed proteins.
In processing of the fish, after the oil is extracted, the fish cake is dried in rotary drum
dryers, finely ground, and packed. The resulting standard product contains 65%
protein. In a given batch of fish cake that contains 80% water (the remainder is bone
dry cake, BDC), 100 kg of water is removed in an hour, and it is found that the fish cake
is then 40% water. Calculate the weight of the fish cake originally put in the dryer.

Not relevant

How many components?

How many unknown variables?
How many independent mass
balance equation?

82
 Example Problem: Drying
Fish caught by human beings can be turned into fish meal and the fish meal can be
used as feed to produce meat for human beings or used directly as food. Fish protein
concentrate, primarily for aesthetic reasons, is used as a supplementary protein food.
As such it competes with soy and other oilseed proteins.
In processing of the fish, after the oil is extracted, the fish cake is dried in rotary drum
dryers, finely ground, and packed. The resulting standard product contains 65%
protein. In a given batch of fish cake that contains 80% water (the remainder is dry
cake), 100 kg of water is removed in an hour, and it is found that the fish cake is then
40% water. Calculate the weight of the fish cake originally put in the dryer.

A tie component enters the

process in only one stream and
leaves the process unchanged
in only one stream.

83
 Example Problem: Drying
Total Balance: A = 100 + B

BDC Balance: 0.2A = 0.6B

Therefore A = 150 kg and B = 50

Check via water Balance: 0.8A=100+ 0.4B 120 = 100+20

84
 Example Problem: Membranes
A seawater stream with a flow rate of 100 kg/hr is continuously fed into a reverse
osmosis unit to produce potable product water and brine (a reject stream). The inlet
stream contains 3.5% salt by weight, the measured percentage recovery (defined as
product water/feed seawater) from the reverse osmosis unit is 55% and the
membranes in the unit remove 99.9% of the salt from the inlet stream. Determine the
flows of the product and reject streams and the % salt content in the these two
streams.
Osmosis

Initially At equilibrium 85
 Example Problem: Membranes
A seawater stream with a flow rate of 100 kg/hr is continuously fed into a reverse
osmosis unit to produce potable product water and brine (a reject stream). The inlet
stream contains 3.5% salt by weight, the measured percentage recovery (defined as
product water/feed seawater) from the reverse osmosis unit is 55% and the
membranes in the unit remove 99.9% of the salt from the inlet stream. Determine the
flows of the product and reject streams and the % salt content in the these two
streams.
Reverse Osmosis

86
 Example Problem: Membranes
A seawater stream with a flow rate of 100 kg/hr is continuously fed into a reverse
osmosis unit to produce potable product water and brine (a reject stream). The inlet
stream contains 3.5% salt by weight, the measured percentage recovery (defined as
product water/feed seawater) from the reverse osmosis unit is 55% and the
membranes in the unit remove 99.9% of the salt from the inlet stream. Determine the
flows of the product and reject streams and the % salt content in the these two
streams.

Seawater: 𝑭 kg/hr Potable Water: 𝑷 kg/hr

(𝒙𝒘𝒂𝒕𝒆𝒓 )𝑭 (𝒙𝒘𝒂𝒕𝒆𝒓 )𝑷
(𝒙𝒔𝒂𝒍𝒕 )𝑭 (𝒙𝒔𝒂𝒍𝒕 )𝑷

How many components?

How many unknown variables?
How many independent mass balance
equation? Brine: 𝑩 kg/hr
Any other equations/specifications? (𝒙𝒘𝒂𝒕𝒆𝒓 )𝑩
What’s the basis? (𝒙𝒔𝒂𝒍𝒕 )𝑩 87
 Example Problem: Membranes
A seawater stream with a flow rate of 100 kg/hr is continuously fed into a reverse
osmosis unit to produce potable product water and brine (a reject stream). The inlet
stream contains 3.5% salt by weight, the measured percentage recovery (defined as
product water/feed seawater) from the reverse osmosis unit is 55% and the
membranes in the unit remove 99.9% of the salt from the inlet stream. Determine the
flows of the product and reject streams and the % salt content in the these two
streams.
Basis

Seawater: 𝑭 =100 kg/hr Potable Water: 𝑷 kg/hr

(𝒙𝒘𝒂𝒕𝒆𝒓 )𝑭 = 𝟎. 𝟗𝟔𝟓 (𝒙𝒘𝒂𝒕𝒆𝒓 )𝑷

(𝒙𝒔𝒂𝒍𝒕 )𝑭 = 𝟎. 𝟎𝟑𝟓 (𝒙𝒔𝒂𝒍𝒕 )𝑷

There are 2 components (salt and water)

There are 6 unknown variables
There are 2 independent mass balance
equations Brine: 𝑩 kg/hr
There are 2 mass fraction summation (𝒙𝒘𝒂𝒕𝒆𝒓 )𝑩
equations and 2 specifications (𝒙𝒔𝒂𝒍𝒕 )𝑩 88
 Example Problem: Membranes
A seawater stream with a flow rate of 100 kg/hr is continuously fed into a reverse
osmosis unit to produce potable product water and brine (a reject stream). The inlet
stream contains 3.5% salt by weight, the measured percentage recovery (defined as
product water/feed seawater) from the reverse osmosis unit is 55% and the
membranes in the unit remove 99.9% of the salt from the inlet stream. Determine the
flows of the product and reject streams and the % salt content in the these two
streams.

Product stream (permeate) flow rate = 55 kg/hr

Brine stream (reject) flow rate = 45 kg/hr

% salt content in Brine stream = 7.78%

% salt content in Product stream = 0.0064%

89