CHAPTER FOUR 4.

MATERIAL AND ENERGY BALANCE

Material and energy balances are very important in an industry. Material balances are
fundamental to the control of processing, particularly in the control of yields of the products. The
first material balances are determined in the exploratory stages of a new process, improved
during pilot plant experiments when the process is being planned and tested, checked out
when the plant is commissioned and then refined and maintained as a control instrument as
production continues.
When any changes occur in the process, the material balances need to be determined again.
4.1. Material Balance
Material Balance on Sugar Dissolving Tank (For Mirinda Orange)

1300+200Lwater

2565kg sugar
SUGER DISOLVING Impurity +ac
TANK cela
Celatom, activated 406o.36
Carbon 7.36kg

3100Lsimple syrup
Input = Output, at steady state
M Sugar + Mwater+ Mcarbon+Mcel =Mss+ Mimpu+ Mcarbon+Mcel
Where: Msugar = mass of sugar, Mcarbon =mass of activated carbon, Mss =mass of simple syrup,
Mwater =mass of water, Mimpu =mass of impurity and Mcel =mass of celatom
Hence, the amount of celatom is equal to the amount of activated carbon by mass.
 Msugar + Mwater+ 2MCarbon =Mss+ Mimpu+ 2Mcarbon , mass of carbon is canceled
Msugar + Mwater= Mss+ Mimpu
Mwater = ρV, density of water is 1000Kg/m3
= 1000Kg/m3 × 1500L*10-3 m3/L
= 1500Kg
Mss= ρssvss, let ρss=ρn=ρsolution ρn =∑ (𝑥𝑖 ρi)n ;where
xi=mass fraction of the ith component
Xi =mi/mn=Vi/Vn ; xsuger=Vsugar/Vss
Vsugar=msugar/ρsugar
= (2565Kg/1.59Kg/L) =1613.21L
Vn=Vw+Vsugar
Vn=1500L+1613.21L
Vn=3113.21L
Xsugar= (1613.21L)/ (3113.21L) =0.52
Xwater =Vw/Vss= (1500L)/ (3113.21L) =0.48
ρn =∑(𝑥𝑖 ρi)n =ρw*xw +ρsu*xsugar
= (1000Kg/m3*0.48) + (1590Kg/m3*0.52) = 1309.8Kg/m3
Msugar + Mwater= Mss+ Mimpu
2565Kg + 1500Kg = ρssvss + Mimpu
2565Kg + 1500Kg = 1309.8Kg/m3 *3.31m3 + Mimpu
Mimpu=4065Kg - 4060.38Kg =4.62Kg/Bach
Since this much impurity is removed by both filter press and strainer, but to do the
material balance on horizontal filter the impurity is differ for different sugar supply so the only
choice to do this task is measuring the amount of oversized impurity rather than mesh analysis so
I got 0.78Kg of oversized solid impurity retained on screen with different nature.
It is the separation mechanism of oversized and under sized mixture. This task is done by passing
simple syrup through 30 mesh double screen (strainer) they operates separately.
Since the oversized impurity retain and discharged but the under sized and dissolved syrup
passes the screen to the filter Dela Toffola for further filtration.
4079.72Kg Simple Syrup
Horizontal Filter
Dela Toffola

0.78Kg Solid Impurity

General material balance
Assumption steady state and it have no reaction
Mass input=mass output
Dissolved syrup =solid impurity retained on screen + under flow
4079.72Kg=0.78Kg+under flow
Munder flow =4079.72Kg - 0.78Kg
= 4078.94Kg
Filter Dela Toffola
The filter Dela Toffola assisted by filter aid mixed tank in which the filter aid diatomaceous is
mixed with water and pumped to the plate of filter to baking on it. Some sugar supplies contain
impurity that cannot be removed by simple filtration or by simple filtration with diatomaceous
earth filter aid such impurities can cause of odors, taste discrepancies and appearance defects in
syrup and beverages. In many cases such sugar can be made acceptable for our products if the
simple syrup is treated with powdered activated carbon at room temperature and then filtered to
remove the carbon. The amount of filter aid is equal to the amount of activated carbon by mass.

10.04Kg Diatomaceous Impurity + Diatomaceous +

Activated Carbon
Filter Della Toffola

4078.94Kg Syrup Pure Simple Syrup

 Mdiatom+Msyrup=Mimp+diatom+celatom+carbon+Msimple syrup Where, Mdiatom=mass of diatomaceous
10.04Kg+4078.94Kg= Mimp+ (10.04Kg+7.36Kg+7.36Kg) +4060.38Kg
Mimpurty by filtration= (4078.94Kg-7.36Kg-7.36Kg-4060.38Kg)
=3.84Kg of impurity per Bach
Material Balance on Concentrate Tank for Mirinda Orange Flavor
3.912Kg Sodium benzoate 4.08Kg NaCl (Sodium Chloride)

90.84Kg Flavor
34.38Kg Citric acid
Concentrate Tank
Anhydrous Dissolved Component

2.04Kg K2SO4
(Potassium sulphate)

Water
We can read the properties and values of each dry component in the table below.
Table 4.1.Properties and Feed Composition of Dry Component and Flavor

Compound Feed mass(Kg) Density(Kg/m3) Volume(L)

Flavor --- ---- 90.84

Citric acid 34.38 881.1 39.02

K2SO4(Potassium Sulfate) 2.04 721 2.8294

Sodium Benzoate 3.912 1500 2.608

NaCl(Sodium Chloride) 4.08 1121.4 3.63831

Water Unknown 1000 Unknown

 Ascorbic acid 0.678 1690 0.4012

Volume contribution of component to the total volume

Vflavor+VK2SO4+Vsodium benzoate+Vw+Vcitric+VNaCl=Vdissolved compt where, Vflavor =volume of
flavor,VK2SO4 =volume of potassium sulfate, Vw = volume of water, Vdc = volume of dissolving
component, V= refers to volume
Vss+Vdc=Vfinished syrup
Vdc= Vfinished syrup - Vss
=3406L-3100L=306L
Vflavor+VK2SO4+Vsodiumbenzoate+Vw+Vcitric+Vascorbic+VNaCl=Vdissolved compt
90.84L+2.8294L+2.608L+ Vw+39.02L+0.4012L+3.63831L=306L Vw=306L-
139.33645L=166.66355L
Mw=ρw*vw=166.66355L*10-3*m3/L*1000Kg/m3 =166.66355Kg
Since dissolving all the above given dry and liquid component within 167L of water to produce
306L of dissolved component in a precise order.
Material Balance on Finished Syrup Preparation (Mix Tank)

3100L Simple Syrup

0.678Kg Ascorbic acid Mix Tank Finished Syrup
305.5988L Dissolved Component

To prepare a finished syrup of 3406L we use 0.678Kg of ascorbic acid and 305.5988L of other
dry component as the mass composition given in the table above.
Vascorbic acid =m/ρ
= (0.678Kg)/ (1.69Kg/L) =0.4012L
Overall Material Balance on Mixer
Mixer unit is the central point in plant operation. Ingredients such as water, finished syrup and
carbon dioxide are combined and filled into sanitary containers, closed, and packed.
Finished Syrup (3406L)
Treated Water (5*VFS)
Mixer Carbonated Mirinda
CO2 (2.12/297.85ml of product) Orange Drink

 The ratio of finished syrup to treated water is 1:5 by volume for Mirinda orange
preparation.
 Amount of CO2 per bottle = 2.15ml.
 Amount of product per bottle =300ml
VCO2=2.15ml/bottle where, VFS=volume of finished syrup, VCO2=volume of carbon dioxide
VCO2=2.15ml from300ml of product
=2.15ml/ (300ml-2.15ml per product volume)
=2.15ml/297.85ml of product=7.2184*10-3
V fs=3406L
Vw =5*Vfs
=5*3406L=17030L
Vproduct to be carbonated=V fs + Vw =3406L+17030L =20,436L VCO2=7.2184*10-
3
*VP Where, VP=volume of product
=7.2184*10-3*20,436L =147.52L
So 147.52L of CO2 is added to carbonate 3406 L of finished syrup
Total volume of product =VTP
VTP= VCO2+ Vw+ Vfs =147.52L+17,030L+3406L =20,582.52L
So the total product produced from 3406L of finished syrup is 20,582.52L
Note that all the above calculation is for the preparation of Mirinda orange product, with same
process and unit operation we can calculate for the other product but with a little numerical value
change. The change is not on the method of calculation rather on the input and output amount
like amount of sugar added, volume of simple syrup ,brix, volume of finished syrup, amount of
dry component added, just a matter of replacing input variable.
Table 4.2. Summary of Material Balance of Specific Unit Operations
Unit Operations Inputs Outputs

Sugar Dissolving Tank Mass of sugar=2565Kg Mass of simple syrup=4060.36Kg

Mass of celatom=7.36Kg Mass of impurities=4.62Kg Mass of
Mass of A. carbon=7.36Kg A.carbon=celatom=7.36Kg
Mass of water=1500Kg

Horizontal Filter Mass of simple Mass of solid impurity=0.78Kg

syrup=4079.72Kg Mass of under flow=4078.94Kg

Filter Dela Toffola Mass of Mass of pure simple

diatomaceous=10.04Kg Mass syrup=4060.38Kg
of simple syrup=4078.94Kg Mass of impurity=3.84Kg
Mass of diatomaceous=10.04Kg
Mass of
A.carbon=celatom=7.36Kg
Mix Tank Volume of simple syrup=3100L Volume of finished syrup=3406L
Volume of ascorbic acid=0.4012L
Volume of dissolving
component=305.5988L

4.2. Energy Balance

Energy Balance on Boiler
73.8% Heat in System

12.7% dry fuel gas loss (1)

8.1% Heat loss due to hydrogen in fuel
(2)

Boiler
1.7% Heat loss due to moisture in fuel
Furnace Oil (100%) (3)
Heat loss due to unburnt residual (5)
1% radiation loss and unaccounted
Loss (6)
 0.3% Heat loss due to moisture in air (4)
Average working time of boiler plant =18 hours/day
Average daily furnace consumption =860L/18hours
Hourly furnace consumption =47.77778L/hr.
Energy content of naphtha=3482348.4MJ/L
Furnace oil is pumped to burner by 1.25KW pump.
General Energy Balance: Energy in = Energy out
E naphtha oil + E pump =E in steam +E loss
E naphtha oil=V naphtha *naphtha oil *burner efficiency
=47.7778L/h*3482348.4MJ/L*100%
=166378943.4MJ/h
166378943.4MJ/h +1.25KW= Ein steam + E loss
166378943.4MJ/3600sec +1.25KJ/sec= Ein steam + E loss
46216373.16KJ/sec +1.25KJ/sec= Ein steam + E loss
46216374.41KW= Ein steam + E loss
E in steam=73.8%*E in
=46216374.41KW*73.8% =34107684.32KW
E loss=sum of the six loss
E loss=26.2%*46216374.41KW
=12108690KW
Loss 1 =46216374.41KW*0.127=5869479.5KW
Loss 2 =46216374.41KW*0.81= 3743526.3KW
Loss 3 =46216374.41KW*0.017=785678.3KW
Loss 4 =46216374.41KW*0.003=138649.1KW
Loss 5 = 46216374.41KW*0.024=1109192.9KW
Loss 6 =46216374.41KW*0.01= 462163.74KW
Therefore, the sum these six losses gives 12108690KW.
Heat Load of Product Heat Exchanger (Chiller)

o
Product cooling is done to reduce the product temperature from ambient to 2 C. This

temperature is facilitating filling operation by reducing foam formation and increase the ability to
accept CO2 or facilitating also carbonation and it also vital role on preservation of product as cold
product has long shelf life than warm product
Working principle of product cooling is Cooling of product is done by heat exchanging
through a chiller by cooling fluid glycol. Glycol is cooled by ammonia where ammonia is
cooled by outer air cooling system. Product is better to cooled by glycol alcohol than
ammonia base to minimize contamination risk and side effect, the cooled product is then
ready to mixing.
Cooling glycol (25oC

Product Heat
Exchanger

Product) Cooled Product (2oC, 7600L/h)

Warm product

3
Density of final product=1.0455g/cm

ρ=xw*ρw+ xfsy*ρfsy

3 3 3
1.0455*10 Kg/m =xw*1000Kg/m +xfsy* ρfsy
 Xw=vw/vtotal=5/6
Xfsy=vfsy/vtot=1/6

3 3 3
1.0455*10 Kg/m =5/6*1000Kg/m +1/6* ρfsy
6273=5000+ρfsy

3
ρfsy= 1273Kg/m

Qin=Qout

Qpump+Qfsy=Qmust be removed to cool

3 3 3
Q=mflowCpfsy∆T-Qpump mflow=ρVflow=7600L/h*1273Kg/m =7.6m /h*1273Kg/m
=9674.8Kg/hr
Cpfsy=XssyCpss+XingCping
Assumption: the specific heat capacity (Cp) of small ingredients has no significant effect on
the overall heat capacity due to the small mass fraction of its component.
Cpp=XwCpw+XfsyCpfsy Cpfsy=XwCpw+XsugCpsug Xw=vw/vfsy

Vw=vdry compt. Dissolving water+Vsugar dissolving water

Vw=167L+1500L=1667L
Xw=vw/vfsy= (1667/3406) =0.4894
Xsug=Vsug/Vfsy= (1613.21L/3406L)=0.474
Cpfsy=XwCpw+XsugCpsug
=0.4894*4.2KJ/Kg.k +0.474*1.244KJ/Kg.k
=2.05548KJ/Kg.k +0.589656KJ/Kg.k
=2.645KJ/Kg.k
Cppro=XwCpw+XfsyCpfsy
Vw=17030L
Vtotal product=20582.52
Xw=17030/20582.52=0.8274
Xfsy=3406/20582.52
=0.1655
Cppro=XwCpw+XfsyCpfsy=0.824*4.2KJ/Kg.k+0.1655*2.645KJ/Kg.k
=3.461KJ/Kg.k+0.43777KJ/Kg.k
=3.89857KJ/Kg.k
Q=mflowCpfsy∆T-Qpump
 =9674.8Kg/hr*3.89857KJ/Kg.k* (25oC-2oC) -3.5KW
=240.97KJ/sec-3.5KW
=237.475KW
So the amount of energy must be removed from product to cool is 237.475KW.
Steam Requirement of Simple Syrup Preparation in Sugar Dissolving

Tank steam (80-95 oC at3bar)

Mass of mixture of
Sugar, water and Simple Syrup (80oC)
Sugar Dissolving
carbon(25oC) Tank

Condensate (60oC)
Condensate(60 oC)

Energy Balance: heat delivered by the steam = heat absorbed by the mixture

QSteam= Qabsorbed by mixture

Qabsorbed by mixture = Mmix * Cpmix*∆T
Mmix =Msuger+Mwater+Mcarbon = 2565Kg+1500Kg+7.36Kg =4072.36Kg
Cpmix =Cpn = ∑ (𝑥𝑖Cp) n
Cpn =xsugarcpsuger+xwcpw+xccpc
Xi=Vi/Vn
Xs=Vs/Vn ; Vs=ms/ρs= (2565Kg/1.59Kg/L) =1613.21L
Vn =vs+vw+vc
VC=mc /ρc=7.36Kg/881Kg m-3=8.354*10-3m3=8.354L
Vn=1613.21L+8.354L+1500L=3121.56L
XS= (1613.21L/3121.56L) =0.52
XW= (1500L/3121.56L)=0.48
XC= (8.354L/3121.56L) =0.002674
Qin= Qout,
Qsteam+ Qjet mixer= Mmix * Cpmix*∆T where Qjet mixer=4.5KW
 Cp=xsugarcpsuger+xwcpw+xccpc
=0.52*1.244KJ/Kg.k +0.48*4.2KJ/Kg.k+0.002674*1.21336KJ/Kg.k
Cpn=2.6661KJ/Kg.k
Qabsorbed by mixture = Mmix * Cpmix*∆T
Qsteam+ Qjet mixer=4072.36Kg *2.6661KJ/Kg.k*55K/30minuts
Qsteam+4.5KW=4072.36Kg *2.6661KJ/Kg.k*55K/1800sec
Qsteam=597152.54KJ/1800sec-4.5KW
=331.751KW-4.5KW=327.25KW
= 327.25KW of energy is required from steam to rise the temperature of 4072.56Kg mixture
from 25oC to 80oC.

Qsteam=Msteamcpsteam∆T=327.25KW
Msteam*4.2KJ/Kg.k* (166.89-60) k=327.25KW
Msteam= (327.25KW/448.94KJ/Kg)
=0.72894Kg/secHeat Load of Simple Syrup Cooling Heat Exchanger
 It is the amount of heat energy to be removed from hot simple syrup by the cooling
fluid (water) in order to reduce.
 The temperature from 80oC to ambient temperature (25oC) which is suitable for the
following production process. 40 minute is required to pump simple syrup to storage
tank through heat exchanger.
 The water cool the syrup and the air cool the water.

Simplesyrup (80oC),3100L/40minutes,

Cooling Water (8oC) Qout

Warm Water Simple Syrup
Qout warm water Cooling Heat
Exchanger
 Cold Syrup (25oC)

General Energy Balance: Qin =Qout

Qout=Mflowrate*Cp*∆T;
Vflow=3100L/40*60 sec
=1.291667L/sec
Mflow= Vflow*
= 1.291667*0.001/sec *1309.8Kg/m3
=1.691 Kg/sec
Cpss =Cpn = ∑ (𝑥𝑖Cp)n
Cpn =xsugarcpsuger+xwcpw
Qout warm water Xi=Vi/Vn
Xs=Vs/Vn ; Vs=ms/ρs=2565Kg/1.59Kg/L
Vs =1613.21L
Vn = vss= vs+vw Vn=Vss=3100L
Xs=Vs/Vss= (1613.21/3100) =0.52
Xw=Vw/Vss = (1500L/3100L) =0.48
Cpn =xsucpsu+xwcpw
=0.52*1.244KJ/Kg.k +0.48*4.2KJ/Kg.k
Cpn =2.679KJ/Kg/k
Qout=Mflowrate*Cpn*∆T+Qpump
Qout=1.691Kg/sec *2.679KJ/Kg.k*55k+5KW
=254.17KJ/sec=254.17KW
As it is the out flow energy from liquid syrup the direction is negative. Which implies that the
energy must be removed from simple syrup to reduce the temperature from 80oC to 25oC.
Qout = -254.17KW this means that the overall load on the heat exchanger.
Table 4.3. Summary of Energy Balance of Specific Unit Operations
Unit Operations Amount of Energy Required(KW)

237.475
 Product Heat Exchanger
Sugar Dissolving Tank 327.25

Simple Syrup Cooling Heat Exchanger 254.17