CHAPTER THREE

MATERIAL AND ENERGY BALANCE

Material and energy balance of any proposed plant is an extremely important aspect of the design
that will influence all other aspects of the project. The balance will be used to specify most of the
equipment that will be used and of course could serve as a means of troubleshooting and
controlling the process after the plant has been set up.
The material and energy balance gives account of all the material and energy inputs and
ascertains that they balance with the outputs. The balance helps to avoid wastage of materials
and energy which in general leads to better economic feasibility.

3.1 MATERIAL BALANCE

Material balances are the basis of process design. Material balance involves the balance on all
the matter involved in the process. Balance is done for each of the components involved in each
unit. Each stream is therefore expected to have sufficient information to determine the flow rate
of each of the components.
A material balance taken over the complete process will determine the quantities of raw
materials required and products produced respectively. Balances over individual process units set
the process stream flows and compositions. (Himmelblau, 2000)
Hence, the design project is aimed at designing a plant that produces 50,000 metric tonnes of
cement per year, using limestone from Ekiti state, Nigeria.
Therefore, the stoichiometric unit conversion of 50,000 metric tonnes of cement per year into
mass flow rate Kg/day. (Assuming 335 operating days, and 30 days for plant maintenance)
1 ton = 1000kg,
Therefore, 50,000ton = 50000000 Kg of cement per annum
1
50000000335
5000000
= 335

= 149253.7313
3.1.1 METHODS OF SOLUTIONS TO MATERIAL BALANCE
Material balance is done in two major ways:

1. Equation based approach

2. Sequential modular approach

The equation based approach involves writing equations for each component in each unit and
solving this simultaneously. The use of matrix algebra could be resorted to in solving the
resulting equations.
In the sequential modular approach, modules are written for each component in each unit and
each module is solved before proceeding to the next unit. This might require assuming values for
some unknown variables and carrying out iterative schemes. A proper degree of freedom
analysis has to be carried out before this method can be employed effectively well. This method
is valuable for relatively complex processes.
Due to the ease of the sequential modular method for the process being designed, this method
will be used in the solution of the material balance.

3.1.2 USES OF MATERIAL BALANCE

i. It assists in the economic evaluation of proposed and existing processes, in process

control and process optimization.

ii. It forms the basis for process design.

iii. Used in the hourly and daily making of decision of plant managers/operators.

iv. Determines raw materials and product quality.

3.1.3 ASSUMPTION FOR THE PROCESS (CEMENT PRODUCTION)

i. The process is a steady state process, i.e. no accumulation of any sort in the system.

ii. There are losses in process and they are within accepted limits.

iii. The flue gases released is a combination of COx, NOx and O2 only.

iv. Theres negligible amount of inert in the air.

v. Effects of side reaction are minimal.

vi. The losses about the crushers is 1% of the mass of raw material fed.

3.1.4 THE CONCEPT OF STOICHIOMETRY

For most processes that involve chemical reaction, stoichiometry is used to give account of the
material exchange between reactants to form product. A stoichiometry shows the ratio of
reactants to product in a chemical equation, obtained from a balanced chemical equation.

3.1.5 THE SUMMARY OF MATERIAL BALANCE OF UNITS

LIMESTONE CRUSHER BALANCE

S2

C-01
S1 S3

Fig 3.2: Limestone Crusher

 Table 3.4: Limestone Mass Flow Composition in the Crusher

Limestone Amount fed: 85%

Component Mass flow (Kg/day)
Stream 1 Stream 2 Stream 3
CaCO3 174961.29 1749.61 56713789.44
SiO2 8998.66 89.99 2916920.16
Fe2O3 683.44 6.83 221538.24
Al2O3 3796.90 37.97 1230768.00
MgCO3 569.54 5.70 184615.20
Inert 835.32 8.35 270768.96
Total 189845.1459 1898.451459 187946.6945
189845.1459

Table 3.5: limestone molar flow composition in the crusher

Component Molar flow (Kmol/day)

Stream 4 Stream 5 Stream 6

CaCO3 1748.04 17.48 26.41

SiO2 149.78 1.50 267.74

Fe2O3 4.24 0.04 20.44

Al2O3 37.24 0.37 93.75

MgCO3 6.76 0.07 3.78

Inert 0.00 0.00 0.00

Total 1946.091526 19.46091526 1926.630611

1946.091526
 CLAY CRUSHER BALANCE

S5

S4 S6
C-02

C-02S

Fig 3.3: Clay Crusher

Table 3.6: Clay Mass Flow Composition in the Crusher

Clay Amount fed: 15%

Component Mass flow (Kg/day)
Stream 4 Stream 5 Stream 6
CaCO3 2670.12 26.70 2643.41
SiO2 16248.51 162.49 16086.03
Fe2O3 3296.61 32.97 3263.64
Al2O3 9655.62 96.55 9558.75
MgCO3 321.61 3.22 318.40
Inert 1309.93 13.10 1296.83
Total 33502.08 335.02 33167.06
33502.08
 Table 3.7: Clay Molar Flow Composition in the Crusher

Component Molar flow (Kmol/day)

Stream 4 Stream 5 Stream 6

CaCO3 26.68 0.27 26.41

SiO2 270.45 2.70 267.74

Fe2O3 20.64 0.21 20.44

Al2O3 94.70 0.95 93.75

MgCO3 3.81 0.04 3.78

Inert - - -

Total 416.28 4.16 412.12

416.28

MIXER BALANCE S7

S6
M-01
S8

S3

Fig 3.3: Mixer Flow Diagram

 Table 3.8: mass flow of the components at the mixer

Component Mass flow (Kg/day)

Stream 3 Stream 6 Stream 7 Stream 8

CaCO3 173211.67 2643.41 - 175855.09

SiO2 8908.67 16086.03 - 24994.70

Fe2O3 676.61 3263.64 - 3940.25
Al2O3 3758.93 9558.75 - 13317.68
MgCO3 563.84 318.40 - 882.24
H2O - - 0.00 0.00
Inert - 1296.83 - 1296.83
Total 187119.73 33167.06 0.00 220286.79
220286.79

Table 3.9: molar flow of the components at the mixer

Component Molar flow (Kmol/day)

Stream 3 Stream 6 Stream 7 Stream 8

CaCO3 1730.56 9333.71 - 575961.64

SiO2 148.28 94623.44 - 143174.04

Fe2O3 4.24 7222.33 - 8609.54

Al2O3 36.87 33132.26 - 45203.35

MgCO3 6.69 1334.69 - 3524.40

H2O - - 0.00 0.00

Inert - - - -

Total 1926.63 412.12 0.00 2338.75

2338.75
KILN BALANCE FLUE GAS

S8 K-01 S9

Fig 3.5: Kiln Flow Diagram

Table 3.10: Mass flow of the componet in the kiln

Component Mass flow (Kg/day)

Stream 8 Stream 9 Flue gas
CaCO3 175855.09 - -
SiO2 24994.70 - -
Fe2O3 3940.25 - -
Al2O3 13317.68 - -
MgCO3 882.24 - -
C2 S - 21988.51 -
C3 S - 65834.14 -
C3 A - 28624.99 -
C4AF - 11990.00 -
CO2 - - 25497386.20
H2O - - -
MgO - 421.75 -
CaO - 12339.47 -
CaSO4 - -
Inert 1296.83 1296.83 -
Total 220286.79 142495.70 77784.77
220280.46
Table 3.11: Molar flow of the components in the kiln

Component Molar flow (Kmol/day)

Stream 8 Stream 9 Flue gas
CaCO3 1756.9696 - -
SiO2 416.0236 - -
Fe2O3 24.6728 - -
Al2O3 130.6167 - -
MgCO3 10.4643 - -
C2 S - 127.6694 -
C3 S - 288.3542 -
C3 A - 105.9439 -
C4AF - 24.6728 -
CO2 - - 1767.4339
H2O - - -
MgO - 10.4643 -
CaO - 220.0452 -
CaSO4 - -
Inert - - -
Total 2338.7471 777.1498 1767.4339
2544.5837

CEMENT MILL BALANCE

S10

S9 CM-01 S11

Fig 3.6: Cement Mill Flow Diagram

 Table 3.12: Mass flow of the components at the cement mill

Component Mass flow (Kg/day)

Stream 9 Stream 10 Stream 11
CaCO3 - - -
SiO2 - - -
Fe2O3 - - -
Al2O3 - - -
MgCO3 - - -
C2 S 21988.51 - 21988.51
C3 S 65834.14 - 65834.14
C3 A 28624.99 - 28624.99
C4AF 11990.00 - 11990.00
CO2 - - -
H2O - - -
MgO 421.75 - 421.75
CaO 12339.47 - 12339.47
CaSO4 - 2497656.07 7495.27
Inert 1296.83 - 1296.83
Total 142495.70 7495.27 149990.97
149990.97

Table 3.13: Molar flow of the components at the cement mill

Component Molar flow (Kmol/day)

Stream 9 Stream 10 Stream 11
CaCO3 0.00 - 0.00
SiO2 0.00 - 0.00
Fe2O3 0.00 - 0.00
Al2O3 0.00 - 0.00
MgCO3 0.00 - 0.00
C2 S 127.67 - 127.67
C3 S 288.35 - 288.35
C3 A 105.94 - 105.94
C4AF 24.67 - 24.67
CO2 - - -
H2O 0.00 - 0.00
MgO 10.46 - 10.46
CaO 220.05 - 220.05
CaSO4 - 40.88 40.88
Inert - - -
Total 777.15 40.88 818.03
818.03