ChE 101.

03
MASS & ENERGY BALANCES
Dr. Abdulhadi Al-Juhani
Department of Chemical Engineering,
King Fahd University of Petroleum & Minerals
3-12-07

Terminal Objective:
upon completion of this module, you will be able to
calculate:
-

mass and energy balances

energy gains and losses for process equipment
utility requirements
refrigeration requirements

using appropriate drawings, diagrams, tables,

equations, and process parameters
2

Enabling Objectives:
In order to achieve the terminal objective, you will be able to:
1.

Interpret information contained in Process Flow Diagram

(PFD) and Piping and Instrumentation Diagram (PID).

2.

Calculate mass and energy balances, using PFD information.

3.

Calculate boiler requirements and the effects of operating

and design parameters on efficiency.

4.

Calculate temperature changes due to energy gains and losses

5.

Calculate utility requirements

6.

Calculate refrigeration requirements.

Process Flow Diagram (PFD):

Figure 1:

PFD of a Depropanizers/Debutanizer system at

Ras Tanura.
(Exercise: point out examples of the 10 items listed in the text)
4

Instrumentation and Piping Diagram (PID):

The difference between PFD and PID, and the use of each

Figure 2:

Typical PID diagram

(Exercise: point out examples of the 15 items listed in the text)
6

Using mass and energy balances

Figure 3:

PFD NGL Absorption and Fractionation

(Exercise: point out examples of 6 items listed in the text)
9

10

11

Using mass and energy balances (contd)

Figure 4:

PROCESS Output (Saudi Aramco Format)

12

13

14

PFD Information

Figure 5:

PFD Atmospheric Section C.D.U.s No. 1 & 2

(Exercise: point out some missing information)
15

16

17

PID/PFD Data
B/CD = B/SD x 0.9
SpGr60 = 141.5 / (131.5 + API) ..............(1)

to convert B/D to Ib/hr:

Ib/hr = (B/D)60 x (350 Ib/B) x (SpGr60) x (D/24 hr).....(2)
convert Ib/hr to Gpm
gpm = (Ib/hr) / (SpGr) / 500..(3)
where 1 B = 42 gal
1 m3 = 264.17 gal
1 Ib = 453.6 g
density of water @ 60 oF = 8.33 Ib/gal = 350 Ib/B

18

Exercise 1
for each stream entering or leaving the attached figure, calculate the
following:
-

sp. gr. @ 60 oF
Ib/hr
Gpm @ actual conditions

then, check the overall material balance:

note: density of water @ 60 oF = 8.33 Ib/gal = 350 Ib/B

19

20

Exercise 1 (contd)
Answer:

Stream

Feed

OVHD

API

77

118.5

68.8

68.8

SpGr60
(eq 1)
B/SD

0.679

0.566

0.706

0.706

32, 110

6, 308

9, 742

16, 060

317, 956

52, 067

0.57

0.54

0.69

0.69

1116

193

291

479

Ib/hr
(eq 2)
Given
SpGr
Gpm
(eq 3)

Naphtha Lean Oil

100, 302 165, 351

21

Calculating Energy Inputs, Outputs, and Losses

Steam Boiler Energy Balances:

Why we should have a blowdown here?

22

Example Problem 1:

Calculate the amount of fuel required for the boiler in fig 6. Then,
calculate the furnace efficiency

23

Example Problem 1 (contd):

Answer:
The following enthalpy data are available:

Stream

T (oF)

P (psia)
174.7

HL
(Btu/Ib)
343.5

HV
(Btu/Ib)
1196.4

Blowdown

370

Steam

434

154.7

--

1237.6

Feedwater

190

214.7

158.0

-24

Example Problem 1 (contd):

Heat Balance: Water side/Process
Heat In:Feedwater = (910, 000 Ib/hr) (158 Btu/Ib) = 143.78 MBtu/hr
heat absorbed
=
QA
Total
= 143.78 + QA
Heat Out: Steam
=
Blowdown =
Total
Heat In
143.78 + QA

=
=

(805,000) (1,237.6) = 996.27 MBtu/hr

(105, 000) (343.5) = 36.07 MBtu/hr
= 1, 032.34 MBtu/hr

Heat Out
1, 032.34

QA = 888.56 MBtu/hr

25

Example Problem 1, Contd

The furnace efficiency can be calculated as follows:
888.56 x 106 Btu/hr (QA)
650F (Given)
20 (Given)
2% (Given)
19,400 Btu/lb (Given)
16,450 Btu/lb (Maxwell, p. 185)

Process heat required

Stack temperature
Percent excess air
Furnace heat loss
Fuel LHV
Heat available at 650F

=
=
=
=
=
=

888.56 x 106
Net Fuel =
16,450
Gross fuel = 1.02 x 54,016

= 54,016 lb/hr
= 55,096 lb/hr

Heat fired = 19,400 x 55,096

= 1,068.9 x 106 Btu/hr

LHV efficiency =

888.56 x 106
6

1, 068.9 x 10

x 100 = 83.1%

ChE 101.03 V (19)

26

Example Problem 1, Contd

Shortcut Calculation:
100
Percent efficiency = (100 (0.0237 + (0.000189)(EA))) (Tst TA )

100 + Q L

= (100 - (0.0237 + (0.000189 )))(650 80 ) [100/(100 + 2)]

= [(100 - 0.02748(570))][0.9804] = 82.7%

What if the ambient temperature was 100F instead of 80F?

Percent Efficiency = [(100 - (0.02748)(650 100 ))] [0.9804 ] = 83.2%
Increasing the ambient temperature by 20F improved the efficiency by
0.5% assuming the same stack temperature.
ChE 101.03 V (20)

27

Exercise 2
Calculate the fuel and Feedwater required for the boiler in fig 15.
How can the furnace efficiency be improved. Use 2% for heat
losses, and use 10% blowdown.
The following enthalpy data are available:

Stream

T (oF)

P (psia)
633

HL
(Btu/Ib)
478.5

HV
(Btu/Ib)
1203.1

Blowdown

492

Steam

700

600

--

1351.8

Feedwater

180

--

148.0

-28

29

Exercise 2 (contd)
Answer:
Feedwater rate
Blowdown
Steam product

=
=
=

water material balance:

F
0.1 F
250, 000
F = 250,000 + 0.1 F
F
Blowdown

= 277, 788 Ib/hr

= 27, 778 Ib/hr

30

Exercise 2 (contd)
Heat Balance: Water side/Process
Heat In:Feedwater = (277, 778 Ib/hr) (148 Btu/Ib) = 41.11 MBtu/hr
heat absorbed
=
QA
Total
= 41.11 + QA
Heat Out: Steam
=
Blowdown =
Total
Heat In
41.11 + QA

=
=

(250,000) (1,351.8) = 337.95 MBtu/hr

(27, 778) (478.5) = 13.29 MBtu/hr
= 351.24 MBtu/hr

Heat Out
351.24

QA = 310.13 MBtu/hr

31

Exercise 2, Contd
Heat in = Heat out 41.11 + QA = 351.24
Heat absorbed
QA = 351.24 - 41.11 = 310.13 MBtu/hr
Heat loss (Given)
= 2%
Fuel LHV (Given)
= 19,400
Heat available
Net fuel
Gross fuel
Heat fired

= 16,725 at 600F Stack and 20% excess air

Maxwell, p. 185
310.13x10 6
=
= 18,543
16, 725
= 1.02 x 18,543
= 18,914
= 18,914 x 19,400 = 366.93 MBtu/hr

LVH efficiency =

310.13x10 6
6

x 100 = 84.5%

366.93x10
Shortcut efficiency assuming the atmospheric air temperature is 100F:
Efficiency= [100 -(0.0237 + 0.000189 EA)(TST - TA )][100/(100 + QL)]
= [100 -(0.0237 + 0.000189)(20))(600 - 100)][100/(100 + 2)]
= [(100 - 13.74)][0.9804] = 84.5%
ChE 101.03 V (26)

32

Exercise 2, Contd
To Increase Efficiency:
Lower stack temperature.
- Add more surface to convection section and increase
boiler feedwater preheat.
- Add more surface to convection section and preheat
another process stream. A 50F reduction in stack
temperature would increase efficiency from 84.5% to 85.9%.
Reduce blowdown rate.
- If boiler feedwater quality allows, the blowdown rate can be
reduced.
- Reduction of blowdown from 10% to 2% would not increase
the efficiency, but would directly reduce fuel use by
decreasing the process heat absorbed.
Reduce percent excess air.
- A reduction of excess air from 20% to 10% increases
efficiency from 84.5% to 85.4%.
ChE 101.03 V (27)

33

Exercise 2, Contd
Furnace Fuel Savings
Case

Base

Lower
Stack Temp.

Percent blowdown

10

10

10

310.13

310.13

302.63

310.13

Stack temperature, F

600

550

600

600

Excess air, percent

20

20

20

10

Furnace efficiency,
percent

84.5

85.91

84.52

85.40

Fuel savings, percent

Base

1.62

2.42

1.04

Heat absorbed,
MBtu/hr

Reduce
Reduce
Blowdown Excess Air

ChE 101.03 V (28)

34

Exercise 2, Contd
Calculation for efficiency Improvement:
Case
Heat in
277,778 x 148 =

1
Base

2
Lower
St ack Temp.

41.11

41.11

3
R educe
B lowdown
255,102 x 148

4
R educe %
Excess A ir

= 37.76

41.11

Heat out
13.29
337.95
351.24

351.24

340.39

351.24

Heat absorbed
St ack
Percent excess air
Heat loss
Fuel LHV
Heat avail.*

310.13
600
20
2%
19,400
16,725

310.13
550
20
2%
19,400
17,000

302.63
600
20
2%
19,400
16,725

310.13
600
10
2%
19,400
16,900

Net fuel
Gross fuel
Heat fired

18,543
18,914
366.93

18,243
18,608
360.99

18,095
18,457
358.06

18,351
18,718
363.13

LHV, percent eff.

84.52

85.91

84.52

85.40

Fuel savings

Base

1.62%

2.41%

1.04%

27,778 x 478.5 =
250,000 x 1,351.8 =

5,102 x 478.5
= 2.44
250,000 x 1,351.8 = 337.95

*Maxwell p. 185
ChE 101.03 V (29)

35

Heat Exchanger Energy Balances

The heat released by the hot

stream must equals the heat
absorbed by the cold stream

Hot

Cold

36

Example Problem 2
The hot stream is to
be cooled to 300F.
Hot

What is the cold stream

outlet temperature?

300F
H = 258 Btu/lb

500,000 lb/hr
500F
H = 410 Btu/lb

Cold
10,000 lb/hr
200F
API = 70
VABP = 210F

Hot stream duty = (410 - 258) x 500,000

= 76 x 10 6 Btu/hr
Cold stream C P data (Maxwell, Pg. 93).
Temperature
200F
300F
400F
ChE 101.03 V (28)

CP+B
0.677
0.736
0.794

B
0.08
0.08
0.08

CP
0.597
0.656
0.714
37

Example Problem 2, Contd

Assume for first trial cold stream out is same as inlet F.

Avg CP = 0.597

Q = mCPT

TOUT =

Q
+ 200
mC P

T = (TOUT - 200)

76 x 10 6
+ 200 = 12, 930F
10, 000 x 0.597

ChE 101.03 V (31)

38

Example Problem 2, Contd

It can be seen that this is an impossible solution. The hot stream
cannot be cooled by the desired amount with the available cold
stream. However, this problem illustrates both the enthalpy and
heat capacity methods of heat exchanger heat balance.
To solve this problem in a practical manner, if the two flow rates
are fixed, and only one heat exchanger shell is available, assume
that the cold stream outlet equals the hot stream outlet, as shown
below.
500F
Hot

TX

TX

Cold
200F

ChE 101.03 V (30)

39

Example Problem 2, Contd

1. (Average CP 300-500F).
2. Hot C p =

H 1 H 2 410 258 152

=
=
= 0.76
500 300 200
T1 T2

3. Assume Cold CP = 0.597 (inlet condition)

4. Q = (m CP t) Hot = (m CP t) Cold
(500,000) (0.76) (500 TX) = (10,000)(0.597) (TX 200)
380 (500 TX)

= 5.97 (TX 200)

190,000 380 TX

= 5.97 TX 1194

191,194
TX

= 385.97 TX
= 495.4

ChE 101.03 V (33)

40

Example Problem 2, Contd

5. Recalculate average Cold CP.
495 CP + B

= 0.85

0.597 + 0.77
2

= 0.6835

CP

CP = 0.77

Resolving 191,367 = 386.8 TX

TX = 494.7
This solution will be the best that can be achieved with the given
conditions using one heat exchanger shell.

ChE 101.03 V (34)

41

Exercise 3.1 (heat integration)

We want to heat integrate a lean oil and feed stream in exercise 1, where it is
proposed to use exchanger E6 to replace E1 in exercise 1 to provide preheat for
the debutanizer feed

42

Exercise 3.1, Contd

Debutanizer Feed
32,110 B/SD
77API
253F
sp. gr. = 0.57

E-2

Lean
Oil

D-1 115F

143F
148 psig

148 psig

P-1

T-1

Debutanizer
Overhead
6,308 B/SD
118.5API
100F
sp. gr. = 0.54

E-6
258F
H=99.270
H=103.270
6
x10 Btu/hr
154 psig
x10 6
322F

346F
E-4

Btu/hr

E-3

Naphtha Product
9,742 B/SD
130F

E-5
Feed

P-2
E-6

Figure 16
ChE 101.03 V (36)

E-7B

E-7A

Lean Oil
16,060 B/SD
68.8API
100F
sp. gr. = 0.69

43

Exercise 3.1 (contd)

1.

Find the exit temperature for the lean oil leaving E6 after
preheating the tower feed?
Answer:
E6 Duty:

253 oF to 258 oF
Q = H = 103.277 99.270 = 4.0 MBtu/hr

Q = mCpT
m = 165, 284 Ib/hr (from exercise 1)

44

Exercise 3.1, Contd

Answer , Contd:
Need average CP of the lean oil, so estimate exit temperature for first
trial.
Use inlet CP to estimate exit temperature.
Ave CP = 0.681
Q
4 x 10 6
=
= 35.5F
mC P 165, 284 x 0.681

= (346 TOUT ) =

TOUT

= 346 - 35.5 = 310.5F

CP

= 346
310.5
100

TOUT

= 346 - 36 = 310F

Rate from
Exercise 1

0.681
0.658
0.524

ChE 101.03 V (38)

45

Exercise 3.1, Contd

2.

Calculate the heat duty of E7AB.

Answer:
Heat duty for E7AB
310F 100F
CP

= 0.66

Avg CP

= 0.66 + 0.524 = 0.592

2

0.524

Q = mCPT = 165,284 x 0.592 x (310 - 100) = 20.55 MBtu/hr

ChE 101.03 V (39)

46

Exercise 3.1, Contd

3.

How much cooling water in lb/hr and 60F gpm is required?

Use 95F to 120F as the water temperature rise.
The heat capacity data for lean oil is:
Temperature,F

CP, Btu/lbF

346

0.681

100

0.524

Use flow rates from Exercise 2.1.

Feed = 317,829 lbs/hr

L.O. = 165,284 lbs/hr

ChE 101.03 V (40)

47

Exercise 3.1, Contd

Answer:
Cooling water rate.
Q = mCPT
Q
20.55 x 10 6
=
= 822, 000 lb/hr
m=
C P T 1 x (120 - 95)
gal
1, 645 gpm
gpm = 822, 000 lb x hr x
=
hr 60 min 8.33 lb @60F

310F
120F
100F
95F

ChE 101.03 V (41)

48

Natural Heat Gain and Loss for Piping

Solar Heat Gain:
QS / L = 300 (Do L) / L ...(4)

Convection Heat Loss:

QC / L = 0.844(Do)0.75 (Tp Ta)1.25 (Full pipe area) ..(5)

Radiation Heat Loss:

QR / L = 0.246 Do [(Tp/100)4 (Ta/100)4] (1/2 pipe area) ..(6)
49

Example Problem 3

Consider a 6 in. nominal size, Schedule 40, Grade B steel pipe filled
with oil. The pipeline is unrestrained and above ground. The
ambient temperature is 100 F. The line is blocked-in at 110 F and
150 psi. What is the maximum temperature the line will reach?

50

Example Problem 3 (contd)

Answer:

Do = 6.625/12 = 0.552
assume a max. T of 160 F for the 1st trial:
Tp = 160 + 460 = 620 R
Ta = 100 + 460 = 560 R
QC / L = 0.844(Do)0.75 (Tp Ta)1.25
= 0.844(0.552)0.75 (620 560)1.25 = 90.25 Btu/hr/ft
QR / L = 0.246 Do [(Tp/100)4 (Ta/100)4]
= 0.246 (0.552) [(620/100)4 (560/100)4] = 67.1 Btu/hr/ft
total heat loss: QT/L = QC/L + QR/L
= 90.25 + 67.1 = 157.4 Btu/hr/ft
51

Example Problem 3 (contd)

Solar Heat Gain:

QS / L = 300 (Do L) / L
= 300 (0.552) = 165.6 Btu/hr/ft

total heat loss < total heat gain:

therefore, the assumed max. T must be increased (e.g. to 163 F)
Trial

Tp (oF)

QC / L
(Btu/hr/ft)

QR / L
(Btu/hr/ft)

QT / L
QS / L
(Btu/hr/ft) (Btu/hr/ft)

160

90.25

67.1

157.4

165.6

163

95.9

71.0

166.9

165.6
52

Heat Loss for Piping

Pipe Heat Loss With Flow

Diam. (ft )
1.0625
Pipe
Qr /L
Temp, F
Btu/hr ft
1
200
741.2
2
190
682.4
3
180
626.3
4
170
572.8
5
160
521.7
6
150
473.1
7
140
426.8
8
130
382.7
9
120
340.9
10
110
301.1
11
100
263.4
12
90
227.7
13
80
193.8
14
70
161.8
15
60
131.5
16
50
103.0
17
40
76.0

Temperatures, F
Air = 50 Sky = -50
Qc /L
Qt /L
Btu/hr ft
Btu/hr ft
1409.6
2150.8
1293.1
1975.5
1178.7
1805.0
1066.5
1639.3
956.6
1478.3
849.1
1322.2
744.4
1171.1
642.4
1025.2
543.7
884.6
448.4
749.5
357.0
620.4
270.1
497.8
188.5
382.3
113.6
275.4
47.8
179.3
0.0
103.0
-47.8
28.3

Q = m C p t
L (Q T /L )Ave = Q
L=

m C p t
(Q T /L) Ave

Wind, mph
Flow, lb/hr
5
50,000
Cp
Length
Cum.
Pipe
Btu/lb F
ft
Length, ft
Temp, R
0.5
121.2
121.2
660
0.5
132.3
253.4
650
0.5
145.2
398.6
640
0.5
160.4
559.0
630
0.5
178.5
737.5
620
0.5
200.5
938.1
610
0.5
227.7
1165.7
600
0.5
261.8
1427.5
590
0.5
306.0
1733.5
580
0.5
365.0
2098.5
570
0.5
447.2
2545.6
560
0.5
568.1
3113.8
550
0.5
760.2
3874.0
540
0.5
1099.8
4973.8
530
0.5
1771.6
6745.4
520
0.5
3809.8
10555.1
510
0.5
500
( Q T /L)1 + (Q T /L) 2
for line 1
(Q T /L) Ave =
2

For line 1 (Q T /L )Ave =

L =

2150.8 +1975.5
= 2063.2
2

( 50,000)(0.5 )(10 )
2063.2

=121.2

Figure 7
ChE 101.03 V (46)

Figure 7:

Heat Loss of Horizontal Pipe at Night With Flow

53

Exercise 3.2: calculating temperature change

1.

A pipeline (Do = 1.0625 ft) is operating at night. The line

contains 20o API hydrocarbon (VABP = 650 oF) flowing at a
rate of 200, 000 Ib/hr. The initial temperature is 200 oF and
the line length is 6300 ft. The average heat loss for the line
has been calculated to be 898.4 Btu/hr/ft of line length with a
wind velocity of 5 mph.
What is the exit temperature of the pipeline?
54

Exercise 3.2, Contd

Answer:
QLOSS = 898.4 x 6300 = 5.66 x 106 Btu/Hr
For initial guess at outlet temperature, use inlet temperature CP.
Temperature

CP+B

CP

200

0.51

0.025

0.485

Inlet CP

= Ave CP = 0.485

= QLOSS = m CP

TOUT

= T - T = 200 - 58 = 142F

5.664 x 10 6
= 58F
200, 000 x 0.485

ChE 101.03 V (48)

55

Exercise 3.2, Contd

Calculate outlet CP - Maxwell (p. 93)
Temperature

CP+B

CP

142

0.485

0.025

0.460

Ave C P = 0.460 + 0.485 = 0.472

2
5.664 x 10 6
= 60 F
200, 000 x 0.472

TOUT

= 200 - 60 = 140F

Check Q.
Q

= 200,000 (0.472) (200 - 140) = 5.664 x 106 Btu/hr

ChE 101.03 V (49)

56

Exercise 3.2, Contd

HEAT LOSS OF HORIZONTAL PIPE AT NIGHT
(Uses SADP-L-043 method with -50F air temperature for radiation)
Diam. (ft )
1.0625
Pipe
Temp, F
1
200
2
190
3
180
4
170
5
160
6
150
7
140
8
130
9
120
10
110
11
100

Qr /L
Btu/hr ft
741.2
682.4
626.3
572.8
521.7
473.1
426.8
382.7
340.9
301.1
263.4

Temperatures, F
Air = 50 Sky = -50
Qc /L
Btu/hr ft
1409.6
1293.1
1178.7
1066.5
956.6
849.1
744.4
642.4
543.7
448.4
357.0

Qt /L
Btu/hr ft
2150.8
1975.5
1805.0
1639.3
1478.3
1322.2
1171.1
1025.2
884.6
749.5
620.4

Wind, mph
5
Cp
Btu/lb F
0.485
0.480
0.476
0.469
0.467
0.462
0.458
0.454
0.450
0.446
0.442

Length
ft
467.7
759.7
825.1
901.4
997.0
1108.5
1247.5
1422.2
1647.4
1947.5

Flow, lb/hr
200,000
Cum.
Length, ft
467.7
1227.4
2052.5
2953.9
3950.9
5059.4
6307.0
7729.1
9376.6
11324.1

Pipe
Temp, R
660
650
640
630
620
610
600
590
580
570
560

ChE 101.03 V (50)

57

Exercise 3.2, Contd

2. An uninsulated horizontal drum 10 ft outside diameter
and 40 ft long is exposed to full sunlight. The air
temperature is 110F. What is the maximum surface
temperature that can be attained?
(A drum is the same geometry as a large pipe) Assume
187F for the first trial and indicate if the next trial will
require a hotter or cooler value.

ChE 101.03 V (51)

58

Exercise 3.2, Contd

Answer:
= 10 ft
Diameter Do
Ta = 110 + 460 = 570R

2nd Trial

Final temperature = 187F (assume for first trial)

= 187 + 460 = 647R
TP
QC/L = 0.844Do0.75 (TP - Ta)1.25

192F
652R

= 0.844 (10)0.75 (647 - 570)1.25 = 1082.6 Btu/hr/ft

1171.1 Btu/hr/ft
TP 4 T a 4
Q R /L = 0.246 D o
-

100
100

4
4

1848.8 Btu/hr/ft
= 0.246(10) 647 - 570 = 1, 714.0 Btu/hr/ft
100
100

QT/L = QR/L + QC/L = 1,082.6 + 1,714 = 2,796.6 Btu/hr/ft 3019.9 Btu/hr/ft

QS/L = 300 Do = 300 x 10 = 3,000 Btu/hr/ft
Since QT < QS, the assumption of 187F is a little low.
After second trial, QT QS, the assumption of 192F is adequate.
ChE 101.03 V (52)

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