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Chapter 5

ENERGY BALANCE

The energy balance of the plants unit operations and processes allows the designer

of the plant an insight on the amount of energy that is utilized in every equipment, what

happens to them, and if transferred or transformed, into what forms or into what body of

matter did it go. The balance of such is particularly important for equipment that involves

the use of heating or produces heat during the extent of the reaction. Power requirements

of various machines and equipment that require energy in the form electricity to run, were

also analyzed to find their energy consumption.

Basis:

1. One day operation

5.1 Banana Pulp Dryer

Dryer (D1)

G2 = 1,420,741.777 kg G1 = 1,420,741.777 kg

Ym3 = 0.0330890 Ym2 = 0.018


Tg2 = 31.5C Tg2 = 28C

F4 = 31,428.57143 kg F5 = 9,990.97744kg
Xs4 = 0.302 Xs4 = 0.95
Xw4 = 0.698 Xw4 = 0.05

Q = 56,119,300.19 kJ W1 = 21,437.59399 kg
5.1.1 Streams

Input Output

F4 = Sized reduced banana pulp (kg) F5 = Dried unripe banana pulp (kg)

G4 = Heated, Dry Air entering (kg) G5 = Heated, Dry Air exiting (kg)

W1 = Waste water (kg)

5.1.2 Assumptions and Conditions

1. The conveyor dryer is operated at adiabatic saturated temperature of entering heated

air which is 31.5C, as per calculation using a psychometric chart (Perry & Green

2008) while the entering heated air is assumed to be at a temperature of 60C, of

similar humid conditions with air in Panabo City, Davao del Norte.

2. The temperature of dried banana pulp leaving the dryer and outlet air is 35C (Hall

1988). The entering unheated air and wet banana pulp are at the same temperatures of

28C (CustomWeather Inc. 2017).

3. The band dryer is operated at 1 atm.

4. The amount of air and banana pulp (without moisture) entering and exiting the dryer

are equal (G1 = G2).

5. Heat Capacity of Banana Pulp is assumed 4.721kJ/kgC (Davila 2016).

6. Heat loss is neglected.

Table 1. Properties of Air in Panabo City, Davao del Norte.


Parameter Value
Temperature 28C
Relative Humidity 78 kg H2O/kg dry air
Source: (CustomWeather Inc. 2017)
5.1.3 Energy Balances

Overall Energy Balance:

1 ( ) + 4 ( ) = 2 ( ) + 5 ( )

Moisture Balance:

1 ( ) + 4 4 = 2 ( ) + 5 5
Enthalpy of Heated Air Entering (HG)

= +
= 113.5 /
Enthalpy of Heated Air Exiting (HM)

= , ( ) +
= (31.6575 + 2560.22 ) /
Enthalpy of Entering, Wet Banana Pulp (HK)


= , ( ) + ,

= 214.1158275 /

Enthalpy of Exiting, Dried Banana Pulp (HZ)


= , ( ) + ,

= 155.3155737 /
Substituting the values calculated to the overall energy balance equation:
81.84251 2560.22 1 = 58.8002538 Eqn 5.1
Substituting the values calculated to the moisture balance equation:
0.0181 1 = 21,437.59399 Eqn 5.2
Solving equations 5.1 and 5.2 simultaneously:
G1 = G2 = 1,534,875.252 kg
Ym = 0.03196699436 kg H2O/kg dry air
Amount of heat supplied by the heater to the dryer, assuming no heat loss:

= ( )1
= (113.5 74)/(1,534,875.252 )
= 60,627,572.45
Solving for the amount of fuel required to supply the amount of heat needed:
2 (1 + ), (2 ) =
= , .
5.2 Banana Starch Dryer

Dryer (D2)

G6 = 42,689.59997 kg G5 = 42,689.59997 kg

Ym3 = 0.0679589813 Ym2 = 0.018


Tg2 = 95C Tg2 = 220C

P2 = 28,571.42857 kg F17 = 8,104.36992 kg


Xs, s18 = 0.950 Xs, f17 = 0.700
Xw, s18 = 0.050 Xw, f17 = 0.300
Ts18 = 35C Tf17 = 28C

Q = 8,607,742.257 kJ W6 = = 2,132.72892 kg
kg

5.2.1 Streams

Input Output

P2 = Sized reduced banana peel (kg) P3 = Dried unripe banana peel (kg)

G5 = Heated, Dry Air entering (kg) G6 = Heated, Dry Air exiting (kg)
O1 = Waste water (kg)

5.2.2 Assumptions and Conditions

1. The conveyor dryer is operated at an assumed temperature of leaving heated air which

is 95C (APV 2000) while the entering heated air is assumed to be at a temperature of

200C, similar humid conditions of air in Panabo City, Davao del Norte (APV 2000;

Perry & Green 2008).

2. The temperature of dried banana pulp leaving the dryer and outlet air is 35C (Hall

1988). The entering unheated air and wet banana pulp are at the same temperatures of

28C (CustomWeather Inc. 2017).

3. The band dryer is operated at 1 atm.

4. The amount of air and banana pulp (without moisture) entering and exiting the dryer

are equal (G5 = G6).

5. Heat Capacity of Banana Starch Suspension is assumed 2.24 kJ/kgC (Ssempebwa

2015).

6. Heat loss is neglected.

For properties of air in Panabo City, Davao del Norte, refer to Table 1.

5.2.3 Energy Balances

Overall Energy Balance:

5 ( ) + 2 ( ) = 6 ( ) + 3 ( )
Moisture Balance:

5 ( ) + 2 ,2 = 2 ( ) + 3 ,3
Enthalpy of Heated Air Entering (HG)

= +

= 275

Enthalpy of Heated Air Exiting (HM)

= , ( ) +
= (95.475 + 2679.6 ) /
Enthalpy of Entering, Wet Banana Pulp (HK)


= , ( ) + ,

= 9.9325331 /

Enthalpy of Exiting, Dried Banana Pulp (HZ)


= , ( ) + ,

= 85.7397761 /
Substituting the values calculated to the overall energy balance equation:
179.5251 2679.6 1 = 110048.9325 Eqn 5.3
Substituting the values calculated to the moisture balance equation:
0.0181 1 = 2132.728926 Eqn 5.4
Solving equations 5.3 and 5.4 simultaneously:
G1 = G2 = 42,689.59997 kg
Ym = 0.0679589813 kg H2O/kg dry air
Amount of heat supplied by the heater to the dryer, assuming no heat loss:

= ( )1
= (275 230)/(426899.59997 )
= 19,210,031.999
Solving for the amount of fuel required to supply the amount of heat needed:
2 (1 + ), (2 ) =
= .

5.3 Banana Peel Dryer

Dryer (D3)

G6 = 217,917.5255 kg G5 = 217,917.5255 kg

Ym3 = 0.0325679 Ym2 = 0.018


Tg2 = 31.5C Tg2 = 28C

P2 = 28,571.42857 kg P3 = 25,396.8254 kg
Xs, p2 = 0.800 Xs, p3 = 0.900
Xw, p2 = 0.200 Xw, p3 = 0.100

Q = 8,607,742.257 kJ O1 = 3174.60317 kg

5.3.1 Streams

Input Output

P2 = Sized reduced banana peel (kg) P3 = Dried unripe banana peel (kg)

G5 = Heated, Dry Air entering (kg) G6 = Heated, Dry Air exiting (kg)

O1 = Waste water (kg)

5.3.2 Assumptions and Conditions

1. The conveyor dryer is operated at adiabatic saturated temperature of entering heated

air which is 31.5C, as per calculation using a psychometric chart (Perry & Green,

2008) while the entering heated air is assumed to be at a temperature of 60C, of

similar humid conditions with air in Panabo City, Davao del Norte.
2. The temperature of dried banana pulp leaving the dryer and outlet air is 35C (Hall

1988). The entering unheated air and wet banana pulp are at the same temperatures of

28C (CustomWeather Inc. 2017).

3. The band dryer is operated at 1 atm.

4. The amount of air and banana pulp (without moisture) entering and exiting the dryer

are equal (G5 = G6)

5. Heat loss is neglected.

For properties of air in Panabo City, Davao del Norte, refer to Table 1.

5.3.3 Energy Balances

Overall Energy Balance:

5 ( ) + 2 ( ) = 6 ( ) + 3 ( )
Moisture Balance:

5 ( ) + 2 ,2 = 2 ( ) + 3 ,3
Enthalpy of Heated Air Entering (HG)

= +
= 113.5 /
Enthalpy of Heated Air Exiting (HM)

= , ( ) +
= (31.6575 + 2569.22 ) /
Enthalpy of Entering, Wet Banana Pulp (HK)


= , ( ) + ,

= 123.1550222 /
Enthalpy of Exiting, Dried Banana Pulp (HZ)


= , ( ) + ,

= 125.3481474 /
Substituting the values calculated to the overall energy balance equation:
81.84251 2560.22 1 = 335,269.987 Eqn 5.3
Substituting the values calculated to the moisture balance equation:
0.0181 1 = 3174.603174 Eqn 5.4
Solving equations 5.3 and 5.4 simultaneously:
G1 = G2 = 217,917.5255 kg
Ym = 0.03256791126 kg H2O/kg dry air
Amount of heat supplied by the heater to the dryer, assuming no heat loss:

= ( )1
= (113.5 74)/(217,917.5255 )
= 8,607,742.257
Solving for the amount of fuel required to supply the amount of heat needed:
2 (1 + ), (2 ) =
= .
5.4 Acid Hydrolysis

P4 = 24888.88889 kg
30C
P5 = 128049.59999 kg
120C

Steam = 17492.52574 kg
120C
Steam = 17492.52574 kg
250C

Acid Hydrolysis Tank


A1 = 103160.7111 kg

5.4.1 Streams

Input Output

P4 = Dried Unripe Banana Peel Flour (kg) P5 = Acid Hydrolysate (kg)

A1 = Dilute H2SO4 (kg)

5.4.2 Assumptions and Conditions

1. Heat evolved from the mixing of sulfuric acid and water is negligible.
2. Heat of reactions to form soluble sugars are negligible.
3. Temperature of entering feed (P4) is equal to the ambient temperature (30C).
4. Operating conditions for the acid hydrolysis is 120C and 300 kPa (Waghmare &
Arya 2016).
5. Superheated steam is injected to the outer jacket of the hydrolysis tank at 250C
and 300 kPa.
6. The steam leave the outer jacket as liquid at 120C, the same as the output
temperature of the acid hydrolysate.
5.4.3 Energy Balances

Overall Heat Balance:


=
= ( )

Table 2. Heat Capacities of Individual Components of Banana Peel


Input Mass (kg) Cp (kJ/kg*K) Tin (C) Tout(C) T(C) Q=mCpT (kJ)
Water 102568.48 4.1805 303.15 393.15 90 38590877.76
Ash 1891.55556 0.879324 303.15 393.15 90 149696.1181
Protein 2090.66667 1.765 303.15 393.15 90 332102.4005
Fat 1169.77778 1.953 303.15 393.15 90 205611.8404
Lignin 572.44444 1.185 303.15 393.15 90 61051.19953
Others 945.77778 0.203 303.15 393.15 90 17279.36004
Starch 10254.22222 1.75 303.15 393.15 90 1615040
Glucan 2314.66667 1.185 303.15 393.15 90 246859.2004
Xylan 796.44444 1.185 303.15 393.15 90 84940.79953
Glucose 575.22983 1.148993 303.15 393.15 90 59484.15433
Rhamnose 129.31391 1.132341 303.15 393.15 90 13178.46979
Arabinose 68.62265 1.132341 303.15 393.15 90 6993.381611
Xylose 24.82096 1.132341 303.15 393.15 90 2529.52116
Mannose 15.76861 1.148993 303.15 393.15 90 1630.622026
Galactose 82.34718 1.148993 303.15 393.15 90 8515.470005
Uronic Acid 1468.34131 2.15865 303.15 393.15 90 285267.1472
H2SO4 3081.12 1.569377 303.15 393.15 90 435189.4976

Total 42,116,246.94
Source: (The Engineering Toolbox 2016b; Valentas et al. 1997).
Table 3. Theoretical data for Heating Steam stream
Parameter Value
Entering Temperature 250C
Operating Pressure 300 kPa
Saturation temperature at given pressure 133.54C
Enthalpy of vapor at saturation temperature 2724.7 kJ/kg
Enthalpy of liquid at saturation temperature 561.429 kJ/kg
Average Cp of steam 1.88 kJ/kg
Source: (Perry & Green 2008).

Heat needed to be supplied by steam:


= 1 + 2 + 3
Heat needed to raise temperature of water to saturation temperature:

1 =
= . /
2 =
= . /
3 =
= . /
= . /

Solving for the amount of steam:


( ) =

( ) = , .
5.5 Acid Hydrolysis Heat Exchanger

P5 = 128049.59999 kg G7 = 64,645.8999 kg
Tp5=120C Tg7=15C

G8 = 64,645.8999 kg
Tg8=30C
Acid Hydrolysis Heat Exchanger P5 = 128049.59999 kg
Tp5=30C

5.5.1 Streams

Input Output

P5 = Hot Acid Hydrolysate (kg) P5 = Cooled Acid Hydrolysate (kg)

G7 = Coolant Ammonia entering (kg) G7 = Coolant Ammonia leaving (kg)

5.5.2 Assumptions and Conditions

1. The system is perfectly isolated or adiabatic.


2. Heat losses are negligible.
3. Heat released by the feed is absorbed by the cooling medium which is ammonia.
4. Output temperature of the cooling medium is the same as the output temperature of the
feed.
5. Operating pressure is equal to atmospheric pressure.
6. The ammonia enters the heat exchanger at 15C.
7. The specific heat capacity of ammonia at 15C is 4.74 kJ/kgK (The Engineering
Toolbox 2016a).

5.5.3 Energy Balances

Heat Balance around the Acid Hydrolysis Heat Exchanger:


= =

Table 4. Heat Capacities of each component and their corresponding heats of reaction.
Component Mass (kg) Cp (kJ/kgK) T Q=mCpT (kJ)
Water 101384.44093 4.18050 10.00000 38145388.97771
Ash 1891.55556 0.87932 10.00000 149696.11811
Protein 2090.66667 1.76500 10.00000 332102.40053
Fat 1169.77778 1.95300 10.00000 205611.84039
Lignin 572.44444 1.18500 10.00000 61051.19953
Others 945.77778 0.20300 10.00000 17279.36004
Starch 2563.55556 1.75000 10.00000 403760.00070
Glucan 231.46667 1.18500 10.00000 24685.92036
Xylan 79.64444 1.18500 10.00000 8494.07953
Glucose 11435.36404 1.14899 10.00000 1182523.79110
Rhamnose 129.31391 1.13234 10.00000 13178.46979
Arabinose 68.62265 1.13234 10.00000 6993.38161
Xylose 839.39248 1.13234 10.00000 85543.06682
Mannose 15.76861 1.14899 10.00000 1630.62203
Galactose 82.34718 1.14899 10.00000 8515.47001
Uronic Acid 1468.34131 2.15865 10.00000 285267.14719
H2SO4 3081.12000 1.56938 10.00000 435189.49760
TOTAL 41,366,911.34304
Source: (The Engineering Toolbox 2016b)

= ( )

= , , .

Mass of ammonia needed as cooling medium:


=
= ()

= , . /

5.6 In-Line Sulfuric Acid Mixer

H1 = 3144.00 kg

A1 = 103160.71570 kg

TA1 = 30C

WA = 100016.71570 kg

TWA = 27.77442 C

5.6.1 Streams

Input Output
H1 = 98% (w/v) H2SO4 solution A1 = Dilute H2SO4 with a concentration of
3.07867 % (w/w)
WA = H2O fed to the mixer

5.6.2 Assumptions and Conditions

1. Heat capacity of H2SO4 is constant.


2. Heat of dilution of H2SO4 is negligible (Aden et al. 2002).

5.6.3 Energy Balances


General energy balance equation for the reaction:
= 2 ( ) + 1 2 4 ()

= 2 ( )

Using the value taken from Perrys Chemical Engineering Handbook (2008).


= 9.304
2

TWA = 27.77442 C

5.7 Fermentation

I = 19341.24970 kg
G = 5469.65920 kg
Inoculum

C = 13785.62370 kg

P6 =155706.81419 kg
P5 = 128050.20743 kg

5.7.1 Streams

Input Output

I = Inoculum G = CO2 Emission

C = Cellulase P6 = Fermented Product


P5 = Acid Hydrolysate

5.7.2 Assumptions and Conditions

1. The operating conditions for saccharification and fermentation is 30C under


atmospheric conditions having a pH of 5.0 (Waghmare & Arya 2016).
2. Only reactions for the production of ethanol produce heat.
3. Hinert = 0 (Aden et al. 2002).

5.7.3 Energy Balances

Heat of Reaction (Horxn) of Ethanol:

= () ()

= 2 + 2 2 6126

From Perrys Chemical Engineering Handbook (2008), at 25C


Hf,CO2 = -393.51 KJ
mol

Hf,EtOH = - 234.95 KJ
mol

Hf,C6 H12 O6 = -1267.11 KJ


mol


= 10.19 = 221,19476

= , , .

Heat of reaction of reactants (Hreactant ):

Table 5. Heat Capacities of each component and their corresponding heats of reaction.
Components Mass (kg) Cp (kJ/kg K) mCp (kJ/K)
Glucose 14541.02503 1.148993 16707.53598
Rhamnose 129.3139071 1.132341 146.4274388
Arabinose 68.62264813 1.132341 77.704238
Xylose 929.9004245 1.132341 1052.964377
Mannose 15.76860851 1.148993 18.11802079
Galactose 82.34717775 1.148993 94.61633081
Total 18,097.36638
Source: (The Engineering Toolbox 2016b).
Hfeed = Hreactants = (( ))(Tfeed)

Hreactants = - 90,486.83191 kJ

Heat of reaction of products (Hprod ):

Table 6. Heat Capacities of each component and their corresponding heats of reaction.
Components Mass (kg) Cp (kJ/kg K) mCP (kJ/K)
Glucose 4216.89726 1.148993 4845.185433
Rhamnose 37.50103305 1.132341 42.46395726
Arabinose 19.90056796 1.132341 22.53422902
Xylose 269.6711231 1.132341 305.3596692
Mannose 4.572896467 1.148993 5.25422603
Galactose 23.88068155 1.148993 27.43873593
CO2 5469.659201 37.24329 203708.1038
EtOH 5724.895037 112.3759 643340.2322
Total 852,296.5723
Source: (The Engineering Toolbox 2016b).
Hreactants = ( )(Tproducts)

Hreactants = - 4,261,482.86130 kJ

Overall Heat of Reaction Htotal :

= + +

= = 5,437,312.78784 kJ
5.8 Distilling Column

V = 13084.24601 kg
C

D = 5947.38455 kg
P6 = 155706.81419 kg
L = 7136.86146 kg

B = 147437.422 kg
R

5.8.1 Streams

Input Output

P6 = Fermented Product B = Bottom Product

L = Liquid Reflux D = Distillate

V = Vapor from Distilling Column

5.8.2 Assumptions and Conditions

1. Beer feed temperature is 99.5C.

2. Distilling column top temperature is 72.8C.

3. Distilling column bottom temperature is 101C.

4. Normal operating pressure at the base of the column is 1 atm (Padukone, 1996).
5.8.3 Energy Balances

Heat Capacity of H2O:


Heat Capacity Constants (Smith et al. 2005):
A = 8.712
B = 1.25 x 10-3
C = 0.18 x 10-6
2 = 18.02 kg/kmol
R = 8.314 kJ/kmolK


2 = [ + ( + 1 ) + 2 ( 2 + + 1) + 2 ] [ ]
2 2 3


where =

At T = 99.5C = 372.65 K T0 = 30C = 303.15 K


, = .

Heat Capacity of EtOH

Heat Capacity Constants (Smith et al. 2005):


A = 33.866
B = -172.60 x 10-3
C = 349.17 x 10-6
MW = 46.06904 kg/kmol
R = 8.314 kJ/kmolK


= [ + ( + 1 ) + 2 ( 2 + + 1) + 2 ] [ ]
2 3


where =

At To = 99.5 C = 372.65 K T0 = 30C = 303.15 K


, = 2.80664
Distillate Sensible Heat, (HD):

Distillate is composed of 95% ethanol and 5% H2O, thus, the average heat capacity of the
distillate is
Cp,distillate = 0.95 ( 2.80664 ) + 0.05 ( 4.22390 )

Cp,distillate = 2.87750

The sensible heat of the distillate is


HD = D Cp,distillate T
HD = -457,052.22612 kJ

Latent Heat of Vapor, Hv:

The vapor-liquid equilibrium data from Geankoplis (1978), states that the boiling point of

ethanol-water mixture is 83.2 C.

At 83C, the latent heat of ethanol and H2O from Van Ness et al. (2007) are:

Hethanol = 793.5195

2 = 2300.68

Since the vapor consist of 95% ethanol and 5% water, the latent heat of the vapor is

Hv = V ( 0.95 Hethanol + 0.05 2 )


Qc=Hv = 13,087.64433 kJ
Sensible Heat of the Feed, Hf:

Assuming that the average heat capacity of other solids is 1.000 kJ/ kg K

Table 7. Heat Capacities of every component in the feed.


Components Mass P6(kg) Cp (kJ/kg K) P6 Cp (kJ/K)
Ethanol 5724.89504 2.80664 16067.71881
Water 114158.64236 4.22390 482194.59704
Others 35823.27680 1.00000 35823.27680
Total 534,085.59265

Hf = P6 Cp T

Hf = 534085.59265 (99.5 -83.2)


Hf = 8,705,595.16020 kJ

Bottoms Sensible Heat of the content of reboiler (HB):

Table 8. Molecular Weights of every Component in the Reboiler


Soluble Components Molecular Weight (kmol/kg) Mass (kg) Moles (kmol)
Glucose 180.16 4216.89726 23.40640
Rhamnose 164.16 37.50103 0.22844
Arabinose 180.16 19.90057 0.11046
Xylose 150.13 269.67112 1.79625
Mannose 180.16 4.57290 0.02538
Galactose 150.13 23.88068 0.15907
Uronic Acid 194.14 1468.34131 7.56331
Total 33.28932
Source: (Perry & Green 2008).

Amount of H2O (solvent) at the bottoms

2 = 113861.1959 kg
Molarity of B:


m =

m = 0.29237 m

Boiling point relative to the molarity of the solution is given by: (SOURCE)

Tb = 0.51(m) Tb = 100 + Tb
Tb = 0.14911 Tb = 100.14911 C

Solving for Cp,bottoms

Cp,bottoms = mEtOH Cp,EtOH + 2 Cp,H2O


Cp,bottoms = 73.718711 2.80664 + 113861.19590 4.22390
Cp,bottoms = 516,968.3918

Solving for HB

HB = Cp,bottoms T
HB = 9,202,037.375 kJ

Reboiler heat input, QB:

QB + HF = QC + HD + HB

QB = QC + HD + HB HF
QB = [(13,087.64433) + (-457,052.22612) + (9,202,037.375) (8705595.16020)] kJ
QB = 11,951,612.08 kJ

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