Material and Energy Balance

Syllabus

Material and Energy balance:

Facility as an energy system Methods for preparing process flow Material and energy balance diagrams.

Purpose of material and energy balance

To Assess the input, conversion efficiency, output and losses To quantify all material, energy and waste streams in a process or a system To find out the difference between calculated/designed values and measured/actual values thereby making it possible to identify previously unknown losses and emissions Powerful tool for establishing basis for improvement and potential savings

Sankey Diagram and its Use

Useful tool to represent input and output energy flow in any energy equipment or system Visual impact on input and output losses to enable energy managers to focus on solutions

Flow charts

Inputs of the process could include raw materials, water, steam, electricity Process Steps should be sequentially classified Wastes / by products could include solids, water, chemicals, energy Output of the process is the final product produced in the plant.

Facility as an Energy System

Raw material 100% Energy Input Energy Facility Transformer DG Set Boilers Chillers Water Supplies Production Facility

100% Heat Output Product

Boiler Plant System

Cooling Tower & Cooling Water Supply System

Guidelines for material and energy balance

While splitting up the total system, choose, simple discrete sub-systems. Choose material and energy balance envelope such that, the number of streams entering and leaving, is the smallest possible. The measurement units may include, time factor or production linkages. Consider a full batch as the reference in case of batch operations. It is important to include start-up and cleaning operation consumptions (of material and energy resources (M&E). Calculate the gas volumes at standard conditions. In case of shutdown losses, averaging over long periods may be necessary. Highlight losses and emissions (M&E) at part load operations if prevalent. For each stream, where applicable, indicate energy quality (pressure, temperature, enthalpy, Kcal/hr, Kw, Amps, Volts etc.).

Example/ Formula
i) Energy Supplied by Combustion: Q =Fuel consumed x Calorific value ii) Energy Supplied by Electricity: Q = kWh x 860 kCals Where, Q = thermal energy flow rate produced by electricity (kJ/h) iii) Continuity Equation

A1V1 = A2V2 v1 v2
where, V is the velocity in m/s , v is the specific volume in m3/kg and A is the cross sectional area of the pipe in m2. iv) Heat addition/rejection of a fluid = mCp diffTemp where, m is the mass in kg, Cp is the specific heat in kCal/kg, DiffTemp is the difference in temperature in k

M & E Calculation Procedure

Clearly identify the problem to be studied. Define a boundary that encloses the entire system or sub-system to be analysed. Entering and leaving mass and energy flows must be measured at the boundary.

The boundary must be chosen in such a way that:

All relevant flows must cross it, all non-relevant flows being within the boundary. Measurements at the boundary must be possible in an easy and accurate manner.

Select an appropriate test period depending on the type of process and product. Carry out the measurements. Calculate the energy and mass flow.

Verify an energy and mass balance. If the balances are outside acceptable limits, then repeat the measurements.
The energy release or use in endothermic and exothermic processes should be taken into consideration in the energy balance

Example:Heat Balance in a Boiler

73.8 % Heat in Steam

12.7 %

Dry Flue Gas Loss Heat loss due to dry flue gas

8.1 % 100 %
Fuel Steam Boiler 1.7 % 0.3 % 2.4 %
Heat loss due to hydrogen in fuel flue gas Heat loss due to moisture in fuel Heat loss due to moisture in air Heat loss due to unburnts in residue Heat loss due to radiation & other unaccounted loss

1.0 %

Mass Balance in a Cement Plant