1. MATERIAL BALANCE ÷Éñ ÌâºëÈ¾Æ By ENG. SAMPATH WIJESOORIYA

2. CONTENT  Definition  Why material balance?  Low of mass conservation  Steps to do a material balance  Example calculation  Exercise  Data required for material balance  Benefits of material balance

3. Definition “Material Balance analysis (MB) is a systematic reconstruction of the way in which a chemical element, a compound or material passes through a natural cycle and/or its economical benefits. An analysis of the material flow, usually is based on the origin of a physical balance.” German investigation Committe, 1993

4. Why Material Balance ÷Éñ ÌâºëÈ¾Æ ¡ÉÊñ ɾàï¾à ¡æÆè?  To Identify the waste steam -÷Éñ ¡Àïºàƾ Ìà»å¾Æ¾à Íß¾å ªæ¾éÄ´  To quantify the waste -¡ÀïºàÆåŠ ÀòÄå¸åºàÄ¨É ª¸¾Æ ¨è×Ä´  For costing purposes -Ãå¾à¶ È ºéÇ¸Æ ¨è×Ä´  Product Development and Modification -¾èËàÀ弾ƾà É摼úÆê¸ê ¨è×Ä´ Íå ¾Éñ¨Ç¸Æ ¨è×Ä´

5. LAW OF MASS CONSERVATION ÌਾའÌâÌà»ü»ü ¾èÆÄÆ “Mass can not be created or destroyed, it can only be Changed“ So Mass will be conserved “ Ìਾà½Æ ÄæÑÄ´ ïÍåà —¾åÊ ¨è×Ä´ ï¾åÍæ¨è ¡ºÇ ¦Æ ïɾºà ¡å¨åÇƨ´ ÀÖÉÚº¾Æ ¨è×Ä Àĸ¨à ¨ÈÍæ¨. ” ¦¾Š Ìਾà½Æ ÌâÌà»ü»ü¨ ïŒ.

6. Simple Form of the Mass Conservation Equation ÌਾའÌâÌà»ü»ü Ìä¨Ç¸ïÆà ÌÇÈ ¡å¨åÇÆ ïƼÉêŠ = ¾èÄæÉêŠ + ¡ÀïºàÆåŠ

7. STEPS TO MATERIAL BALANCE ÷Éñ ÌâºëÈ¾Æ Ì¿Íå ɾ ÀèÆÉÇƾà 1.Identify the production processing steps ¾èËàÀå ¼¾ ¨èòÆåÉÈèïÆà ÀèÆÉÇƾà Íß¾å ªæ¾éÄ 2.Drawing the process flow diagram (PFD) ¾èËàÀå¼¾ ªæÈéŠ Çç ̴; ¡æ¿ûÄ 3.Identify all the input & output material to the each and every processing steps of the PFD ¾èËàÀå¼¾ ªæÈéŠ Çç Ì´Íï¾à ɾ ÌèÆõÄ ¾èËàÀå¼¾ ÀèÆÉÇƾà Ì¿Íå ɾ ïƼÉêŠ Íå ¾èÄÉêŠ Íß¾åªæ¾éÄ 4.Select a system Boundary and Basis for Calculation ª¸¾Æ Ì¿Íå ÌêóÌê ÌéÄåɾà Íå ¨åÈ ÀÇÌƾà Íß¾å ªæ¾éÄ 5.Indicating the known quantitative values of each and every input and output material ÌèÆõÄ ¼¾à¾å ïƼÉêŠ Íå ¾èÄÉêŠ ÉÈ ÀòÄå¸åºàĨ ¡ªÆ¾à Ì´Í¾à ¨Ç ªæ¾éÄ 6.Appling the material balance equation for the selected system boundary ïºåàÇ媺à À¼à½ºèÆ Ì¿Íå ÷Éñ ÌâºëȾ Ìä¨Ç¸Æ ïƼûÄ 7.Solve the equation to calculate the unknown values Ìä¨Ç¸ —̼å ï¾å¼¾à¾å ¡ªÆ¾à ïÌåÆå ªæ¾éÄ

8. IDENTIFY THE PRODUCTION PROCESSING STEPS SortingDisintegration Issuing CoconutDrying HatchatingCooling PeelingGrading WashingPacking Sterilization

9. DRAWING THE PROCESS FLOW DIAGRAM (PFD) Split Coconut Germinated Coconut Empties Coconut Water Shells Rotten Nuts Coconut Water Coconut Pieces Wet Pairings Rotten Nuts Coconut Pieces Coconut Water Washed Water Coconut Pieces Water

10. DRAWING THE PROCESS FLOW DIAGRAM (PFD) Water with Coconut Milk Coconut Pieces Water Coconut Milk Coconut Pieces DC Dust Coconut Oil Under Dried DC Charred Pieces Coarse DC DC Polythene with Paper Bags Treads

11. EXAMPALE ¤¼åÍǸ Calculation of material waste in the process of making a cake. ï¨à¨à Ìç¼ûû Ìèóɾ ÷Éñ ¡ÀïºàÆåÄ ª¾¸Æ ¨è×Ä Menu: Flour (Àè›) – 250 g, Sugar (Ìé¾è ) – 250 g, Butter (´Ú) – 250g, Eggs (”ºàºÇ )- 4 (250 g) Final product- Made cake with the weight of 950 g Making of Cake Flour(250g) Trimming scrapes (30 g) ( Y = ?) Made Cake( 950g ) Sugar Butter (250g) Egg (250g)

12. APPLING THE MATERIAL BALANCE EQUATION ÷Éñ ÌâºëȾ Ìä¨Ç¸Æ ïƼûÄ Input = output + waste ïƼÉêŠ = ¾èÄæÉêŠ + ¡ÀïºàÆåŠ Sugar +Flour +Butter + Egg = Made Cake + Trimming+ Scrapes Ìé¾è +Àè› + Â´Ú + ”ºàºÇ = ¾èËàÀå¼úº ï¨à¨à + ¨æÀéƾ ï¨å´Ìà + Ãå°¾ïÆà ¡æïȾ ï¨å´Ìà 250 +250+250+250 = 950+30+Y Y = 20g

13. EXERCISE ¡ÃñåÌÆ How to Apply Material Balance for a Dryer ? —°È¨ ƾàºòƨà Ì¿Íå ÷Éñ ̾àºëÈ¾Æ ïÆå¼åª¾à¾å ¡å¨åÇÆ Feeding rate of wet material – 2000kg/day —°È¨Æ´ ¼ú¾¨´ ïÆå¼¾ ﺺ ÷Éñ ÀòÄå¾Æ -2000 kg Moisture content of wet material – 60% ﺺà ÷Éñ ºëÈ ¡¶âªë °È ÀòÄå¸Æ - 60% Production rate of dry material – 800 kg/day —°È¨ïÆ¾à ¼ú¾¨´ ÈÂ媺Íæ¨è —ÆÈè ¾èËàÀå¼¾ ÀòÄå¸Æ - 800 kg Residual Moisture content– 5% —ÆÈè ¾èËàÀå¼¾ ÷Éñ ºëÈ ¡¶âªë °È ÀòÄå¸Æ - 5% Calculate ª¾¸Æ ¨è×Ä 1.Amount of water evaporated ÉåËàÀÑ ªèÆ °È ÀòÄå¸Æ 2.Amount of dry material wasted in drying —°È¾ ¨èòÆåÉÈèïÆà¼û ¡Àïºà ªèÆ ÷Éñ ÀòÄå¸Æ

14. DATA SOURCES FOR MATERIAL BALANCE ÷Éñ ÌâºëÈ¾Æ Ì¿Íå ɾ ¼ºàº ÀòÃÉƾà  Purchasing records ȼû ªæ¾éïŠ ÉåÚºå  Stores records ªÂ¶å ÉåÚºå  Production Records ¾èËàÀå¼¾ ÉåÚºå  Garbage Records ÷Éñ ¡ÀÍǸ ÉåÚºå  Security Reports ¡åǨà˨ ÉåÚºå  Sales records —¨ë¸êŠ ÉåÚºå

15. BENEFITS OF MATERIAL BALANCE ÷Éñ ÌâºëȾïÆà ÉåÌè  To do a quantitative analysis of Raw material, Production and Waste Steams ¡Äê÷Éñ, ¾èËàÀ弾ƾà Íå ¡ÀïºàÆåŠ ÀòÄå¸åºàÄ¨É — ÊàïÈàË¸Æ ¨ÈÍæ¨è ÑÄ  To Identify the inefficient areas of the production process ¾èËàÀå¼¾ ¨èòÆåÉÈèïÆà ¡¨åÚƨàËÄ Ìà»å¾ Í߾媺Íæ¨è ÑÄ  To increase the production efficiencies ¾èËàÀå¼¾ ¨èòÆåÉÈèïÆà ¨åÚƨàËĺåÉ ÉÚ½¾Æ ¨Çªº Íæ¨è ÑÄ  To reduce the waste generation ¡À÷Éñ ¡æºèÑÄ ¡ÉÄ ¨Çªº Íæ¨è ÑÄ  To compare the raw material consumption and final production ¡Äê÷Éñ ÀÖïÃåà°¾Æ Íå ¾èËàÀå¼¾ ÀòÄå¸Æ¾à ÌâÌ¾à¼¾Æ ¨È Íæ¨èÑÄ

16. Project Consultant The SWITCH-Asia Programme c/o CCC Solutions (Pvt) Ltd 3rd Floor, IBM Bldg., 48, Nawam Mawatha, Colombo 02, Research Engineer Industrial Technology Institute 303, Bauddhaloka Mawatha Colombo 07 Tel: 011 5588873 Fax: 011 5588866 Email: sampathw@cccsolutions.org Web: www.chamber.lk/switchasia THANK YOU ! ÌàºíºèÆè ! SAMPATH WIJESOORIYA ( B.Sc. Eng.)