9780131382275

The Definitive, Fully Updated Guide to Separation Process Engineering ;Now with a Thorough Introduction to Mass Transfer Analysis Separation Process Engineering, Third Edition,is the most comprehensive, accessible guide available on modern separation processes and the fundamentals of mass transfer. Phillip C. Wankat teaches each key concept through detailed, realistic examples using real data ;including up-to-date simulation practice and new spreadsheet-based exercises. Wankat thoroughly covers each of today's leading approaches, including flash, column, and batch distillation; exact calculations and shortcut methods for multicomponent distillation; staged and packed column design; absorption; stripping; and more. In this edition, he also presents the latest design methods for liquid-liquid extraction. This edition contains the most detailed coverage of membrane separations and of sorption separations (adsorption, chromatography, and ion exchange) available. Updated with new techniques and references throughout, Separation Process Engineering, Third Edition,also contains more than 300 new homework problems, each tested in the author's Purdue University classes. This new edition includes Modular, up-to-date process simulation examples and homework problems, based on Aspen Plus and easily adaptable to any simulator Extensive new coverage of mass transfer and diffusion, including both Fickian and Maxwell-Stefan approaches Detailed discussions of liquid-liquid extraction, including McCabe-Thiele, triangle and computer simulation analyses; mixer-settler design; Karr columns; and related mass transfer analyses Thorough introductions to adsorption, chromatography, and ion exchange ;designed to prepare students for advanced work in these areas Complete coverage of membrane separations, including gas permeation, reverse osmosis, ultrafiltration, pervaporation, and key applications A full chapter on economics and energy conservation in distillation Excel spreadsheets offering additional practice with problems in distillation, diffusion, mass transfer, and membrane separation [Author bio] Phillip C. Wankatis Clifton L. Lovell Distinguished Professor of Chemical Engineering and director of undergraduate degree programs at Purdue University's School of Engineering Education. His current research interests include adsorption, large-scale chromatography, simulated moving bed systems, and distillation, as well as improvements in engineering education. He received the 2007 Distinguished Education Alumni Award of Distinction from Purdue's College of Education, and the 2005 Shreve Prize in Chemical Engineering. With K. S. Knaebel, he contributed the Mass Transfer section to Perry's Handbook of Chemical Engineering, Eighth Edition(McGraw-Hill, 2008).

Phillip C. Wankat is Clifton L. Lovell Distinguished Professor of Chemical Engineering and director of undergraduate degree programs at Purdue University’s School of Engineering Education. His current research interests include adsorption, large-scale chromatography, simulated moving bed systems, and distillation, as well as improvements in engineering education. He received the 2007 Distinguished Education Alumni Award of Distinction from Purdue’s College of Education, and the 2005 Shreve Prize in Chemical Engineering. With K. S. Knaebel, he contributed the Mass Transfer section to Perry’s Handbook of Chemical Engineering, Eighth Edition (McGraw-Hill, 2008).

Preface         xvii
Acknowledgments         xix

About the Author         xxi

Nomenclature         xxiii

Chapter 1: Introduction to Separation Process Engineering 1

1.1. Importance of Separations 1

1.2. Concept of Equilibrium 2

1.3. Mass Transfer 4

1.4. Problem-Solving Methods 5

1.5. Prerequisite Material 7

1.6. Other Resources on Separation Process Engineering 7

1.7. Summary–Objectives 10

References 10

Homework 11

Chapter 2: Flash Distillation 13

2.1. Basic Method of Flash Distillation 13

2.2. Form and Sources of Equilibrium Data 15

2.3. Graphical Representation of Binary VLE 18

2.4. Binary Flash Distillation 22

2.5. Multicomponent VLE 30

2.6. Multicomponent Flash Distillation 34

2.7. Simultaneous Multicomponent Convergence 42

2.8. Three-Phase Flash Calculations 47

2.9. Size Calculation 48

2.10. Utilizing Existing Flash Drums 53

2.11. Summary–Objectives 54

References 54

Homework 56

Appendix A. Computer Simulation of Flash Distillation 67

Appendix B. Spreadsheets for Flash Distillation 73

Chapter 3: Introduction to Column Distillation 79

3.1. Developing a Distillation Cascade 79

3.2. Distillation Equipment 86

3.3. Specifications 88

3.4. External Column Balances 91

3.5. Summary–Objectives 95

References 95

Homework 95

Chapter 4: Column Distillation: Internal Stage-by-Stage Balances 101

4.1. Internal Balances 101

4.2. Binary Stage-by-Stage Solution Methods 105

4.3. Introduction to the McCabe-Thiele Method 112

4.4. Feed Line 116

4.5. Complete McCabe-Thiele Method 124

4.6. Profiles for Binary Distillation 127

4.7. Open Steam Heating 129

4.8. General McCabe-Thiele Analysis Procedure 134

4.9. Other Distillation Column Situations 140

4.10. Limiting Operating Conditions 146

4.11. Efficiencies 148

4.12. Simulation Problems 150

4.13. New Uses for Old Columns 151

4.14. Subcooled Reflux and Superheated Boilup 153

4.15. Comparisons between Analytical and Graphical Methods 155

4.16. Summary–Objectives 156

References 158

Homework 159

Appendix A. Computer Simulations for Binary Distillation 173

Appendix B. Spreadsheets for Binary Binary Distillation 177

Chapter 5: Introduction to Multicomponent Distillation 183

5.1. Calculational Difficulties 183

5.2. Stage-By-Stage Calculations for Constant Molal Overflow and Constant Relative Volatility 189

5.3. Profiles for Multicomponent Distillation 193

5.4. Bubble-Point and Dew-Point Equilibrium Calculations 198

5.3. Summary–Objectives 203

References 203

Homework 203

Appendix. Spreadsheet Calculations for Ternary Distillation with Constant Relative Volatility 209

Chapter 6: Exact Calculation Procedures for Multicomponent Distillation 215

6.1. Introduction to Matrix Solution for Multicomponent Distillation 215

6.2. Component Mass Balances in Matrix Form 217

6.3. Initial Guesses for Flow Rates and Temperatures 220

6.4. Temperature Convergence 221

6.5. Energy Balances in Matrix Form 224

6.6. Introduction to Naphtali-Sandholm Simultaneous Convergence Method 227

6.7. Discussion 229

6.8. Summary–Objectives 230

References 230

Homework 230

Appendix. Computer Simulations for Multicomponent Column Distillation 237

Chapter 7: Approximate Shortcut Methods for Multicomponent Distillation 243

7.1. Total Reflux: Fenske Equation 243

7.2. Minimum Reflux: Underwood Equations 248

7.3. Gilliland Correlation for Number of Stages at Finite Reflux Ratio 253

7.4. Summary–Objectives 257

References 257

Homework 258

Chapter 8: Introduction to Complex Distillation Methods 265

8.1. Breaking Azeotropes with Other Separators 265

8.2. Binary Heterogeneous Azeotropic Distillation Processes 266

8.3. Steam Distillation 275

8.4. Two-Pressure Distillation Processes 279

8.5. Complex Ternary Distillation Systems 281

8.6. Extractive Distillation 290

8.7. Azeotropic Distillation with Added Solvent 296

8.8. Distillation with Chemical Reaction 300

8.9. Summary–Objectives 303

References 304

Homework 305

Appendix. Simulation of Complex Distillation Systems 321

Chapter 9: Batch Distillation 329

9.1. Binary Batch Distillation: Rayleigh Equation 331

9.2. Simple Binary Batch Distillation 332

9.3. Constant-Level Batch Distillation 336

9.4. Batch Steam Distillation 337

9.5. Multistage Batch Distillation 340

9.6. Operating Time 344

9.7. Summary–Objectives 346

References 347

Homework 347

Chapter 10: Staged and Packed Column Design 357

10.1. Staged Column Equipment Description 357

10.2. Tray Efficiencies 365

10.3. Column Diameter Calculations 370

10.4. Balancing Calculated Diameters 376

10.5. Sieve Tray Layout and Tray Hydraulics 378

10.6. Valve Tray Design 386

10.7. Introduction to Packed Column Design 388

10.8. Packed Column Internals 388

10.9. Height of Packing: HETP Method 390

10.10. Packed Column Flooding and Diameter Calculation 392

10.11. Economic Trade-Offs for Packed Columns 400

10.12. Choice of Column Type 401

10.13. Summary–Objectives 404

References 405

Homework 408

Appendix. Tray And Downcomer Design with Computer Simulator 416

Chapter 11: Economics and Energy Conservation in Distillation 419

11.1. Distillation Costs 419

11.2. Operating Effects on Costs 425

11.3. Changes in Plant Operating Rates 432

11.4. Energy Conservation in Distillation 433

11.5. Synthesis of Column Sequences for Almost Ideal Multicomponent Distillation 437

11.6. Synthesis of Distillation Systems for Nonideal Ternary Systems 442

11.7. Summary–Objectives 447

References 447

Homework 449

Chapter 12: Absorption and Stripping 455

12.1. Absorption and Stripping Equilibria 457

12.2. McCabe-Thiele Solution for Dilute Absorption 459

12.3. Stripping Analysis for Dilute Systems 462

12.4. Analytical Solution for Dilute Systems: Kremser Equation 463

12.5. Efficiencies 469

12.6. McCabe-Thiele Analysis for More Concentrated Systems 470

12.7. Column Diameter 474

12.8. Dilute Multisolute Absorbers and Strippers 476

12.9. Matrix Solution for Concentrated Absorbers and Strippers 478

12.10. Irreversible Absorption and Co-Current Cascades 482

12.11. Summary–Objectives 484

References 484

Homework 485

Appendix. Computer Simulations for Absorption and Stripping 494

Chapter 13: Liquid-Liquid Extraction 499

13.1. Extraction Processes and Equipment 499

13.2. Countercurrent Extraction 503

13.3. Dilute Fractional Extraction 511

13.4. Immiscible Single-Stage and Cross-Flow Extraction 515

13.5. Concentrated Immiscible Extraction 519

13.6. Immiscible Batch Extraction 520

13.7. Extraction Equilibrium for Partially Miscible Ternary Systems 522

13.8. Mixing Calculations and the Lever-Arm Rule 524

13.9. Partially Miscible Single-Stage and Cross-Flow Systems 528

13.10. Countercurrent Extraction Cascades for Partially Miscible Systems 531

13.11. Relationship between McCabe-Thiele and Triangular Diagrams for Partially Miscible Systems 539

13.12. Minimum Solvent Rate for Partially Miscible Systems 540

13.13. Extraction Computer Simulations 542

13.14. Design of Mixer-Settlers 543

13.15. Introduction to Design of Reciprocating-Plate (Karr) Columns 557

13.16. Summary–Objectives 558

References 559

Homework 561

Appendix. Computer Simulation of Extraction 572

Chapter 14: Washing, Leaching, and Supercritical Extraction 575

14.1. Generalized McCabe-Thiele and Kremser Procedures 575

14.2. Washing 576

14.3. Leaching with Constant Flow Rates 582

14.4. Leaching with Variable Flow Rates 584

14.5. Supercritical Fluid Extraction 587

14.6. Application to Other Separations 590

14.7. Summary–Objectives 590

References 590

Homework 591

Chapter 15: Introduction to Diffusion and Mass Transfer 599

15.1. Molecular Movement Leads to Mass Transfer 600

15.2. Fickian Model of Diffusivity 602

15.3. Values and Correlations for Fickian Binary Diffusivities 616

15.4. Linear Driving-Force Model of Mass Transfer for Binary Systems 622

15.5. Correlations for Mass-Transfer Coefficients 628

15.6. Difficulties with Fickian Diffusion Model 640

15.7. Maxwell-Stefan Model of Diffusion and Mass Transfer 641

15.8. Advantages and Disadvantages of Different Diffusion and Mass-Transfer Models 655

15.9. Summary—Objectives 655

References 656

Homework 657

Appendix. Spreadsheet for Example 15-6 661

Chapter 16: Mass Transfer Analysis for Distillation, Absorption, Stripping, and Extraction 663

16.1. HTU-NTU Analysis of Packed Distillation Columns 663

16.2. Relationship of HETP and HTU 673

16.3. Mass Transfer Correlations for Packed Towers 675

16.4. HTU-NTU Analysis of Absorbers and Strippers 683

16.5. HTU-NTU Analysis of Co-Current Absorbers 688

16.6. Prediction of Distillation Tray Efficiency 690

16.7. Mass-Transfer Analysis of Extraction 693

16.8. Rate-Based Analysis of Distillation 708

16.9. Summary–Objectives 712

References 713

Homework 714

Appendix. Computer Rate-Based Simulation of Distillation 721

Chapter 17: Introduction to Membrane Separation Processes 725

17.1. Membrane Separation Equipment 727

17.2. Membrane Concepts 731

17.3. Gas Permeation 733

17.4. Reverse Osmosis 749

17.5. Ultrafiltration (UF) 765

17.6. Pervaporation (PERVAP) 771

17.7. Bulk Flow Pattern Effects 781

17.8. Summary–Objectives 788

References 788

Homework 790

Appendix. Spreadsheets for Flow Pattern Calculations for Gas Permeation 798

Chapter 18: Introduction to Adsorption, Chromatography, and Ion Exchange 805

18.1. Sorbents and Sorption Equilibrium 806

18.2. Solute Movement Analysis for Linear Systems: Basics and Applications to Chromatography 819

18.3. Solute Movement Analysis for Linear Systems: Thermal and Pressure Swing Adsorption and Simulated Moving Beds 828

18.4. Nonlinear Solute Movement Analysis 851

18.6. Mass and Energy Transfer in Packed Beds 870

18.7. Mass Transfer Solutions for Linear Systems 877

18.8. LUB Approach for Nonlinear Systems 886

18.9. Checklist for Practical Design and Operation 890

18.10. Summary–Objectives 892

References 892

Homework 895

Appendix. Introduction to the Aspen Chromatography Simulator 909

Appendix A: Aspen Plus Troubleshooting Guide for Separations            915

Appendix B: Instructions for Fitting VLE and LLE Data with Aspen Plus           919

Appendix C: Unit Conversions and Physical Constants           921

Appendix D:Data Locations           923

Answers to Selected Problems           931

Index         939

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Separation Process Engineering Includes Mass Transfer Analysis

Separation Process Engineering Includes Mass Transfer Analysis

0131382276

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