Separation Process Engineering: Includes Mass Transfer Analysis

The Definitive, Learner-Friendly Guide to Chemical Engineering Separations--Extensively Updated, Including a New Chapter on Melt Crystallization Efficient separation processes are crucial to addressing many societal problems, from developing new medicines to improving energy efficiency and reducing emissions. Separation Process Engineering, Fifth Edition, is the most comprehensive, accessible guide to modern separation processes and the fundamentals of mass transfer. In this completely updated edition, Phillip C. Wankat teaches each key concept through detailed, realistic examples using actual data--with up-to-date simulation practice, spreadsheet-based exercises, and references. Wankat thoroughly covers each separation process, including flash, column, and batch distillation; exact calculations and shortcut methods for multicomponent distillation; staged and packed column design; absorption; stripping; and more. His extensive discussions of mass transfer and diffusion enable faculty to teach separations and mass transfer in a single course. And detailed material on liquid-liquid extraction, adsorption, chromatography, and ion exchange prepares students for advanced work. New and updated content includes melt crystallization, steam distillation, residue curve analysis, batch washing, the Shanks system for percolation leaching, eutectic systems, forward osmosis, microfiltration, and hybrid separations. A full chapter discusses economics and energy conservation, including updated equipment costs. Over 300 new and updated homework problems are presented, all extensively tested in undergraduate courses at Purdue University. New chapter on melt crystallization: solid-liquid phase equilibrium, suspension, static and falling film layer approaches, and 34 questions and problems New binary VLE equations and updated content on simultaneous solutions New coverage of safety and fire hazards New material on steam distillation, simple multi-component batch distillation, and residue curve analysis Expanded discussion of tray efficiencies, packed column design, and energy reduction in distillation New coverage of two hybrid extraction with distillation, and the Kremser equation in fractional extraction Added sections on deicing with eutectic systems, eutectic freeze concentration, and scale-up New sections on forward osmosis and microfiltration Expanded advanced content on adsorption and ion exchange including updated instructions for eight detailed Aspen Chromatography labs Discussion of membrane separations, including gas permeation, reverse osmosis, ultrafiltration, pervaporation, and applications Thirteen up-to-date Aspen Plus process simulation labs, adaptable to any simulator This guide reflects an up-to-date understanding of how modern students learn: designed, organized, and written to be exceptionally clear and easy to use. It presents detailed examples in a clear, standard format, using real data to solve actual engineering problems, preparing students for their future careers.

Table of Contents:
Preface xxiii Acknowledgments xxv About the Author xxvii Nomenclature xxix   Chapter 1. Introduction to Separation Process Engineering 1 1.0 Summary—Objectives 1 1.1 Importance of Separations 1 1.2 Concept of Equilibrium 3 1.3 Mass Transfer Concepts 4 1.4 Problem-Solving Methods 5 1.5 Units 6 1.6 Computers and Computer Simulations 7 1.7 Prerequisite Material 7 1.8 Other Resources on Separation Process Engineering 9 References 10 Problems 11   Chapter 2. Flash Distillation 13 2.0 Summary—Objectives 13 2.1 Basic Method of Flash Distillation 13 2.2 Form and Sources of Equilibrium Data 15 2.3 Binary VLE 17 2.4 Binary Flash Distillation 26 2.5 Multicomponent VLE 32 2.6 Multicomponent Flash Distillation 36 2.7 Simultaneous Multicomponent Convergence 40 2.8 Three-Phase Flash Calculations 45 2.9 Size Calculation 45 2.10 Using Existing Flash Drums 50 References 51 Problems 52 Appendix A. Computer Simulation of Flash Distillation 62      Lab 1. Introduction to Aspen Plus 62      Lab 2. Flash Distillation 69 Appendix B. Spreadsheets for Flash Distillation 72   Chapter 3. Introduction to Column Distillation 75 3.0 Summary—Objectives 75 3.1 Developing a Distillation Cascade 75 3.2 Tray Column Distillation Equipment 82 3.3 Safety 85 3.4 Specifications 86 3.5 External Column Balances 88 References 92 Problems 92   Chapter 4. Binary Column Distillation: Internal Stage-by-Stage Balances 99 4.0 Summary—Objectives 99 4.1 Internal Balances 99 4.2 Binary Stage-by-Stage Solution Methods 103 4.3 Introduction to the McCabe-Thiele Method 109 4.4 Feed Line 113 4.5 Complete McCabe-Thiele Method 120 4.6 Profiles for Binary Distillation 123 4.7 Open Steam Heating 125 4.8 General McCabe-Thiele Analysis Procedure 129 4.9 Other Distillation Column Situations 134 4.10 Limiting Operating Conditions 141 4.11 Efficiencies 143 4.12 Subcooled Reflux and Superheated Boilup 145 4.13 Simulation Problems 146 4.14 New Uses for Old Columns 148 4.15 Comparisons between Analytical and Graphical Methods 149 References 150 Problems 150 Appendix A. Computer Simulation of Binary Distillation 165      Lab 3. Binary Distillation 165 Appendix B. Spreadsheet for Binary Distillation 169   Chapter 5. Introduction to Multicomponent Distillation 171 5.0 Summary—Objectives 171 5.1 Calculational Difficulties of Multicomponent Distillation 171 5.2 Profiles for Multicomponent Distillation 176 5.3 Stage-by-Stage Calculations for CMO 181 References 186 Problems 187 Appendix A. Simplified Spreadsheet for Stage-by-Stage Calculations      for Ternary Distillation 192   Chapter 6. Exact Calculation Procedures for Multicomponent Distillation 195 6.0 Summary—Objectives 195 6.1 Introduction to Matrix Solution for Multicomponent Distillation 195 6.2 Component Mass Balances in Matrix Form 196 6.3 Initial Guesses for Flow Rates and Temperatures 200 6.4 Temperature Convergence 201 6.5 Energy Balances in Matrix Form 203 6.6 Introduction to Naphtali-Sandholm Simultaneous Convergence Method 206 6.7 Discussion 207 References 208 Problems 208 Appendix. Computer Simulations for Multicomponent Column Distillation 214      Lab 4. Simulation of Multicomponent Distillation 214      Lab 5. Pressure Effects and Tray Efficiencies 216      Lab 6. Coupled Columns 220   Chapter 7. Approximate Shortcut Methods for Multicomponent Distillation 223 7.0 Summary—Objectives 223 7.1 Total Reflux: Fenske Equation 223 7.2 Minimum Reflux: Underwood Equations 228 7.3 Gilliland Correlation for Number of Stages at Finite Reflux Ratios 231 References 234 Problems 235   Chapter 8. Introduction to Complex Distillation Methods 241 8.0 Summary—Objectives 241 8.1 Breaking Azeotropes with Hybrid Separations 241 8.2 Binary Heterogeneous Azeotropic Distillation Processes 243 8.3 Continuous Steam Distillation 251 8.4 Pressure-Swing Distillation Processes 257 8.5 Complex Ternary Distillation Systems 259 8.6 Extractive Distillation 266 8.7 Azeotropic Distillation with Added Solvent 272 8.8 Distillation with Chemical Reaction 274 References 277 Problems 278 Appendix A. Simulation of Complex Distillation Systems 292      Lab 7. Pressure-Swing Distillation for Separating Azeotropes 292      Lab 8. Binary Distillation of Systems with Heterogeneous Azeotropes 295      Lab 9. Simulation of Extractive Distillation 298 Appendix B. Spreadsheet for Distillation curve Generation for Constant      Relative Volatility at Total Reflux 302   Chapter 9. Batch Distillation 303 9.0 Summary—Objectives 303 9.1 Introduction to Batch Distillation 303 9.2 Batch Distillation: Rayleigh Equation 305 9.3 Simple Binary Batch Distillation 307 9.4 Constant-Mole Batch Distillation 312 9.5 Batch Steam Distillation 314 9.6 Multistage Binary Batch Distillation 317 9.7 Multicomponent Simple Batch Distillation and Residue Curve Calculations 321 9.8 Operating Time 324 References 326 Problems 326 Appendix A. Calculations for Simple Multicomponent Batch Distillation and      Residue Curve Analysis 334   Chapter 10. Staged and Packed Column Design 337 10.0 Summary—Objectives 337 10.1 Staged Column Equipment Description 338 10.2 Tray Efficiencies 344 10.3 Column Diameter Calculations 351 10.4 Balancing Calculated Diameters 356 10.5 Sieve Tray Layout and Tray Hydraulics 358 10.6 Valve Tray Design 364 10.7 Introduction to Packed Column Design 366 10.8 Packings and Packed Column Internals 366 10.9 Packed Column Design: HETP Method 368 10.10 Packed Column Flooding and Diameter Calculation 371 10.11 Economic Trade-Offs for Packed Columns 378 10.12 Choice of Column Type 379 10.13 Fire Hazards of Structured Packings 381 References 382 Problems 385 Appendix. Tray and Downcomer Design with Computer Simulator 392      Lab 10. Detailed Design 392   Chapter 11. Economics and Energy Efficiency in Distillation 397 11.0 Summary—Objectives 397 11.1 Equipment Costs 397 11.2 Basic Heat Exchanger Design 404 11.3 Design and Operating Effects on Costs 406 11.4 Changes in Plant Operating Rates 414 11.5 Energy Reduction in Binary Distillation Systems 415 11.6 Synthesis of Column Sequences for Almost Ideal Multicomponent Distillation 419 11.7 Synthesis of Distillation Systems for Nonideal Ternary Systems 425 11.8 Next Steps 429 References 430 Problems 431   Chapter 12. Absorption and Stripping 439 12.0 Summary—Objectives 440 12.1 Absorption and Stripping Equilibria 441 12.2 McCabe-Thiele Solution for Dilute Absorption 444 12.3 Stripping Analysis for Dilute Systems 446 12.4 Analytical Solution for Dilute Systems: Kremser Equation 447 12.5 Efficiencies 452 12.6 McCabe-Thiele Analysis for More Concentrated Systems 453 12.7 Column Diameter 457 12.8 Dilute Multisolute Absorbers and Strippers 458 12.9 Matrix Solution for Concentrated Absorbers and Strippers 460 12.10 Irreversible Absorption and Cocurrent Cascades 463 References 465 Problems 466 Appendix. Computer Simulations of Absorption and Stripping 474      Lab 11. Absorption and Stripping 474   Chapter 13. Liquid-Liquid Extraction 481 13.0 Summary—Objectives 481 13.1 Introduction to Extraction Processes and Equipment 481 13.2 Equilibrium for Dilute Systems and Solvent Selection 486 13.3 Dilute, Immiscible, Countercurrent Extraction 489 13.4 Immiscible Single-Stage and Crossflow Extraction 499 13.5 Concentrated Immiscible Extraction 502 13.6 Immiscible Batch Extraction 506 13.7 Extraction Equilibrium for Partially Miscible Ternary Systems 508 13.8 Mixing Calculations and the Lever-Arm Rule 511 13.9 Partially Miscible Single-Stage and Crossflow Systems 513 13.10 Partially Miscible Countercurrent Extraction 516 13.11 Relationship Between McCabe-Thiele and Triangular Diagrams for Partially      Miscible Systems 522 13.12 Minimum Solvent Rate for Partially Miscible Systems 523 13.13 Extraction Computer Simulations 525 13.14 Design of Mixer-Settlers 526 References 537 Problems 538 Appendix. Computer Simulation of Extraction 545      Lab 12. Extraction 545   Chapter 14. Washing, Leaching, and Supercritical Extraction 551 14.0 Summary—Objectives 551 14.1 Generalized McCabe-Thiele and Kremser Procedures 551 14.2 Washing 552 14.3 Leaching 559 14.4 Introduction to Supercritical Fluid Extraction 565 References 568 Problems 568   Chapter 15. Introduction to Diffusion and Mass Transfer 575 15.0 Summary−Objectives 576 15.1 Molecular Movement Leads to Mass Transfer 577 15.2 Fickian Model of Diffusivity 578 15.3 Values and Correlations for Fickian Binary Diffusivities 593 15.4 Linear Driving-Force Model of Mass Transfer for Binary Systems 601 15.5 Correlations for Mass Transfer Coefficients 615 15.6 Difficulties with Fickian Diffusion Model 626 15.7 Maxwell-Stefan Model of Diffusion and Mass Transfer 627 15.8 Advantages and Disadvantages of Different Diffusion and Mass Transfer Models 641 15.9 Useful Approximate Values 642 References 642 Problems 643 Appendix. Spreadsheets for Examples 15-10 and 15-11 650   Chapter 16. Mass Transfer Analyses for Distillation, Absorption, Stripping, and Extraction 653 16.0 Summary—Objectives 653 16.1 HTU-NTU Analysis of Packed Distillation Columns 653 16.2 Relationship of HETP and HTU 661 16.3 Correlations for HTU Values for Packings 663 16.4 HTU-NTU Analysis of Absorbers and Strippers 670 16.5 HTU-NTU Analysis of Cocurrent Absorbers 675 16.6 Prediction of Distillation Tray Efficiency 677 16.7 Mass Transfer Analysis of Extraction 679 16.7.4.3 Conservative Estimation of Mass Transfer Coefficients for Extraction 689 16.8 Rate-Based Analysis of Distillation 690 References 693 Problems 695 Appendix. Computer Rate-Based Simulation of Distillation 702      Lab 13. Rate-Based Modeling of Distillation 702   Chapter 17. Crystallization from Solution 705 17.0 Summary–Objectives 706 17.1 Basic Principles of Crystallization from Solution 706 17.2 Continuous Cooling Crystallizers 712 17.3 Evaporative and Vacuum Crystallizers 722 17.4 Experimental Crystal Size Distribution 729 17.5 Introduction to Population Balances 734 17.6 Crystal Size Distributions for MSMPR Crystallizers 736 17.7 Seeding 750 17.8 Scaleup 755 17.9 Batch and Semibatch Crystallization 756 17.10 Precipitation 761 References 764 Problems 765 Appendix. Spreadsheet 772   Chapter 18. Melt Crystallization 773 18.0 Summary–Objectives 773 18.1 Equilibrium Calculations for Melt Crystallization 774 18.2 Suspension Melt Crystallization 780 18.3 Introduction to Solid-Layer Crystallization Processes: Progressive Freezing 793 18.4 Static Solid-Layer Melt Crystallization Process 808 18.5 Dynamic Solid-Layer Melt Crystallization 809 18.6 Zone Melting 819 18.7 Post-Crystallization Processing 824 18.8 Scaleup 827 18.9 Hybrid Crystallization–Distillation Processes 828 18.10 Predictions 833 References 834 Problems 836   Chapter 19. Introduction to Membrane Separation Processes 841 19.0 Summary—Objectives 844 19.1 Membrane Separation Equipment 844 19.2 Membrane Concepts 847 19.3 Gas Permeation (GP) 850 19.4 Osmosis and Reverse Osmosis (RO) 865 19.5 Ultrafiltration (UF)` 881 19.6 Pervaporation 891 19.7 Bulk Flow Pattern Effects 902 References 905 Problems 907 Appendix A. Spreadsheet for Crossflow GP 918   Chapter 20. Introduction to Adsorption, Chromatography, and Ion Exchange 923 20.0 Summary—Objectives 924 20.1 Adsorbents and Adsorption Equilibrium 924 20.2 Solute Movement Analysis for Linear Systems: Basics and      Applications to Chromatography 935 20.3 Solute Movement Analysis for Linear Systems: Temperature and      Pressure Swing Adsorption and Simulated Moving Beds 942 20.4 Nonlinear Solute Movement Analysis 963 20.5 Ion Exchange 970 References 978 Problems 980   Chapter 21. Mass Transfer Analysis of Adsorption, Chromatography, and Ion Exchange 991 21.0 Summary—Objectives 991 21.1 Mass and Energy Transfer in Packed Beds 991 21.2 Mass Transfer Solutions for Linear Systems 1000 21.3 Nonlinear Systems 1008 21.4 Checklist for Practical Design and Operation 1019 References 1021 Problems 1022 Appendix. Aspen Chromatography Simulator 1030      Lab AC1. Introduction to Aspen Chromatography 1031      Lab AC2. Convergence for Linear Isotherms 1035      Lab AC3. Convergence for Nonlinear Isotherms 1036      Lab AC4. Cycle Organizer 1038      Lab AC5. Flow Reversal 1041      Lab AC6. Ion Exchange 1045      Lab AC7. SMB and TMB 1048      Lab AC8. Thermal Systems 1051   Answers to Selected Problems 1057   Appendix A. Aspen Plus Troubleshooting Guide for Separations 1063 Appendix B. Instructions for Fitting VLE and LLE Data with Aspen Plus 1067 Appendix C. Unit Conversions and Physical Constants 1071 Appendix D. Data Locations 1073   Index