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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 available of membrane separations and of sorption separations (adsorption, chromatography, and ion exchange). 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. Coverage includesModular, 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
Contents
Preface xvii Acknowledgments xixAbout the Author xxiNomenclature xxiii Chapter 1: Introduction to Separation Process Engineering 11.1. Importance of Separations 11.2. Concept of Equilibrium 21.3. Mass Transfer 41.4. Problem-Solving Methods 51.5. Prerequisite Material 71.6. Other Resources on Separation Process Engineering 71.7. Summary-Objectives 10References 10Homework 11 Chapter 2: Flash Distillation 132.1. Basic Method of Flash Distillation 132.2. Form and Sources of Equilibrium Data 152.3. Graphical Representation of Binary VLE 182.4. Binary Flash Distillation 222.5. Multicomponent VLE 302.6. Multicomponent Flash Distillation 342.7. Simultaneous Multicomponent Convergence 422.8. Three-Phase Flash Calculations 472.9. Size Calculation 482.10. Utilizing Existing Flash Drums 532.11. Summary-Objectives 54References 54Homework 56Appendix A. Computer Simulation of Flash Distillation 67Appendix B. Spreadsheets for Flash Distillation 73 Chapter 3: Introduction to Column Distillation 793.1. Developing a Distillation Cascade 793.2. Distillation Equipment 863.3. Specifications 883.4. External Column Balances 913.5. Summary-Objectives 95References 95Homework 95 Chapter 4: Column Distillation: Internal Stage-by-Stage Balances 1014.1. Internal Balances 1014.2. Binary Stage-by-Stage Solution Methods 1054.3. Introduction to the McCabe-Thiele Method 1124.4. Feed Line 1164.5. Complete McCabe-Thiele Method 1244.6. Profiles for Binary Distillation 1274.7. Open Steam Heating 1294.8. General McCabe-Thiele Analysis Procedure 1344.9. Other Distillation Column Situations 1404.10. Limiting Operating Conditions 1464.11. Efficiencies 1484.12. Simulation Problems 1504.13. New Uses for Old Columns 1514.14. Subcooled Reflux and Superheated Boilup 1534.15. Comparisons between Analytical and Graphical Methods 1554.16. Summary-Objectives 156References 158Homework 159Appendix A. Computer Simulations for Binary Distillation 173Appendix B. Spreadsheets for Binary Binary Distillation 177 Chapter 5: Introduction to Multicomponent Distillation 1835.1. Calculational Difficulties 1835.2. Stage-By-Stage Calculations for Constant Molal Overflow and Constant Relative Volatility 1895.3. Profiles for Multicomponent Distillation 1935.4. Bubble-Point and Dew-Point Equilibrium Calculations 1985.3. Summary-Objectives 203References 203Homework 203Appendix. Spreadsheet Calculations for Ternary Distillation with Constant Relative Volatility 209 Chapter 6: Exact Calculation Procedures for Multicomponent Distillation 2156.1. Introduction to Matrix Solution for Multicomponent Distillation 2156.2. Component Mass Balances in Matrix Form 2176.3. Initial Guesses for Flow Rates and Temperatures 2206.4. Temperature Convergence 2216.5. Energy Balances in Matrix Form 2246.6. Introduction to Naphtali-Sandholm Simultaneous Convergence Method 2276.7. Discussion 2296.8. Summary-Objectives 230References 230Homework 230Appendix. Computer Simulations for Multicomponent Column Distillation 237 Chapter 7: Approximate Shortcut Methods for Multicomponent Distillation 2437.1. Total Reflux: Fenske Equation 2437.2. Minimum Reflux: Underwood Equations 2487.3. Gilliland Correlation for Number of Stages at Finite Reflux Ratio 2537.4. Summary-Objectives 257References 257Homework 258 Chapter 8: Introduction to Complex Distillation Methods 2658.1. Breaking Azeotropes with Other Separators 2658.2. Binary Heterogeneous Azeotropic Distillation Processes 2668.3. Steam Distillation 2758.4. Two-Pressure Distillation Processes 2798.5. Complex Ternary Distillation Systems 2818.6. Extractive Distillation 2908.7. Azeotropic Distillation with Added Solvent 2968.8. Distillation with Chemical Reaction 3008.9. Summary-Objectives 303References 304Homework 305Appendix. Simulation of Complex Distillation Systems 321 Chapter 9: Batch Distillation 3299.1. Binary Batch Distillation: Rayleigh Equation 3319.2. Simple Binary Batch Distillation 3329.3. Constant-Level Batch Distillation 3369.4. Batch Steam Distillation 3379.5. Multistage Batch Distillation 3409.6. Operating Time 3449.7. Summary-Objectives 346References 347Homework 347 Chapter 10: Staged and Packed Column Design 35710.1. Staged Column Equipment Description 35710.2. Tray Efficiencies 36510.3. Column Diameter Calculations 37010.4. Balancing Calculated Diameters 37610.5. Sieve Tray Layout and Tray Hydraulics 37810.6. Valve Tray Design 38610.7. Introduction to Packed Column Design 38810.8. Packed Column Internals 38810.9. Height of Packing: HETP Method 39010.10. Packed Column Flooding and Diameter Calculation 39210.11. Economic Trade-Offs for Packed Columns 40010.12. Choice of Column Type 40110.13. Summary-Objectives 404References 405Homework 408Appendix. Tray And Downcomer Design with Computer Simulator 416 Chapter 11: Economics and Energy Conservation in Distillation 41911.1. Distillation Costs 41911.2. Operating Effects on Costs 42511.3. Changes in Plant Operating Rates 43211.4. Energy Conservation in Distillation 43311.5. Synthesis of Column Sequences for Almost Ideal Multicomponent Distillation 43711.6. Synthesis of Distillation Systems for Nonideal Ternary Systems 44211.7. Summary-Objectives 447References 447Homework 449 Chapter 12: Absorption and Stripping 45512.1. Absorption and Stripping Equilibria 45712.2. McCabe-Thiele Solution for Dilute Absorption 45912.3. Stripping Analysis for Dilute Systems 46212.4. Analytical Solution for Dilute Systems: Kremser Equation 46312.5. Efficiencies 46912.6. McCabe-Thiele Analysis for More Concentrated Systems 47012.7. Column Diameter 47412.8. Dilute Multisolute Absorbers and Strippers 47612.9. Matrix Solution for Concentrated Absorbers and Strippers 47812.10. Irreversible Absorption and Co-Current Cascades 48212.11. Summary-Objectives 484References 484Homework 485Appendix. Computer Simulations for Absorption and Stripping 494 Chapter 13: Liquid-Liquid Extraction 49913.1. Extraction Processes and Equipment 49913.2. Countercurrent Extraction 50313.3. Dilute Fractional Extraction 51113.4. Immiscible Single-Stage and Cross-Flow Extraction 51513.5. Concentrated Immiscible Extraction 51913.6. Immiscible Batch Extraction 52013.7. Extraction Equilibrium for Partially Miscible Ternary Systems 52213.8. Mixing Calculations and the Lever-Arm Rule 52413.9. Partially Miscible Single-Stage and Cross-Flow Systems 52813.10. Countercurrent Extraction Cascades for Partially Miscible Systems 53113.11. Relationship between McCabe-Thiele and Triangular Diagrams for Partially Miscible Systems 53913.12. Minimum Solvent Rate for Partially Miscible Systems 54013.13. Extraction Computer Simulations 54213.14. Design of Mixer-Settlers 54313.15. Introduction to Design of Reciprocating-Plate (Karr) Columns 55713.16. Summary-Objectives 558References 559Homework 561Appendix. Computer Simulation of Extraction 572 Chapter 14: Washing, Leaching, and Supercritical Extraction 57514.1. Generalized McCabe-Thiele and Kremser Procedures 57514.2. Washing 57614.3. Leaching with Constant Flow Rates 58214.4. Leaching with Variable Flow Rates 58414.5. Supercritical Fluid Extraction 58714.6. Application to Other Separations 59014.7. Summary-Objectives 590References 590Homework 591 Chapter 15: Introduction to Diffusion and Mass Transfer 59915.1. Molecular Movement Leads to Mass Transfer 60015.2. Fickian Model of Diffusivity 60215.3. Values and Correlations for Fickian Binary Diffusivities 61615.4. Linear Driving-Force Model of Mass Transfer for Binary Systems 62215.5. Correlations for Mass-Transfer Coefficients 62815.6. Difficulties with Fickian Diffusion Model 64015.7. Maxwell-Stefan Model of Diffusion and Mass Transfer 64115.8. Advantages and Disadvantages of Different Diffusion and Mass-Transfer Models 65515.9. Summary-Objectives 655References 656Homework 657Appendix. Spreadsheet for Example 15-6 661 Chapter 16: Mass Transfer Analysis for Distillation, Absorption, Stripping, and Extraction 66316.1. HTU-NTU Analysis of Packed Distillation Columns 66316.2. Relationship of HETP and HTU 67316.3. Mass Transfer Correlations for Packed Towers 67516.4. HTU-NTU Analysis of Absorbers and Strippers 68316.5. HTU-NTU Analysis of Co-Current Absorbers 68816.6. Prediction of Distillation Tray Efficiency 69016.7. Mass-Transfer Analysis of Extraction 69316.8. Rate-Based Analysis of Distillation 70816.9. Summary-Objectives 712References 713Homework 714Appendix. Computer Rate-Based Simulation of Distillation 721 Chapter 17: Introduction to Membrane Separation Processes 72517.1. Membrane Separation Equipment 72717.2. Membrane Concepts 73117.3. Gas Permeation 73317.4. Reverse Osmosis 74917.5. Ultrafiltration (UF) 76517.6. Pervaporation (PERVAP) 77117.7. Bulk Flow Pattern Effects 78117.8. Summary-Objectives 788References 788Homework 790Appendix. Spreadsheets for Flow Pattern Calculations for Gas Permeation 798 Chapter 18: Introduction to Adsorption, Chromatography, and Ion Exchange 80518.1. Sorbents and Sorption Equilibrium 80618.2. Solute Movement Analysis for Linear Systems: Basics and Applications to Chromatography 81918.3. Solute Movement Analysis for Linear Systems: Thermal and Pressure Swing Adsorption and Simulated Moving Beds 82818.4. Nonlinear Solute Movement Analysis 85118.6. Mass and Energy Transfer in Packed Beds 87018.7. Mass Transfer Solutions for Linear Systems 87718.8. LUB Approach for Nonlinear Systems 88618.9. Checklist for Practical Design and Operation 89018.10. Summary-Objectives 892References 892Homework 895Appendix. Introduction to the Aspen Chromatography Simulator 909 Appendix A: Aspen Plus Troubleshooting Guide for Separations 915Appendix B: Instructions for Fitting VLE and LLE Data with Aspen Plus 919Appendix C: Unit Conversions and Physical Constants 921Appendix D:Data Locations 923Answers to Selected Problems 931Index 939