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Separation Process Engineering: Includes Mass Transfer Analysis, Fourth Edition
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Separation Process Engineering: Includes Mass Transfer Analysis, Fourth Edition
by Phillip C. Wankat
Separation Process Engineering: Includes Mass Transfer Analysis, Fourth Edition
About This E-Book
Title Page
Copyright Page
Dedication Page
Contents
Preface
Acknowledgments
About the Author
Nomenclature
Chapters 1 through 16
Greek
Chapter 17
Greek
Chapter 18
Greek letters
Chapter 19
Greek letters
Chapter 1. Introduction to Separation Process Engineering
1.0 Summary—Objectives
1.1 Importance of Separations
1.2 Concept of Equilibrium
1.3 Mass Transfer Concepts
1.4 Problem-Solving Methods
Problem-Solving Heuristics
1.5 Units
1.6 Computers and Computer Simulations
1.7 Prerequisite Material
1.8 Other Resources on Separation Process Engineering
References
Homework
Chapter 2. Flash Distillation
2.0 Summary—Objectives
2.1 Basic Method of Flash Distillation
2.2 Form and Sources of Equilibrium Data
2.3 Graphical Representation of Binary VLE
2.4 Binary Flash Distillation
2.4.1 Sequential Solution Procedure
2.4.2 Simultaneous Solution Procedure
2.4.3 Simultaneous Solution and Enthalpy-Composition Diagram
2.5 Multicomponent VLE
2.6 Multicomponent Flash Distillation
2.7 Simultaneous Multicomponent Convergence
2.8 Three-Phase Flash Calculations
2.9 Size Calculation
2.10 Using Existing Flash Drums
References
Homework
Chapter 2. Appendix A. Computer Simulation of Flash Distillation
Chapter 2 Appendix B. Spreadsheets for Flash Distillation
2.B.1 Binary Flash Distillation with Excel
2.B.2 Multicomponent Flash Distillation with Excel
Chapter 3. Introduction to Column Distillation
3.0 Summary—Objectives
3.1 Developing a Distillation Cascade
3.2 Distillation Equipment
3.3 Specifications
3.4 External Column Balances
References
Homework
Chapter 4. Binary Column Distillation: Internal Stage-by-Stage Balances
4.0 Summary—Objectives
4.1 Internal Balances
4.2 Binary Stage-by-Stage Solution Methods
4.3 Introduction to the McCabe-Thiele Method
4.4 Feed Line
4.5 Complete McCabe-Thiele Method
4.6 Profiles for Binary Distillation
4.7 Open Steam Heating
4.8 General McCabe-Thiele Analysis Procedure
4.9 Other Distillation Column Situations
4.9.1 Partial Condensers
4.9.2 Total Reboilers
4.9.3 Side Streams or Withdrawal Lines
4.9.4 Intermediate Reboilers and Intermediate Condensers
4.9.5 Stripping and Enriching Columns
4.10 Limiting Operating Conditions
4.11 Efficiencies
4.12 Simulation Problems
4.13 New Uses for Old Columns
4.14 Subcooled Reflux and Superheated Boilup
4.15 Comparisons Between Analytical and Graphical Methods
References
Homework
Chapter 4 Appendix A. Computer Simulation of Binary Distillation
Chapter 4 Appendix B. Spreadsheets for Binary Distillation
Chapter 5. Introduction to Multicomponent Distillation
5.0 Summary—Objectives
5.1 Calculational Difficulties
5.2 Profiles for Multicomponent Distillation
5.3 Stage-by-Stage Calculations for CMO
References
Homework
Chapter 5 Appendix A. Simplified Spreadsheet for Stage-by-Stage Calculations for Ternary Distillation
Chapter 5 Appendix B. Automated Spreadsheet with VBA for Stage-by-Stage Calculations for Ternary Distillation
Chapter 6. Exact Calculation Procedures for Multicomponent Distillation
6.0 Summary—Objectives
6.1 Introduction to Matrix Solution for Multicomponent Distillation
6.2 Component Mass Balances in Matrix Form
6.3 Initial Guesses for Flow Rates and Temperatures
6.4 Temperature Convergence
6.5 Energy Balances in Matrix Form
6.6 Introduction to Naphtali-Sandholm Simultaneous Convergence Method
6.7 Discussion
References
Homework
Chapter 6 Appendix. Computer Simulations for Multicomponent Column Distillation
Chapter 7. Approximate Shortcut Methods for Multicomponent Distillation
7.0 Summary—Objectives
7.1 Total Reflux: Fenske Equation
7.2 Minimum Reflux: Underwood Equations
7.3 Gilliland Correlation for Number of Stages at Finite Reflux Ratios
References
Homework
Chapter 8. Introduction to Complex Distillation Methods
8.0 Summary—Objectives
8.1 Breaking Azeotropes with Other Separators
8.2 Binary Heterogeneous Azeotropic Distillation Processes
8.2.1 Binary Heterogeneous Azeotropes—Single-Column System
8.2.2 Binary Heterogeneous Azeotropes—Two-Column System
8.2.3 Drying Organic Compounds That Are Partially Miscible with Water
8.3 Steam Distillation
8.4 Pressure-Swing Distillation Processes
8.5 Complex Ternary Distillation Systems
8.5.1 Distillation Curves
8.5.2 Residue Curves
8.6 Extractive Distillation
8.7 Azeotropic Distillation with Added Solvent
8.8 Distillation with Chemical Reaction
References
Homework
Chapter 8 Appendix A. Simulation of Complex Distillation Systems
Chapter 8 Appendix B. Spreadsheet for Residue Curve Generation
Chapter 9. Batch Distillation
9.0 Summary—Objectives
9.1 Introduction to Batch Distillation
9.2 Batch Distillation: Rayleigh Equation
9.2.1 Mixed Distillate Product
9.2.2 Distillate Product Fractions
9.3 Simple Binary Batch Distillation
9.4 Constant-Mole Batch Distillation
9.5 Batch Steam Distillation
9.6 Multistage Binary Batch Distillation
9.6.1 Constant Reflux Ratio
9.6.2 Variable Reflux Ratio
9.7 Multicomponent Simple Batch Distillation
9.8 Operating Time
References
Homework
Chapter 9 Appendix A. Spreadsheet for Simple Multicomponent Batch Distillation, Constant Relative Volatility
Chapter 10. Staged and Packed Column Design
10.0 Summary—Objectives
10.1 Staged Column Equipment Description
10.1.1 Trays, Downcomers, and Weirs
10.1.2 Inlets and Outlets
10.2 Tray Efficiencies
10.3 Column Diameter Calculations
10.4 Balancing Calculated Diameters
10.5 Sieve Tray Layout and Tray Hydraulics
10.6 Valve Tray Design
10.7 Introduction to Packed Column Design
10.8 Packings and Packed Column Internals
10.9 Height of Packing: HETP Method
10.10 Packed Column Flooding and Diameter Calculation
10.11 Economic Trade-Offs for Packed Columns
10.12 Choice of Column Type
References
Homework
Chapter 10 Appendix. Tray and Downcomer Design with Computer Simulator
Chapter 11. Economics and Energy Conservation in Distillation
11.0 Summary—Objectives
11.1 Equipment Costs
11.2 Basic Heat Exchanger Design
11.3 Design and Operating Effects on Costs
11.4 Changes in Plant Operating Rates
11.5 Energy Conservation in Distillation
11.6 Synthesis of Column Sequences for Almost Ideal Multicomponent Distillation
11.7 Synthesis of Distillation Systems for Nonideal Ternary Systems
References
Homework
Chapter 12. Absorption and Stripping
12.0 Summary—Objectives
12.1 Absorption and Stripping Equilibria
12.2 McCabe-Thiele Solution for Dilute Absorption
12.3 Stripping Analysis for Dilute Systems
12.4 Analytical Solution for Dilute Systems: Kremser Equation
12.5 Efficiencies
12.6 McCabe-Thiele Analysis for More Concentrated Systems
12.7 Column Diameter
12.8 Dilute Multisolute Absorbers and Strippers
12.9 Matrix Solution for Concentrated Absorbers and Strippers
12.10 Irreversible Absorption and Cocurrent Cascades
References
Homework
Chapter 12 Appendix. Computer Simulations of Absorption and Stripping
Chapter 13. Liquid-Liquid Extraction
13.0 Summary—Objectives
13.1 Extraction Processes and Equipment
13.2 Dilute, Immiscible, Countercurrent Extraction
13.2.1 McCabe-Thiele Method for Dilute Systems
13.2.2 Kremser Method for Dilute Systems
13.3 Dilute Fractional Extraction
13.4 Immiscible Single-Stage and Cross-Flow Extraction
13.5 Concentrated Immiscible Extraction
13.6 Immiscible Batch Extraction
13.7 Extraction Equilibrium for Partially Miscible Ternary Systems
13.8 Mixing Calculations and the Lever-Arm Rule
13.9 Partially Miscible Single-Stage and Cross-Flow Systems
13.10 Countercurrent Extraction Cascades for Partially Miscible Systems
13.10.1 External Mass Balances
13.10.2 Difference Points and Stage-by-Stage Calculations
13.10.3 Complete Partially Miscible Extraction Problem
13.11 Relationship Between McCabe-Thiele and Triangular Diagrams for Partially Miscible Systems
13.12 Minimum Solvent Rate for Partially Miscible Systems
13.13 Extraction Computer Simulations
13.14 Design of Mixer-Settlers
13.14.1 Mixer Design
13.14.2 Settler (Decanter) Design
References
Homework
Chapter 13 Appendix. Computer Simulation of Extraction
Chapter 14. Washing, Leaching, and Supercritical Extraction
14.0 Summary—Objectives
14.1 Generalized McCabe-Thiele and Kremser Procedures
14.2 Washing
14.3 Leaching with Constant Flow Rates
14.4 Leaching with Variable Flow Rates
14.5 Introduction to Supercritical Fluid Extraction
14.6 Application of McCabe-Thiele and Kremser Methods to Other Separations
References
Homework
Chapter 15. Introduction to Diffusion and Mass Transfer
15.0 Summary–Objectives
15.1 Molecular Movement Leads to Mass Transfer
15.2 Fickian Model of Diffusivity
15.2.1 Fick’s Law and the Fickian Definition of Diffusivity
15.2.2 Steady-State Binary Fickian Diffusion and Mass Balances without Convection
15.2.3 Unsteady Binary Fickian Diffusion with No Convection (Optional)
15.2.4 Steady-State Binary Fickian Diffusion and Mass Balances with Convection
15.3 Values and Correlations for Fickian Binary Diffusivities
15.3.1 Fickian Binary Gas Diffusivities
15.3.2 Fickian Binary Liquid Diffusivities
15.3.3 Numerical Solution with Variable Binary Diffusivity
15.4 Linear Driving-Force Model of Mass Transfer for Binary Systems
15.4.1 Film Theory for Dilute and Equimolar Transfer Systems
15.4.2 Transfer through Stagnant Films: Absorbers and Strippers
15.4.3 Binary Mass Transfer to Expanding or Contracting Objects
15.5 Correlations for Mass Transfer Coefficients
15.5.1 Dimensionless Groups
15.5.2 Theoretically Derived Mass Transfer Correlations
15.5.3 Semi-Empirical and Empirical Mass Transfer Coefficient Correlations
15.5.4 Correlations Based on Analogies
15.6 Difficulties with Fickian Diffusion Model
15.7 Maxwell-Stefan Model of Diffusion and Mass Transfer
15.7.1 Introductory Development of the Maxwell-Stefan Theory of Diffusion
15.7.2 Maxwell-Stefan Equations for Binary Nonideal Systems
15.7.3 Determining Independent Fluxes Nj,z
15.7.4 Maxwell-Stefan Difference Equation Formulations
15.7.5 Relationship between Maxwell-Stefan and Fickian Diffusivities
15.7.6 Ideal Ternary Systems
15.7.7 Ternary Mass Transfer to Expanding or Contracting Objects
15.7.8 Nonideal Ternary Systems
15.8 Advantages and Disadvantages of Different Diffusion and Mass Transfer Models
References
Homework
Chapter 15 Appendix. Spreadsheets Examples 15-10 and 15-11
Chapter 16. Mass Transfer Analysis for Distillation, Absorption, Stripping, and Extraction
16.0 Summary—Objectives
16.1 HTU-NTU Analysis of Packed Distillation Columns
16.2 Relationship of HETP and HTU
16.3 Mass Transfer Correlations for Packed Towers
16.3.1 Bolles and Fair Correlation for Random Packings
16.3.2 Simple Correlations for Random Packings
16.4 HTU-NTU Analysis of Concentrated Absorbers and Strippers
16.5 HTU-NTU Analysis of CoCurrent Absorbers
16.6 Prediction of Distillation Tray Efficiency
16.7 Mass Transfer Analysis of Extraction
16.7.1 Extraction Mass Transfer Equations and HTU-NTU Analysis
16.7.2 Calculation of Stage Efficiency in Extraction Mixers
16.7.3 Drop Size in Mixers
16.7.4 Mass Transfer Coefficients in Mixers
16.8 Rate-Based Analysis of Distillation
References
Homework
Chapter 16 Appendix. Computer Rate-Based Simulation of Distillation
Chapter 17. Crystallization from Solution
17.0 Summary–Objectives
17.1 Basic Principles of Crystallization from Solution
17.1.1 Crystallization Process
17.1.2 Binary Equilibrium and Crystallizer Types
17.2 Continuous Cooling Crystallizers
17.2.1 Equilibrium and Mass Balances for Single Solute Producing Pure Solute Crystals
17.2.2 Eutectic Systems
17.3 Evaporative and Vacuum Crystallizers
17.3.1 Equipment
17.3.2 Analysis of Evaporative Crystallizers for Single-Solute Systems Producing Pure Solute Crystals
17.3.3 Simultaneous Mass, Energy, and Equilibrium Calculations
17.4 Sieve Analysis
17.5 Introduction to Population Balances
17.6 Crystal Size Distributions for MSMPR Crystallizers
17.6.1 Crystal Nucleation and Growth
17.6.2 Development of MSMPR Equation and Determination of G and no from Experiment
17.6.3 Development and Application of Distributions for MSMPR Crystallizers
17.7 Seeding
17.7.1 CSD Analysis for Growth on Seeds in Continuous Crystallizers
17.7.2 Controlling Crystal Size by Seeding
17.8 Batch and Semibatch Crystallization
17.8.1 Temperature Control for Batch Cooling Crystallizers
17.8.2 Antisolvent Crystallization
17.9 Precipitation
17.9.1 Precipitation by Antisolvent Addition
17.9.2 Precipitation by Salting Out
References
Homework
Chapter 17 Appendix. Spreadsheets
Chapter 18. Introduction to Membrane Separation Processes
18.0 Summary—Objectives
18.1 Membrane Separation Equipment
18.2 Membrane Concepts
18.3 Gas Permeation
18.3.1 Gas Permeation of Binary Mixtures
18.3.2 Binary Permeation in Perfectly Mixed Systems
18.3.3 Multicomponent Permeation in Perfectly Mixed Systems
18.3.4 Effect of Holes in Membrane
18.4 Reverse Osmosis (RO)
18.4.1 Analysis of Osmosis
18.4.2 Analysis of Reverse Osmosis
18.4.3 RO in Well-Mixed Modules
18.4.4 Mass Transfer Analysis of Concentration Polarization
18.5 Ultrafiltration (UF)
18.6 Pervaporation (Pervap)
18.6.1 Pervap Basics
18.6.2 Pervap Design Using Experimental Data
18.6.3 Theoretical Design of Pervap Systems
18.7 Bulk Flow Pattern Effects
18.7.1 Binary Crossflow Permeation
18.7.2 Binary Cocurrent and Countercurrent Permeation
References
Homework
Chapter 18 Appendix. Spreadsheet for Crossflow Gas Permeation
Chapter 19. Introduction to Adsorption, Chromatography, and Ion Exchange
19.0 Summary—Objectives
19.1 Sorbents and Sorption Equilibrium
19.1.1 Definitions
19.1.2 Sorbent Types
19.1.3 Adsorption Equilibrium Behavior
19.2 Solute Movement Analysis for Linear Systems: Basics and Applications to Chromatography
19.2.1 Movement of Solute in a Column
19.2.2 Solute Movement Theory for Linear Isotherms
19.2.3 Application of Linear Solute Movement Theory to Purge Cycles and Elution Chromatography
19.3 Solute Movement Analysis for Linear Systems: Temperature and Pressure Swing Adsorption and Simulated Moving Beds
19.3.1 Temperature Swing Adsorption
19.3.2 Pressure Swing Adsorption
19.3.3 Simulated Moving Beds
19.4 Nonlinear Solute Movement Analysis
19.4.1 Diffuse Waves
19.4.2 Shock Waves
19.5 Ion Exchange
19.5.1 Ion Exchange Equilibrium
19.5.2 Movement of Ions
19.6 Mass and Energy Transfer in Packed Beds
19.6.1 Mass Transfer and Diffusion
19.6.2 Column Mass Balances
19.6.3 Lumped Parameter Mass Transfer
19.6.4 Energy Balances and Heat Transfer
19.6.5 Derivation of Solute Movement Theory
19.6.6 Detailed Simulators
19.7 Mass Transfer Solutions for Linear Systems
19.7.1 Lapidus and Amundson Solution for Local Equilibrium with Dispersion
19.7.2 Superposition in Linear Systems
19.7.3 Linear Chromatography
19.8 LUB Approach for Nonlinear Sorption Systems
19.9 Checklist for Practical Design and Operation
References
Homework
Chapter 19 Appendix. Aspen Chromatography Simulator
Appendix A. Aspen Plus Troubleshooting Guide for Separations
Appendix B. Instructions for Fitting VLE and LLE Data with Aspen Plus
Reference
Appendix C. Unit Conversions and Physical Constants
Unit Conversions
Ideal Gas Values
Useful Physical Constants
Appendix D. Data Locations
Answers to Selected Problems
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
Chapter 7
Chapter 8
Chapter 9
Chapter 10
Chapter 11
Chapter 12
Chapter 13
Chapter 14
Chapter 15
Chapter 16
Chapter 17
Chapter 18
Chapter 19
Index
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