Separation Process Principles- Chemical and Biochemical Operations, 3rd Edition

849 Pages·2011·20.18 MB·English

by  J. D. Seader

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SEPARATION PROCESS
PRINCIPLES
Chemical and Biochemical
Operations
THIRD EDITION
J. D. Seader
DepartmentofChemicalEngineering
UniversityofUtah
Ernest J. Henley
DepartmentofChemicalEngineering
UniversityofHouston
D. Keith Roper
RalphE.MartinDepartmentofChemicalEngineering
UniversityofArkansas
John Wiley & Sons, Inc.
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LibraryofCongressCataloging-in-PublicationData
Seader,J.D.
Separationprocessprinciples:chemicalandbiochemicaloperations/J.D.Seader,ErnestJ.Henley,D.Keith
Roper.—3rded.
p.cm.
Includesbibliographicalreferencesandindex.
ISBN978-0-470-48183-7(hardback)
1. Separation(Technology)–Textbooks. I.Henley,ErnestJ.II.Roper,D.Keith.III.Title.
TP156.S45S3642010
0
660.2842—dc22 2010028565
PrintedintheUnitedStatesofAmerica
10 9 8 7 6 5 4 3 2 1
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About the Authors
J. D. Seader is Professor Emeritus of Chemical Engi- 17 years, he was a trustee of CACHE, serving as President
neering at the University of Utah. He received B.S. and from1975to1976anddirectingtheeffortsthatproducedthe
M.S. degrees from the University of California at Berke- seven-volume Computer Programs for Chemical Engineer-
ley and a Ph.D. from the University of Wisconsin- ing Education and the five-volume AIChE Modular Instruc-
Madison. From 1952 to 1959, he worked for Chevron tion. An activeconsultant, he holds nine patents, and served
Research, where he designed petroleum and petro- on the Board of Directors of Maxxim Medical, Inc., Proce-
chemical processes, and supervised engineering research, dyne,Inc.,Lasermedics,Inc.,andNanodyne,Inc.In1998he
including the development of one of the first process received the McGraw-Hill Company Award for ‘‘Outstand-
simulation programs and the first widely used vapor- ingPersonalAchievementinChemicalEngineering,’’andin
liquid equilibrium correlation. From 1959 to 1965, he 2002,hereceivedtheCACHEAwardoftheASEEfor‘‘rec-
supervised rocket engine research for the Rocketdyne ognitionofhiscontributiontotheuseofcomputersinchemi-
Division of North American Aviation on all of the cal engineering education.’’ He is President of the Henley
engines that took man to the moon. He served as a Pro- Foundation.
fessor of Chemical Engineering at the University of
Utah for 37 years. He has authored or coauthored 112 D. Keith Roper is the Charles W. Oxford Professor of
technical articles, 9 books, and 4 patents, and also coau- Emerging Technologies in the Ralph E. Martin Depart-
thored the section on distillation in the 6th and 7th edi- ment of Chemical Engineering and the Assistant Director
tions of Perry’s Chemical Engineers’ Handbook. He was of the Microelectronics-Photonics Graduate Program at
a founding member and trustee of CACHE for 33 years, the University of Arkansas. He received a B.S. degree
serving as Executive Officer from 1980 to 1984. From (magna cum laude) from Brigham Young University in
1975 to 1978, he served as Chairman of the Chemical 1989 and a Ph.D. from the University of Wisconsin-
Engineering Department at the University of Utah. For Madison in 1994. From 1994 to 2001, he conducted
12 years he served as an Associate Editor of the journal, research and development on recombinant proteins,
Industrial and Engineering Chemistry Research. He microbial and viral vaccines, and DNA plasmid and viral
served as a Director of AIChE from 1983 to 1985. In gene vectors at Merck & Co. He developed processes for
1983, he presented the 35th Annual Institute Lecture of cell culture, fermentation, biorecovery, and analysis of
AIChE; in 1988 he received the Computing in Chemical polysaccharide, protein, DNA, and adenoviral-vectored
Engineering Award of the CAST Division of AIChE; in antigens at Merck & Co. (West Point, PA); extraction of
2004 he received the CACHE Award for Excellence in photodynamic cancer therapeutics at Frontier Scientific,
Chemical Engineering Education from the ASEE; and Inc. (Logan, UT); and virus-binding methods for Milli-
in 2004 he was a co-recipient, with Professor Warren D. pore Corp (Billerica, MA). He holds adjunct appoint-
Seider, of the Warren K. Lewis Award for Chemical ments in Chemical Engineering and Materials Science
Engineering Education of the AIChE. In 2008, as part of and Engineering at the University of Utah. He has auth-
the AIChE Centennial Celebration, he was named one of ored or coauthored more than 30 technical articles, one
30 authors of groundbreaking chemical engineering U.S. patent, and six U.S. patent applications. He was
books. instrumental in developing one viral and three bacterial
vaccine products, six process documents, and multiple
Ernest J. Henley is Professor of Chemical Engineering at bioprocess equipment designs. He holds memberships in
theUniversityofHouston.HereceivedhisB.S.degreefrom Tau Beta Pi, ACS, ASEE, AIChE, and AVS. His current
the University of Delaware and his Dr. Eng. Sci. from area of interest is interactions between electromagnetism
Columbia University, where he served as a professor from and matter that produce surface waves for sensing,
1953to1959.HealsohasheldprofessorshipsattheStevens spectroscopy, microscopy, and imaging of chemical, bio-
Institute of Technology, the University of Brazil, Stanford logical, and physical systems at nano scales. These
University,CambridgeUniversity,andtheCityUniversityof surface waves generate important resonant phenomena in
New York. He has authored or coauthored 72 technical biosensing, diagnostics and therapeutics, as well as in
articles and 12 books, the most recent one being Probabi- designs for alternative energy, optoelectronics, and
listic Risk Management for Scientists and Engineers. For micro-electromechanical systems.
iii
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Preface to the Third Edition
Separation ProcessPrincipleswasfirstpublishedin1998to (cid:1) Chapter 14: Microfiltration is now included in Section 3
provide a comprehensive treatment of the major separation ontransport,whileultrafiltrationiscoveredinanewsec-
operations in the chemical industry. Both equilibrium-stage tiononmembranesinbioprocessing.
and mass-transfer models were covered. Included also were (cid:1) Chapter15:ArevisionofpreviousSections15.3and15.4
chaptersonthermodynamicandmass-transfertheoryforsep- into three sections, with emphasis in new Sections 15.3
aration operations. In the second edition, published in 2006, and 15.6 on bioseparations involving adsorption and
the separation operations of ultrafiltration, microfiltration, chromatography. A new section on electrophoresis for
leaching, crystallization, desublimation, evaporation, drying separating charged particles such as nucleic acids and
of solids, and simulated moving beds for adsorption were proteinsisadded.
added. This third edition recognizes the growing interest of
(cid:1) Chapter17:Bioproductcrystallization.
chemical engineers in the biochemical industry, and is
renamed SeparationProcess Principles—Chemical and Bio- (cid:1) Chapter18:Dryingofbioproducts.
chemicalOperations. (cid:1) Chapter 19: Mechanical Phase Separations. Because
In 2009,the National Research Council(NRC),at the re- of the importance of phase separations in chemical
quest of the National Institutes of Health (NIH), National and biochemical processes, we have also added this
Science Foundation (NSF), and the Department of Energy new chapter on mechanical phase separations cover-
(DOE), released a report calling on the United States to ing settling, filtration, and centrifugation, including
launch a new multiagency, multiyear, multidisciplinary ini- mechanical separations in biotechnology and cell
tiative to capitalize on the extraordinary advances being lysis.
made in the biological fields that could significantly help
Otherfeaturesnewtothiseditionare:
solve world problems in the energy, environmental, and
healthareas.Tohelpprovideinstructionintheimportantbio-
(cid:1) Study questions at the end of each chapter to help the
separations area, we have added a third author, D. Keith
reader determine if important points of the chapter are
Roper,whohasextensiveindustrialandacademicexperience
understood.
inthisarea.
(cid:1) Boxesaroundimportantfundamentalequations.
NEW TOTHISEDITION (cid:1) Shadingofexamplessotheycanbeeasilyfound.
(cid:1) Answerstoselectedexercisesatthebackofthebook.
Bioseparationsarecorollaries tomanychemicalengineering
(cid:1) Increased clarity of exposition: This third edition has
separations. Accordingly, the material on bioseparations has
beencompletelyrewrittentoenhanceclarity.Sixtypages
beenaddedasnewsectionsorchaptersasfollows:
were eliminated from the second edition to make room
forbiomaterialandupdates.
(cid:1) Chapter1:Anintroductiontobioseparations,includinga
(cid:1) More examples, exercises, and references: The second
descriptionofatypicalbioseparationprocesstoillustrate
itsuniquefeatures. edition contained 214 examples, 649 homework exer-
cises,and839references.Thisthirdeditioncontains272
(cid:1) Chapter2:Thermodynamicactivityofbiologicalspecies
examples,719homeworkexercises,andmorethan1,100
inaqueoussolutions,includingdiscussionsofpH,ioniza-
references.
tion, ionic strength, buffers, biocolloids, hydrophobic
interactions,andbiomolecularreactions.
SOFTWARE
(cid:1) Chapter 3: Molecular mass transfer in terms of driving
forces in addition to concentration that are important in
Throughout the book, reference is made to a number of
bioseparations, particularly for charged biological com-
software products. The solution to many of the examples
ponents.ThesedrivingforcesarebasedontheMaxwell-
is facilitated by the use of spreadsheets with a Solver
Stefanequations.
tool, Mathematica, MathCad, or Polymath. It is particu-
(cid:1) Chapter 8: Extraction of bioproducts, including solvent larly important that students be able to use such pro-
selection for organic-aqueous extraction, aqueous two- grams for solving nonlinear equations. They are all
phase extraction, and bioextractions, particularly in Karr described at websites on the Internet. Frequent reference
columnsandPodbielniakcentrifuges. is also made to the use of process simulators, such as
v
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vi PrefacetotheThirdEdition
ASPEN PLUS, ASPEN HYSYS.Plant, BATCHPLUS, Part 5 consists of Chapter 19, which covers the mec-
CHEMCAD, PRO/II, SUPERPRO DESIGNER, and UNI- hanical separation of phases for chemical and biochemical
SIM. Not only are these simulators useful for designing processes by settling, filtration, centrifugation, and cell
separation equipment, but they also provide extensive lysis.
physical property databases, with methods for computing Chapters6,7,8,14,15,16,17,18,and19beginwitha
thermodynamic properties of mixtures. Hopefully, those detailed description of an industrial application to famil-
studying separations have access to such programs. Tuto- iarizethestudentwithindustrialequipmentandpractices.
rials on the use of ASPEN PLUS and ASPEN HYSYS. Where appropriate, theory is accompanied by appropriate
Plant for making separation and thermodynamic-property historical content. These descriptions need not be pre-
calculations are provided in the Wiley multimedia guide, sented in class, but may be read by students for orienta-
‘‘Using Process Simulators in Chemical Engineering, 3rd tion. In some cases, they are best understood after the
Edition’’ by D. R. Lewin (see www.wiley.com/college/ chapteriscompleted.
lewin).
TOPICAL ORGANIZATION HELPFUL WEBSITES
This edition is divided into five parts. Part 1 consists of Throughout the book, websites that present useful, sup-
five chapters that present fundamental concepts applica- plemental material are cited. Students and instructors are
ble to all subsequent chapters. Chapter 1 introduces oper- encouraged to use search engines, such as Google or
ations used to separate chemical and biochemical Bing, to locate additional information on old or new dev-
mixtures in industrial applications. Chapter 2 reviews or- elopments. Consider two examples: (1) McCabe–Thiele
ganic and aqueous solution thermodynamics as applied to diagrams, which were presented 80 years ago and are cov-
separation problems. Chapter 3 covers basic principles of ered in Chapter 7; (2) bioseparations. A Bing search on the
diffusion and mass transfer for rate-based models. Use of formerlistsmorethan1,000websites,andaBingsearchon
phase equilibrium and mass-balance equations for single thelatterlists40,000Englishwebsites.
equilibrium-stage models is presented in Chapter 4, while Some of the terms used in the bioseparation sections of
Chapter 5 treats cascades of equilibrium stages and hyb- thebookmaynotbefamiliar.Whenthisisthecase,aGoogle
rid separation systems. search may find a definition of the term. Alternatively, the
The next three parts of the book are organized according ‘‘Glossary of Science Terms’’ on this book’s website or
to separation method. Part 2, consisting of Chapters 6 to 13, the ‘‘Glossary of Biological Terms’’ at the website: www
describesseparationsachievedbyphaseadditionorcreation. .phschool.com/science/biology_place/glossary/a.html may
Chapters6through8coverabsorptionandstrippingofdilute beconsulted.
solutions, binary distillation, and ternary liquid–liquid Other websites that have proven useful to our students
extraction, with emphasis on graphical methods. Chapters 9 include:
to 11 present computer-based methods widely used in pro-
cess simulation programs for multicomponent, equilibrium-
(1) www.chemspy.com—Finds terms, definitions, syno-
based models of vapor–liquid and liquid–liquid separations.
nyms, acronyms, and abbreviations; and provides
Chapter 12 treats multicomponent, rate-based models, while
linkstotutorialsandthelatestnewsinbiotechnology,
Chapter 13 focuses on binary and multicomponent batch
the chemical industry, chemistry, and the oil and gas
distillation.
industry. It also assists in finding safety information,
Part 3, consisting of Chapters 14 and 15, treats separa-
scientificpublications,andworldwidepatents.
tions using barriers and solid agents. These have found
increasing applications in industrial and laboratory opera- (2) webbook.nist.gov/chemistry—Contains thermo-
tions, and are particularly important in bioseparations. chemical data for more than 7,000 compounds
Chapter 14 covers rate-based models for membrane sepa- and thermophysical data for 75 fluids.
rations, while Chapter 15 describes equilibrium-based and (3) www. ddbst.com—Provides information on the com-
rate-based models of adsorption, ion exchange, and chro- prehensive Dortmund Data Bank (DDB) of thermo-
matography, which use solid or solid-like sorbents, and dynamicproperties.
electrophoresis. (4) www.chemistry.about.com/od/chemicalengineerin1/
Separations involving a solid phase that undergoes a
index.htm—Includes articles and links to many web-
change in chemical composition are covered in Part 4,
sitesconcerningtopicsinchemicalengineering.
which consists of Chapters 16 to 18. Chapter 16 treats
(5) www.matche.com—Provides capital cost data for
selective leaching of material from a solid into a liquid
manytypesofchemicalprocessing
solvent. Crystallization from a liquid and desublimation
from a vapor are discussed in Chapter 17, which also (6) www.howstuffworks.com—Provides sources of easy-
includes evaporation. Chapter 18 is concerned with the to-understand explanations of how thousands of
drying of solids and includes a section on psychrometry. thingswork.
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PrefacetotheThirdEdition vii
RESOURCES FORINSTRUCTORS
bioseparations, mainly in later sections of each chapter. Ins-
tructors who choose not to cover bioseparations may omit
Resourcesforinstructorsmaybefoundatthewebsite:www.
thosesections.However,theyareencouraged toatleastass-
wiley.com/college/seader.Includedare:
igntheirstudentsSection1.9,whichprovidesabasicaware-
(1) Solutions Manual, prepared by the authors, giving nessofbiochemicalseparationprocessesandhowtheydiffer
detailedsolutionstoallhomeworkexercisesinatuto- from chemical separation processes. Suggested chapters for
rialformat. several treatments of separation processes at the under-
(2) Erratatoallprintingsofthebook graduatelevelare:
(3) A copy of a Preliminary Examination used by one of
SEPARATIONS ORUNITOPERATIONS:
the authors to test the preparedness of students for a
course in separations, equilibrium-stage operations,
3CreditHours:Chapters1,3,4,5,6,7,8,(14,15,or17)
andmasstransfer.Thisclosed-book,50-minuteexami-
4CreditHours:Chapters1,3,4,5,6,7,8,9,14,15,17
nation,which has been given onthesecond day ofthe
course, consists of 10 problems on topics studied by 5 Credit Hours: Chapters 1, 3, 4, 5, 6, 7, 8, 9, 10, 13, 14,
students in prerequisite courses on fundamental princi- 15,16,17,18,19
ples of chemicalengineering. Students must retake the
examinationuntilall10problemsaresolvedcorrectly. EQUILIBRIUM-STAGE OPERATIONS:
(4) Image gallery of figures and tables in jpeg format,
3CreditHours:Chapters1,4,5,6,7,8,9,10
appropriateforinclusioninlectureslides.
4CreditHours:Chapters1,4,5,6,7,8,9,10,11,13
These resources are password-protected, and are available
onlytoinstructorswhoadoptthetext.Visittheinstructorsec-
MASS TRANSFERANDRATE-BASED
tionofthebookwebsiteatwww.wiley.com/college/seaderto
registerforapassword. OPERATIONS:
3CreditHours:Chapters1,3,6,7,8,12,14,15
RESOURCES FORSTUDENTS
4 Credit Hours: Chapters 1, 3, 6, 7, 8, 12, 14, 15, 16, 17,
18
Resources for students are also available at the website:
www.wiley.com/college/seader.Includedare:
(1) Adiscussionofproblem-solvingtechniques BIOSEPARATIONS:
(2) Suggestionsforcompletinghomeworkexercises 3 Credit Hours: Chapter 1, Sections 1.9, 2.9, Chapters 3,
(3) GlossaryofScienceTerms 4, Chapter 8 including Section 8.6, Chapters 14, 15,
(4) Erratatovariousprintingsofthebook 17,18,19
Note that Chapter 2 is not included in any of the above
course outlines because solution thermodynamics is a pre-
SUGGESTED COURSEOUTLINES
requisite for all separation courses. In particular, students
We feelthatourdepthofcoverageisoneofthe mostimpor- who have studied thermodynamics from ‘‘Chemical, Bio-
tant assets of this book. It permits instructors to design a chemical, and Engineering Thermodynamics’’ by S.I.
course that matches their interests and convictions as to Sandler, ‘‘Physical and Chemical Equilibrium for Chemi-
what is timely and important. At the same time, the student cal Engineers’’ by N. de Nevers, or ‘‘Engineering and
isprovidedwitharesourceonseparationoperationsnotcov- Chemical Thermodynamics’’ by M.D. Koretsky will be
ered in the course, but which may be of value to the student well prepared for a course in separations. An exception is
later. Undergraduate instruction on separation processes is Section 2.9 for a course in Bioseparations. Chapter 2 does
generally incorporated in the chemical engineering curricu- serve as a review of the important aspects of solution
lum following courses on fundamental principles of thermo- thermodynamics and has proved to be a valuable and
dynamics, fluid mechanics, and heat transfer. These courses popular reference in previous editions of this book.
are prerequisites for this book. Courses that cover separation Students who have completed a course of study in mass
processes may be titled: Separations or Unit Operations, transfer using ‘‘Transport Phenomena’’ by R.B. Bird, W.E.
Equilibrium-Stage Operations, Mass Transfer and Rate- Stewart,andE.N.LightfootwillnotneedChapter3.Students
BasedOperations,orBioseparations. whohavestudiedfrom‘‘FundamentalsofMomentum,Heat,
This book contains sufficient material to be used in andMassTransfer’’byJ.R.Welty,C.E.Wicks,R.E.Wilson,
coursesdescribed byanyoftheabovefour titles.TheChap- and G.L. Rorrer will not need Chapter 3, except for Section
ters to be covered depend on the number of semester credit 3.8 if driving forces for mass transfer other than concentra-
hours.ItshouldbenotedthatChapters1,2,3,8,14,15,17, tionneed tobe studied. Like Chapter 2,Chapter3can serve
18, and 19 contain substantial material relevant to asavaluablereference.
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viii PrefacetotheThirdEdition
Although Chapter 4 is included in some of the outlines, WilliamL.Conger,Virginia JohnOscarson,Brigham
much of the material may be omitted if single equilibrium- PolytechnicInstituteand YoungUniversity
stage calculations are adequately covered in sophomore StateUniversity TimothyD.Placek,Tufts
coursesonmassandenergybalances,usingbookslike‘‘Ele- KennethCox,RiceUniversity University
mentary Principles of Chemical Processes’’ by R.M. Felder R.BruceEldridge,University RandelM.Price,Christian
and R.W. Rousseau or ‘‘Basic Principles and Calculations in ofTexasatAustin BrothersUniversity
ChemicalEngineering’’byD.M.HimmelblauandJ.B.Riggs. RafiqulGani,Institutfor MichaelE.Prudich,Ohio
Considerable material is presented in Chapters 6, 7, and 8 Kemiteknik University
on well-established graphical methods for equilibrium-stage RamB.Gupta,Auburn DanielE.Rosner,Yale
calculations. Instructors who are well familiar with process University University
simulators may wish to pass quickly through these chapters ShamsuddinIlias,North RalphSchefflan,Stevens
andemphasizethealgorithmicmethodsusedinprocesssimu- CarolinaA&TState InstituteofTechnology
lators, as discussedin Chapters 9 to 13.However, asreported University RossTaylor,Clarkson
by P.M. Mathias in the December 2009 issue of Chemical KennethR.Jolls,IowaState University
Engineering Progress, thevisual approachofgraphical meth- UniversityofScienceand VincentVanBrunt,
ods continues to provide thebest teaching tool for developing Technology UniversityofSouth
insightandunderstandingofequilibrium-stageoperations. AlanM.Lane,Universityof Carolina
Asafurtherguide,particularlyforthoseinstructorsteach- Alabama
ing an undergraduate course on separations for the first time
orusingthisbookforthefirsttime,wehavedesignatedinthe
The preparation of this third edition was greatly aided by
Table of Contents, with the following symbols, whether a
thefollowinggroupofreviewers,whoprovidedmanyexcel-
section(§)inachapteris:
lent suggestions for improving added material, particularly
(cid:3)
Important for a basic understanding of separations and
thaton bioseparations. We areverygratefultothe following
therefore recommended for presentation in class, unless alr-
Professors:
eadycoveredinapreviouscourse.
O Optional because the material is descriptive,is covered
RobertBeitle,Universityof JoergLahann,University
inapreviouscourse,orcanbereadoutsideofclasswithlittle
Arkansas ofMichigan
ornodiscussioninclass.
RafaelChavez-Contreras, SankarNair,Georgia
(cid:1)
Advanced material, which may not be suitable for an UniversityofWisconsin- InstituteofTechnology
undergraduatecourseunlessstudentsarefamiliarwithapro- Madison AmynS.Teja,Georgia
cesssimulatorandhaveaccesstoit. TheresaGood,Universityof InstituteofTechnology
BAtopicinbioseparations. Maryland,BaltimoreCounty W.VincentWilding,
RamB.Gupta,Auburn BrighamYoung
A number of chapters in this book are also suitable for a University University
graduate course in separations. The following is a suggested BrianG.Lefebvre,Rowan
courseoutlineforagraduatecourse: University
GRADUATE COURSEONSEPARATIONS Paul Barringer of Barringer Associates provided valuable
guidance for Chapter 19. Lauren Read of the University of
2–3CreditHours:Chapters10,11,12,13,14,15,17
Utahprovidedvaluableperspectivesonsomeofthenewmat-
erialfromastudent’sperspective.
ACKNOWLEDGMENTS
J.D.Seader
The following instructors provided valuable comments and
ErnestJ.Henley
suggestionsinthepreparationofthefirsttwoeditionsofthis
D.KeithRoper
book:
RichardG.Akins,Kansas WilliamA.Heenan,Texas
StateUniversity A&MUniversity–
PaulBienkowski, Kingsville
UniversityofTennessee RichardL.Long,New
C.P.Chen,Universityof MexicoStateUniversity
AlabamainHuntsville JerryMeldon,Tufts
University
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