Separation Process Principles with Applications Using Process Simulators

554 Pages·2015·0.57 MB·English

by  J. D. Seader

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iv AbouttheAuthors
chemicals, optoelectronics, and energy as well as with uni- Biological Engineering and a member of the Arkansas
versities in translating discovery to disruptive innovation Academy of Science. He holds memberships in Tau Beta Pi,
through university–industry partnerships. He has authored ASEE, ACS, SPIE, and AIChE. His research examines elec-
or coauthored more than 65 technical articles, one book, trodynamicsinbiochemicalandnano-opticalmaterialsystems
two book chapters, three U.S. patents, and six U.S. patent important to advanced biomanufacturing, biomedicine, opto-
applications.Hewasinstrumentalindevelopingoneviraland electronics, and sustainable energy, with recent advances
threebacterialvaccineproducts,16GoodManufacturingPro- in computation, nanolithography, spectroscopy, and electron
cess documents, and multiple bioprocess equipment designs. microscopyofnanoplasmonicmetamaterialsandpolymerthin
He is a fellow of the American Institute for Medical and films.
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Preface to the Fourth Edition
INTRODUCTION STUDENT-FRIENDLYFEATURES
Separation Process Principles was first published in 1988 to Eachchapterbeginsbystatinganaverageofnineinstructional
providearigorousandcomprehensivetreatmentofindustrial objectives to give the student an introduction to the author’s
separationprocessesintheformofastudent-friendlytextbook expectations.Inchaptersthatintroduceseparationtechnology,
format.Bothequilibrium-stageandmass-transfer(rate-based) thisisfollowedbyaflowsheetanddescriptionofanindustrial
modelswerecovered.Includedalsowerechaptersonthermo- process to demonstrate how the technology is used to create
dynamic and mass-transfer theory for separation operations. saleableproducts.Thetheoryneededtodesignequipmentor
Five of the 15 chapters began with an example of an indus- simulateaseparationoperationisdevelopedandapplications
trial separation process and descriptions of how and why aredemonstratedbymorethan200examples,manyofwhich
modernprocessdesigntechniquesevolved.The2006second makeuseofprocesssimulators.
editionexpandedthecoverageofmass-transfer-baseddesign Each chapter ends with study questions suitable for class
methods by adding three new chapters (16, 17, and 18) discussion(theinvertedclassroom)orqualitativeexamination
covering leaching, washing, crystallization, desublimation, questions. There are more than 600 homework exercises,
evaporation, and drying of solids. In the 2011 third edition, many of which require the use of a process simulator. Other
thecontentwasenlargedtoincludeapproximately175pages examplesandexercisesinvolvenonlinearequationswithrec-
on biochemical separations as well as a new Chapter 19 ommendationsforusingMatlabtosolvethem.Inpreparation
covering mechanical phase separations such as filtration ofthefourthedition,textwasclarifiedbasedonstudentfeed-
and centrifugation. The title of the third edition, Separation back, and errors were eliminated. Following a suggestion by
Process Principles—Chemical and Biochemical Operations, some reviewers, chapter-specific nomenclature sections have
reflectedthisexpansion. been added. A general nomenclature lists symbols common
This new condensed fourth edition focuses on material to many of the chapters. Each chapter-specific nomenclature
widely taught in undergraduate separations courses and keyssymbolstoequations,figures,orchaptersections.These
on process simulations using Aspen Plus, CHEMCAD, and revisionsinthefourtheditionreflectourdesiretopreparean
ChemSeptodesignseparationoperations.Hence,thenewtitle accessible introduction to chemical separations that includes
for the fourth edition: Separation Process Principles–with themethodsandequationsusedbyprocesssimulatorsandthe
Applications Using Process Simulators. Professor Seader problemsandopportunitiesthishascreated.
began using process simulation programs in 1957 while
engagedinprocessdesigninthepetroleumindustryandwas
TOPICALORGANIZATION
theAIChEInstituteLectureronthissubjectin1984.Professor
Henley founded what is now Chemstations and was its first Chapter 1 provides the student with a classification of
president (when it was named COADE). Professor Roper separationoperationsandanoverviewofindustrialchemical
introduced simulation to vaccine process development in engineering separations. The next two chapters review ther-
1997.Authorsofthisfourtheditionbelievethatstudentswho modynamics and mass transfer, as applied to separation
learntosolveseparationproblemswithprocesssimulatorsas operations, at a level consistent with the level of this book.
juniorswillbewellpreparedtotackledifficultprocessdesign Chapter 4, which introduces design specifications, and
problemsintheirsenioryear.Thefourtheditionprovidescom- equilibrium flash calculations are a prerequisite for all sub-
parisonsoffeaturesofprocesssimulatorsaswellasexamples sequent chapters. Chapter 5, which is also a prerequisite for
ofhowtheyareusedtosolveindustrial-leveldesignproblems. all subsequent chapters, extends the single-stage concept
Much of the material removed from the third edition— to multiple-equilibrium-stage processing units, including a
biochemical separation process principles in: sections of degrees-of-freedom analysis for determining the number of
Chapters 1, 2, 3, 8, 14, and 15; Chapters 16, 17, and 18, design variables that can be specified for a given separation
and Chapter 19 on mechanical phase separations—is being process. A further prerequisite is Chapter 6, which describes
prepared bytheauthorsforinclusioninavolumedevoted to trays and packing, introduces general graphical methods,
bioseparationoperations.Meanwhile,thiscontentwillremain stage efficiencies, and a transfer unit design method for
availablefromthepublisherinthethirdedition. packedunits.
v
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vi PrefacetotheFourthEdition
Once the contents of the first six chapters have been combination of a web browser (e.g., Chrome, Firefox, and
mastered, the subsequent chapters can be studied in any InternetExplorer)andageneralsearchengine(e.g.,Google,
order preferred by the reader or the instructor, with a few Yahoo, Bing, and Ask) has made it so simple to search for
exceptions: (1) Concepts of minimum stage and minimum information that the number of internet users has increased
refluxarementionedearlyinthetext,butaquantitativeelab- fromabout400millionin2000toalmost3billion(compared
oration, using McCabe–Thiele diagrams, resides in Section toaworldpopulationof7.2billion)in2014.
7.2.McCabe–Thielediagramsareusedinthreeotherchapters Some useful websites for the study of separation pro-
to help readers visualize concepts such as pinch points. cesses are presented in chapters of this book. However, such
(2) Unique technology such as Freundlich and Langmuir websites are sometimes removed from the Internet. Readers
isothermsisfullydevelopedinChapter15butappliedearlier. ofthisbookareencouragedtoconducttheirownsearchesby
(3) Mathematical tools such as solution methods for stiff usingkeywords.ManysubjectshavearticlesintheWikipedia,
differential equations and the Newton–Raphson method for a free, open-ended encyclopedia on the internet. An initial
solving nonlinear algebraic equations are described where search,wheretheword“wiki”isaddedtothekeyword(s)is
applied. In these three instances, the reader is referred to a oftenuseful.Forexample,ifthekeywords“distillationwiki”
booksectionwherethetechniqueisfullydeveloped. are entered in the Google search engine, a 13-page article
To help students obtain an awareness of a section’s com- appearsthatprovidesexcellentbackgroundmaterialonawide
plexity,sectiontitleslistedinthetableofcontentsincludethe spectrumofthesubject.
followingsymbolsasprefixes: The15most-usedwebsitesare:
∗ Important for a basic understanding of separations and Searchengines(Google,Yahoo,Bing,andAsk)
thereforerecommendedforpresentationinclass,unless Socialnetworkingwebsites(Facebook,Twitter,Instagram,
alreadycoveredinapreviouscourse. LinkedIn,andPinterest)
o Optional because the material is descriptive, probably News, Entertainment, Purchases, and Information
covered in a previous course, or can be read outside of (YouTube,Amazon,eBay,MSN)
classwithlittleornodiscussioninclass.
Blogcreation(WordPress)
•
Advancedmaterialsuitableforanundergraduatecourse
Students using this book are encouraged to communicate
ifstudentsarefamiliarwith,andhaveaccessto,aprocess
with each other and their instructors via social networking
simulator.
websitestoenhancetheirlearningofseparationprocesses.
NEWTOTHISEDITION
RESOURCESFORINSTRUCTORS
The focus on using process simulators to design separa-
Thewebsitewww.wiley.com/college/seaderfurnishesthefol-
tion processes required some rearrangement and revision of
lowingresourcesintheInstructorCompanionSite:
Chapters1,2,and4–13,whichdealwithoperationscovered
in process simulators. Many of the examples and exercises 1. Instructor’sSolutionManual
havebeenrevisedandnewonesadded.Somechapterscontain
2. ResourcesforInstructors-Anintroduction
correlations that stretch the state of the art. Chapter 7, for
3. ImageGallery
example, develops an improved method for obtaining plate
efficiencies for sieve-tray columns that is just beginning to 4. PowerPointslides
appearinprocesssimulators. 5. SamplePreliminaryExamination
HELPUL WEBSITES In the 1980s, local computer net-
6. SuggestionsforCompletingHomeworkExercise
works began to interconnect in a global system, called the
7. SuggestedReviewofPrerequisiteMaterial
Internet. In late 1990, Tim Berners-Lee at the European
Organization for Nuclear Research (CERN), Switzerland, Instructorsadoptingthisbookmustrequestapasswordfrom
completedallthetoolsrequiredforsharinginformationover theirWileysalesrepresentative.
the Internet. This included the HyperText Transfer Protocol
(HTTP), the HyperText Markup Language (HTML), and a
RESOURCESFORSTUDENTS
document-information system called the World Wide Web
(WWW). In early 1991, the first-known web page was sent Students are encouraged to consult www.wiley.com/college/
over the internet by Lee to Paul Jones of UNC-Chapel Hill. seaderforthefollowingresourcesintheStudentCompanion
Physicistsaroundtheworldcouldnowquicklyandefficiently Site:
share data. Later that year, the WWW became available to
1. SuggestionsforCompletingHWExercises
the public, but its popularity was restrained until the release
of the Mosaic web browser in December 1992. Today the 2. SuggestedReviewofPrerequisiteMaterial
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PrefacetotheFourthEdition vii
ACKNOWLEDGEMENTS Dr. D. Keith Roper is currently on intergovernmental
personnel assignment with the National Science Foundation.
Since publication of the3rd edition of thisbook, the authors
Any opinions, findings, and conclusions or recommenda-
have received valuable comments, corrections, and sug-
tions expressed in this book are those of the authors and
gestions from Professor Phillip R. Westmoreland of North
do not necessarily reflect the views of the National Science
Carolina University, Professor Shuguang Deng of New
Foundation.
Mexico State University, Professor Daniel E. Rosner of Yale
University,andparticularlyProfessorN.LawrenceRickerof
J.D.Seader
theUniversityofWashington.
ErnestJ.Henley
Theselectionofthecontentforthe4theditionwasgreatly
D.KeithRoper
influencedbytheresponsesofreviewerstotwosurveyscon-
ductedbyWiley.

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Contents
AbouttheAuthors iii 3. MassTransferandDiffusion 46
∗
PrefacetotheFourthEdition v 3.0 InstructionalObjectives 46
∗
GeneralNomenclature xiii 3.1 Steady-State,OrdinaryMolecular
DimensionsandUnits xvii Diffusion 47
∗
3.2 DiffusionCoefficients(Diffusivities) 51
1. SeparationProcesses 1 ∗
3.3 Steady-StateandUnsteady-StateMassTransfer
∗
1.0 InstructionalObjectives 1
ThroughStationaryMedia 58
∗
1.1 IndustrialChemicalProcesses 1 ∗
3.4 MassTransferinLaminarFlow 60
∗
1.2 BasicSeparationTechniques 3 ∗
3.5 MassTransferinTurbulentFlow 68
⚬
1.3 SeparationsbyPhaseCreation 4 ∗
3.6 ModelsforMassTransferinFluidswitha
⚬
1.4 SeparationsbyPhaseAddition 6
Fluid–FluidInterface 73
⚬
1.5 SeparationsbyBarrier 7 ∗
3.7 Two-FilmTheoryandOverallMass-Transfer
⚬
1.6 SeparationsbyanExternalFieldor
Coefficients 76
Gradient 7
Nomenclature,Summary,References,Study
∗
1.7 BriefComparisonofCommonSeparation
Questions,Exercises
Operations 8
1.8∗ SeparationProcesses,ProductPurity, 4. SingleEquilibriumStagesandFlash
ComponentRecovery,andSeparation Calculations 87
∗
Sequences 9 4.0 InstructionalObjectives 87
∗
Summary,References,StudyQuestions, 4.1 Gibbs’PhaseRuleandDegreesof
Exercises Freedom 88
∗
4.2 BinaryVapor–LiquidSystemsat
2. ThermodynamicsofSeparationOperations 16
Equilibrium 89
∗
2.0 InstructionalObjectives 16 ∗
4.3 EquilibriumTwo-PhaseFlashCalculations 93
∗
2.1 PhaseEquilibria 16 ∗
4.4 TernaryLiquid–LiquidSystemsat
∗
2.2 Ideal-Gas,Ideal-Liquid-SolutionModel 20
Equilibrium 97
⚬
2.3 GraphicalRepresentationofThermodynamic ⚬
4.5 MulticomponentLiquid–LiquidSystems 101
Properties 21 ∗
4.6 Liquid–SolidSystems 102
⚬
2.4 NonidealThermodynamicProperty ∗
4.7 Gas–LiquidSystems 104
Models 23 ∗
4.8 Gas–SolidSystems 105
⚬
2.5 P-v-T Equation-of-State(EOS)Models 23 ⦁
4.9 Three-PhaseEquilibriumSystems 107
⚬
2.6 HighlyNonidealLiquidSolutions 27
Nomenclature,Summary,References,Study
2.7⚬ GibbsExcessFree-Energy(gE)Models 29
Questions,Exercises
⚬
2.8 PredictiveModels 34
⚬
2.9 ElectrolyteSolutionModels 36 5. MultistageCascadesandHybridSystems 118
2.10⚬ PolymerSolutionModels 36 5.0∗ InstructionalObjectives 118
2.11∗ K-ValueMethodsinProcessSimulators 36 5.1∗ CascadeConfigurations 118
2.12∗ ExergyandSecond-LawAnalysis 37 5.2∗ Single-SectionLiquid–LiquidExtraction
Nomenclature,Summary,References,Study Cascades 119
Questions,Exercises
ix
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x Contents
5.3∗ Two-SectionDistillationCascades 121 8.2⚬ GeneralDesignConsiderations 239
5.4⚬ MembraneCascades 123 8.3∗ Hunter–NashGraphicalEquilibrium-Stage
⚬
5.5 HybridSystems 125 Method 243
5.6∗ DegreesofFreedomandSpecificationsfor 8.4⚬ TheoryandScale-UpofExtractor
Cascades 125 Performance 252
Nomenclature,Summary,References,Study Nomenclature,Summary,References,Study
Questions,Exercises Questions,Exercises
6. AbsorptionandStripping 137 9. ApproximateMethodsforMulticomponent
6.0∗ InstructionalObjectives 137 Distillation 267
6.1⚬ EquipmentforVapor–Liquid 9.0∗ InstructionalObjectives 267
∗
Separations 138 9.1 Fenske–Underwood–Gilliland(FUG)
6.2⚬ GeneralDesignConsiderations 143 Method 267
6.3∗ GraphicalMethodforTrayedTowers 144 9.2∗ UsingtheShortcut(FUG)MethodwithProcess
6.4∗ KremserGroupMethodforMulticomponent Simulators 279
AbsorptionandStripping 148 Nomenclature,Summary,References,Study
6.5∗ StageEfficiencyandColumnHeightforTrayed Questions,Exercises
Columns 154
10. Equilibrium-BasedMethodsforMulticomponent
∗
6.6 Flooding,ColumnDiameter,andTrayLayout
Absorption,Stripping,Distillation,and
forTrayedColumns 161
Extraction 284
∗
6.7 Rate-BasedMethodforPackedColumns 164
∗
10.0 InstructionalObjectives 284
∗
6.8 Packed-ColumnLiquidHoldup,Diameter,
∗
10.1 SimpleModelforaVapor–LiquidEquilibrium
Flooding,PressureDrop,andMass-Transfer
Stage 284
Efficiency 169
⦁
10.2 EvolutionofMethodsforSolvingtheMesh
⦁
6.9 Reactive(Chemical)Absorption 180
Equations 286
Nomenclature,Summary,References,Study
∗
10.3 StrategiesforApplyingProcess-Simulator
Questions,Exercises
Methods 287
∗
7. DistillationofBinaryMixtures 191 10.4 MainMathematicalProcedures 291
7.0∗ InstructionalObjectives 191 10.5∗ Bubble-Point(BP)andSum-Rates(SR)
7.1⚬ EquipmentandDesignConsiderations 193 Methods 294
7.2∗ McCabe–ThieleGraphicalMethodforTrayed 10.6∗ Simultaneous-CorrectionMethod 297
∗
Towers 193 10.7 Inside-OutMethod 304
7.3⚬ ExtensionsoftheMcCabe–Thiele 10.8⦁ RigorousMethodsforLiquid–Liquid
Method 203 Extraction 309
7.4∗ EstimationofTrayEfficiencyfor Nomenclature,Summary,References,Study
Distillation 208 Questions,Exercises
∗
7.5 ColumnandReflux-DrumDiameters 215
11. EnhancedDistillationandSupercritical
∗
7.6 Rate-BasedMethodforPackedDistillation
Extraction 320
Columns 216 ∗
11.0 InstructionalObjectives 320
Nomenclature,Summary,References,Study ∗
11.1 UseofTriangularGraphs 321
Questions,Exercises ∗
11.2 ExtractiveDistillation 332
⦁
8. Liquid–LiquidExtractionwithTernary 11.3 SaltDistillation 335
⦁
Systems 231 11.4 Pressure-SwingDistillation 337
8.0∗ InstructionalObjectives 231 11.5⦁ HomogeneousAzeotropicDistillation 339
8.1⚬ EquipmentforSolventExtraction 233 11.6∗ HeterogeneousAzeotropicDistillation 343
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Contents xi
⦁
11.7 ReactiveDistillation 352 14. MembraneSeparations 408
⦁ ∗
11.8 Supercritical-FluidExtraction 357 14.0 InstructionalObjectives 408
⚬
Nomenclature,Summary,References,Study 14.1 MembraneMaterials 410
⚬
Questions,Exercises 14.2 MembraneModules 414
∗
14.3 MassTransferinMembranes 416
12. Rate-BasedModelsforVapor–LiquidSeparation
∗
14.4 Dialysis 430
Operations 368
⚬
14.5 Electrodialysis 432
⦁
12.0 InstructionalObjectives 368
∗
14.6 ReverseOsmosis 434
⦁
12.1 Rate-BasedModel 370
∗
14.7 GasPermeation 438
⦁
12.2 ThermodynamicPropertiesandTransport-Rate
⚬
14.8 Pervaporation 441
Expressions 372
Nomenclature,Summary,References,Study
⦁
12.3 MethodsforEstimatingTransportCoefficients
Questions,Exercises
andInterfacialArea 375
⦁
12.4 VaporandLiquidFlowPatterns 375 15. Adsorption,IonExchange,and
⦁
12.5 MethodofCalculation 376 Chromatography 451
∗
Nomenclature,Summary,References,Study 15.0 InstructionalObjectives 451
∗
Questions,Exercises 15.1 Sorbents 453
∗
15.2 EquilibriumConsiderations 461
13. BatchDistillation 385 ∗
15.3 KineticandTransportRate
∗
13.0 InstructionalObjectives 385
Considerations 470
∗
13.1 DifferentialDistillation 385 ⚬
15.4 EquipmentforSorptionOperations 475
∗
13.2 BinaryBatchRectification 388 ∗
15.5 SlurryandFixed-BedAdsorption
⦁
13.3 BatchStrippingandComplexBatch
Systems 479
Distillation 390 ∗
15.6 Continuous,CountercurrentAdsorption
⦁
13.4 EffectofLiquidHoldup 391
Systems 494
∗
13.5 Stage-by-StageMethodsforBatch ⚬
15.7 Ion-ExchangeCycle 502
Rectification 391 ∗
15.8 ChromatographicSeparations 503
∗
13.6 Intermediate-CutStrategy 400
Nomenclature,Summary,References,Study
⦁
13.7 OptimalControlbyVariationofReflux
Questions,Exercises
Ratio 401
Nomenclature,Summary,References,Study AnswerstoSelectedExercises 519
Questions,Exercises Index 521
∗
SuitableforanUGcourse
⚬
Optional
⦁
Advanced
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