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INTRODUCTION
Fraz Saeed Butt
Masters in Chemical and Energy Engineering (August 2014),
Otto Von Guericke University, Germany.
E-mail: fraz@giki.edu.pk
Office: M06, FMCE
Phone Extension: 2427
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COURSE
CONTENT
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REFERENCE BOOKS
Text Book:
1. Ernest J. Henley, J. D. Seader, D. Keith Roper, “Separation Process Principles”
3rd Edition, 2011, John Wiley and Sons Inc. ISBN: 978047064611
2. McCabe & Smith, “Unit Operations of Chemical Engineering”, 7th Edition.
Reference Books:
3. Coulson J.M., Richardson J.F. “Coulson & Richardson’s Chemical Engineering
Series” Volume I, 6th Revised edition, 1999. Butterworth-Heinemann Ltd; ISBN:
9780750644440
4. Coulson J. M, Richardson J. F., “Coulson & Richardson’s Chemical
Engineering Series”, (Particle Technology and Seperation Processes) Volume II,
2002, 5th revised edition, Butterworth-Heinemann Ltd; ISBN: 9780750644457 6
MARKS DIVISION
Mid-Term 30 %
Final Term 45 %
Quizes, Assignments, Group Projects, Presentations 25 %
Note:
A part of the Mid-term syllabus will also be included in the Final exam.
Book Reading is highly recommended, a part of the exam will taken from Text book as well.
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QUIZES
4 Quizzes in total (Best 3 will be considered).
No Retake of missed Quizzes until and unless:
Health Reasons, Family Issues or any other Random Reason.
In either case, leave form should be submitted after being signed by the Dean of the
department.
Quiz retake will only be in a form of “Oral Exam”.
Checking of any Quiz and relevant discussion in only liable within 24 hours of result display.
(after that any request regarding checking and discussion will not be entertained).
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ATTENDENCE AND DISCIPLINE
45 lectures in total, more than 80%
attendance is required to sit in the
final exam.
Any student having attendance less
than 80% will not be allowed to
attend the remaining classes.
Discipline….!!!!!!!!!
No one will be allowed to enter into
the class after 5 minutes.
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CLASS TIMINGS
TIMING DAY Lecture Hall
09:00-09:50 a.m Tuesday LH1
02:30-03:20 p.m Wednesday LH1
10:30-11:20 p.m Thursday LH1
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TRANSFER
PROCESSES
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TRANSFER PROCESSES
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TRANSFER PROCESSES
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TRANSFER PROCESSES
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TRANSFER PROCESSES
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OPERATION TYPES
A chemical or biological plant is operated in a Batch-wise, semi-continuous or continuous manner.
The operations may be divided into two major types,
Key Operations:
Operations that are unique to Chemical Engineering and involves changes in Chemical
Composition.
Key operations may include,
1. Chemical Reactions,
2. Separation of Chemical Mixture.
Auxiliary Operations:
Heat addition or removal (Heat Exchangers), Shaft work (Pumps or Compressors), Mixing or
dividing of streams, Solid Agglomeration, Size Reduction of solids, and separation of solids by
size.
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MODES OF OPERATIONS
Separations processes can be run in various modes of operation:
Batchwise: no flows,
Continuous: continuous flows in and out of separators,
Semicontinuous: pauses in flows.
BASIC DESCRIPTION OF OPERATIONS
Block Flow Diagrams :
Indicate,
Key Operations by rectangles while Flows and Streams by lines.
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BASIC SEPARATION TECHNIQUE
(SEPARATION BY PHASE ADDITION)
This technique includes the addition of another fluid phase which selectively
absorbs, extracts or strips certain species from the feed.
The most common operations of this type are,
Liquid-liquid extraction where the feed is liquid and a second immiscible
liquid phase is added,
Absorption, where the feed is vapor and liquid of low volatility is added.
In both cases, species solubilities are significantly different in the added
phase.
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BASIC SEPARATION TECHNIQUES
(SEPARATION BY SOLID AGENT)
Another technique of growing importance is contacting a vapor
or liquid feed with solid reagent.
The solid reagents are mostly porous to achieve high surface
area and differences in species adsorbability is exploited.
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BASIC SEPARATION TECHNIQUES
(SEPARATION BY BARRIER)
Less common, but of growing importance is the use of barrier.
Usually a polymeric membrane, which involves a gas or liquid
feed and exploits differences in species permeabilities through
the barrier.
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BASIC SEPARATION TECHNIQUES
(SEPARATION BY FORCE FIELD OR GRADIENT)
Finally, external fields (centrifugal, thermal, electrical, flow etc)
are applied in special cases to liquid or gas feeds.
For example, in electrophoresis being especially useful for
separating proteins by exploiting differences in electric charge
and diffusivity.
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
Separation Processes developed by early civilizations include,
1. Extraction of Metals from Ores,
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
Separation Processes developed by early civilizations include,
2. Extraction of Perfume from Flowers,
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
Separation Processes developed by early civilizations include,
3. Extraction of Potash from the Ashes of burnt Plants,
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
Separation Processes developed by early civilizations include,
4. Evaporation of Sea Water to obtain Salt,
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
Separation Processes developed by early civilizations include,
5. Refining of Rock Asphalt,
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
Separation Processes developed by early civilizations include,
6. Distilling of Liquors,
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
Separation process in context to human body,
7. Kidney functionality in Separating water and waste products of metabolism from blood,
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
8. Chromatography (an example of lab scale separation of hydrocarbons),
To determine the composition of complex mixtures, Various constituents of mixture travels at
different speed based upon their affinities with
stationary phase.
As Preparative Separation technique to recover chemicals.
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
9. Distillation Column (an example of Industrial Scale separation of hydrocarbons),
11. Drying,
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
12. Absorption and Desorption Column,
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
13. Crystallization,
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
14. Membrane Separation,
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MASS TRANSFER PROCESSES
(SEPARATION PROCESSES)
Separation process in context to human body,
15. Function of lungs,
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(A) SEPARATION BY PHASE ADDITION
OR CREATION 42
(A) SEPARATION BY PHASE ADDITION OR CREATION
If the feed is a single phase solution, a second separable phase
must be developed before separation of species can be
achieved.
The second phase can be developed by an Energy-Separating
Agent (ESA) and/or added as a Mass-Separating Agent (MSA).
An ESA involves heat transfer or transfer of shaft work (energy
transfer) to or from the mixture (an example of shaft work is the
creation of vapor from liquid phase by reducing the pressure).
MSA may be miscible with the liquid feed mixture, but may
selectively alter the partitioning of species between liquid and
vapor phase…Alternatively an MSA may be partially immiscible
with one or more mixture components.
MSA facilitates a separation process when used in conjunction with
ESA, as in Extractive Distillation. 43
EXTRACTIVE DISTILLATION
(EXAMPLE REGARDING MSA & ESA IN CONJUNCTION)
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DISADVANTAGES OF
USING MSA
Need for an
additional separator
to recover the MSA
for recycle.
Need for MSA
makeup.
Possible MSA product
contamination.
More difficult design
procedure.
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WHEN THE FEED MIXTURE INCLUDES SPECIES THAT DIFFER WIDELY IN VOLATILITY
Operation: Distillation
E.g. Separation of crude oil
into its constituents
WHEN THE VOLATILITY DIFFERENCE BETWEEN TWO SPECIES TO BE SEPARATED IS
SO SMALL AS TO NECESSITATE MORE THAN ABOUT 100 TRAYS
A miscible mass separating agent (MSA)
is added, acting as a solvent.
Which increases the volatility difference
among species in the feed.
Thereby reducing the number of trays.
Generally, the MSA is the least volatile
species and is introduced near the top of
the column.
A subsequent operation, usually
distillation, is used to recover the MSA for
recycling. Operation: Extractive distillation
E.g. Separation of acetone and
methanol
If it is difficult to condense the If the feed is vapor and the
vapor leaving the top of a stripping section of the column
distillation column, a liquid MSA is not needed, the operation is
called an absorbent may be referred to as absorption.
fed to the top tray in place of
reflux. The resulting operation E.g. Separation of carbon
is called reboiled absorption. dioxide from combustion
products.
E.g. Removal of ethane and
lower molecular weight
hydrocarbons for LPG
production.
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It make use of microporous and nonporous membranes as semipermeable
barriers for selective separations.
Fabricated mainly from natural fibers and synthetic polymers.
Membranes are fabricated into flat sheets, tubes, hollow fibers, or spiral-
wound sheets.
For microporous membranes, separation is effected by rate of species
diffusion through the pores.
For nonporous membranes, separation is controlled by differences in
solubility in the membrane and rate of species diffusion.
The most complex and selective membranes are found in the trillions of
cells in the human body.
Osmosis: involves transfer, by a concentration gradient of a solvent
through a membrane into a mixture of solute and solvent. The membrane is
almost impermeable to the solute.
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PROTON EXCHANGE MEMBRANE
IN FUEL CELLS (PEMFC)
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PROTON EXCHANGE MEMBRANE
IN FUEL CELLS (PEMFC)
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Reverse osmosis: In this operation transport of solvent in the opposite direction is
effected by imposing a pressure higher than the osmotic pressure on the feed side.
Using a nonporous membrane, reverse osmosis desalts brackish water commercially.
Dialysis: is the transport by a concentration gradient of small solute molecules
through a porous membrane. Microporous membranes selectively allow small solute
molecules and/or solvents to pass through the membrane, while preventing large
dissolved molecules and suspended solids from passing through.
Microfiltration: refers to the retention of molecules from 0.02 to 10 mm.
Ultrafiltration: refers to the retention of molecules that range from 1 to 20nm.
Pervaporation: Same as reverse osmosis but the species transported through the
nonporous membrane is evaporated as a result lesser pressure is needed.
Gas permeation: Separation of gases by selective membrane using pressure as a
driving force.
Liquid membranes: which is only a few molecules thick can be formed from
surfactant-containing mixtures at the interface between two fluid phases.
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(C) SEPARATION BY SOLID AGENTS
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(C) SEPARATION BY SOLID AGENTS
The solid, in the form of Granular material or packing, is the adsorbent itself,
or it acts as an inert support for a thin layer of adsorbent by selective
adsorption or chemical reaction with species in the feed.
Adsorption is confined to the surface of solid adsorbent, unlike absorption,
that occurs throughout the absorbent.
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ADSORPTION VS ABSORPTION
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ADSORPTION
Adsorption is used to remove species in low
concentrations and is followed by desorption to
regenerate the adsorbents.
These include activated carbon, aluminum
oxide, silica gel, and synthetic sodium or
calcium, aluminosilicate, zeolites (molecular
sieves).
Equipment consists of a cylindrical vessel
packed with a bed of solid adsorbent particles
through which the gas or liquid flows.
Because regeneration is conducted
periodically, two or more vessels are used, one
desorbing while the other adsorb.
CHROMATOGRAPHY
Separate gas or liquid mixtures by passing them through a packed bed.
The bed may be solid particles (gas–solid chromatography or a solid–inert support
coated with a viscous liquid (gas–liquid chromatography).
Components move through the bed at different rates, thus effecting the separation.
Because of selective adsorption on the solid surface, or absorption into liquid
absorbents followed by desorption.
ION EXCHANGE
Resembles adsorption in that solid particles are used and regenerated.
However, a chemical reaction is involved.
In water softening, an organic or inorganic polymer in its sodium form removes
calcium ions by a calcium–sodium exchange. After prolonged use, the (spent) polymer,
saturated with calcium, is regenerated by contact with a concentrated salt solution.
(D) SEPARATION BY EXTERNAL FIELD
OR GRADIENT 84
(D) SEPARATION BY EXTERNAL FIELD OR GRADIENT
External Fields can take advantage of differing degrees of response of
molecules and ions to force fields.
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(D) SEPARATION BY EXTERNAL FIELD OR GRADIENT
Centrifugation operation, establishes a pressure field that separates fluid mixtures
according to molecular weight. It is used to separate uranium isotopes and large
polymer molecules according to molecular weight.
Thermal diffusion, uses temperature gradient to enhance diffusion rate.
In electrodialysis, cation- and anion-permeable membranes carry a fixed charge,
thus preventing migration of species of like charge.
In electrophoresis, the different migration velocities of charged colloidal or
suspended species in a electric field is exploited. Positively charged species, such
as dyes, hydroxide sols ad colloids migrate to cathode while most small,
suspended, negatively charged particles go to the anode.
Another separation technique for biochemical and heterogeneous mixtures of
micromolecular and colloidal materials is field-flow fractionation. An electrical or
magnetic field or thermal gradient is established perpendicular to a laminar-flow
field that will cause separation.
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COMPONENT RECOVERIES AND
PRODUCT PURITIES 89
COMPONENT RECOVERIES AND PRODUCT PURITY
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COMPONENT RECOVERIES AND PRODUCT PURITY
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COMPONENT RECOVERIES AND PRODUCT PURITY
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COMPONENT RECOVERIES AND PRODUCT PURITY
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COMPONENT RECOVERIES AND PRODUCT PURITY
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COMPONENT RECOVERIES AND PRODUCT PURITY
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COMPONENT RECOVERIES AND PRODUCT PURITY
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COMPONENT RECOVERIES AND PRODUCT PURITY
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COMPONENT RECOVERIES AND PRODUCT PURITY
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COMPONENT RECOVERIES AND PRODUCT PURITY
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COMPONENT RECOVERIES AND PRODUCT PURITY
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COMPONENT RECOVERIES AND PRODUCT PURITY
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SEPARATION SEQUENCE
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SEPARATION SEQUENCE
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SEPARATION SEQUENCE
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SEPARATION SEQUENCE
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SEPARATION FACTOR
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SEPARATION FACTOR
If the feed enters near the middle of the column as in distillation, it has both
Enriching and Stripping sections, and is often possible to achieve a sharp
separation between two key components.
The Stripping section purifies the heaving key and enriching section purifies the
light key.
A measure of relative degree of separation between two key components, ‘i’ and
‘j’, is the Separation Factor or Power (SP), defined in term of component splits as
measured by the compositions of the two products, (1) and (2):
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SEPARATION FACTOR
Achievable values of SP depend on the number of stages and the properties of
components ‘i’ and ‘j’.
In general, components ‘i’ and ‘j’ and products ‘1’ and ‘2’ are selected so that
𝑆𝑃𝐼,𝐽 > 1.
Then the large value corresponds to high degree of separation and low value
corresponds to low degree of separation.
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SELECTION OF FEASIBLE SEPARATION
PROCESSES 114
SELECTION OF FEASIBLE SEPARATION PROCESSES
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SELECTION OF FEASIBLE
SEPARATION PROCESSES
Keller’s Correlation
Technological and Use Maturities
Ease of Scale-Up
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KELLER’S CORRELATION
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TECHNOLOGICAL AND USE MATURITIES OF SEPARATION PROCESS
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EASE OF SCALE-UP
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