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Coulson and Richardson’s CHEMICAL ENGINEERING VOLUME 2 FIFTH EDITION Particle Technology and Separation Processes Related Butterworth-Heinemann Titles in the Chemical Engineering Series by J. M. COULSON & J. F. RICHARDSON Chemical Engineering, Volume 1, Sixth edition Fluid Flow, Heat Transfer a...

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CHEMICAL ENGINEERING VOLUME 2 FIFT H EDIT ION Part icle Technology and Separat ion Proce… zee shan

Coulson and Richardson's Chemical Engineering Muhammad Usama CHEMICAL_ ENGINEERING_ filt er Anur gimir

Coulson and Richardson’s

CHEMICAL ENGINEERING VOLUME 2 FIFTH EDITION Particle Technology and Separation Processes

Related Butterworth-Heinemann Titles in the Chemical Engineering Series by J. M. COULSON & J. F. RICHARDSON Chemical Engineering, Volume 1, Sixth edition Fluid Flow, Heat Transfer and Mass Transfer (with J. R. Backhurst and J. H. Harker) Chemical Engineering, Volume 3, Third edition Chemical and Biochemical Reaction Engineering, and Control (edited by J. F. Richardson and D. G. Peacock) Chemical Engineering, Volume 6, Third edition Chemical Engineering Design (R. K. Sinnott) Chemical Engineering, Solutions to Problems in Volume 1 (J. R. Backhurst, J. H. Harker and J. F. Richardson) Chemical Engineering, Solutions to Problems in Volume 2 (J. R. Backhurst, J. H. Harker and J. F. Richardson)

Coulson and Richardson’s

CHEMICAL ENGINEERING VOLUME 2 FIFTH EDITION

Particle Technology and Separation Processes J. F. RICHARDSON University of Wales Swansea and

J. H. HARKER University of Newcastle upon Tyne with

J. R. BACKHURST University of Newcastle upon Tyne

OXFORD AMSTERDAM BOSTON LONDON NEW YORK PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO

Butterworth-Heinemann An imprint of Elsevier Science Linacre House, Jordan Hill, Oxford OX2 8DP 225 Wildwood Avenue, Woburn, MA 01801-2041 First published 1955 Reprinted (with revisions) 1956, 1959, 1960 Reprinted 1962 Second edition 1968 Reprinted 1976 Third edition (SI units) 1978 Reprinted (with revisions) 1980, 1983, 1985, 1987, 1989 Fourth edition 1991 Reprinted (with revisions) 1993, 1996, 1997, 1998, 1999, 2001 Fifth edition 2002 Copyright  1991, 2002, J. F. Richardson and J. H. Harker. All rights reserved The right of J. F. Richardson and J. H. Harker to be identified as the authors of this work has been asserted in accordance with the Copyright, Designs and Patents Act 1988 All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London, England W1P 0LP. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to the publishers British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloguing in Publication Data A catalogue record for this book is available from the Library of Congress ISBN 0 7506 4445 1

Typeset by Laserwords Private Limited, Chennai, India Printed and bounded in Great Britain by the Bath Press, Bath

Preface to the Fifth Edition .......................................

xvii

Preface to the Fourth Edition ....................................

xix

Preface to the 1983 Reprint of the Third Edition .....

xxi

Preface to Third Edition .............................................

xxiii

Preface to Second Edition .........................................

xxv

Preface to First Edition ..............................................

xxvii

Acknowledgements ...................................................

xxix

INTRODUCTION ..........................................................

xxxi

1 Particulate Solids ....................................................

1

1.1. INTRODUCTION .....................................................

1

1.2. PARTICLE CHARACTERISATION .........................

2

1.3. PARTICULATE SOLIDS IN BULK ..........................

22

1.4. BLENDING OF SOLID PARTICLES .......................

30

1.5. CLASSIFICATION OF SOLID PARTICLES ............

37

1.6. SEPARATION OF SUSPENDED SOLID PARTICLES FROM FLUIDS ..........................................

67

1.7. FURTHER READING ..............................................

91

1.8. REFERENCES ........................................................

92

1.9. NOMENCLATURE ..................................................

93

2 Particle Size Reduction and Enlargement ............

95

2.1. INTRODUCTION .....................................................

95

2.2. SIZE REDUCTION OF SOLIDS ..............................

95

2.3. TYPES OF CRUSHING EQUIPMENT ....................

106

2.4. SIZE ENLARGEMENT OF PARTICLES .................

137

2.5. FURTHER READING ..............................................

143

2.6. REFERENCES ........................................................

143

2.7. NOMENCLATURE ..................................................

144

3 Motion of Particles in a Fluid .................................

146

3.1. INTRODUCTION .....................................................

146

3.2. FLOW PAST A CYLINDER AND A SPHERE .........

146

3.3. THE DRAG FORCE ON A SPHERICAL PARTICLE ......................................................................

149

3.4. NON-SPHERICAL PARTICLES ..............................

164

3.5. MOTION OF BUBBLES AND DROPS ....................

168

3.6. DRAG FORCES AND SETTLING VELOCITIES FOR PARTICLES IN NON- NEWTONIAN FLUIDS .......

169

3.7. ACCELERATING MOTION OF A PARTICLE IN THE GRAVITATIONAL FIELD .......................................

173

3.8. MOTION OF PARTICLES IN A CENTRIFUGAL FIELD .............................................................................

185

3.9. FURTHER READING ..............................................

187

3.10. REFERENCES ......................................................

188

3.11. NOMENCLATURE ................................................

189

4 Flow of Fluids through Granular Beds and Packed Columns ........................................................

191

4.1. INTRODUCTION .....................................................

191

4.2. FLOW OF A SINGLE FLUID THROUGH A GRANULAR BED ...........................................................

191

4.3. DISPERSION ..........................................................

205

4.4. HEAT TRANSFER IN PACKED BEDS ...................

211

4.5. PACKED COLUMNS ..............................................

212

4.6. FURTHER READING ..............................................

232

4.7. REFERENCES ........................................................

232

4.8. NOMENCLATURE ..................................................

234

5 Sedimentation .........................................................

237

5.1. INTRODUCTION .....................................................

237

5.2. SEDIMENTATION OF FINE PARTICLES ..............

237

5.3. SEDIMENTATION OF COARSE PARTICLES .......

267

5.4. FURTHER READING ..............................................

286

5.5. REFERENCES ........................................................

286

5.6. NOMENCLATURE ..................................................

288

6 Fluidisation ..............................................................

291

6.1. CHARACTERISTICS OF FLUIDISED SYSTEMS ......................................................................

291

6.2. LIQUID-SOLIDS SYSTEMS ....................................

302

6.3. GAS-SOLIDS SYSTEMS ........................................

315

6.4. GAS-LIQUID SOLIDS FLUIDISED BEDS ...............

333

6.5. HEAT TRANSFER TO A BOUNDARY SURFACE ......................................................................

334

6.6. MASS AND HEAT TRANSFER BETWEEN FLUID AND PARTICLES ...............................................

343

6.7. SUMMARY OF THE PROPERTIES OF FLUIDISED BEDS ..........................................................

357

6.8. APPLICATIONS OF THE FLUIDISED SOLIDS TECHNIQUE ..................................................................

358

6.9. FURTHER READING ..............................................

364

6.10. REFERENCES ......................................................

364

6.11. NOMENCLATURE ................................................

369

7 Liquid Filtration .......................................................

372

7.1. INTRODUCTION .....................................................

372

7.2. FILTRATION THEORY ...........................................

374

7.3. FILTRATION PRACTICE ........................................

382

7.4. FILTRATION EQUIPMENT .....................................

387

7.5. FURTHER READING ..............................................

434

7.6. REFERENCES ........................................................

435

7.7. NOMENCLATURE ..................................................

435

8 Membrane Separation Processes ..........................

437

8.1. INTRODUCTION .....................................................

437

8.2. CLASSIFICATION OF MEMBRANE PROCESSES .................................................................

437

8.3. THE NATURE OF SYNTHETIC MEMBRANES ......

438

8.4. GENERAL MEMBRANE EQUATION .....................

442

8.5. CROSS-FLOW MICROFILTRATION ......................

442

8.6. ULTRAFILTRATION ...............................................

446

8.7. REVERSE OSMOSIS .............................................

452

8.8. MEMBRANE MODULES AND PLANT CONFIGURATION .........................................................

455

8.9. MEMBRANE FOULING ..........................................

464

8.10. ELECTRODIALYSIS .............................................

465

8.11. REVERSE OSMOSIS WATER TREATMENT PLANT ............................................................................

467

8.12. PERVAPORATION ...............................................

469

8.13. LIQUID MEMBRANES ..........................................

471

8.14. GAS SEPARATIONS ............................................

472

8.15. FURTHER READING ............................................

472

8.16. REFERENCES ......................................................

473

8.17. NOMENCLATURE ................................................

474

9 Centrifugal Separations ..........................................

475

9.1. INTRODUCTION .....................................................

475

9.2. SHAPE OF THE FREE SURFACE OF THE LIQUID ...........................................................................

476

9.3. CENTRIFUGAL PRESSURE ..................................

477

9.4. SEPARATION OF IMMISCIBLE LIQUIDS OF DIFFERENT DENSITIES ...............................................

478

9.5. SEDIMENTATION IN A CENTRIFUGAL FIELD .....

480

9.6. FILTRATION IN A CENTRIFUGE ...........................

485

9.7. MECHANICAL DESIGN ..........................................

489

9.8. CENTRIFUGAL EQUIPMENT ................................

489

9.9. FURTHER READING ..............................................

500

9.10. REFERENCES ......................................................

500

9.11. NOMENCLATURE ................................................

501

10 Leaching ................................................................

502

10.1. INTRODUCTION ...................................................

502

10.2. MASS TRANSFER IN LEACHING OPERATIONS ................................................................

503

10.3. EQUIPMENT FOR LEACHING .............................

506

10.4. COUNTERCURRENT WASHING OF SOLIDS ....

515

10.5. CALCULATION OF THE NUMBER OF STAGES .........................................................................

519

10.6. NUMBER OF STAGES FOR COUNTERCURRENT WASHING BY GRAPHICAL METHODS .....................................................................

526

10.7. FURTHER READING ............................................

540

10.8. REFERENCES ......................................................

540

10.9. NOMENCLATURE ................................................

540

11 Distillation ..............................................................

542

11.1. INTRODUCTION ...................................................

542

11.2. VAPOUR LIQUID EQUILIBRIUM .........................

542

11.3. METHODS OF DISTILLATION TWO COMPONENT MIXTURES ............................................

555

11.4. THE FRACTIONATING COLUMN ........................

559

11.5. CONDITIONS FOR VARYING OVERFLOW IN NON-IDEAL BINARY SYSTEMS ...................................

581

11.6. BATCH DISTILLATION .........................................

592

11.7. MULTICOMPONENT MIXTURES ........................

599

11.8. AZEOTROPIC AND EXTRACTIVE DISTILLATION ...............................................................

616

11.9. STEAM DISTILLATION .........................................

621

11.10. PLATE COLUMNS ..............................................

625

11.11. PACKED COLUMNS FOR DISTILLATION .........

638

11.12. FURTHER READING ..........................................

649

11.13. REFERENCES ....................................................

649

11.14. NOMENCLATURE ..............................................

652

12 Absorption of Gases .............................................

656

12.1. INTRODUCTION ...................................................

656

12.2. CONDITIONS OF EQUILIBRIUM BETWEEN LIQUID AND GAS ..........................................................

657

12.3. THE MECHANISM OF ABSORPTION .................

658

12.4. DETERMINATION OF TRANSFER COEFFICIENTS .............................................................

666

12.5. ABSORPTION ASSOCIATED WITH CHEMICAL REACTION .................................................

675

12.6. ABSORPTION ACCOMPANIED BY THE LIBERATION OF HEAT .................................................

681

12.7. PACKED TOWERS FOR GAS ABSORPTION .....

682

12.8. PLATE TOWERS FOR GAS ABSORPTION ........

702

12.9. OTHER EQUIPMENT FOR GAS ABSORPTION ................................................................

709

12.10. FURTHER READING ..........................................

714

12.11. REFERENCES ....................................................

715

12.12. NOMENCLATURE ..............................................

717

13 Liquid Liquid Extraction ......................................

721

13.1. INTRODUCTION ...................................................

721

13.2. EXTRACTION PROCESSES ................................

722

13.3. EQUILIBRIUM DATA ............................................

725

13.4. CALCULATION OF THE NUMBER OF THEORETICAL STAGES ..............................................

728

13.5. CLASSIFICATION OF EXTRACTION EQUIPMENT ..................................................................

742

13.6. STAGE-WISE EQUIPMENT FOR EXTRACTION ................................................................

744

13.7. DIFFERENTIAL CONTACT EQUIPMENT FOR EXTRACTION ................................................................

750

13.8. USE OF SPECIALISED FLUIDS ..........................

763

13.9. FURTHER READING ............................................

766

13.10. REFERENCES ....................................................

767

13.11. NOMENCLATURE ..............................................

769

14 Evaporation ...........................................................

771

14.1. INTRODUCTION ...................................................

771

14.2. HEAT TRANSFER IN EVAPORATORS ...............

771

14.3. SINGLE-EFFECT EVAPORATORS .....................

778

14.4. MULTIPLE-EFFECT EVAPORATORS .................

780

14.5. IMPROVED EFFICIENCY IN EVAPORATION .....

791

14.6. EVAPORATOR OPERATION ...............................

802

14.7. EQUIPMENT FOR EVAPORATION .....................

805

14.8. FURTHER READING ............................................

823

14.9. REFERENCES ......................................................

823
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