Definition:-

Reactor is an equipment or container into which the reactants are introduced, then mixed and heated until the reaction temperature is reached.
Flow sheet symbol:-

Reaction types carried out in Reactor:Exothermic reaction Endothermic reaction Isothermal Reaction Other types of reactions:Irreversible reaction Reversible reaction Consecutive reaction Simultaneous reaction

REACTORS

Continuous Stirred Tank Reactor (CSTR)

Batch Stirred Tank Reactor (BSTR)

Semi Batch Reactor

Plug Flow Reactor

In these reactors the reactant flow continuously into the reactor and the products flow out continuously. Under ideal conditions, in well agitated system, an uniform concentration is maintained throughout the vessel.

In a PFR, one or more fluid reagents are pumped through a pipe or tube. The chemical reaction proceeds as the reagents travel through the PFR

Advantages:1)Uniform partocle mixing 2)Uniform temperature 3)Ability to operate reactor in continuous state

Disadvantages:1)Increase in reactor vessel size 2)Pumping requirements and pressure drop

These are used exclusively for liquid phase reactions. The reactants are added to empty vessel and controls are removed after the completion of reaction.

In these reactors one of the reactor is initially charged batch wise, while the other reactant is fed into the reactor continuously.

Reaction rates and Kinematics. Reactor time constant Runaway reaction

The reaction rate coefficient exponentially increases with temperature.

K=Specific reaction rate coefficient (per min)

=Pre-exponential factor E=activation energy (BTU/mole) R=Perfect gas constant(1.99 BTU/(mole)(R)) T=absolute temperature (R)

Figure below illustrates the strong dependency of k on reaction temp for values of =e(29) and E/R=20000.

Fig below relate fractional conversion with time for continuous reactor and batch reactor.

Shinskey, suggested that if dead time can be kept under 35% of the thermal time constant of the reactor, the process can be stabilized, where as if it approaches 100% the reactor will be uncontrolled.

Runaway Reaction:Runaway reaction occur in exothermic reaction , in which an increase in temperature speeds up the reaction , which in turns release more heat and raises the temperature further. In order to compensate this cycle , highly self-regulating cooling systems are required. One of the most self regulating cooling system is a bath of boiling water. Exothermic reactions produces heat and Endothermic reactions consumes heat. Endothermic reactions are inherently self-regulating. The reactor itself can be Isothermal ie. It is operated at constant temperature or Adiabatic.

Following graph shows the , relation of time with released , operating temperature and chemical concentration.

Following graphs shows the , relation between time and reactor temperature.

Following graphs shows the , relation between time and heat generated.

Temperature Control:1)
2) 3) 4)

Feedback Control (once through cooling) Recirculated cooling water method. Cascade temperature Control. Temperature control by boiling coolant.

Simple temperature control scheme. Reaction temperature is sensed and flow of heat transfer medium to reactor jacket is manipulated.

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ADVANTAGES :Simplicity Low maintainence cost. DISADVANTAGES:Non linearity and dynamic features. Formation fo cold spots and hot spots as the water is not circulated uniformly. Variable residence time of cooling water as the jacket flow rate decreases. Varying dead time.

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Temperature response of uncontrolled chemical reactor to step change in load

Inorder to overcome above disadvantages recirculated control scheme is used . Here there is high rate of water circulation through jacket.

ADVANTAGES :Dead time is constant. High heat transfer coefficient. Elimination of hot spots and cold spots.
DISADVANTAGE:As jacket has constant heat transfer area, at low loads the process and process gain is large.

The above disadvantage can be overcome by using variable gain control valve.

Process variable Manipulated variable

Purpose of slave loop is to correct outside disturbances without allowing them to affect the reaction rate Advantages: Removes non-linearity Easily compensated with equql percentage valve whose gain increases as the system gain drops Eliminates deadtime from the system Disadvantages Continous change in varaibles to maintain value of process variable

Used in Gas phase Reactor usually at high pres & high temp In cases where both temp & press sensitive a vey stable heat removal s/m is required Reactor vessel is filled with boiling water

Single cooling or heating media is insufficient

Board questions appeared on this topic so far:1) Short note on temp control of reactor. 2) Explain P and ID of reactor (Exothermic reaction). 10M 10M

3) What are reactor characteristics? Draw the temperature Profiles. Explain Runaway reaction. 10M References: Bela G. Liptak