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Reactor Lecture 1 PDF
Reactor Lecture 1 PDF
Third Year
.
[Introduction to Chemical Reaction Engineering ] | [Chapter-One]..University of Technology-Chemical Engineering Department-Dr.Farah Al-Sudani
1.Introduction
Chemical kinetics is the study of chemical reaction rates and reaction mechanisms. The
study of chemical reaction engineering (CRE) combines the study of chemical kinetics
with the reactors in which the reactions occur. Chemical kinetics and reactor design are
at the heart of producing almost all industrial chemicals.
It is primarily a knowledge of chemical kinetics and reactor design that distinguishes
the chemical engineer from other engineers. The selection of a reaction system that
operates in the safest and most efficient manner can be the key to the economic
success or failure of n chemical plant.
Design of the reactor is no routine matter, and many alternatives can be proposed for a
process. In searching for the optimum it is not just the cost of the reactor that must be
minimized. One design may have low reactor cost, but the materials leaving the unit
may be such that their treatment requires a much higher cost than alternative designs.
Hence, the economics of the overall process must be considered. Reactor design uses
information, knowledge, and experience from a variety of areas-thermodynamics,
chemical kinetics, fluid mechanics, heat transfer, mass transfer, and economics.
Chemical reaction engineering is the synthesis of all these factors with the aim of
properly designing a chemical reactor.
To find what a reactor is able to do we need to know the kinetics, the contacting
pattern and the performance equation. We show this schematically in Figure (1).
2.Type of Reactors.
Both types can be used as continuous reactors or batch reactors. Most commonly,
reactors are run at steady-state, but can also be operated in a transient state. When a
reactor is first brought back into operation (after maintenance or inoperation) it would
be considered to be in a transient state, where key process variables change with time.
Both types of reactors may also accommodate one or more solids (reagents, catalyst, or
inert materials), but the reagents and products are typically liquids and gases.
U
There are three main basic models used to estimate the most important process
variables of different chemical reactors:
Batch Reactor
Chemical reactions occurring in a reactor may be exothermic, meaning giving off heat,
or endothermic, meaning absorbing heat. A chemical reactor vessel may have a cooling
or heating jacket or cooling or heating coils (tubes) wrapped around the outside of its
vessel wall to cool down or heat up the contents.
U
Batch Reactor
Characteristics
Kinds of
Usage
Phases Present
1. Gas phase
1. Small scale production
2.Liquid
phase
2. Intermediate or one
shot production
3.Liquid Solid
Advantages
Disadvantages
5.Pharmaceutical,
Fermentation
4
Figure(2) simple batch reactor .
Semi-batch reactors operate much like batch reactors in that they take place in a single stirred
tank with similar equipment . It modified allow reactant addition and/or product removal in time.
A semi-batch reactor, however, allows partial filling of reactants with the flexibility of adding more
as time progresses. Semi-batch reactors are used primarily for liquid-phase reactions , two-phase
reactions in which a gas usually is bubbled continuously through the liquid , and also for
biological and polymerization reaction.
U
Type of Reactor
Characteristics
Kinds of Phases
Present
1. Gas phase
2. Liquid phase
3. Liquid Solid
Run at steady state ,the flow rate in must equal the mass flow
rate out, otherwise the tank will overflow or go empty
(transient state).
The feed assumes a uniform composition throughout the
reactor, exit stream has the same composition as in the tank.
The reaction rate associated with the final (output)
concentration.
Reactor equipped with an impeller to ensure proper mixing.
Dividing the volume of the tank by the average volumetric flow
rate through the tank gives the residence time, or the average
amount of time a discrete quantity of reagent spends inside the
tank.
Usage
1. When agitation
is required
2. Series
configurations for
different
concentration
streams
Advantages
Disadvantages
1. Continuous operation
2. Good temperature control
3. Easily adapts to two phase
runs
4. Simplicity of construction
5.Low operating (labor) cost
6. Easy to clean
1. Lowest conversion
per unit volume, very
large reactors are
necessary to obtain
high conversions
2. By-passing and
channeling possible
with poor agitation
Figure (3) Flow sheet for the manufacture of nitrobenzene from benzene using
a cascade of CSTR
Type of Reactor
Characteristics
Kinds of
Phases
Present
1.
Primarily
Gas
Phase
Usage
1. Large Scale
2. Fast Reactions
3. Homogeneous Reactions
4. Heterogeneous Reactions
5. Continuous Production
6. High Temperature
Advantages
Disadvantages
1. High Conversion
per Unit Volume
1. Undesired thermal
gradients may exist
2. Low operating
(labor) cost)
2. Difficult temperature
control
3.Good heat
transfer
3. Shutdown and
cleaning may be
expensive
4.Hot spot occur for
exothermic reaction
Other types
Reactor
of
reactors:-
Catalytic
reactors(packed
bed
and
Fluidized-bed
Type of Reactor
Characteristics
Kinds of Phases
Usage
Present
1. Gas-Soli phase
2. Liquid-Solid
Heterogeneous
phase
reaction
3. Gas-Liquid Solid
Advantages
Disadvantages
Type of Reactor
Fluidized-bed Reactor
Characteristics
Kinds of Phases
Present
1. Gas-Solid phase
2. Liquid-Solid
phase
3. Gas-Liquid
Solid phase
Usage
1.Heterogeneous
reaction
2. reactor can
handle large
amounts of feed
and solids
Advantages
Disadvantages
1.Good mixing
2. temperature is relatively
uniform throughout
3. Catalyst can be
continuously regenerated with
the use of an auxiliary loop
4. good temperature control
1. Bed-fluid mechanics
not well known
2. Severe agitation can
result in catalyst
destruction and dust
formation
3. Uncertain scale-up
Figure(5) Fluidized-bed
Reactors
it classify according to
Five traditional types of chemical reactions are
1. Decomposition reactions: single compound decomposes to two or more other
substances,decomposition of calcium carbonate by heating it.
CaCO3(s) ---> CaO(s) + CO2(g)
2. Combination reactions (Synthesis reactions)
3. Single-replacement reactions (Displacement reactions):copper displaces silver
from an aqueous solution of silver nitrate is an example of a single-replacement
reaction.
Cu(s) + 2 AgNO3(aq) ---> Cu(NO3)2(aq) + 2 Ag(s)
4. Double-replacement reactions (Metathesis reactions):Precipitation
one type of double-replacement reaction. An example is
reactions
are
Homogeneous reaction
Decomposition N2O N2O (g)+2O2(g) 2 N2(g) + O2(g)
Heterogeneous reaction
Ammonium chloride synthesis or decomposition
3() + () 4 ()
11
12
Batch Reactor
%%%%
=
%%
%%%
disappear
homogeneous reaction 2a
&
',,
,
=
disappear
'(
homogeneous reaction 2b
disappear
heterogeneous reaction 2(
(' ' -,
disappear
heterogeneous or homogeneous reaction
'(
2d
disappear
heterogeneous reaction 2e
0' ' -,
= + * =.
%%
%%%
&
%%%% .3
The rate of reaction per unit weight catalyst, -rA, (e,g., -rA), and thi rate of reaction per unit
volume, -rA, , are related through the bulk density ,(mass of solid /volume) of the catalyst
particles in the fluid media:
13
34*5
..4
36
Where * is the molal rate of flow component A into the volume element.
element
-rA= f {temperature
temperature dependent term,concetration dependent term}
= mole/m3.time
2.Conceptes of Kinetics
1. Stoichiometry.
b c d
where , , the Stoichiometric Coefficients ,
a a a
14
Molecules are lost and formed by reaction , and mass conservation requires
that amounts of species are related by Stoichiometry as:b
c
1 mole of A and of B consumed , while
a
a
mole of D formed or appear
d
mole of C and
a
789:
7; .=>7:
c
789:
Rate of formation of C ? @ A = ? A ; .=>7:
7
a
789:
d
Rate of formation of D ? B A = ? A 7; .=>7:
a
@
Rate of formation of D ? B A = C D ? @ A
@
E&5
F
E&G
F
&H
F
&I
F
Examples (1),(2)
********************************************************************
k A (T )
K '
K L
, ( L( L '
K L
789:
7; .=>7:
rA = [k A (T )] [ f (C A , C B ,K)] ..5
[Reaction Rate and Conceptes of Kinetics][Chapter
Kinetics][Chapter[Chapter-Two]..University
Two]..University of TechnologyTechnology-Chemical Engineering DepartmentDepartment-Dr.Farah AlAl-Sudani
15
k A (T ) = Ae E RT 6
ln (k ) = ln ( A)
E1
7
R T
A Pre-exponential
exponential factor (frequency factor)
E Activation
ctivation energy (J/mol)
R Gas
as constant (8.314 J/molK,
J/mol 1.987 cal/mol K)
T Absolute
bsolute temperature (K)
Activation Energy
Activation energy has been equated with minimum energy that must be
possessed by reacting molecules before the reaction will occur.
Heat
Absorbed
Heat
Released
16
ln (r2 ) ln(k 2 ) E 1 1
=
=
ln(r1 ) ln (k1 ) R T1 T2 8
Example
Example
(4)
(5)
of
chemical
reaction
*********************************************************************
17
rA = [k A (T )] [ f (C A , C B ,K)].5
f (C A , C B ,K)
One of the most common general forms of this dependence is the product of
concentrations of the individual reacting species, each of which is raised to a power .
Reaction Order.
Elementary Reaction
A reaction order for which each
Stoichiometric coefficient as shown :-
specie
is
identical
to
its
aA + bB cC + dD
rA = kC Aa C Bb
o a and b represent the reaction order with respect to the reactant
A and B respectively ,
over all reaction order( n ) = a + b
A products
Order
Zero
Rate Equation
First
rA = kC A
s-1
Second
rA = kC A2
V.mol-1.s-1
Third
rA = kC A3
( V.mol-1 )2.s-1
nth order
Units
mol.V-1.s-1
rA = k
(concentration)1-n.s-1
rA = kC An
k2
CDCH2
rB = k1 C B2
Kc
2A B + C
k A
rA = k AC A2
rA = k AC B CC
rA,net = rA + r A = k AC A2 + k AC B CC
rA,net = 0 = k AC A2 + k AC B CC
Equilibrium condition
Equilibrium relationship
k AC A2 = k AC B CC
k A C B CC
=
= KC
k A
C A2
2 C B CC
Rate law in term Equilibrium relationship rA = k A C A
KC
Example (6)
[Reaction Rate and Conceptes of Kinetics][Chapter
Kinetics][Chapter[Chapter-Two]..University
Two]..University of TechnologyTechnology-Chemical Engineering DepartmentDepartment-Dr.Farah AlAl-Sudani
19
Non-Elementary Reaction
Do not
reaction
follow
the
Stoichiometric
coefficients
for
the
overall
Homogeneous Reactions :
Gas-phase synthesis of phosgene,
CO + Cl 2
COCl 2
2N 2O
2N 2 + O2
rN2O =
k N 2 O C N 2O
1 + k CO2
Heterogeneous Reactions :
Heterogeneous reaction and corresponding rate law is the
hydrodemethylation of toluene (T) to form benzene (B) and methane (M)
carried out over a solid catalyst.
.
C6 H 5CH3 + H 2 cat
C2 H 6 + CH4
rT =
k PH 2 PT
1 + K B PP + K T PT
k=
mol toluene
kg cat .s.kPa 2
4. Molecularly Reaction.
The term molecularity refers to number of atoms, ions, or molecules
involved in the rate-limiting step of the reaction.
20
X =
mole A reacted
mole A fed
.8
Y=
H ro d ln K eq ..10
d GRo / RT
=
=
dT
RT 2
dT
Van't Hoff equation
yield :
H r
dT
2
298 RT
T
ln K eq = ln K 298 +
.11
H r (T ) = H ro (T298 ) + C p dT
T
T298
....12
ln K eq = ln K 298
H r 298 1
1
R T 298
..13
For endothermic reactions, the equilibrium constant, Keq, increases with increasing
temperature. While for exothermic reactions, Keq and Xeq decreases with increasing
temperature.
21
Figure (2.3) show the variation of the concentration equilibrium constant and
equilibrium conversion as a function of temperature for an exothermic reaction.
reac
22
Volumn system V
Fjo + G j Fj =
dN j
..4.1
dt
V2
rj 4
rj 2
rj 3
rj1
V4
rj 5
V5
V6
G j ,1 = r j ,1V1
V3
i =1
i =1
G j = G j ,i = r j ,i Vi
V1
Let m , V 0
V
G j = rj dV
Fjo + r j dV Fj =
dN j
dt
4.2
From this general mole balance equation we can develop the design equations for
the various types of industrial reactors:
r
batch, semi-batch.
batch. and continuous-flow
continuous
reactors.
[Reactor Sizing and Design]
Design][Chapter[Chapter-Four]
Four]
]..
..University
..University of TechnologyTechnology-Chemical Engineering DepartmentDepartment-Dr.Farah AlAl-Sudani
PART ONE
Batch Reactor
Isothermal Operation
ideal restrictions
Mole Balance
F j ,o = F j = 0
V
Fjo + rj dV Fj =
V
r j dV =
dN j
dN j
dt
...............................4.3
dt
r jV =
dN j
..4.4
dt
A B
As the reaction proceeds. the number of moles of A decreases and the number of
moles of B increases, as shown in Figure below
The time t necessary to reduce the initial number of moles NAo to a final number
of mole NA can be estimated as :
from equation 4.4
dN A
rAV = 4.4
dt
dt =
dN A
rAV
t=
NA
dN A
rAV
..4.5
moles of A
moles of A
reacted or consumed = initially fed moles of A reacted
moles of A fed
at t = 0
moles of A
reacted or consumed = [N ] [ X ]
A0
moles of A
in reacter (remain) at
time t
moles of A
moles of A
the reactor at t = 0
[N A ] = [N A0 ] [N A0 ] [X ]
N A = N Ao (1 X )
X=
N Ao N A
N Ao
dN A
= rAV
dt
N Ao
dX
= rAV
dt
N A = N Ao (1 X )
N A0
t=
NA
.4.6
Differential form
Batch Reactor Design Equation
m
dN A
r AV
t = N Ao
X (t )
dX
rAV
4.7
Integral form
Used in the Interpretation of
Lab Rate Data
Space time or Mean Residence Time= is the time necessary to process one reactor
mmmmmmmmmmmmmmmmmmm volume of fluid based on entrance conditions.
t B =t +t D
dC A
dt
rA =
dC A
..4.8.(Reaction Time)
C Ao r
A
t=
CA
r
A
to estimate reaction time
1
rA
t = N Ao
X (t )
dX
rAV
Area
X
X1
t=
N Ao
* Area
V
Or
1
From equation 4.7 plot
vs. CA and evaluate the area under the curve
rA
to estimate reaction time
dC A
C Ao r
A
t=
1
rA
t = Area
Area
CA
CA
CA
CAo
Example
o For the reactions in which the rate depends only on the concentration of
one species then rA = f (CA)
First order and Irreversible :-
A B
rA = kC A
dC A
1 C A dC A
=
C Ao kC
k C Ao C A
A
t=
CA
1 C
t = . ln A
k C Ao
C A = C Ao e kt
Second order and Irreversible :-
A B
rA = kC A2
dC A
1 C A dC A
=
C Ao kC 2
k C Ao C A2
A
t=
CA
1 1
1
t =
k C A C Ao
CA =
C Ao
1 + C Ao kt
A B
kt =
rA = kC An
1
n +1
C An +1 C Ao
n +1
C A = C Ao 1 + (n 1)kC
1
n +1 1 n
Ao
Example
[Reactor Sizing and Design]
Design][Chapter[Chapter-Four]
Four]
]..
..University
..University of TechnologyTechnology-Chemical Engineering DepartmentDepartment-Dr.Farah AlAl-Sudani
Bimolecular Reactions
o when the rate law depends on more than one species , we must relate the
concentrations of the different species to eac2h other "as a function of
conversion rA = f ( X ) ". This relationship is most easily established with
the aid of a Stoichiometric table.
In formulating our stoichiornetsic table, we shall take species A component as
our basis of calculation (i.e.. limiting reactant) and then divide through by the
stoichiometric coefficient of A , in order to put everything on a basis of "pet mole
of A ".
Stoichiornetsic table presents the following information
o Column I: the particular species
o Column 2: the number of moles of each species initially present
o Column 3: the change in the number of moles brought about by reaction
o Column 4: the number of moles remaining in the system at time t
o Column 5: concentrations as a function of conversion of each species
b
c
d
A + B C + D
a
a
a
The rate law is :
a b CCc C Dd
rA = k A C AC B
K
C
Specie
Initial
Change
NAo
NBo = NAo B
-(b/a)NAo X
NB = NAo[
B (b/a)X]
NCo = NAo C
+(c/a)NAo X
NC = NAo[
C +(c/a)X]
NDo = NAo D
+(d/a)NAo X
ND = NAo[
D +(d/a)X]
-NAo X
Remaining
NI = NAo
NA = NAo(1 X)
NI = NAo I
NTo = NAo i
Concentration
C A = C A 0 (1 X )
X
a
CC = C A0 C + X
a
C D = C A0 D + X
a
CIo
C B = C A0 B
NT = NTo +
NAoX
Where
Concentration (batch):
Ci =
Ni
V
CA =
N A N A0 (1 X )
=
= C A0 (1 X )
V
V0
CB =
N B N A0
b
b
=
B X = C A0 B X
V
V0
a
a
N D N A0
c
c
=
C + X = C A0 C + X
V
V0
a
a
N
N
d
d
C D = D = A0 D + X = C A0 D + X
V
V0
a
a
CC =
Mole balance equation and the rate law are coupled and then solved
Example
[Reactor Sizing and Design]
Design][Chapter[Chapter-Four]
Four]
]..
..University
..University of TechnologyTechnology-Chemical Engineering DepartmentDepartment-Dr.Farah AlAl-Sudani
T0
P0
Z 0
.4.9
Change in the total number of moles during reaction in gas phase reaction system,
but with constant temperature and pressure, and the compressibility factor will not
change significantly during the course of the reaction ,
N
V = V0 T
NT 0
Where
NT = NTo +
NAoX
N
NT
= 1+ Ao X
NT 0
NT 0
y Ao =
N Ao
NT 0
N Ao
= y Ao 4.10a.
NT 0
Then
NT
= 1 + X
NT 0
N T N To
..4.10b
NT 0 X
N Tf N To
NT 0
.4.11
= (change in total number of mole for complete conversion ) / (total moles fed)
Then the volume as a function of conversion :
V = V0 (1 + X ) .4.12
Specie
N
CA = A
V
N A0 (1 X )
V
N
CB = B
V
N B 0 ( B - (b/a) X )
V
N
CC = C
V
N Co ( C + (c/a) X )
V
N
CD = D
V
N D 0 ( D - (d/a) X )
V
N
CI = I
V
N Ao I
V
C A0 (1 X )
(1 + X )
N B0 ( B - (b/a)X )
Vo (1 + X )
C B 0 ( B - (b/a) X )
(1 + X )
N Co ( C + (c/a) X )
Vo (1 + X )
CCo ( C + (c/a)X )
(1 + X )
C D 0 ( D - (d/a)X )
(1 + X )
N A0 (1 X )
Vo (1 + X )
N D 0 ( D - (d/a)X )
Vo (1 + X )
N Ao I
Vo (1 + X )
C Ao I
(1 + X )
Example
Non-Isothermal Operation
Chemical reactors can liberate or absorb very large amounts of energy , and the handling of
this energy is a major concern in reaction engineering. It is important to estimate the
temperature increase or decrease in an adiabatic reactor in which no heat is add or
removed, and exothermic reactor and also the composition of the reaction mixture at any
time.
Energy Balance
Heat Generated by
Reaction
H r (T ) (rAV )
Q& = UA(Ta T )
Heat Accumulated by
Reaction
dT
V C p,i Ci
dt
T = reaction temperature K
Ta= wall temperature K
TR= reference temperature K
A = heat transfer area m2
Cpi = specific heat KJ/Kmol
U = overall heat transfer KJ/s.m2.K
H r =enthalpy change in the reaction per mole of Areacting
The number of moles of species i at any X is =
Then energy balance is :
N i = N A0 ( i + i X )
dT
H r (T ) ( rAV ) + UA(Ta T ) = C p ,i N i
dt
dT
dt
.4.13
Energy and mole balance equations with the rate law are coupled and then solved
N Ao
dX
= r AV
dt
H r is calculated as
T
H r (T ) = H ro (TR ) + C p dT
TR
N
V = V0 T
NT 0
T0
P0
Z 0
T P
V = V0 (1 + X ) 0
T0 P
Z 0
If the compressibility factor will not change significantly during the course of the
reaction Zo=Z
T P
V = V0 (1 + X ) 0
T0 P
Specie
N
CA = A
V
N A0 (1 X )
V
N A 0 (1 X ) To
V o (1 + X ) T
N
CB = B
V
N B 0 ( B - (b/a) X )
V
N B 0 ( B - (b/a) X ) To
Vo (1 + X )
T
Po
C B 0 ( B - (b/a) X ) To
(1 + X )
T
Po
N
CC = C
V
N Co ( C + (c/a) X )
V
N Co ( C + (c/a) X ) To
V o (1 + X )
T
Po
C Co ( C + (c/a) X ) To
(1 + X )
T
Po
N
CD = D
V
N D 0 ( D - (d/a) X )
V
N D 0 ( D - (d/a) X ) To
V o (1 + X )
T
Po
C D 0 ( D - (d/a) X ) To
(1 + X )
T
Po
N
CI = I
V
N Ao I
V
N Ao I To
V o (1 + X ) T
Po
Po
C A0 (1 X ) To
(1 + X ) T
C Ao I To
(1 + X ) T
Po
Po
Example
[Reactor Sizing and Design]
Design][Chapter[Chapter-Four]
Four]
]..
..University
..University of TechnologyTechnology-Chemical Engineering DepartmentDepartment-Dr.Farah AlAl-Sudani
A batch reactor is usually well mixed, so that may neglect the special variation in
temperature and species concentration .
Batch reactors operated adiabatically are often used to determine the reaction
orders, activation energies, and specific reaction rates of exothermic reactions by
monitoring the temperature-time trajectories for different initial conditions.
H r (T ) ( rAV ) = (C p ,i N i )
dT
dt
H r (T ) ( rAV ) = N A0 ( i C p ,i + CpX )
dT
dt
.4.14
Energy and mole balance equations with the rate law are coupled and then
solved:
C
X =
i
p ,i
(T To )
H r (T )
T = To +
H r (T )X
i C p,i + CpX
Example
Equilibrium Conversion
The highest conversion that can be achieved in reversible reactions is the
equilibrium conversion XEB. For endothermic reactions, the equilibrium
conversion increases with increasing temperature up to a maximum of 1.0.
For exothermic reactions, the equilibrium conversion decreases with increasing
temperature
Figure ( ) show the variation of the concentration equilibrium constant as a
function of temperature for an exothermic reaction the corresponding equilibrium
conversion XEB as a function of temperature.
X EB =
C
i
p ,i
(T To )
..4.15
H r (T )