CHAPTER 2

INTRODUCTION TO TYPES OF REACTOR

3.1 IDEAL REACTOR

• Ideal reactors are useful models to find the performance
equation.
• The performance equation can represent the best approach
(optimum) of contacting the reactants. Thus, for this reason,
all engineers often try to design real reactors so that their flows
approach these ideals.
• When the behaviour of real rxtors deviates from an ideal
reactors, it can be described by appropriate combination of
ideal reactors (modeling of real rxtors with ideal reactors).
3.2 INDUSTRIAL REACTORS
• The common of industrial reactor are :
a. Batch reactor
b. CSTR (Continuous-Stirred Tank Reack)
c. PFR (Plug Flow Reactor)
d. PBR (Packed Bed Reactor)
e. FBR (Fluidized Bed Reactor)
f. Slurry reactor
g. Semi-batch reactor
h. Trickle bed reactor

3.3 BATCH REACTOR

3.3.1 Characteristic
• The simplest rxtors used in chemical processes.
• Closed systems » no materials enters or leaves the reactor
during the time of the rxn takes place (non-flow rxtor).
• Operate under unsteady-state conditions » process in
which the conditions inside the reactor change over time.
• Tank consists stirrer/impeller/agitator device » very well mixed
and integral heating/cooling system.
• Sometimes a cooling or insulation jacket is supplied and in
some cases heat exchanger coil are around the vessel (rxtor).
3.3.2 Operation
• The rxtants are fed into the reactor.
• Then, the rxn process is started » the rxtants allowed to react,
and products are formed inside the rxtor.
• After a specified time, the process is complete and the
products with the unrxted rxtants are then removed.
• The process steps are repeated for the next batch.

3.3.3 Applications
• Typically used :
a. For liquid phase rxns that required long rxn time.
b. A small amount of products is desired (small scale
productions).

c. Difficult to run in continuous system.

d. A new process (testing or optimization stage).

• Example of applications :
a. Pharmaceutical industry » produce drugs.
b. Fermentation » production of beer or ale.

3.3.4 Advantages
1. Can obtain high conversions per unit volume by leaving
rxtants in rxtor for extended periods of time.
2. Versatile » can be used to produce many product
consecutively.
3. Good for producing a small amounts of products.
4. Easy to clean.
3.3.5 Disadvantages
1. High operation cost (cost of labor per unit of production).
2. Difficult to maintain large scale production.
3. Long downtime for cleaning » periods of no production.
4. Quality of product is more variable than with continuous
operations.

Figure 1 : Batch Reactor Diagrams

3.4 CSTR REACTOR

3.4.1 Characteristic
• Open systems » materials is free to enters or leaves the rxtor
(continuous flow of rxtants and products).
• Operate under steady-state conditions » conditions in the
rxtor are constant with time.
• Uniform composition» consists stirrer/impeller/agitator in rxtor
tank.
• Have relatively uniform properties (temp, density etc.)
throughout the rxtor.
• Exit stream has the same composition and conditions as inside
the tank.
3.4.2 Operation
• Rxtants are continuously introduced into the rxtor.
• The rxtants are well mixed in the tank » stirring/ impeller/
agitator.
• Products are removed continuously during the rxn processes.

3.4.3 Application
• Typically used in homogeneous liquid-phase flow rxns.
• Commonly used in process industries :
a. Product » dyes
b. Pharmaceutical actives
c. Adhesives
d. Polymerization
e. Wastewater treatment

3.4.3 Advantages
1. Can easily control temperature (uniform temp gradient).
2. Uniform mixing.
3. Low cost to construct.
4. Rxtor has large heat capacity.
5. Interior of rxtor is easily accessed.

3.4.4 Disadvantages
1. Conversion of rxtants to product volume of rxtor is small
compared to other flow rxtors.
2. By-passing and channeling possible with poor agitation.
 Figure 2 : CSTR Diagrams

3.5 PLUG FLOW REACTOR (PFR)

3.5.1 Characteristic
• Also known as tubular reactor.
• Consist of hollow pipe or tube through which rxtants flow.

• Operated at steady-state.
• Rxtants are continually consumed as they flow down the length
of the rxtor.
• For ideal tubular rxtor » assume to be complete mixing
perpendicular to the direction of flow.
• There is ideally no back-mixing in the rxtor.

3.5.2 Operation
• Rxtants are continuously fed into the rxtor.
• As plug flow down the rxtor, the rxtion will take place.
• This would result in an axial concentration gradient » change in
concentration over a distances from left to right but not radial
direction.
• Products and unrxted rxtants flow out of the reactor
continuously.
• When isothermal operation is possible, temp will also vary with
the axial direction.

3.5.3 Application
• Wide variety of applications in either gas or liquid phase
systems.
• Common industrial uses :
a. Gasoline production.
b. Oil cracking.
c. Synthesis of ammonia from its elements.
d. Oxidation of sulfur dioxide to sulfur trioxide.

3.5.4 Advantages
1. High conversion rate per unit rxtor volume.
2. Good for large capacity processes.
3. Good for rapid rxns.
4. Product quality is invariable.
5. Low operating (labor) cost.

3.5.5 Disadvantages
1. Rxtor temp difficult to control.
2. Hot spots may occur within rxtor for exothermic process.
3. Difficult to control due to temp and composition variations.
4. High maintenance cost.
 Figure 3 : PFR Diagrams

3.6 PACKED-BED REACTOR (PBR)

3.6.1 Characteristics
• Also known as fixed bed rxtor.
• Often used for catalytic processes.
• Consist of cylindrical shell with convex heads.
• Most are vertical, and allow rxtants to flow by gravity.

3.6.2 Operation
• Rxtants enter the rxtor (tube or column shape) on the top.
• Upon entering the rxtor, the rxtants flow through the packed
bed (porous) of catalyst.
• By contacting with the catalyst pellets, the rxtants react to
form products.
• Then the products exit the rxtor on the bottom.
• The concentration gradient within the rxtor » the
concentration of rxtants decreases from top to bottom.

3.6.3 Application
• Widely used in small scale commercial rxtions
• Example : catalytic cracking,
a. CO + H2O → CO2 + H2
b. C6H5CH2CH3 → C6H5CH=CH2 + H2

3.6.4 Advantages
1. High conversion rate per weight of catalyst
2. Easy to build

3. More contact btw rxtant and catalyst than in other types of

rxtors.
4. More product is formed due to increased rxtant/catalyst
contact.
5. Effective at high temp and pressures
6. Low cost of construction, operation and maintenance.

3.6.5 Disadvantages
1. Reactor temp difficult to control
2. Side rxtions are possible
3. Catalyst difficult to replace
4. Temp gradients may occur
 Figure 4 : PBR Diagrams

3.9 SEMI-BATCH REACTOR

3.9.1 Characteristics
• Lies between batch and continuous reactors in terms of
operation.
• Open systems like CSTRs, and run on an unsteady state basis
like batch reactors.
• Usually consists of a single stirred tank (similar to batch
reactor).

3.9.2 Operation
• At initial; rxtants is charged into reactor.
• Reactor is then started, and additional reactants are added
continuously to the tank.
• The reactor is then allowed to run until the desired conversion
is achieved, at which point the products and remaining rxtants
are removed from the tank.
• A semi-batch reactor may be a well-stirred tank reactor to
which material is added during the operation. For a liquid phase
reaction with no effluent stream, the reacting volume will
increase with time

3.9.3 Application
• Not commonly used like other reactors.
• It is can be used for two-phase (i.e. solid/ liquid) rxns.
• It is used when a rxn has a few unwanted side rxns, or has a
high heat of rxn.

3.9.4 Advantages
1. Good temperature control
2. Unwanted side-reactions is minimum

3.9.5 Disadvantages
1. High labor cost per unit product
2. Difficult to achieve for large scale production
3. Difficult to analyze the reactor operations