CHAPTER. 4- i INTRODUCTION TO REACTOR DESIGN Sntredickir to reactor design Os gist viv the chay wt fare ure will deal with same more dlincuuion on the acackor, thud ty and bare eapations merded foro Aectebor to be dexgmed The Readr mut: chudy Hu cha pier Lufore the ctart o this chosen. oan r breulon Bypedy neachion bo ee ene es ics type ay horde os matdod colled Reactor? Thus reactor, the heat of chumucal buicen, & tobe dried te prowl te conditions macesary “for Chemecctl Acct tn to proceed. oe ne Aecctor det, three Chimgs, ik peoucees Rewidemce time iD tranfus Jak i) agitater or amines PRINCIPAL FACTORS INVOLVED YN THE DESIGN OF REACTOR: Te p purmcifal fosters which, mud be comidned im the dai: 6 es Nando ae Phases urwélued, © tian me ty B= apikation for units or mpecposi cabal , batch o& Conkisrtous jo produchion rake TYPES OF REACTORS: Chemical rvacters omnay Rawr ov vamiely of Ades, and. opeating conditions. We herr. i dauiy hors vi eee caput mad 2) Goud an math 0 ost b) a toteC) Based ow mo. Of phases vrvSued, - @) BASED ON METHOD OF OPERATION: The Acackow 1) Batch Aracker . 2) Contimous flo (Steady. ctate fms) rsackor % 3) Semir-bately (Somir- Covtimous) 1) BATCH REACTOR: A batch rvacter fas maith viflow rer outflow, of Mactamts oy products while the Avactioy Us camced, out. In such, Avankion extomk o% reaction amd O Aca eli onintire tut dime. Thus Comboribion Cl auith, time. for phases bl neato yb nd ate ae . Condiemt ov Contaml bomure. INDUSTRIAL BATCH REACTOR, ASO SEE prise Also hee p- Lu 2) CONTNUOUS REACTORS OR STEADY-STATE. FLOW REACTOR: The Keackanto are eon fe amd, produth are cnkiruouty Aumasd bom the Aracker. On Auth sacker the tntomk & dsocchcon may vary with teins position Ue heacker mot with tome. Thus atany 5 mat witty tume. (They omay be Contimaus - ntcrteds tank or CSTR stubulon ens). . el (CSTR) CTuBuLar ) 3) SEMI -BATCHOR UN- STEADY-STATE REACTORS: the Acackants ore introduced. portialtyy amd odditimal Aractamte are added progiemcuely unter the darinkd qprontcay § added. Atamatinely , one may change the Acactants at once oma contimaualey Mrmeus poduich an tht foumed.Simi - batch neackoro omar be wither, ty Reactor mw which volume amd comparitiou Changes it) Reackou m which vume cl Changes Luck compsackion Os \ i Un— chained. ( ) ti) Reackoro on which ume x 5 covtamt Lut c cb b) BASED ON SHAPE: 1) Tank reactor 2) Tabular reactor, 1) TANK REACTOR: . MMOL Er Gish eaopepata cnet mn Aw ideal tome acackor cout dhteh ming O fo eftictent that the cortemls are umiyptan uv Om ponies amd tumbarcttunedinoughouk 9 catted ar ateined tank er well mined, rcackor. The Armfple tomk acacker onary be operated tn a Vanety oy modes , batch, -Semi- batch er eonkimuos~ fla When contimaous called Continuous — Atixred tamk Avackor (CSTR) OL batkanin avacker. 2) TUBULAR REACTOR: Tebular Avattor 2 ore dv which there &mo omuriong Uv the, dnechion oy flow viv the Be Arakor . The Avactomts one conkimoualy Corsurmec Ge Os they flow im the onittl (dourwthe length Avacter) duicctiny, Thus He corcon- tration Vorcen along the anual duichron. 7 alto called flow rancher (PER), fag flow Aeactor, Hiker Fimo Avacter, um-amired flow Another. :_ eee _ 0). BASED.ON..NO. OF PHASES INVOLVED:.....-.— 1) H 2) sc sanuttscm the -fact rah henttion vlibuna b -fatnagimtos © § » the Agaction o, SO, ond O, on. Vy O, & scout ost be tru.if the Aeckiory Were -.@ himole hem. ous, thus the clawdicccttcon & “eg fs notin _ We hau conridered the clasfccabion hi Hy React, mow We Ace. differant. By AgauckOMs. |. |: . We do ct using diyeremt harwes.mnuoluved. Cie. u ; | cthad clampication) . GH the work..o¢ Acader to. « |-thereactors whether they arebatch, cant hemi. |. | batch, tamk or. tubular... _ | REACTORS FOR GAS PHASE: fn - Useraly Contimrour cperatione. a Agac~ “| tier Acute bs Acgh tha hontee ence _carrted oxct. in | Amath Aecrtlory Apace e-9..vnvflarner O. arc. Fer slower Adcackiens teuger. Reaction. Al ane heguured. Cmu- i _. |.oadin tm batches , ov tin. tybimders.g nkermart Cormbur— |. -.| tliny engines one mot q bEemccal ( imelurtwad) orpettanct:.” | Lange reaction ‘vessel Flame Electric are Autoclave Reaction engine — i | C7 Examples: Examples: Example: Example Example { acetylene ory): laboratory): — i - from methane, cotnbustion of i eombustion chlorine } - ~ of nitrogen detonating } rs i si FIG=1. Reactors for gas-phase reactions... “~~ ‘(5) _|... LIQUID PHASE_REACTORS.: —_... ——e Batch ehanktens_are predomimamt- . Rest. emir Rh Acacten& to. ih the ohteLanks |e i wlth agiteter., ancl loss Crmmér.cre curkaclours, | } F exucchles a ; Autoclave 9 Crucible : Vat. = 1 Nil 7 Examples: Example: Examples: Example: diuzotizntion, numerous xluss melting, glass melting dye coupling, orgunie” —. - Siemens-Martin potash recovery’, processes furnace benrene retiniig oe _ FIG-2.“ Reactors for liquid-phase reactions. _ : REACTORS FOR. GASES. .AND..LIQUIDS REACTIONS #0... — _|_..9m_the. chemical, wrcluuday, Agcuckions betuceen. gettand | eapriala ALCO... bch Reactions the Lesarrol. Aclk _Jomoty be..t +1) The nak peeuce au, Combinvabony 0 gar ane Ligue, Jorge, the absarftien oy 3, Hel, ev NO, b ata. ov -|dituke,. rotten op. fu Co.cdd s-hychechtore, acca, omikue, laud Avs chinelly, ob Aaduckcorvey. cme. jf. 8 --2) The farigronbion he. rit >. the absoxy op HS] 2 oF . esr Aag thos gos jp OA oe 3) The expos: vepiliden ope cy maans oa | 92-9 -9-Che. stone hides ie bee : Lrutfidle. belubior welt, Conbmn, disxtdes al hae OCs ural sate. ora. an | Aeakcons tact gus’ onsd.tipaids thrce Lode. ypeet— 2 | tonkerctinng denen auailale'crce ba? 3). dy } aI) Starface..cortarckers 5 °) Mechanica. webe.- = 1 Surgace Contacters_ ——! Surfoce contacter Wetted-wall absorber =f NICE absorption in carbon — tubes Bubble-cap column ——— a “Th @ G Ad A t Ee Fxample: Example: = 0g xerubbing MCT absorption | 3 Me: nical absorber Drum scrubber Plate serubber sninpe: oni serubbing, nepuration from coke-oven jas FIGS* 2 Contacting devi | 2- Gaseous dispersion systems Converter —G Example: steel production Rotary serubber 1s for reuetions between gases and liquids. /a) ~ | Ame ew lows wong Aleurly, The gos plows abrir the qd - Layer...The Tal arco ou. ele a the mining. ucthin a the Waid &, theregere Relative Arnot. Cth ebacting a Aoacker » and the 4 Agacke. Ir the wvkled - toate absorber the Uapetd {lows clown a vertical uke, whele the 5 kes wutth the Laud. _| dict Od Une an thle! ewer the bed ron... | Aeckion ar tk ours dowry thisugh, ching material, | Auch, a Rasch Mngt» Bast sosidl ee. ekew — |The gay Con: evo Aas t the Uqped- Om aprag neacker the (eqed | uh ane. ts. Vided. bekuretm the the droplets cmd. the. - | labovalahy gas bubiier, ts mibredticed. ite te quad. 4 brah holes armel. the furbeee - cop cdliirrn, in while hy the Liquid Gomadintey didtbuted. on toa _| gu Atrmilar ddartbuker » 04.5 the. fam. thi_seeek midumay. - - | the dau pa us cernucls oy. tro. — | dences.are the uekted-walt abrarbrs, the packed-bed | : gous, ur the Aurferce oy the Uqped. mw ether parallel _|. -] or. Cambor — cunramt blow The pasked=bedl o,f mtly or. Coumbu-eurenity wlth... | a] bY mm way pore dasplel bo. that ov large miofa—. ; “Lowy abrucecch, other. Fimally, this greetp ase _|- toh the. _.{1)_Srv.the brmpse bungee contacter’ the Liqucd ts ecthor.ab |. aged Gtr cekal egy ar aan of os Loum wie iiuthe, on oe cole fren me a3 “TL concomtatc Cplimclens sore of -toRich Aoteubes tohele the.._}.." “Othar Atmatons Mattonary. Theiymer hstobing cylin LL ‘ ag - 3) The thild, pups the achowionl aortas \_ —Vrmadle.of packing mateatalcnckored m Acheemdong |. Thaeugh the Adtotion 4 the dium the mg | Contirely tmeeted wlth bon laps 340 thak im | -Leqpce ing te the mag A2cct tucth each other. | S| AGo belongs thy CAR the Cmbripugal Jaukbes, —| which mold’ the. Hike seautberand, Adauy Aoubbe. - In beth. there , ajtecdl Us. 2 auyecl because of. the en | Aataton, and thus qeed incting 6 gas armel teopuced |. \ i | | _ |B otkatmed . on ..| -REACTORS. FOR_GASES AND SOLIDS: ‘The most suitable type of reactor for chemical reactions in which gases and ~~~} ~- solids take part depends upon various factors. The classification of the reac- tors is possible from several different points of view. First of all, the reactors can be distinguished on the basis of whether the solid material is converted in stoichiometric proportions or not. Vor example, the solid material is not nverted in stoichiometric proportions when it serves as a catalyst or heat ia medium for a gas reaction, Further, the reactors can. be divided uc- rding'to whether the solid material remains at rest. in the reactor or whether it passes throughthe reactor in batchivise or continuous fashion. Finally, it is ulko possiblé to divide the reactors according to a heat, transfer point of view, ie. whether the reactor is for an exothermic or.an endothermic reaction or -| — whether the reactor operates at very high or moderate temperatures, Euch __. classification scheme has advantages and: disadvantages, ‘The classification xcheme mentioned secondly will be chosen here (ef. Fig. 8-41) as follows: oH] se _ |...) (1) Reactors with fixed solids he (1) The solid material is a catalyst (2) The solid material is used for heat transfer +, | Gl) Reactors with solids in motion 11) Batch operation 1.:42(2).Continuous operation “The second group includes _.... | @)-The moving-bed reactor, in which the solid particles move through the reactor under the force of gravity, ~~ (b). The rotary kiln’ and the multicompartment reactor, in which the solid - ~~ particles are kept in motion by mechanical means, (©) The fluidized;bed reactor with the particles being fluidized by a gns -stslreain, (a) ‘The dilute-phase, cocurrent-flow reactor, in which the solid material -_ is carried along with the flowing gas, and ‘(e) The dilute-phase, countercurrent-flow reactor, in which the solid par- ~- icles fall through the risinReactor with Bateh Moving-hed Multicompartnent ; fixed solids reactor reactor reactor 8 ; - 1 S o5@ wise) += sample: ing =| = ‘elcination of ore of limestone ‘ Dilutephase, Dilute-phase. - Fluidized-bed coeurrent-flow countercurren Kotary kiln reactor reactor flow reactor a S46 G oo te Examples: Example: Example: [om roasting oul Toasting of ore, cracking, gasification of ore f ure of oe — © Frey Reactors for reactions between gases and solids. "REACTORS. FOR .LIQUDS AND SOLIDS: fo PO Dypes dee mont >. 9.5. “REACTORS FoR.Gaséous _'LiQuID - SOLID SYSTEMS: “| Ft puch Asackes fpr gare sotial~ a_egpuid.- ote hesteoms Gon Mpegs Pie one used. iRotary Agitated sphere alrumn SL ——--- J example: Example: 4 fii.) dyeing antimony ~L- from tin 3 fo ore a chloride - | -— ‘ —-[n Serew Spinning Fhuidine nozzle rewetor > P sii —}-- b 11 _t i Exumple: Example: Ky superphosphate Bune water softening ff digester, fron rod - phosphate ——|-— t ie: i(a) oO @ 4 [To stack in RET in [ee 4 JTo stack ‘Nir preheat (e) @ Burners, (h) ‘To stack f [To stack Th BASIC TYPES OF TUBULAR FURNACES (tod) 4 gaFUNDAMENTAL. DESIGN EQ.UATIONS:. The dtasting pomnt fev at cn themabnal balanced. 2x asec. fev amy weal Amattsiab balance om d aeacant 4 i ithe foo, | element oy Vue (aay) AV Arum Can be atten as; Rate of fino Rake of flaw Rae of la. of of A unto - GA out | _ | A by Chemical the Vaume * | the wlume > | Atackions with Cement elemont, tm the lume (onder [time (rnitus/ time) Clemame (rméy bime) Rake o% occultation, OBA within the a VOurme elemaont (mus / tarne) Or ow Abort foun, te Nae pcan * ata - OF Atatlamt erito amd. ouk the voters eee Rake 6, dina-ppeanamce 0 the duck Of Rexcmnr : te ig opti ore duane ac ~ Aeachion ake per amit Volurme,-erctlurated 9 the properties appre} frcha sca fate ropa Umit vBume ts t the uibrinsic, ante g the chemical Aeasbiny only | the Vume eemenk & Unite tne tumbucture and corumbiation (ie. thecore mo heat yma. Fane limitations . on EM aed conumion 8 aciamts © balich- The femal teem. Anpuusemt the rate oy chamge on waning Maadling bron tha ec oy, Che othar three Gems. “ Where the dv within the, Avaot (L nipoum Unde steeping, me conden the whe Aeacter. formakeral Se12. Whee the chim usithin the reactor os mot unitormu, ikomudk be made our ov digerembiol element of ume omd then concombrabionne Gmdibxns ( FOR TUBULAR FLOW REACTORS) for the. batch, Aeackor the fist ture bens are zo. For Cenkiwous (ow reactors ing ak beady - cake , te : pay operating j Whos um ctaady .ctake cmditions are vuablued, UE unitt Jur. mecamary unbegrate our bie a Well a curr vOumne vir order fo datemune the performance charackwidics a the Aenckor. ; Senco accte & Chimnical Aeactions Smoumally cheng Eompratune de 7&5 eentcal to know the af cacly pomk metre Acackor un order to be alte be utilize the amakut balance » When there ore Umperature gradions am, enngy balance br Onypaction uuikhy the matuwal balamee in order to dekumine the tumperature amd com da preuatling al eet fount: vre the Arackr at a partionlartume. Thegomercl enugy balance fer anv element 6 Vume Av ounatime dt tan be utitkeror culty im the acackar, kU oracenany bo c & jn nde, Emargiz in matter, Enungyy tamafentel eno witathe =| fiooubey | Som Aasncumshings Volume, Vitus. element dlennenk Wourne element13 = . Foy Com-Hetam ets the Com cosesfimding & ee ee 6, material to the lume elermunt and cut, th omboun wi additiav 5 the & eudinay a ety ntl matncat, Uy mete and chemical heacteus, Che enthalpy teem u i are Athoughy heak effec tm i eam Agasch pera ay ohaft werk effec are > aucrllyy tachoutat Acackiow Aaken btn nat ated eypation Juut Ceca are msplucite vi thd. The is eens amd fourthy terms difperrmees en b ature Oe doves Cn O% the and ard aang Aiea, Theonegy + cos abraded samo i arra, dursct Agflectin 6, enthatpy change axowiated) | aa Reackem (je. heat & rvaction). Bom the Aumaray » ut Cony write the Volume, nal element, = OL ww Adar forms heat viput - heak owkput > Stenppensonce by acne For chimed tomks the Agactor catints te ge temperature amel, compatibion throughout andl Ub pomible to Uuaie bre balance cur the entire Avocker. ote on A Gate AHN ac arnty thee fod fort amd 2nd bens are ocoumubabion ten For cit pati ohn chat uk feds re orate tomagr War ev lot page omitted 7+ (13.0) »~, | tumpovabure mae be independent, % poxckion, ama the emagy - balance amunt he wither ono. ifjrsmbcal element ss Arathor VOurme. The dtsuttamt cdixeembiak eyptatkion Chim rut be Add, we congucbion with, the difainbial pation durribing the mate hol balance ow the diffatmeval dlemank. NOTES: The purpose of balance sto deserche the te eae Coe rn od actos (erat © Rach bime for bakehy Anaskor.) Ao that the kate be ansinyped. to thak pot. pepe mt VoLUME ELEMENT ! heat bw heat leaues F : REFERENCES: 1). LEVENSPIEL, O.: Chomical Reackiorw Engimecring » Ind ed. hry Wiley & Sou, l72. ‘nginening 12) HG TR: ,C-G.: Ar Ontieduckion to Chemical Engimesing — | -Kimabict Reattot Devigns 5 Tikow Wily finan © 3) Smith, 0M. Chomical Enaimarung Iumetccs, md ed., Meftaw. — WRG. (970. : i wot) WALAS, 6M. 1 Reactiary Kamebics For Chemical, Enpiocers, MeGraw - WLP Rook Co.» 1959. 5) WAR, BROTZ»W, : Fundamentals 4 Chemical Reackcer Enginerning » Addison Worsley , Rublish img Co. » 1965. ; 6) FOGLER , H-S.: Elements chemdeeh, Reackion, Engenunimg, Imd ed., Prontice Hall Intemational, 1192.