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Design
Introduction
Almost all chemical engineering process
contains three operations.
Homogenous
Heterogeneous
Types of reactors
1.Batch- uniform composition
everywhere in reactor but
changes with time
2. Semi batch- in semi-batch one
reactant will be added when
reaction will proceed
3. Continuous reactor
a. Mixed flow- this is uniformly
mixed , same composition
everywhere, within the reactor
and at exit
b. Plug flow- flow of fluid through
reactor with order so that only
lateral mixing is possible.
Reactor design parameter
Reactor design basically means which type and
size of reactor and method of operation we
should employ for a given conversation
Parameters
• Volume of reactor
• Flow rate
• Concentration of feed
• Reaction kinetic
• Temperature
• pressure
Isothermal reactor design algorithm
Plug flow and mixed flow reactor design
Fig-4
Design for parallel reaction
• When a reactant gives two product
(desired, and undesired)simultaneously
with different rate constant then this is
called a parallel reaction.
• To keep maximum amount of desired
product we can take following steps.
• Ifa1>a2 or the desired reaction is of higher
order then keep reactant concentration
high for high product concentration.
• If a1<a2 than for desired reaction keep
reactant concentration low.
• For a1=a2 change in reactant
concentration will not affect the product
then, because rate constant k1 and k2 are
different at different temperature so, we
can keep our temperature such that
desired product will be high or use of
catalyst would be a option which are
selective in nature.
Reactor design for multiple reaction
• In multiple reaction reactor design contacting pattern is most important factor to get a
particular product.
• In irreversible reaction in series like
the mixing of fluid of different composition is the key to formation of intermediate. The
maximum possible amount of intermediate is obtained if fluid of different composition and
different stage of conversation are not allowed to mixed.
• In series of reaction if intermediate reactant is our desired product than semi batch reactor will
be used.
Irreversible series-parallel reaction
• Multiple reaction that consist of steps in
Halogenations of alkane is a
series and steps in parallel reaction.
example of this kind of
• In these reaction proper contacting reaction where reaction is
pattern is very important. parallel with respect to
• The general representation of these halogen
reaction are
Integral reactor
• Reaction type
• Reactor type
• Economics
• Rate of deactivation
• Other process
requirement
Reaction type
• Chemical kinetics of reaction can be known by knowing the type of
reaction
• For reactor selection reaction type will tell us about heat of reaction
either reaction is endothermic or exothermic.
• Selectivity is defined as reaction rate ratio for two parallel reaction.
• Catalyst are used to increase reaction rate and selectivity for a
specific reaction.
• We can determine what type of catalyst will be used.
• Reaction temperature range will be determined.
Reactor type
• Reactor may be a plug flow or mixed flow or
batch flow reactor or other.
• Contacting pattern of reaction will be known.
• In case of expensive catalyst and high heat
transfer rate required, mixed flow(fludized
bed) reactor are used.
• For high mass transfer plug flow (packed bed)
reactor will be used.
Economics
• For reactor design overall economics should
be considered.
• Like instead of different size of mixed flow
reactor in series, equal size mixed flow reactor
are economically good.
• If catalyst is not very expensive then we may
opt to non-regeneration but for expensive
regeneration must be considered.
Packed bed
• Solid fluid contact will be most efficient
• High amount of catalyst will be used
• Heat transfer will be difficult
• Pressure drop will be high
• Effective for mass transfer control system
• With increase in temperature side reaction
will be a problem and less selectivity
• Sintering of catalyst may happen
Fluidized bed
• Industrially most widely used
• Heat transfer are very good
• Pressure drop is low
• Catalyst can easily replaced for regeneration
• Amount of catalyst necessary is less
• Surface area per unite mass of catalyst will be
large
Fluidized bed catalytic reactor design
Types of fluidized bed catalytic reactor
• Bubbling fluidized bed(BFB)- industrial
solid catalyzed reactor generally works as
bubbling fluidized bed reactor. Calculation
of conversion for bubbling flow varies
between plug flow to mixed flow.
• Turbulent fluidized bed reactor(TFB)- at
high gas velocity BFB transform in to TFB
in this case no distinct bubble of gas will
flow and solid movement will be violent.
• Fast fluidized bed- transition from TFB
with very high speed of gas this FFB will
formed.
• Pneumatic conveying bed- highest gas
velocity for fluidization are choking
velocity and after that it will converted
into pneumatic bed and this reactor
pneumatic conveying fluidized bed
reactor.
• In all three model TFB, BFB, PCB solid
entrain out of bed regularly.
Bubbling fluidized bed
Model for bubbling fluidization
• Dispersion and tank series model
Reaction type
Burning of coal is a exothermic reaction
C + O2 = CO2 + heat
Reactor selection
For burning of coal contact of air and coal is very important
Resistance to mass transfer will be
1. film above the coal
2. Ash layer with burning of coal
3. Resistance due to chemical reaction
So, very high mass transfer resistance
conti………
Ignition temperature
For burning of coal minimum
ignition required so, heat
should be recycled
Plug flow reactor with recycle
will be most suitable reactor
for this system
Mass Transfer resistance and
rate equation
Total resistance = film resistance
Plug flow reactor
+ ash resistance + reaction
resistance
• Know as we know the rate of reaction by
knowing all resistance
• We know the flow type and reactor type is
plug flow
• We know feed rate from heat balance of
burning of coal
• From performance equation we will get the
volume of reactor
References
Chemical Reaction Engineering
(Octave Levenspeil)
Elements of Chemical Reaction Engineering
(H. Scott Fogler)
Chemical Reactor Design
(Peter Harriott)
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