CH 2

CHE 402
Kinetics & Reactor

Design
Dr. Eid Al-Mutairi

Chapter 2:
Conversion and Reactor
Sizing
Dr. Eid Al-Mutairi

CHE 402- Dr. Eid Al-Mutairi
Objectives
Define conversion and space time.
Write the mole balances in terms of conversion for a

batch reactor, CSTR, PFR, and PBR.
Size reactors either alone or in series once given the

molar flow rate of A, and the rate of reaction, - rA, as a
function of conversion, X.
Reactor Mole Balance

Summary
Conversion
Conversion
moles reacted
X=
moles fed
Conversion
moles reacted
X=
moles fed
For irreversible reaction, the maximum value of X is that for complete

conversion, i.e. X=1.0
For reversible reactions, the maximum value of X is the equilibrium
conversion, i.e. X=Xe
Batch Reactor Conversion

For example, let’s examine a batch reactor with the following design
equation:
dN A
= rA V
dt

equation: dN A
= rA V
dt
Consider the reaction:
moles reacted
moles remaining = moles fed - moles fed •
moles fed

equation:
dN A
= rA V
dt
moles reacted
moles fed

equation: dN A
= rA V
dt
moles reacted
moles fed
Differential Form:
Integral Form:
CSTR Conversion
Algebraic Form:
There is no differential or integral form for a CSTR.

PFR Conversion
PFR
dF A
= rA
dV
FA = F A0 (1− X)
PFR Conversion
dF A
= rA
PFR dV
FA = F A0 (1− X)
PFR Conversion
dF A
= rA
PFR dV
FA = F A0 (1− X)
Differential Form:
Integral Form:
Design Equations
Design Equations
Design Equations
Design Equations
V
Design Equations
V
Design Equations
Concentration
For liquid phase FA0=CA0 v0
For gas phase: CA0=PA0/RT0=yA0P0/RT0
FA0= v0yA0P0/RT0
Example 2-1
A gas of pure A at 830 kPa (8.2 atm) enters a
reactor with volumetric flow rate v0 of 2
dm3/s at 500 K. Calculate the entering
concentration of A, CA0, and the entering
molar flow rate, FA0.
Reactor Sizing
Example 2-2 [CSTR]

Numerical Evaluation of
Integrals
The integral to calculate the PFR volume can be evaluated
using Simpson’s One-Third Rule (see Appendix A.4 on p. 1013):
Reactor Sizing
Numerical Evaluation of
Integrals
The integral to calculate the PFR volume can be evaluated
using Simpson’s One-Third Rule (see Appendix A.4 on p. 1013):
Example
Example
X⎛ 1 ⎞
V = F A0 ∫0 ⎜ ⎟ dX
⎝ − rA ⎠ 0.010
Example
X⎛ 1 ⎞
V = F A0 ∫0 ⎜ ⎟ dX
⎝ − rA ⎠ 0.010
Example
X⎛ 1 ⎞
V = F A0 ∫0 ⎜ ⎟ dX
⎝ − rA ⎠ 0.010
50
1 40
30
−rA 20
10
0.2 0.4 0.6 0.8
X
Solution 0.8
= FA0 [ f ( X 0 ) + 4 * f ( X 1 ) + f ( X 2 )]
dX h
FA0 ∫
0
− rA 3
Solution 0.8
= FA0 [ f ( X 0 ) + 4 * f ( X 1 ) + f ( X 2 )]
dX h
FA0 ∫
0
− rA 3
h=0.4 X0=0 X1=0.4 X2=0.8

Solution 0.8
= FA0 [ f ( X 0 ) + 4 * f ( X 1 ) + f ( X 2 )]
dX h
FA0 ∫
0
− rA 3
h=0.4 X0=0 X1=0.4 X2=0.8
0.8
V = FA0 ∫
dX
=2
0.4
[ f (0) + 4 * f (0.4) + f (0.8)]
0
− rA 3
Solution 0.8
= FA0 [ f ( X 0 ) + 4 * f ( X 1 ) + f ( X 2 )]
dX h
FA0 ∫
0
− rA 3
h=0.4 X0=0 X1=0.4 X2=0.8
0.8
V = FA0 ∫
dX
=2
0.4
[ f (0) + 4 * f (0.4) + f (0.8)]
0
− rA 3
0.8
V = FA0 ∫
dX
=2
0 .4
[100 + 4 *125 + 500]
0
− rA 3
Solution 0.8
= FA0 [ f ( X 0 ) + 4 * f ( X 1 ) + f ( X 2 )]
dX h
FA0 ∫
0
− rA 3
h=0.4 X0=0 X1=0.4 X2=0.8
0.8
V = FA0 ∫
dX
=2
0.4
[ f (0) + 4 * f (0.4) + f (0.8)]
0
− rA 3
0.8
V = FA0 ∫
dX
=2
0 .4
[100 + 4 *125 + 500]
0
− rA 3
V=293.3 L
Example 2-2 [PFR]

Reactor Sizing- Summary

Given -rA as a function of conversion, -rA=f(X), one can size any
type of reactor.
50
1 40
30
We do this by constructing a Levenspiel plot. −rA 20
10
0.2 0.4 0.6 0.8
FA0 1
Here we plot either −r A or −r A as a function of X.
FA0
For −r A
vs. X, the volume of a CSTR is: XEXIT
F A0 (X − 0 ) Equivalent to area of rectangle

V=
− rA on a Levenspiel Plot
EXIT
FA0
For −r A
vs. X, the volume of a PFR is:
VPFR = ∫0
XF
A0
− rA
dX = area under the curve
=area
Reactor Staging
Reactors In Series
Reactors In Series
Reactors In Series
Reactors in Series
Also consider a number of CSTRs in series:
Reactors in Series
Finally consider a number of CSTRs in series:
We see that we approach the PFR reactor volume for a

large number of CSTRs in series:
FA 0
− rA
X
Example 2-5
PFRs in series
FA1
X1=0.4
FA0
FAe
X2=0.8
PFRs in series
FA1
X1=0.4
FA0
FAe
X2=0.8
x2 x 1 x 2
dX dX dX
∫0 FA0 − rA = ∫0 FA0 − rA + x∫ FA0 − rA
1
PFRs in series
FA1
X1=0.4
FA0
FAe
X2=0.8
x2 x 1 x 2
dX dX dX
∫0 FA0 − rA = ∫0 FA0 − rA + x∫ FA0 − rA
1
FA0/-rA
X
Example 2-6
PFRs, CSTRs reactor volumes and

sequencing
Space time
V
time necessary to process one
reactor volume of fluid based on
τ=
v0
entrance conditions
Space velocity v0 1
- LHSV SV = =
-GHSV
V τ
Typical Space time for Industrial Reactors
Reactor Type Mean Residence Production

Time Range Capacity
Batch 15 min – 20 h Few kg/h to

100,000 tons/yr
CSTR 10 min-4h 10 - 3M tons/yr
Tubular 0.5 s-1 h 50- 5M tons/yr

CH 2

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CHE 402

Kinetics & Reactor

Dr. Eid Al-Mutairi

Dr. Eid Al-Mutairi

 Write the mole balances in terms of conversion for a

 Size reactors either alone or in series once given the

Reactor Mole Balance

For irreversible reaction, the maximum value of X is that for complete

Batch Reactor Conversion

Batch Reactor Conversion

 Consider the reaction:

Batch Reactor Conversion

Consider the reaction:

Batch Reactor Conversion

There is no differential or integral form for a CSTR.

 For gas phase: CA0=PA0/RT0=yA0P0/RT0

Example 2-2 [CSTR]

h=0.4 X0=0 X1=0.4 X2=0.8

h=0.4 X0=0 X1=0.4 X2=0.8

h=0.4 X0=0 X1=0.4 X2=0.8

h=0.4 X0=0 X1=0.4 X2=0.8

Example 2-2 [PFR]

Reactor Sizing- Summary

F A0 (X − 0 ) Equivalent to area of rectangle

 We see that we approach the PFR reactor volume for a

PFRs, CSTRs reactor volumes and

Typical Space time for Industrial Reactors

Reactor Type Mean Residence Production

Batch 15 min – 20 h Few kg/h to

CSTR 10 min-4h 10 - 3M tons/yr

Tubular 0.5 s-1 h 50- 5M tons/yr

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Write the mole balances in terms of conversion for a

Size reactors either alone or in series once given the

Consider the reaction:

Consider the reaction:

For gas phase: CA0=PA0/RT0=yA0P0/RT0

We see that we approach the PFR reactor volume for a