BKF2453: TUTORIAL FOR CHAPTER 2

Reactor design equation as a function of conversion of limiting reactant

1. Define the conversion of reactions with single reactant for:-
a) Batch reactors
b) Flow reactors
c) Liquid phase reaction based on concentration
d) Gaseous reaction based on concentration
2. Transform the following mole balance equations into forms of conversion function.
CA
dCA
a) t= ∫
C A0
rA
ν 0 ( C A 0 −C A )
b) V =
−r A
C
−ν 0 d C A
A

c) V =
k C∫ C A
A0

3. For the irreversible gas-phase reaction:

A2B 
the following correlation was determined from the laboratory data (the initial concentration of
A is 200 mol m-3):
1
For X≤0.5: =3.0 m3.s. mol-1
−r A
1
For X>0.5: =3.0+10 (X - 0.5) m3.s. mol-1
−r A
The volumetric flow rate is 5 dm3 s-1
a) Construct the data and plot the Levenspiel plot for this reaction
b) Determine the conversion that will be achieved in a Continuous Stirred Tank Reactor
(CSTR) that has a volume of 2.9 m3.
c) Calculate the plug-flow reactor (PFR) volume that is necessary to achieve 70 %
conversion.
d) Two flow reactors are needed in series arrangement for this reaction, either CSTR
followed by PFR or PFR followed by PFR. As an engineer, which reactor arrangement
would you recommend in order to have minimum volume of reactors and the conversion
of first reactor is 50 % while the second reactor’s conversion is 90 %? Justify your
suggestion.

4. An aqueous decomposition of A producing R is studied in a flow reactor.

A→R

Table 1 shows the results obtained in a steady state run. The process has a constant initial molar
flow rate of 5.7 mol s-1 with CA0 = 1.3 mol dm-3.

Table 1: Raw Data

CA, mol dm-3 -rA, mol dm-3 min-1

 1.3 0.09
1 0.18
0.8 0.2
0.7 0.17
0.6 0.12
0.5 0.088
0.39 0.065
0.29 0.053
0.18 0.045
0.08 0.04
a) Construct the Levenspiel plot for this process.
b) Calculate the volume of CSTR needed to achieve 54% conversion.
c) The conversion is expected to increase with the addition of another flow reactor to
the system. As an engineer, you have been given a task to select whether to use PFR
or CSTR in series after the reactor in (b). The process is targeting to achieve 86%
conversion. By using calculation, select the most economical reactor.
5. As a process engineer, you are required to design a reactor system for carrying out the non-
elementary gas phase reaction of

AB

1
k1C 2
rB  A

which has the rate law 1  k 2C A

a) The feed is composed of 100 lb mol/h of pure A. Construct Levenspiel plot to represent
this reaction. In your opinion, what system (i.e., type and arrangement) of flow reactors,
either one alone or two in series, would you recommend for continuous processing of a
feed of pure A in order to minimize the total reactor volume? (90% conversion of A is
desired.). Please use the estimation of the reactor size(s) as the basis of your answers.
Additional information:
k1 = 10.0 (lb-mol/ft 3) 0.5 h -1
k 2 = 6.0 ft 3/lb mol
vO = 400 ft 3/h
6. The following irreversible homogeneous gas phase reaction
A → 3B
occurs at temperature of 215oC. The power rate law is non-elementary with k = 10 -2 (mol/liter)½
s-1. Proceed to find the space time required for achieving 50% conversion of A if the reaction is
carried out in a plug flow reactor (PFR)?
Additional information:
Inert in the feed = 50% by mole
Pressure = 5 atm
Assume ideal gas
7.

8.
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10.
11.

12. [Q3 Test Sem 1 2013-2014]

The pyrolysis of methyl acetoxypropionate has been studied at different temperatures and a variety
of pressures. The reaction is as follows:
CH3COOCH(CH3)COOCH3  CH3COOH + CH2 = CHCOOCH3
Below 565 °C the gaseous reaction is found to be the first order with a rate constant given by k = 7.8
x l09 exp(-19220/T) s-1, where T is expressed in Kelvin degrees. A tubular reactor (internal diameter,
ID = 0.15 m) is available for the process. The pure feedstock enters the reactor at 5 atm at a flow
rate of 226 kg hr-1. The ideal gas behaviour shall be assumed. Pressure drop across the reactor may
be neglected.
a) Determine the space time required to achieve 90% conversion if the reaction is conducted
isothermally at 500 °C.
(10 Marks)
b) Determine length of the reactor will be required to convert 90% of the r aw feedstock to methyl
acrylate
(5 Marks)
c) If the feedstock entering the reactor is diluted with 50% of N 2, determine the conversion for the
same length of the reactor used for (a).
(10Marks)

13. [Q3 Test Sem 2 2013-2014]

The elementary reversible liquid phase reaction

A k B
k1
3 -1
occurs in an isothermal well-mixed reactor with the -1 feed of 100 dm min flow containing 20% A and
80% inert . 75% conversion of A is desired. Molar ratio of A:B at equilibrium is 1:10 and from initial
rate study, the specific rate constant of forward reaction, k1 = 12.5 min-1.
a) Estimate the volume of the reactor
(10 Marks)
b) If a plug flow reactor (PFR) is used to replace the above reactor, determine the volume of the
PFR.
(8 Marks)
c) If A is diluted up to 5%, the reaction can be considered irreversible with the rate law
-rA = k1CA
How the volume of the PFR in (b) will change with the same conversion?
(7 Marks)
14. [Q2 Sem2 2011-2012]
 15. Test Sem 1 2014-2015
The reversible liquid phase reaction:

A 2B

was carried out isothermally (T = 350K) in a batch reactor and the concentration equilibrium constant, KC
and the forward rate constant k1 was found as 1.6 ml dm -3 and 2.0 h-1. In order to carry out the process
in flow system, continuous stirred tank reactor (CSTR) and Plug flow reactor (PFR) are considered. The
inlet molar flow rate should be, FA0 = 10 ml h-1 and initial concentration of A, CA0 = 0.1 mol/dm3. The feed
should be free of B.

a) Determine the equilibrium conversion.

(4 marks)
b) Construct the Levenspiel Plot
(8 Marks)
 c) Determine* the volume of a single CSTR and a PFR to achieve 97% of the equilibrium conversion.
(6 Marks)
d) You are provided a 40 dm3 CSTR and a 40 dm 3 PFR. Arrange* the reactors in such a way so that
you can achieve maximum conversion. Point out the conversion you will achieve and give
justification of the reactor arrangement.
(7 Marks)

*
Use Levenspiel plot to answer (c) and (d).

16. Test Sem 1 2015-2016

Consider an elementary liquid-phase reaction,

3 A +2 B → 2C +1 D

This reaction takes place in an isothermal flow reactor. The feed contains molar flow rate of A, B and
inert, denoted as FAo, FBO and FIO, respectively.

a) Construct the stoichiometric table to show the concentration of each species can be written as a
function of conversion if the reactor initially contains of equal molar of inert, A and B
(10 Marks)

b) If the reactor initially contains of equal molar inert, A and B of 5 mol dm -3 and the rate constant
is 0.025 (dm3 mol-1)4 s-1, express the rate law as a function of conversion.
(5 Marks)

c) The reaction is performed in CSTR-PFR-CSTR reactors in series sequence as resulted in rates as

shown in Table 1. The final conversion of A is 80 % while the intermediate conversion exit from
the CSTR reactor (1st reactor) is 40% and 70% conversion of A exit from the PFR reactor (2 nd
reactor). Estimate the total volume of all reactors.

Table 1

X 0 0.2 0.4 0.6 0.8

FAo/-rA 200 220 250 400 1000
 17. Test Sem 1 2017-2018
A gas phase nonelementary reaction
2 A →B+C
Is carried out isothermally (T = 200 ⁰C) in a reactor. The specific rate constant at 200 ⁰C was
found as, k = 0.015 (mol) 1/2/(dm3)1/2.min. The rate of the reaction as a function of conversion is
given in Table 1.
Table 1: Rate vs conversion data
x 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
-rA ,
mol/dm3.min 0.0054 0.0051 0.0048 0.0045 0.0042 0.0038 0.0034 0.0029
a) The reaction was conducted in a batch reactor (rigid vessel). Initially reactant A was
diluted with an inert gas (N2) at a molar ratio of 1:1. The total pressure in the reactor was
10 atm. Estimate the time required to achieve 30% conversion.
(6 Marks)
b) It was planned to evaluate the performance of flow reactors for the above reaction. The
reactant, A, diluted with an inert gas (N 2) at a molar ratio of 1:1 was fed to the reactor at
10 atm and 200 ⁰C. The volumetric flow rate was 7.5 dm 3/min. Compare the space time
required for a CSTR and a PFR to achieve 30% conversion.
(10 Marks)
c) To further increase the conversion to 50%, a chemical engineer proposed to operate a
PFR achieving 30% conversion followed by a CSTR in series. However, another
chemical engineer argued that a CSTR is preferred to be operated first achieving 30%
conversion connected in series with a PFR if the reaction order, n<1. Verify if the
argument is correct in the context of the problem.
(9 Marks)

18.