Reactor design

Chapter Three

Chapter Three
Multiple-Reactor Systems
1- Series

xN >xi >> x2>x1 CAN < CAi << CA2 < CA1

for constant density:

C A 0  C A1
x1 
C A0
C A0  C A N
XN 
C A0
**FA1=FA0(1-x1)
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Reactor design
Chapter Three

FA2= FA0(1-x2) or FA2=FA1(x1-x2)

Mixed Flow Reactors of Equal Sizes in Series

Let:
1- You have three CSTRs equal in volume (V1=V2=V3=V).
2- The irreversible reaction is first order
3- The mixture has constant density (Q0=Q1=Q2=Q3=Q)
(  1 =  2 =  3=  )
4- The temperature is constant (k1=k2=k3=k)

For 1st. tank

v 1 C A0  C A1 C A0  C A1
1    
Q0 rA1 kC A1
C A0
C A1 
1   1k
C A1 C A0 x 1 1
x 1  1  1   x 1  1
C A0 kC A1 1   1k
 1k
x1 
1   1k

For 2nd. tank

C A1
C A2 
1   2k
C A0
C A2 
(1   1k )(1   2 k )
C A0
C A2 
(1   k ) 2

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Reactor design
Chapter Three

1
x 2  1
(1   1k )(1   2 k )
1
x 2  1
(1   k ) 2

For 3rd. tank

C A0
C A3 
(1   k ) 3
1
x3  1
(1   k ) 3

For Nth. Tank

C A0
C AN 
(1   k ) N
1
xN  1
(1   k ) N

If V1≠V2≠V3
1
x N  1
(1   1k )(1   2 k )(1   3k )

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Reactor design
Chapter Three

Example 1
Acetic anhydride is to be hydrolyzed in three CSTRs operating in series . If the
volumes of each reactor is 1800 ml, and the feed rate is 582 ml/min. Estimate the
degree of hydrolysis (xA) accomplished in each reactor and the total fraction
hydrolyzed. The reaction can be assumed first order with rate expressed by
equation:-
-rA = 0.1558 CA

Solution:-
V1=V2=V3=1800 ml
v 1800
   3.093min
Q 0 582
 k  0.1558
1
x 1  1  0.325
1 k
1
x 2  1  0.545
(1   k ) 2
1
x 3  1  0.693
(1   k )3

Mixed Flow Reactors of Different Sizes in Series

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Reactor design
Chapter Three

Example 1
A system of three Stirred tank reactor is to be designed to treat a solution
containing 4 mol/lit of reactant A. An experiment with small reactor in the
laboratory gave the kinetics data given below. If the feed rate to the reactor is 200
lit/hr.
1- what fraction will be obtained if each of the three tanks has a volume of 600
lit?.
2- calculate the volume of the tanks required for the same Overall conversion if
two equal tanks are used and if only one tank used?.

CA ( mol/lit) 0.5 1 1.5 2 2.5 3 3.5 4

-rA (mol/lit.hr) 0.05 0.09 0.13 0.18 0.25 0.35 0.48 0.65

Solution:-
1- plot -rA Vs CA The slop = - 1/ 
1  rA V 1 600 1
   slop 1    3  slop  
 C A1 C A 0 Q 0 200 3

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Reactor design
Chapter Three

From plot CA1= 2.91 ,

CA2= 2.1 .
CA3=1.705 x3=0,57
2- By trail & error :
1 26 *102
  slop  0.183 
 2.58  4
V
 1  5.46  V  1093lit
Q0
V t  2V  2184lit

1 15*102  0
  slop   0.0655
3-  1.71  4
  15.267 V  3053lit

Determining the Best System for a Given Conversion.

Suppose we want to find the minimum size of two mixed flow reactors in series to
achieve a specified conversion of feed which reacts with arbitrary but known
kinetics.

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Reactor design
Chapter Three

V t V 1 V 2

Plug Flow Reactors in Series

V1 V2

FA 0 FA 0

V t V 1 V 2

A combination of PFRs giving a particular final conversion have the

same volume as a single PFR which gives the same total conversion.
A series of CSTRs can be useful to reduce the overall volume:

Reactors of Different Types in Series

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Reactor design
Chapter Three

2- Parallel
CA1
CA0 FA1
CA0 FA01 x1
FA0 x0 Q1
x0 Q01
Q0 CA
FA
CA2
x
CA0 FA2 Q
FA02 x2
x0 Q2
Q02

Q 0  Q 01  Q 02
1-
FA 0  FA 01  FA 02
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Reactor design
Chapter Three

2-  1   2  

If V1=V2
Q0
Q 01  Q 02 
2
F
FA 01  FA 02  A0
2

If V1≠V2
ex: V1=2V2

1   2
2V 2 V 2
  Q 01  2Q 02  FA 01  2FA 02
Q 01 Q 02

3- x1=x2=x
CA1 =CA2=CA
FA1=FA2=FA

If x1≠x2
C A 1  C A 0 (1  x 1 )
FA 1  FA 0 (1  x 1 )

4- if the mixture constant density:

Q01=Q1, Q02= Q2
or else
Q1  Q 01 (1   x 1 )

5- FA=FA1+FA2
Q0= Q01+Q02

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Reactor design
Chapter Three

H.
H.WW
How can you calculate CA and X if x1≠x2

H.W
Show what is the volumetric and mole flow rate ratios for D to E branches?.

Sheet No. 3
1- A liquid reactant stream (1 mol/lit) passes through two mixed flow reactors in series. The
concentration of A in the exit stream of 1st. reactor is 0.5 mol/lit. Find the concentration in
the exit stream of 2nd. reactor. The reaction is second order with respect to A and
(V2/V1=2).

2- An aqueous reactant stream (4 mol/lit) passes through a mixed flow reactor followed by a
plug flow reactor . Find the concentration at the exit of the PFR if in the mixed flow reactor
CA= 1 mol/lit, the reaction is second order with respect to A, and the volume of PFR unit
is three times of mixed reactor.

3- Reactant A( A R , C A0 = 26 mol/lit) passes in steady flow through four equal size mixed
flow reactors in series (  total= 2 min) . When steady state is achieved the concentration
of A is found to be (11 , 5 , 2 , 1 mol/ m 3) in the four units . For this reaction, what  must
be in PFR so as to reduce the concentration from 26 to 1 mol/m3.

4- We wish to treat 10 lit/min of liquid feed containing 1 molA/lit to x =99%, A R,

CA
 rA  , mol/lit.min. Suggest a good treatment for doing this using two mixed flow
0 .2  C A
reactor and find the size of the two units needed. Sketch the final design chosen.

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Reactor design
Chapter Three

5- At present elementary liquid-phase reaction A + B R + S. takes place in PFR using

equimolar quantities of A and B, x= 96%, CA0=CB0=1 mol/lit. If a MFR is ten times as
large as the PFR were hooked up in series with the exiting unit, which unit should come
first and by fraction could production be increased for the setup?.

6- The kinetics of the aqueous-phase decomposition of A is investigated in two mixed

flow reactors in series, the 2nd. reactor has twice the volume of the 1 st. reactor. At a steady –
state with a feed concentration of 1 mol/lit. In the first reactor the concentration is 0.5
mol/A/lit and residence time of 96 sec. while the concentration in the last reactor is 0.25
mol/lit. Find the kinetics of decomposition.

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