Lecture 1

Reactor Design (I)

Dr. Usama Al-Rawi

The chemical reactor is the heart of any chemical process. Chemical

processes turn inexpensive chemicals into valuable ones, and chemical
engineers are the only people technically trained to understand and handle
them. While separation units are usually the largest components of a
chemical process, their purpose is to purify raw materials before they
enter the chemical reactor and to purify products after they leave the
reactor.

Design of chemical reactors is also at the forefront of new chemical

technologies. The major challenges in chemical engineering involve

1. Searching for alternate processes to replace old ones,

2. Finding ways to make a product from different feedstocks, or
3. Reducing or eliminating a troublesome byproduct.

Chemical Identity
A chemical species is said to have reacted when it has lost its chemical
identity. The identity of a chemical species is determined by the kind,
number, and configuration of that species' atoms.

Three ways a chemical species can lose its chemical identity:

1. Decomposition
2. Combination
3. Isomerization

Why Study Reaction Engineering (R. E.)

1. It is the knowledge that distinguishes chemical engineers from others.
2. It is the heart of producing all chemicals.
3. It is the necessary knowledge for safe and efficient operation of a
chemical plant.
4. Its principle applies to
a. Petroleum Industry and Chemical Industry
b. Living Systems
c. Waste Treatment
d. Semiconductor Industry

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Basic Concepts in R. E.

 Chemical Species Involved in a Reaction System.

The identity of a chemical species is determined by the kind, number
and configuration of that species’ atoms.
H H H CH3
C C and C C
CH3 CH3 CH3 H
cis-2-butene trans-2-butene
 Chemical Reaction:
A detectable number of molecules of one or more species have lost
their identity and assumed a new identity
NaOH + HCl  NaCl + H 2 O

 Classification of Chemical Reactions:

 Homogeneous vs. Heterogeneous Reactions
(Gas/Liquid Phase Reactions; Gas-Solid Phase Catalytic Reactions)
 Reversible and Irreversible Reactions

A Simplified Roadmap of R. E.
Chemical Species and Chemical Reactions

Reaction Rate & Mechanism Reaction Engineering

 The principles for sizing of chemical
 The path that a reaction follows.
reactors.
 The rate of chemical reaction.  Effects of heat of reaction.
1 dN A d  N A / V  dC A  Diffusion and other transport effects on
 rA    
V dt dt dt heterogeneous reactions.
 Non ideal reactors.
Typically expressed in differential
Typically expressed in integral forms and
forms and concerns chemical
concerns integral/cumulative effects of
reaction at a point of a reactor
chemical reactions in a reactor

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Reactor Types
1- Batch Reactor

It is used for
1. Small Scale Operations
2. Intermediate or One Shot Production
3. Pharmaceutical/Fermentation
4. Gas/Liquid/Liquid-Solid Phase
Reaction
Advantage:
1. High Conversion
2. Operational Flexibility
Disadvantage:
1. High Labor Cost
2. Product quality may vary.
3. Difficult to Achieve Large Scale Production

2- Continuous-Stirred Tank Reactor (CSTR)

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It is used for
1. Processes requiring agitation
2. Liquid/Gas-Liquid/Solid-Liquid Reactions
Advantage:
1. Continuous Operation
2. Good Temperature Control
3. Low Cost
Disadvantage:
 Low Conversion

3- Plug Flow Reactors (PFR)

It is used for
1. Gas-Phase Reactions
2. Large Scale, Fast Reactions
Advantage:
1. Continuous Operations
2. Relatively Easy to Maintain
3. High Conversion
4. Low Operating Cost
Disadvantage:
 Difficult to Control Temperature

4- Other Reactors
 Semibatch Reactors
Either one reactant is charged and the other is fed continuously or
one of the products can be removed continuously.

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 Tubular Fixed Bed Reactor

Tubular reactors that is packed with solid catalyst particles
 Fluidized Bed Reactor
A heterogeneous reaction takes place when catalyst particles are
fluidized.

5- Industrial Reactor