BKF2453 CHEMICAL REACTION ENGINEERING I AND BKF2413

CHEMICAL ENGINEERING THERMODYNAMICS

Mini Project (Reactor Design and Thermodynamics) for Semester I of
Session 2019/2020
1 Introduction

Mini project of reactor design is a problem-based learning. This project is also integrated with the
chemical engineering thermodynamics subject for students who are taking both subjects in the same
semester. It requires submission of a report by a group of 4 or 5 of students from each section. The
project would be supervised by lecturers of the sections and the students’ achievement would be
evaluated using a rubric by them. The description in the rubric should be the guideline for the report.

The students are instructed to propose a reactor design as given below. Discussion must cover all
aspects from all chapters of the subject. At the end of this project, the students are expected to be able
to:-

1. Apply chemistry, thermodynamics and chemical reaction fundamentals such as reactant

limitation, mole balance, rate law and stoichiometry in reactor design

2. Analyze reaction and determine reactor scheme for desired conversions, selectivity and yield

3. Design reactor under various heat effect

2 Case Study

A new catalyst has been proposed for the synthesis of methanol from carbon monoxide and
hydrogen gas but carbon dioxide, formaldehyde and water are produced as well. This catalyst
is reasonably active between temperatures of 330 K to about 430 K. The reactions involved in
the synthesis include

k and K1
CO + 2H 2  1  
 CH 3OH
k and K
CO + H 2 O   2  2  CO 2 + H 2

1
 CH 3OH 
k3
 CH 2O + H 2

All the above reactions are elementary and take place in the gas phase. The pressure drop will
be neglected due to the cylindrical shape of the catalyst mounted onto the reactor tubing.
Therefore the reactor follows plug flow reactor behaviour (PFR). As an initial guess, the feed
consists of hydrogen gas, carbon monoxide, carbon dioxide and steam in the molar ratio of
7:3:3:2. The total molar flow rate is calculated from annual production capacity of the
process. The entering pressure may be varied between 1 atm and 160 atm and the entering
temperature between 300 K and 400 K. Tubular (PFR) reactor volumes between 0.1 m 3 and 2
m3 are available for use.

Additional information

 30, 620  1 1 
K1  131, 667  0.00198T  exp 
2
  
 R  298 T   L2 mol -2

 9,834  1 1 
K 2  103,943exp    
 R  298 T  

 78,500  1 1 
k1  0.933exp    
 R  330 T   L2 mol-2 s-1

18, 000  1 1 
k2  0.636 exp    
 R  300 T   L mol-1 s-1

 43, 434  1 1 
k3  0.244 exp    
 R  325 T   s-1

Where R = 1.987 cal mol-1

3 Tasks

Please solve these reactor problems below for 40,000 tonnes per annum production of
methanol (8000 hrs of operation per year):-

1. Discuss the chemistry, thermodynamics fundamental of the reactions. Decide the

strategy to optimize feed conditions, reactor scheme and reaction temperature. Is PFR
suitable reactor type for this production? (3 Marks)
2. Determine heat effect of the PFR or other reactor (if the suitable reactor is different)
(8 Marks) – Integrated with Chemical Engineering Thermodynamics subject

2
 3. Estimate the optimum PFR or other reactor (if the suitable reactor is different) for the
production of methanol (4 Marks)

Please distribute work fairly among your group members and mention the distribution in
the submitted report. The submission will be done according to the following timeframe:-

Week 12 – Task 1

Week 13 - Task 2 and 3

Week 14 – Correction

Report Submission of the Reactor Design by Each Group to the Respective Lecturers

END OF QUESTION PAPER