1

INDEX
SR NO SUBJECT PAGE NO
1. BALL MILL DIAGRAM 2
2. THEORY 3–6
3. ADVANTAGES & DISADVANTAGES 7
4. EXPERIMENTAL MANUAL 8 – 10
5. PRECAUTIONS 11
6. BALL MILL DETAILED DIAGRAM 12
7. BALL MILL WIRING DIAGRAM 13
8. DIMENSSIONS FOR FOUNSATION 14

INTRODUCTION:

FIXED BED REACTOR EXPERIMENTAL MANUAL

 2

This is a vertical cylindrical vessel containing fine solid particles that are
either catalyst or reactant. The fluid reactant stream is introduced at the
bottom of the reactor at a rate such that solids are floated in the fluid stream
without being carried out of the system. Under this condition the entire bed
particles behave like a boiling liquid, which tends to equalize the composition
of reaction mixture & temperature throughout the bed. It is applied
extensively to solid-fluid reaction, such as the catalytic cracking of petroleum
hydrocarbon, the conversion of uranium oxide to uranium fluorides for
reduction of some mineral ores and gasification of coal.
Fixed-bed reactors are commonly used in the chemical industry
to carry out heterogeneously catalyzed gas-phase reactions.
A fixed bed reactor is a cylindrical tube filled with catalyst pellets with
reactants flowing through the bed and being converted into products. ... The
flow of a fixed bed reactor is typically downward. Packed bed reactor.
Fixed-bed reactors come in all sizes, but we generally group them as
laboratory-scale, pilot plant-scale, or commercial-scale. We operate
laboratory-scale fixed-bed reactors when developing a new process,
investigating a new solid-supported catalyst, qualifying for commercial use a
different catalyst, and supporting an existing commercial process.
We use pilot plant-scale fixed-bed reactors when developing a new
process or supporting an existing commercial process. Depending on the
process, we may qualify a new or different solid-supported catalyst in a pilot
plant; this usually occurs when we want to qualify the test catalyst using
commercial plant feeds. We also use pilot plant-scale fixed-bed reactors to
determine the contractual performance criteria of a given solid-supported
catalyst. This last use of pilot plant-scale fixed-bed reactors is done for
catalysts containing precious metals or for catalysts licensed with a royalty

FIXED BED REACTOR EXPERIMENTAL MANUAL

 3

fee. Silver-containing solid-supported, ethylene oxide catalysts are an example

of catalysts marketed per pilot plant performance criteria.
We operate commercial-scale fixed-bed reactors to produce product
for market.
Upscaling involves moving a catalyst or process from the laboratory,
through a pilot plant, to a commercial plant. We upscale when developing a
new process or a new catalyst. Downscaling occurs for existing commercial
processes that are old enough to have had their original pilot plants
dismantled. But a time comes for such commercial processes when it is
desirable to build a new pilot plant for solving current operating problems.
Upscaling and downscaling require models. We use these models to
reduce the time spent experimenting at the laboratory-scale and the time
spent validating at the pilot plant-scale, which ultimately reduces the cost of
the research program. The major cost savings from modeling come from not
building a nonfunctional commercial-scale fixed-bed reactor or an
inappropriate pilot plant-scale fixed-bed reactor. A nonfunctional commercial-
scale fixed-bed reactor is one that does not produce product meeting
published specifications or one that does not produce product at an economic
rate. An inappropriate pilot plant-scale fixed-bed reactor is one that operates,
unbeknownst to us, in a process regime different from that of the commercial-
scale fixed-bed reactor. Thus, the importance of models.

FIXED BED REACTOR EXPERIMENTAL MANUAL

 4

DESIGN AND CONCEPT

Fixed-bed reactors are the main type of catalytic reactors for large-
scale chemical synthesis. The process is characterized by different gaseous
chemical species reacting on the catalyst surface placed in a fixed position
inside the reactor. There are two main types of fixed-bed reactors (1)
adiabatic and (2) multi tubular fixed-bed reactors (Fig. 8.4). Adiabatic reactors
are used where there is only one main reaction pathway, whereas the multi
tubular fixed-bed reactors are utilized for product specificity and separation.
The reactant gases flow uniformly over the fixed bed in an adiabatic process,
whereas in the multi tubular reactor the feed gas follows the path of a heat
carrier that allows for control of different temperature profiles around the
fixed tubular catalysts (Eigenberger, 1992). The methanation reactions
described in Eqs. (8.3) and (8.4) are evidently highly exothermic and therefore
require better control over temperature. Several configurations of the two
types of fixed-bed reactors have been explored over the last two to three
decades. Many of the methanation reactors discussed in research articles deal
with the methanation of syngas as a feed gas, however, a similar concept was
applied to PtG where CO2, CO, and H2 come from two different sources
instead of a gasification process. More recently, plants have started to work
with methanation for biogas upgradation from wastewater treatment plants,
bioethanol production plants, and some use bottled gas as a source as CO2
(Thema et al., 2019).

FIXED BED REACTOR EXPERIMENTAL MANUAL

 5

ADVANTAGES:
 Fluidized-bed reactors offer a much higher efficiency in heat exchange,
compared to fixed beds.
 Better temperature control, due to the turbulent gas flow and rapid
circulation. At the same time, the high gas velocities do not cause any
pressure drop issues and smaller catalyst particles can be employed.

DISADVANTAGES:
 Difficult temperature control.
 Temperature gradients may occur.
 Catalyst difficult to replace.
 Channeling of gas stream can occur, leading to ineffective regions in the
reactor.
 Side reactions possible.
 Heat transfer to or from reactor can be difficult.

FIXED BED REACTOR EXPERIMENTAL MANUAL

 6

BALL MILL EXPERIMENTAL MANUAL

AIM:

APPARATUS:

PROCEDURE:

OBSERVATION:
CALCULATION:

RESULT:

FIXED BED REACTOR EXPERIMENTAL MANUAL

 7

PRECAUTIONS:
 Do proper foundation for smooth operation.
 Always tighten the V nut provided on ball mill door very tightly.
 Never try to touch Ball Mill when it is running.
 When discharging feed from Ball mill always use tray to avoid spillage
of feed or balls.
 Check Oil level in Gear box time to time.

FIXED BED REACTOR EXPERIMENTAL MANUAL

 8

FIXED BED REACTOR EXPERIMENTAL MANUAL

 9

FIXED BED REACTOR EXPERIMENTAL MANUAL

 10

FIXED BED REACTOR EXPERIMENTAL MANUAL