Chapter 4-Applications of Reactor Design-Part A BKEL

Chapter 4.
Applications of reactor design

CONTENT
PART A: Design for single reactions (chapter 6-OL)
4.1. Size comparison of single reactors
4.2. Multiple-reactor Systems
Part B: Design for multiple reactions
4.3 Design for parallel reactions (chapter 7-OL)
4.4 Design for reactions in series (chapter 8-OL)


4.1.1 Mixed Versus Plug Flow Reactors, First- and
Second-Order Reactions
4.1.2 Variation of Reactant Ratio for Second-Order
Reactions
– Batch reactor, plug flow reactor Figure 4.2
– Mixed reactor, Figure 4.3

4.2.1. Plug Flow Reactors in Series and/or in Parallel
4.2.2. Equal-Size Mixed Flow Reactors in Series
(1) First-Order Reaction
(2) Second-Order Reactions
4.2.3. Mixed Flow Reactors of Different Sizes in Series
(1) Finding the Conversion in a Given System
(2) Determining the Best System for a Given
Conversion
4.2.4 Reactors of Different Types in Series
Part B: Design for multiple reactions
4.3. Design for parallel reactions (chapter 7-OL)
4.3.1. Qualitative Discussion About Product Distribution
4.3.2. Quantitative Treatment of Product Distribution
and of Reactor Size
4.4. Design for reactions in series (chapter 8-OL)
4.4.1. Qualitative Discussion About Product Distribution
4.4.2. Quantitative Treatment, Plug Flow or Batch
Reactor
4.4.3. Quantitative Treatment, Mixed Flow Reactor
The reactor system selected will influence the economics of the

process by dictating the size of the units needed and by fixing
the ratio of products (product distribution) formed.
For single reactions, product distribution is fixed; hence, the

important factor in comparing designs is the reactor size.
PART A: Design for single reactions
4.1.1 Mixed Versus Plug Flow Reactors, 1st and 2nd Reactions
X
Af
Vm XAf − XAo V𝑝 dXA
= = න
FAo (− rAf ) FAo (−rA )
0
• The ratio of sizes of mixed and plug flow reactors will depend
on the extent of reaction, the stoichiometry, and the form of
the rate equation.
• For the general case, a comparison of Eqs. 3.9 and 3.14 will
give this size ratio.
• Let us make this comparison for the reactions with the nth-
order rate law:
(4.1)
where n varies anywhere from zero to three.

For mixed flow
(4.2)
Whereas for plug flow, Eq. 3.14 gives
(4.3)
Dividing Eq. 4.2 by Eq. 4.3 gives
(4.4)
With constant density, or ε = 0, this expression integrates to
(4.5)
Equations 4.4 and 4.5 are displayed in graphical form in Fig. 4.1 to provide a
quick comparison of the performance of plug flow with mixed flow reactors.
Mixed flow reactor, FAo .XA= -rA. V
any eA eA =0, XA = (CAo- CA)/CAo
General case eA =0
Plug flow reactor:
any eA eA=0:
General case eA =0
General Graphical Comparison
Same conditions, Vm > Vp
Comparison of performance of mixed flow and plug flow reactors for any
reaction kinetics
𝑽 𝑭𝑨𝒐
PART A: Design for single reactions 𝝉=
𝝊
𝝊=
𝑪𝑨𝒐
𝑪 𝐕
4.1. Size comparison of single reactors ➔ 𝝉 = 𝑨𝒐
𝑭𝑨𝒐
st nd
4.1.1 Mixed Versus Plug Flow Reactors, 1 and 2 Reactions
For identical feed composition
CAo and flow rate FAo
➢ Vm vs Vp , size ratio Vm/Vp
➢ increasing of n?
➢ low X vs high X?
➢ the effect of e?
Figure 4.1 Comparison of

performance of single mixed
flow and plug flow reactors
for the nth-order reactions
Figure 4.1 shows the following:
1. For any particular duty and for all positive

reaction orders the mixed reactor
is always larger than the plug flow reactor. The
ratio of volumes increases with reaction order.
2. When conversion is small, the reactor

performance is only slightly affected
by flow type. The performance ratio increases
very rapidly at high conversion;
consequently, a proper representation of the
flow becomes very important in this range of
conversion.
3. Density variation during reaction affects

design; however, it is normally of
secondary importance compared to the
difference in flow type.
4.1.2 Variation of Reactant Ratio for Second-Order Reactions
Second-order reactions of one component
When a large excess of reactant B is used then its concentration does not change
appreciably (CB ~ CBO) and the reaction approaches first-order behavior with
respect to the limiting component A, or
Thus in Fig. 4.1, and in terms of the limiting component A, the size ratio of
mixed to plug flow reactors is represented by the region between the first-order
and the second-order curves.
For plug flow or batch reactor
CB0
M = ⟩ 1
CA0
CA0 V 1 M − XA
𝜏M≠ 1 = = ln , M ≠ 1
FA0 M≠ 1
k CA0 (M − 1) M(1 − XA )
CA0 V 1 XA
𝜏M= 1 = = , M = 1
FA0 M= 1
k CA0 (1 − XA )
– Batch reactor, plug flow reactor Figure 4.2
eA=0

CAo and flow rate FAo : y axis
gives us the ratio of VM1/VM=1
or M1/ M=1
For plug flow or

batch reactor
For mixed flow

CA0 V XA
𝜏M≠ 1 = = , M ≠ 1
FA0 M≠ 1
k CA0 (1 − XA ) (M − XA )
CA0 V 1 XA
𝜏M= 1 = = , M = 1
FA0 M= 1
k CA0 (1 − XA )2
– Mixed reactor, Figure 4.3
eA=0

CAo and flow rate FAo : y axis
gives us the ratio of VM1/VM=1
or M1/ M=1
For mixed flow

reactor
Example 4.1
At present the elementary liquid-phase reaction A + B → products,
with -rA=500(liter/mol.min)CA.CB takes place in a plug flow reactor using
equimolar quantities of A and B.
+ Reactor volume is 0.1 liter,
+ Reactant stream v=0.05 l/min,
CAo = CBo = 0.01 mol/liter.
(a) Find the conversion of reactant XAf ?
(b) For the same conversion, find the volumetric of mixed flow reactor?
(c) For the same plug flow reactor volume, find the conversion of mixed flow
reactor?
➢ If the concentration of feed is CAo = 0.01 mol/liter; CBo = 0.015 mol/liter.
(d) For the same reactant stream, find the conversion of reactant in plug flow
reactor ?
(e) For the same initial conversion, by how much can the treatment rate be
increased ?
(f) Find reactant stream v’ for the mixed flow reactor with Vm=100l, XAf=99%

Conversion
X
Aj
V dXA
= න
FA0 − rA
0
X
PART A: Design for single reactions V
Aj
dXA
4.2. Multiple-reactor Systems = න
FA0 − rA
0
• Consider N plug flow reactors connected in series,
• X1, X2, . . . , XN is the fractional conversion of component A
leaving reactor 1, 2, . , N.
Basing the material balance on the feed rate of A to the first
reactor, we find for the ith reactor from Eq. 3.15
X
Aj
dXA
FA0 − rA
0
Basing the material balance on the feed rate of A to the first
reactor, we find for the ith reactor from Eq. 3.15
(4.6)
or for the N reactors in series
(4.7)
Hence, N plug flow reactors in series with a total volume V

gives the same conversion as a single plug flow reactor of
volume V.
X
Aj
dXA
FA0 − rA
0
• The fluid streams that meet have the same composition.
Thus, for reactors in parallel V/F or  must be the same for
each parallel line. Any other way of feeding is less efficient.
X
Aj
dXA
FA0 − rA
0
Example 4.2 Operating A Number Of Plug Flow Reactors

The reactor setup shown in Fig. consists of three plug flow
reactors in two parallel branches. Branch D has a reactor of
volume 50 liters followed by a reactor of volume 30 liters.
Branch E has a reactor of volume 40 liters.
What fraction of the feed should go to branch D?
❑ In plug flow, the concentration of reactant decreases progressively through
the system.
❑ In mixed flow, the concentration drops immediately to a low value.
❑ Because of this fact, a plug flow reactor is more efficient than a mixed flow
reactor for reactions whose rates increase with reactant concentration,
such as nth-order irreversible reactions, n > 0.
❑ Consider a system of N mixed flow reactors connected in series:

• The concentration is uniform in each reactor,
• The concentration changes as fluid moves from reactor to reactor.
This stepwise drop in concentration, illustrated in Fig. 4.4, suggests that the
larger the number of units in series, the closer should the behavior of the
system approach plug flow.
Figure 4.4 Concentration profile through an N-stage mixed flow reactor system
compared with single flow reactors.

Conversion
𝐶𝐴 𝑉𝑖 𝑉𝑖 𝐶𝐴 (𝑋𝐴𝑖 − 𝑋𝐴𝑖−1 ) 𝐶𝐴𝑖−1

Mass balance for A = 1 + 𝑘𝜏𝑖
𝜏𝑖 = 0 = = 0 (4.9) 𝐶𝐴𝑖
about vessel i 𝐹𝐴0 𝑣 (−𝑟𝐴 ) (4.10)
The space-time  (or mean residence time t) is the same in
all the equal-size reactors of volume Vi
1
𝐶𝐴0 𝑁
𝐶𝐴0 1 𝐶𝐴 𝐶𝐴 𝐶𝐴 𝑁
= = 0 . 1 . . . . . 𝑁−1 = (1 + 𝑘𝜏𝑖 )𝑁 𝜏𝑁 𝑚 = 𝑁𝜏𝑖 = −1
𝑘 𝐶𝐴𝑗
𝐶𝐴𝑁 1 − 𝑋𝐴𝑁 𝐶𝐴1 𝐶𝐴2 𝐶𝐴𝑁
(4.11) (4.12)
For N → ∞, this equation reduces to the plug flow equation
(4.13)
With Eqs. 4.12 and 4.13 we can compare performance of

N reactors in series with a plug flow reactor or with a single mixed flow
reactor. This comparison is shown in Fig. 4.4 for first-order reactions in
which density variations are negligible.
Figure 4.5 Comparison of performance of a series of N equal-size mixed flow

reactors with a plug flow reactor for the first-order reaction A→R, e=0
For the same processing rate of identical feed the ordinate measures the volume ratio VN/VP directly.
(2) Second -Order Reaction
N reactors in series:
(4.14)
Whereas for plug flow:
(4.15)
A comparison of the performance of these reactors is shown in Fig. 4.5.

(2) Second -Order Reaction
Figure 4.6 Comparison of
performance of a series of
N equal-size mixed flow
reactors with a plug flow
reactor for elementary
second-order reactions
2A →R; A+B→R
For the same processing rate of identical feed the

ordinate measures the volume ratio VN/Vp or space-time ratio N/p directly.
Example 4.3 At present 90% of reactant A is converted into product
by a second-order reaction in a single mixed flow reactor.
❑ We plan to replace by two reactors in series ( total volume is
similar to the one being used).
(a) For the same treatment rate as that used at present, how will this
addition affect the conversion of reactant?
(b) For the same 90% conversion, by how much can the treatment
rate be increased?
❑ We plan to place a second reactor similar to the one being
used in series with it.
(c) For the same treatment rate as that used at present, how will this
addition affect the conversion of reactant ?
(d) For the same 90% conversion, by how much can the treatment
rate be increased?

Conversion
Consider three mixed flow reactors in series as shown in Figure 4.7
Figure 4.7 Notation for a series of unequal-size mixed flow reactors.

Noting that ε = 0, it can be written for component A in the first reactor:
(4.16)
or
(4.17)
Similarly, for the ith reactor we may write:
(4.18)
Figure 4.8 Graphical procedure for finding compositions in a series of mixed flow reactors.
4.18)
4.18)
Draw the curve (-rA)=f (CA).

(a) CAo is given (point L).
(b) CA1 and (-rA)1 : point M
(c) Slope of the line : 𝐿𝑀 = 𝑀𝑁/𝑁𝐿 = −𝑟𝐴1 / 𝐶𝐴1 − 𝐶𝐴0 = −1/𝜏1
From L, draw a line of slope (-1/1) until it cuts the rate curve at M, this gives CA1 .
Similarly, from N, draw a line of slope (-1/2) until it cuts the rate curve at P, to obtain
C
(2) 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. It can be written for component A in the first and second
reactor:
(4.19)
These relationships are displayed in Fig. 4.9 for two alternative reactor
arrangements, both giving the same final conversion X2.
(2) Determining the Best System for a Given Conversion
Figure 4.8 Graphical representation of the variables for two mixed flow reactors in
series.
Figure 4.8 shows that the total reactor volume is as small as possible (total
shaded area is minimized) when the rectangle KLMN is as large as possible.

Chapter 4-Applications of Reactor Design-Part A BKEL

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Chapter 4-Applications of Reactor Design-Part A BKEL

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Chapter 4.

Applications of reactor design

PART A: Design for single reactions (chapter 6-OL)

4.1. Size comparison of single reactors

4.2. Multiple-reactor Systems

Part B: Design for multiple reactions

4.3 Design for parallel reactions (chapter 7-OL)

4.4 Design for reactions in series (chapter 8-OL)

4.1. Size comparison of single reactors

4.2. Multiple-reactor Systems

The reactor system selected will influence the economics of the

For single reactions, product distribution is fixed; hence, the

where n varies anywhere from zero to three.

Whereas for plug flow, Eq. 3.14 gives

Dividing Eq. 4.2 by Eq. 4.3 gives

Same conditions, Vm > Vp

➢ Vm vs Vp , size ratio Vm/Vp

Figure 4.1 Comparison of

1. For any particular duty and for all positive

2. When conversion is small, the reactor

3. Density variation during reaction affects

Second-order reactions of one component

For plug flow or batch reactor

For identical feed composition

For plug flow or

For mixed flow

For identical feed composition

For mixed flow

4.2. Multiple-reactor Systems

or for the N reactors in series

Hence, N plug flow reactors in series with a total volume V

Example 4.2 Operating A Number Of Plug Flow Reactors

❑ Consider a system of N mixed flow reactors connected in series:

4.2. Multiple-reactor Systems

𝐶𝐴 𝑉𝑖 𝑉𝑖 𝐶𝐴 (𝑋𝐴𝑖 − 𝑋𝐴𝑖−1 ) 𝐶𝐴𝑖−1

With Eqs. 4.12 and 4.13 we can compare performance of

Figure 4.5 Comparison of performance of a series of N equal-size mixed flow

Whereas for plug flow:

A comparison of the performance of these reactors is shown in Fig. 4.5.

For the same processing rate of identical feed the

4.2. Multiple-reactor Systems

Consider three mixed flow reactors in series as shown in Figure 4.7

Figure 4.7 Notation for a series of unequal-size mixed flow reactors.

Similarly, for the ith reactor we may write:

Draw the curve (-rA)=f (CA).

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