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Reactors can also refer to bioreactors, nuclear reactors, fission reactors or chemical reactors.
Chemical reactions can be either spontaneous (requiring no input of energy), or require the input of
some type of energy, e.g. heat, light or electricity.
What is Thermodynamics?
Thermodynamics is the science of energy conversion involving heat and other forms of energy.
Thermodynamics typically involves the interrelationship between temperature, volume and
pressure.
What is Conversion?
The percentage of reactants converted to products inside a chemical reactor or unit process.
moles of A reacted
XA =
moles of A fed
Information required:
i) Reaction e.g. A + 2B C
ii) Which is the limiting reagent
Rate of Reaction
Introduction
r = kCA 1.1
(where k is assumed to be a function of temperature only)
where:
A = pre-exponential factor or frequency factor
E = activation energy, J/mol
“Well behaved reactions” follow elementary kinetics; i.e. the rate law follows the stoichiometric co-
efficient of the reaction.
Irreversible Reactions
Fist order irreversible reaction:
AB rA = kCA
Example:
A + 2B C
A B
Catalyst surface
Gas phase concentration no longer determines the rate. The adsorbed concentration of the reactant
determines rate of catalytic reactions (these concentrations are very difficult to measure).
Reversible Reactions
Elementary kinetics for a reversible reaction:
A B
2A B rA = -k1CA2 +k2CB
A + 2B C + D rA = -k1CACB2 +k2CCCD
At equilibrium, rA = 0
0 = -k1CACB2 +k2CCCD
k1 CC CD
∴ = = k eq
k 2 CA CB 2
k1
k eq =
k2
Where both sides of this equation are functions of temperature only.
If rA = -k1CACB2 +k2CCCD:
If the feed is only A and B and the concentration approaches zero, the effect of k 2CCCD is small and
the reaction appears irreversible.
For a conversion approaching one, the effects of k2CCCD are more significant.
The sign depends on whether we define rate as a formation or consumption. In reactor theory, we
work with a rate of formation since we are interested in what products are formed.
What this means is that the rate is negative because we work with a number of moles of feed, which
are then consumed.
A + 2B C + D rA = -k1CACB2 +k2CCCD
Units of:
mol
rA m3 .s
2
(m3 )
k1 (mol)2 .s third order
m3
k2 mol.s second order
Types of Reactors
Various types of ideal reactors exist in industry. These are typically broken into batch (and semi
batch) reactors and continuous flow reactors. The most common continuous flow reactors include:
- Continuous Stirred Tank Reactors (CSTR)
- Plug Flow reactors (PFR); and
- Packed Bed Reactors.
Additionally, there are several other reactors which are not modeled as ideal reactors:
- Differential Side stream Reactor (DSR);
- Fluidised Bed Reactor (FBR); and
- Packed columns.
Batch Reactors
A batch reactor is a vessel where reaction takes place and has NO flows in or out during the reaction
taking place inside it.
A typical batch reactor consists of a tank with an agitator and integral heating/cooling system.
These vessels may vary in size from less than 1 litre (lab scale) to more than 15 000 litres.
Example:
Slowly adding a chemical to a batch reaction to push equilibrium in a certain direction
The removal of carbon dioxide in a fermentation reaction.
Example:
Solution:
Definition of Conversion
Xxxxxxxxxxxxxx
Solution:
Design Equations
Batch Reactor
By definition, a batch reactor is non-steady state.
Why? Concentration and temperature changes with time.
Given:
AB
1st order irreversible reaction
Solving:
NA │t+ ∆t − NA │t
= rA . V
∆t
Taking lim t 0
dNA
= rA . V
dt
Therefore:
dNA
= −kCA . V
dt
Substitute for NA
d(CA . V)
= −kCA . V
dt
For a batch reactor, the volume of the reactant and the reactor are the same.
For gases, we use partial pressures, not concentrations (in a constant volume reactor, pressure
changes). Use ideal gas equation for substitution.
Let:
NA = NA0 − 2x Reactive balances
NB = NB0 + x
Since volume is constant NOTE: will only work for constant density and volume
CA = CA0 − 2x [2]
CB = CB0 + x
From (2)
CA = CA0 − 2x
Solving:
x t
−2dx
∫ 0 0 = ∫ dt
o (−k1 CA + k 2 CB ) + (2k1 + k 2 )x o
(−k1 CA0 + k 2 CB0 ) + (2k1 + k 2 )x −2
ln [ 0 0 ]. =t
−k1 CA + k 2 CB 2k1 + k 2
CA,f
CA
With: rA = -kCA2
Q f CA,f + V(−kCA 2 ) = QCA
Example:
What CSTR reactor volume do we need to achieve a 90%
conversion given the following information?
rA = -kCA
k = 0.1 /min
Q = 50 litres per minute
CA0 = 2 mol/litre
Solution:
It can be shown that:
𝑄(𝐶𝐴,𝑓 − 𝐶𝐴 ) 𝑄(𝐶𝐴,𝑓 − 𝐶𝐴 )
𝑉= =
−𝑟𝐴 𝑘𝐶𝐴
CA = 2mol/l – (0.9 X 2 mol/l) = 0.2 mol/l
50(2−0.2)
∴𝑉= = 4500 litres
0.1 𝑥 0.2
Solution:
𝑄(𝐶𝐴,𝑓 − 𝐶𝐴 ) 𝑄(𝐶𝐴,𝑓 − 𝐶𝐴 )
𝑉= =
−𝑟𝐴 𝑘𝐶𝐴
𝑄𝐶𝐴0 50 𝑥 2
For the first CSTR: 𝐶𝐴,1 = = = 0.2 𝑚𝑜𝑙/𝑙
𝑄+𝑘𝑉 50+0.1 𝑥 4500
𝑄𝐶𝐴0 50 𝑥 0.2
For the second CSTR:𝐶𝐴,2 = = = 0.02 𝑚𝑜𝑙/𝑙
𝑄+𝑘𝑉 50+0.1 𝑥 4500
0.2 mol/l
2 mol/l
0.02 mol/l
V1 = V2 = 4500l
2 − 0.02
𝐶𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛 = = 99%
2
Subheading?
Q(CA,f − CA )
V=
−rA
QCA,f − QCA
V=
−rA
NA,f − NA
V=
−rA
NA . X
V=
−rA
NA . X
V=
−rA
X
V = NA . ( )
−rA
SUB-HEADING
For a CSTR it was shown that:
Q f CA,f + VrA = QCA
Q f CA0 + VrA = QCA
OR
Q f CA0 − QCA
−rA =
V
Q f CA0 QCA
−rA = −
V V
Qf Q
−rA = CA0 − CA
V V
Q Qf
−rA = − CA + CA0
V V
(y = mx + c)
CSTR3 CSTR2
CSTR1
-ra
Slope = -Q/V
Solution:
Graphically, a plot of –ra vs. CA gives a mixing line for a CSTR with a slope = -Q/V
50𝑙. 𝑚𝑖𝑛−1
Slope = − = −0.01𝑚𝑖𝑛−1
4500𝑙
And CA0 = 2 mol/l
0.06
-ra 1 x CSTR
0.02 CSTR1
CSTR2
0.2 0.6 2
Ca
For n equal volumes CSTR reactors in series (1st order irreversible, constant density):
𝐶𝐴0
𝐶𝐴𝑛 =
𝑉 𝑛
(1 + 𝑘. )
𝑄
V + V
V
CA
Assume perfect mixing radially and no axial mixing (along length of reactor)
At any point long the reactor we have a certain concentration CA and rate of reaction rA.
Example:
The reaction A B has a rate rA = -kCA, with k = 2 min-1. A feed flow rate of 150 l/min has concentration
CA0 = 1.6 mol/l and CB0 = 0.1 mol/l. What are the exit concentrations and conversion in a 120 l PFR?
Solution:
𝑑𝑁̇𝐴
= 𝑟𝐴 AND 𝑟𝐴 = −𝑘𝐶𝐴
𝑑𝑉
We need NA in terms of CA: 𝑁𝐴 = 𝑄𝐶𝐴 (Assuming density is constant and therefore flowrate is constant.)
𝑑𝑄𝐶𝐴
Therefore: = −𝑘𝐶𝐴
𝑑𝑉
𝑑𝑄𝐶𝐴
= 𝑑𝑉
−𝑘𝐶𝐴
𝐶𝐴 𝑉
𝑄
∫ 𝑑𝐶𝐴 = ∫ 𝑑𝑉
𝐶𝐴0 −𝑘𝐶𝐴 0
𝑄 𝐶𝐴
𝑙𝑛 =𝑉
−𝑘 𝐶𝐴0
𝐶𝐴 −𝑘𝑉
𝑙𝑛 =
𝐶𝐴0 𝑄
𝐶𝐴 −𝑘𝑉
=𝑒 𝑄
𝐶𝐴0
−𝑘𝑉
𝐶𝐴 = 𝐶𝐴0 . 𝑒 𝑄 = 0.323 𝑚𝑜𝑙/𝑙
Solution:
For V = 20 litres XA = 23.4%
For V = 40 litres XA = 41.3%
For V = 80 litres XA = 65.6%
For V = 120 litres XA = 79.8%
For V = 160 litres XA = 88.2%
Doubling the reactor volume increases the volume; but does not double it. Rate starts off high when
the concentration of reactants is high. As concentration of reactants decreases the rate decreases.
rA
Concentration
Example:
Assuming a PFR with the following condition: A 2B rA = -k1CA + k2CB2
Calculate the volume required to achieve a conversion X.
Solution:
𝑑𝑁̇𝐴
= 𝑟𝐴 = −𝑘1 𝐶𝐴 + 𝑘2 𝐶𝐵 2
𝑑𝑉
In terms of CA: 𝑁𝐴 = 𝑄𝐶𝐴 Assuming density is constant and therefore flowrate is constant.
Therefore:
𝑑𝑄𝐶𝐴
= −𝑘1 𝐶𝐴 + 𝑘2 𝐶𝐵 2
𝑑𝑉
But:
CA = CA0 – x
CB = CB + 2x
And dCA/dx = -1
−𝑑𝑥 2
𝑄 = −𝑘1 (𝐶𝐴 0 − 𝑥) + 𝑘2 (𝐶𝐵 0 + 2𝑥)
𝑑𝑉
𝑥 𝑉
−𝑑𝑥
𝑄∫ 2 = ∫ 𝑑𝑉
0 0
0 −𝑘1 (𝐶𝐴 − 𝑥) + 𝑘2 (𝐶𝐵 + 2𝑥) 0
BUT: k1 and k2 are functions of temperature. If they were constant we could use partial fractions. But
they are not, so we can’t integrate.
Therefore:
dX
−Ṅ Ao = rA
dV
dX
ṄAo = dV
− rA
x V
dX
ṄAo ∫ = ∫ dV
0 − rA 0
x
dX
V = ṄAo ∫
0 − rA
CSTRs in series
Suppose we extend the above example to n-tanks in series
CA0
For first reactor: CA1 = V [1]
1+k.
Q
CA1
For second reactor: CA2 = V [2]
1+k.
Q
CA0
Equation [2] into [1] CA1 = V 2
(1+k. )
Q
For n equal volumes CSTR reactors in series (1st order irreversible, constant density):
CA0
CAn =
V n
(1 + k. )
Q
Useful but very limited as ALL the above conditions must be true for ALL reactors
Solution:
𝐶𝐴0
Since the reaction is for 1st order irreversible, constant density, we can use: 𝐶𝐴𝑛 = 𝑉 𝑛
(1+𝑘. )
𝑄
Example:
What overall conversion will you obtain by adding multiple (identical) CSTRs in series, given the following information?
What is the total volume compared to the volume of a single CSTR needed to achieve the same conversion?
Solution:
Volume of Conversion at the
No of Conc. in Conc. out single Total end of n CSTR's Equivalent volume if
CSTRs (mol/l) (mol/l) reactor (l) Volume (l) (%) only 1 CSTR was used (l)
1 2 0.2 4500 4500 90 4500
2 0.2 0.02 4500 9000 99 49500
3 0.02 0.002 4500 13500 99.9 499500
4 0.002 0.0002 4500 18000 99.99 4999500
5 0.0002 0.00002 4500 22500 99.999 49999500
6 0.00002 0.000002 4500 27000 99.9999 499999500
7 0.000002 2E-07 4500 31500 99.99999 4999999500
PFR in Series
Given that the concentration changes along the length of a PFR, adding multiple reactors in series is
simply equal to extending the length of the first PFR.
If split equally, we don’t gain anything. The same is true for non-equal splitting. CSTRs may be used
in series to reduce the size of a single CSTR (but no gain is achieved in reducing total volume).
We may add reactors in series as a means of backup or due to space limitations or costs of single
large reactors.
Levenspiel Plots
xxxxxxx
Example:
Given the following data, draw a graph of -1/rA vs conversion. What can you determine from the graph?
X 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.85
rA -0.0053 -0.0052 -0.0050 -0.0045 -0.0040 -0.0033 -0.0025 -0.0018 -0.00125 -0.001
Solution:
X 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.85
-rA 0.0053 0.0052 0.0050 0.0045 0.0040 0.0033 0.0025 0.0018 0.00125 0.001
1/-rA 189 195 200 222 250 303 400 556 800 1000
V
τ≡
Q0
where:
= Mean Residence Time (sec)
V = Reactor Volume (m3)
Q0 = Incoming Volumetric Flowrate (m3/sec)
Example:
The first order reaction (A B) is carried out isothermally
in a CSTR with a volume of 1827 litres. A feed of 180 l/min
containing A at an initial concentration of 3.0 mol/l is fed to
the reactor. It is required that we achieve conversion of
89% of A. What is the residence time of the reactor?
Solution:
𝑉
𝜏=
𝑄
= (1827 l)/(180l/min)
= 10.15 min
Space Velocity
Space velocity is defined as:
Q0 1
SV ≡ =
V τ
where:
SV = Space velocity (/sec)
V = Reactor Volume (m3)
Q0 = Incoming Volumetric Flowrate (m3/sec)
= Mean Residence Time (sec)
While this appears to be the inverse of Mean Residence Time (MRT), this may not always be the
case. This is since the entering flowrates may be defined differently to the actual conditions. A
liquid-hourly, gas-hourly and weight-hourly space velocity are defined according to the conditions
below, even though the actual conditions may be different.
aA + bB → cC + dD
We can define the rates of reaction (formation or consumption) of chemicals B, C and D (relative to
A) as:
rA rB rC rD
− = − = =
a b c d
Or:
a a a
rA = rB = − rC = − rD
b c d
Additional Reading
Fogler, HS, 2006. Elements of Chemical Reaction Engineering, 4th ed., Pearson International Edition.
Fogler, HS, 2011. Essentials of Chemical Reaction Engineering, Pearson International Edition.
Froment, GF, Bischoff KB, de Wilde J, 2011. Chemical Reactor Analysis and Design, 3rd ed., Wiley.
Murphy, RM, 2007. Introduction to Chemical Processes – Principles, Analysis, Synthesis, McGraw Hill.
Roberts, GW, 2009. Chemical Reactions and Chemical Reactors, Wiley.
Stolen, KA, Harb, JN, 2011. Introduction to Chemical Engineering – Tools for Today and Tomorrow,
5th ed., Wiley.