Submitted it partial fulfillment of the
Requirements for the award of
Diploma in chemical engineering
INTERNSHIP REPORT
Submitted by
Harsh Upadhyay
Enrollment :- 20T13018
Diploma in chemical
Internship period :- 26thAug to 9ndSep
ITM(SLS)BARODA UNIVERSITY
PALDI,VADODARA,GUJARAT
ACKNOWLEDGMENT
I would like to express my special thanks of gratitude to my class coordinator or mentor as well
as our university for providing the golden opportunity to do on the topic of Batch reactor which
also helped me in doing a lot of research and I come know about many new things .
I new really thankful to them.
Secondly I would also like to thank my family who helped me a lot in finishing this project
within the limited.
It helped me increase my knowledge skills.
Thanks again to all who supported
ABSTRACT
Theory of any subject is important but if learned without practical exposure, the knowledge
remains incomplete. In order to be a good engineer one needs to remain updated with latest
developments in his field as well as their practical applications. Hence this training, provided an
excellent opportunity for my over all development as an engineer.
Batch reactor
INTRODUCTION
Simplest reactor open / closed vessel
Reactants are placed inside the reactor and
allowed to react over time
Products and unconverted reactants are removed
and the process is repeated
Closed system - unsteady state operation
Fitted with a stirrer
May have a jacket / cooling or heating coils
inside the reactor
Generally constant volume / some designed at
constant pressure
Materials of construction different linings
How does batch reactors work?
Batch reactors are simply vessels that hold the reactants and allow them to mix. The batch
reactor contains 4 main components.
1) The reactor vessel.
2) The reaction medium.
3) The headspace: an empty space above the medium. The headspace accommodates changes in
the liquid volume.
4) The agitator: it is crucial as it allows the mixing of several components, and allows us to
introduce or remove reaction heat.
Batch reactors are used from small round bottom flasks in the lab to thousands of litres in
manufacture.
A batch reactor is the simplest type of reactor vessels use for chemical or industrial processes. A
typical batch reactor consists of a tank where chemical reactions occur. These tanks also have an
agitator and an internal heating or cooling system. Tank sizes range from one liter to 15,000
liters.
CONNSTRUCTION
A typical batch reactor consists of a storage tank with an agitator and integral
heating/cooling system. These vessels may vary in size from less than 1 litre to more than
15,000 litres. They are usually fabricated in steel, stainless steel, glass-lined steel, glass or exotic
alloy.
WORKING Principal
The batch reactor in the laboratory is typically loaded with materials and heated to a desired
temperature. Then, after a given time, the reactor is brought to room temperature and the
contents are analyzed. Because the vessel is sealed, the mass of the materials in the vessel
cannot change and the volume is constant.
batch reactor has neither inflow nor out flow of reactants or products while the reaction is
being carried out .
This is unsteady state operation where the composition change with time .
USES OF BATCH REACTOR
Used in variety of applications
Typically for liquid phase reactions that
require long reaction times
Used only when small amount of product is
required
Favored when a process is in developmental
stage or to produce expensive products
Used to make a variety of products at different
times
APPLICATION
Batch reactor are often used in the process industry.
Batch reactor also have many laboratory application such as small scale production and
inducing fermentation for Beverage product
They also have many uses in medical production
Batch reactor are also highly used in waste water treatment
They are effective in reducing BOD (Biological oxygen demand ) of influent
untreated water
Characteristics of a Batch Reactor
(1) Each batch is a closed system.
(2) The total mass of each batch is fixed.
(3) The reaction(residence) time t for all elements of fluid is
the same.
4) The operation of the reactor is
inherently unsteady-state for example, batch
composition changes with respect to time.
(5) It is assumed that, at any time, the batch is
uniform (e.g., in composition, temperature,
etc.), because of efficient stirring.
Advantages
High conversions can be obtained
Versatile, used to make many products
Good for producing small amounts
Easy to Clean
Dis-advantages
High cost of labor per unit of production
Difficult to maintain large scale production
Long idle time (Charging Discharging times)
leads to periods of no production
No instrumentation Poor product quality
GUIDELINES FOR SELECTING BATCH PROCESSES
Production rates Sometimes batch process, if
the plants have production capacity less
than 10x106 lb/yr (5x106 kg/hr).
Usually batch process, if the plants have production
capacity less than 1x106 lb/yr (0.5x106
kg/hr).
Where multiproduct plants are produced
using the same processing
equipment.
Market forces Where products
are seasonal (e.g., fertilizers). Short
product lifetime (e.g., organic pigments).
Operational problems Long reaction times
(when chemical reactions are slow).
Handling slurries at low flow rates. Rapidly fouling
materials (e.g., materials foul equipment so
rapidly that shutdown and frequent cleaning are
required)..
Material of Construction (MOC)
In this section we provide the information regarding MOC of various part of the vessel.
As you can see in sketch a vessel can be divided in different parts like Main Shell, Dish
Ends, Nozzle Flanges, Nozzle Pipes, Support, Nuts & Bolts, Gaskets, etc.
Material of construction depends on the fluid corrosive properties, erosive nature for
handling slurries & solid catalyst suspension, operating temperature and pressure. In
chemical process industries you can find vessel MOC of Mild Steel, Stainless Steel,
Inconel, Hastelloy etc. In case of non-metal construction MOC can be MS-Glass lined,
rubber lined, PP/HDPE lined, out of this glass lined reactor most widely used in our
industries.
A B
Batch process material balance
MATERIAL BALANCE
Over all material Balance A+B = C
Component material Balance A.CA+B.CB =C.CC
C
block diagram batch reactor
Baffles
in a static mixer, baffles are used to minimize the tangential component of velocity which causes
vortex formation, and thus promotes mixing. In a chemical reactor, baffles are often attached to
the interior walls to promote mixing and thus increase heat transfer and possibly chemical
reaction rates.
Types of baffles
Single segmental.
Double segmental
No tube in window baffle
Tripple segmental
Agitator
An agitator is a device which is used to import motion in the form of stirring to the liquids
or semi solids.
The types of agitators
paddle agitators,
anchor agitators ,
helical ribbon agitators,
mechanical agitators (rotating)
Turbine agitator
Blade type agitator
CONCLUSION
Batch reactors can be used for almost any reaction – their flexibility is excellent.
Although there some challenges, the scalability of batch reactors is good and there is a lot
of scale-up experience
Reaction control is rather limited – highly exothermic and fast reactions suffer from the
limited heat and mass transfer rates. As a result, product quality suffers.
Energy efficiency is also average due to the heat required every time at start-up. Large
surface and difficult heat recovery lead to energy loses.
The catalyst lifetime is moderate to poor because the (solid) catalyst separation is often
challenging.
The key advantage of the batch reactors is flexibility and multipurpose operation – that is
why these rectors are used in most chemical processes.
References
Batch reactors are used to study the behavior of fluids with materials under various conditions of
temperature and pressure. In a chemical process, horizontal or vertical vessels are also used to
store fluids or to provide a volume so that a mixture of liquid and vapor can separate into two
distinct phases.
