Department of Chemical and Biomolecular Engineering

CN2105 Reaction Engineering

Unit 4:
Reactor Design for Single
Reactions

Prof Ning Yan, 2023/2024 Sem 2

 2

Recap
𝑑𝑁 𝑑𝑚
Mole balance equation: 𝐹 𝑟 𝑑𝑉 𝐹 𝑚𝑖𝑛 𝑚out
𝑉 𝑑𝑡 𝑑𝑡
Design equations:
1 𝑑𝑁 𝑁 𝑑𝑥 𝑑𝑥
𝑟 𝑡 𝑁
𝑉 𝑑𝑡 𝑉 𝑑𝑡 0 𝑟𝑉

𝐹 𝑥 𝑐 𝑥
𝑉 𝜏
𝑟 𝑟

𝑑𝐹 𝑑𝑥 𝑑𝑥 𝑑𝑥
𝑟 𝐹 𝑉 𝐹 𝜏 𝑐
𝑑𝑉 𝑑𝑉 0 𝑟 0 𝑟
 3

Warm-up exercise
Is the reaction positive order, negative order or 0th order?
negative: the lower the conc. , the higher the rate

A→B

t or
From the figure, t or 𝜏 𝑟 We also know, when t or 𝜏 𝑐
 4

Learning Objectives (Unit 4)

• Design of ideal reactors for single reactions
• Reactor selection
• Reactor sequencing
• Recycle reactors and autocatalytic reactions
 5

Design of Ideal Batch Reactor

• Design equation (differential form):
𝑁 𝑑𝑥
𝑟
𝑉 𝑑𝑡
• where A is the limiting reactant and V is the reaction volume, which may not be
equal to the reactor volume.

• Design equation for time of reaction:

𝑑𝑥
𝑡 𝑁
0 𝑟 𝑉
1
• The integral is equal to the area under the curve (AUC) of the plot of
𝑉
against xA.
• Under constant temperature and pressure, V = V0(1 + εAxA)
 6

Design of Ideal Batch Reactor

𝑡 𝑁 × AUC
area under curve when x=1 is infinite
since reaction takes infinite time to complete
1 𝑥
if epsilon>0, reactant gets more diluted as
nth order reactions (n > 1) 𝑐 𝑐
reaction progresses, rate will decrease
1 𝜀 𝑥
εA > 0
𝑟 𝑘𝑐
1 εA = 0
𝑟 𝑉 At the same 𝑥 ,

𝜀 𝑐 |𝑟 |
εA < 0

xA 𝑉
• For first order reactions, the curve is independent of εA.
 7

Design of Ideal Batch Reactor

• If the batch reactor operates under constant temperature and pressure:
𝑑𝑥
𝑡 𝑁
0 𝑟 𝑉 1 𝜀 𝑥
V0 is not reactor volume
𝑁 𝑑𝑥
𝑉
𝑡 0 𝑟 1 𝜀 𝑥
• The above equation calculates the initial reaction volume.
• If εA ≠ 0, the reaction volume varies during the reaction according to the function
V = V0(1 + εAxA).
• If the design parameter is the reactor volume, it must be equal to or larger
than the reaction volume at all time:
• For εA < 0, Vr = V0
• For εA > 0, Vr = V0(1 + εAxA)
 8

Design of Ideal Batch Reactor

For batch reactor of constant density (V = V0)
• Design equation:
𝑑𝑥 𝑑𝑥
𝑡 𝑁 𝑐
0 𝑟 𝑉 0 𝑟
• Since cA = cA0(1 − xA) and dcA = −cA0dxA:
𝑑𝑐 𝑑𝑐
𝑡
𝑟 𝑟
 9

Design of Ideal CSTR

• Design equations:
𝐹 𝑥 1
𝑉 𝐹 ×𝑥
𝑟 𝑟
𝐹 1 1
𝜏 ×𝑥 𝑐 ×𝑥
𝑣 𝑟 𝑟
1
• The value of ×𝑥 is equal to the area of the shaded rectangle in the plot
1
of against xA:

1
𝑟
Exit

xA
 10

Design of Ideal CSTR

For CSTR of constant density (v = v0)
• Design equations:
1 1
𝑉 𝑐 𝑣 ×𝑥 𝑣 × 𝑐 𝑐
𝑟 𝑟
1
𝜏 × 𝑐 𝑐
𝑟
1
• The value of × 𝑐 𝑐 is equal to the area of the shaded rectangle in the
1
plot of against cA:

1
𝑟
Exit Inlet

cA cA0
 11

Design of Ideal PFR

• Design equations:
𝑑𝑥
𝑉 𝐹
0 𝑟
𝐹 𝑑𝑥 𝑑𝑥
𝜏 𝑐
𝑣 0 𝑟 0 𝑟
1
• The integral is equal to the AUC of the plot of against xA:

1
𝑟

xA
 12

Design of Ideal PFR

For PFR of constant density (v = v0)
• Design equations:
𝑑𝑥 𝑑𝑐
𝑉 𝑐 𝑣 𝑣
0 𝑟 𝑟
𝑑𝑐
𝜏
𝑟
1
• The integral is equal to the AUC of the plot of against cA:

1
𝑟

cA cA0
 13

Reactor Selection always take the least volume

• The choice between batch and flow reactors usually depends on the
requirements of the product and process.
• The choice of the flow reactor (CSTR or PFR) almost always depends on which
one can conduct the reaction with the smallest reactor volume.

For positive order reactions

• VCSTR = FA0 × area of rectangle
• VPFR = FA0 × AUC
1
• VCSTR > VPFR
𝑟

xA
 14

Reactor Selection
For negative order reactions
• VCSTR = FA0 × area of rectangle
1
• VPFR = FA0 × AUC
𝑟
• VCSTR < VPFR

xA

For zeroth order reactions

• VCSTR = VPFR
1
doesn't matter
𝑟
How about the one on the right?

xA
negative to positive order (consider combining 2 reactors)
 15

Quiz 1
1. If εA is negative, does the reaction volume in a piston-type constant pressure
batch reactor increase or decrease as the reaction progresses?

2. If ε A is positive, does the reaction volume in a flow reactor increase or

decrease as the reaction progresses?

3. For a half order reaction, should a CSTR or PFR be chosen to keep the
reactor size smaller?
 16

Recap
Positive order reaction (A → products)

𝑟 𝑟

𝑥 𝑐

1 1
𝑟 𝑟

𝑥 𝑐
 17

Recap
Negative order reaction (A → products) 0th order reaction (A → products)

𝑟 𝑟
1
𝑟 or

𝑥 𝑐
𝑐 𝑜𝑟 𝑥
1 1
𝑟 𝑟

𝑥 𝑐
 18

Recap
Positive order reaction
Design equations:
1 1
𝐹 ,𝑣 𝐹 ,𝑥 𝑟 𝑟

1
𝑉/𝐹 𝑥
𝐹 𝑥 𝑟
𝑉
𝑟 1 0.5 0.9 𝑥 0.25𝑐 0.5𝑐 𝑐 𝑐
𝜏/𝑐 𝑥
𝑟 Negative order reaction
1 1
𝑐 𝑐
Constant density: 𝑥 𝑟 𝑟
𝑐

1
𝜏 𝑐 𝑐
𝑟

0.5 0.9 𝑥 0.25𝑐 0.5𝑐 𝑐 𝑐

 19

Recap
Positive order reaction
Design equations:
1 1
𝐹 ,𝑥 𝑟 𝑟
𝐹 ,𝑣

1
𝑉 𝐹 𝑑𝑥
0 𝑟
𝑑𝑥
𝑉 𝐹
0 𝑟 1 0.5 0.9 𝑥 0.25𝑐 0.5𝑐 𝑐 𝑐
𝜏/𝑐 𝑑𝑥 Negative order reaction
0 𝑟
1 1
𝑐 𝑐 𝑑𝑐 𝑟 𝑟
Constant density: 𝑥 𝑑𝑥
𝑐 𝑐

𝑑𝑐 𝑑𝑐
𝜏
𝑟 𝑟

0.5 0.9 𝑥 0.25𝑐 0.5𝑐 𝑐 𝑐

 20

Recap
Positive order reaction
1
𝑟

1
𝑟

0.5 0.9 𝑥
xA
Negative order reaction
1 1
𝑟 𝑟
0 V1 0.5 V2 0.9

0.5
𝑉 /𝐹
𝑟
0.9 0.5
𝑉 /𝐹
𝑟
0.5 0.9 𝑥
splitting into 2 CSTR makes the volume lower
 21

Conversion in Sequence of Reactors

• When the calculated design volume for a single reactor is too large to be
practical, the same reaction may instead be conducted in a combination of
reactors of the same or different types, arranged in series, parallel or a mixture
of both.

• When reactors are connected in series, it is mathematically more convenient to

define the conversion after any reactor with respect to the feed to the first
reactor (instead of the feed to that particular reactor, i.e. “conversion per pass”).

• This definition is useful only if there are no side streams and the feed enters
only through the first reactor of the series.
 22

Conversion in Sequence of Reactors

• Consider two CSTRs in series:

FA0 FA1 FA2

xA0 = 0 V1 xA1 V2 xA2
𝐹 𝐹 1 𝑥
𝐹 𝐹 1 𝑥
• Mole balance around V2:
𝐹 𝐹 𝑟 𝑉
• Combining the above equations gives:
𝐹 𝑥 𝑥
𝑉
𝑟 𝐹 𝑥 0
𝑉
• More generally: 𝑟
𝐹 𝑥 𝑥
𝑉
𝑟
 23

Conversion in Sequence of Reactors

Example: Design equations for 3 PFRs in series

V1 V2 V3
FA0 = FA1 = FA2 = FA3 =
100 mol s−1 50 mol s−1 30 mol s−1 10 mol s−1

• Conversions based on feed to first reactor:

𝑥 0.50, 𝑥 0.70, 𝑥 0.90
• Design equations (recommended):
0.50 𝑑 0.70 𝑑 0.90 𝑑
𝑉 𝐹 0
,𝑉 𝐹 0.50
,𝑉 𝐹 0.70

• Design equations based on conversions per pass (not recommended):

0.50 𝑑 0.40 𝑑 0.67 𝑑
𝑉 𝐹 0
,𝑉 𝐹 0
,𝑉 𝐹 0
 24

CSTRs in Series

FA0 FA1 FA2 FA(N−1) FAN

xA0 = 0 V1 xA1 V2 xA2 xA(N−1) VN xAN

𝐹 𝑥 𝑟 𝑉
𝐹 𝑥 𝑥 𝑟 𝑉
⋮
𝐹 𝑥 𝑥 𝑟 𝑉
• Summing up:
𝐹 𝑥 𝑟 𝑉 𝑟 𝑉 … 𝑟 𝑉
• The volume of a single CSTR required to conduct the same reaction:
𝐹 𝑥 𝑟 𝑉
 25

CSTRs in Series
• Substitute into the previous equation:
𝑟 𝑟
𝑉 𝑉 𝑉 … 𝑉
𝑟 𝑟

• For positive order reactions, −rAn > −rAN (n = 1, 2, …, N − 1):

𝑉 𝑉 𝑉 … 𝑉

• For negative order reactions, −rAn < −rAN (n = 1, 2, …, N − 1):

𝑉 𝑉 𝑉 … 𝑉

• For zeroth order reactions, −rAn = −rAN (n = 1, 2, …, N − 1):

𝑉 𝑉 𝑉 … 𝑉
 26

Equal Size Constant Density CSTRs in Series

FA0, v0 FA1, v1 FA(N−1), vN−1 FAN, vN

xA0, cA0 V1, τ1 xA1, cA1 V2, τ2 xA(N−1), cA(N−1) VN, τN xAN, cAN

𝐹 𝑥 𝑥
𝑉
𝑟
• Since the system is constant density, v0 = v1 = v2 = … = vN:
𝐹 𝑥 𝑥 𝑐 𝑥 𝑥 𝑐 𝑐
𝜏
𝑣 𝑟 𝑟 𝑟
• For first order kinetics, rAn = −kcAn:
𝑐 𝑐
𝜏
𝑘𝑐
 27

Equal Size Constant Density CSTRs in Series

• Apply the above equation to each reactor and let τ1 = τ2 = … = τN = τ:
𝑐 𝑐 𝑐
𝜏 ⇒ 1 𝑘𝜏
𝑘𝑐 𝑐
𝑐 𝑐 𝑐 𝑐
𝜏 ⇒ 1 𝑘𝜏 ⇒ 1 𝑘𝜏
𝑘𝑐 𝑐 𝑐
⋮
𝑐 𝑐 𝑐 𝑐
𝜏 ⇒ 1 𝑘𝜏 ⇒ 1 𝑘𝜏
𝑘𝑐 𝑐 𝑐
• Rearranging gives:
1
1 𝑐 𝑁
𝜏 1
𝑘 𝑐
• Multiply by N to obtain overall space time:
1
𝑁 𝑐 𝑁
𝜏 1
𝑘 𝑐
 28

Equal Size Constant Density CSTRs in Series

• As N → ∞: 𝑎 1
1 lim ln 𝑎
𝑁 𝑐 𝑁 1 𝑐 𝑧→0 𝑧
𝜏 1 → ln
𝑘 𝑐 𝑘 𝑐
• This is the space time of a PFR.
• Therefore: 1
𝑐 𝑁
𝑁 1
𝜏 𝑐
𝑐 𝑓 𝑥 ,𝑁
𝜏 ln
𝑐
 29

Equal Size Constant Density CSTRs in Series

 30

Different Size Constant Density CSTRs in Series

FA0, v0 FA1, v1 FA(N−1), vN−1 FAN, vN

xA0, cA0 V1, τ1 xA1, cA1 V2, τ2 xA(N−1), cA(N−1) VN, τN xAN, cAN

𝑐 𝑐 𝑟 1
𝜏 ⇒
𝑟 𝑐 𝑐 𝜏
𝑐 𝑐 𝑟 1
𝜏 ⇒
𝑟 𝑐 𝑐 𝜏
⋮
𝑐 𝑐 𝑟 1
𝜏 ⇒
𝑟 𝑐 𝑐 𝜏

Self‐study
not tested
 31

Different Size Constant Density CSTRs in Series

• Graphical solutions of:
1 1 1
, , …,

Self‐study
 32

Different Size Constant Density CSTRs in Series

• Given the number of reactors (N), feed composition (cA0), product composition
(cAN) and rate law:
• Number of equations = N (mole balance around each reactor)
• Number of unknowns = 2N − 1 (τ1, τ2, …, τN, cA1, cA2, …, cA(N−1))

• There can be multiple solutions for the space times and intermediate
concentrations (equivalently, reactor volumes and intermediate conversions).

• The optimal solution is the one that gives the smallest total reactor volume.
Refer to Levenspiel pg 132-133 for details.

Self‐study
 33

Rules of Thumb for CSTRs in Series

• There may exist an optimal arrangement where the total reactor volume is
minimised (for a given conversion) or the conversion is maximised (for a given
total volume). Depending on the shape of the rate-concentration curve, there
may be more than one, exactly one or no optimal arrangement.

• For nth order reactions (n > 0), there is always one optimal arrangement:
• For n > 1, the small reactors should be placed before larger ones.
• For n = 1, the reactors should have equal sizes.
• For n < 1, the large reactors should be placed before smaller ones.

• The advantage of a minimum-size system over an equal-size system is usually

quite small and the overall economic considerations almost always favour the
equal-size system.
 34

CSTRs in Parallel

FA0 α1FA0 xA1 xAf

xA0 = 0 V1

α2FA0 xA2 FA0 FA

V2 = xA0 = 0
V xA

αNFA0 xAN

VN

xA1 = xA2 = …. = xAN = xA V = V1 +V2 +…+ VN

 35

CSTRs in Parallel
• Consider the case where xA1 = xA2 = … = xAN = xAf (all τ’s are equal):
𝛼 𝐹 𝑥 𝑟 𝑉
𝛼 𝐹 𝑥 𝑟 𝑉
⋮
𝛼 𝐹 𝑥 𝑟 𝑉
• Summing up:
𝐹 𝑥 𝑟 𝑉 𝑉 … 𝑉
• The volume of a single CSTR required to conduct the same reaction:
𝐹 𝑥 𝑟 𝑉
• Substitute into the previous equation:
𝑉 𝑉 𝑉 … 𝑉
• This relation applies for CSTRs in parallel as long as the conversion is the
same for all reactors.
 36

Exercise
The first order reaction A → B is carried out in a CSTR to produce a marketable product
containing 90 mol% B with balance A. In anticipation of an increase in the demand for this
product to 4 times of its current production capability at the same purity, the management
decided to acquire more CSTR(s) with the same specifications as the one in use. Engineer 1
proposed to buy three more CSTRs while Engineer 2 proposed to buy just one.

The conversion will be kept the same as there is no incentive to produce a purer product.

(a) Is this a prudent decision, i.e. can you instead make do with the current reactor to meet the
new market demand?

Yes, this is a prudent decision as it is not possible to increase the product throughput without
additional resources (i.e. a new reactor).
 37

Exercise (continued)
(b) If you are the manager, whose recommendation will you follow?
F0,1CSTR 0.1F0,1CSTR
If CSTRs are connected in parallel, 3 more CSTRs are needed.
x0 = 0 V x = 0.9
If CSTRs are connected in series, use design equation of CSTR:
𝐹 , 𝑥 𝐹 , 𝑥 𝐹 , 0.9 𝐹 , 0.9 ……
When N = 1, 𝑉
𝑟 𝑟 𝑘𝑐 0.1𝑘𝑐
F0,1CSTR 0.1F0,1CSTR
𝐹 , 𝑥 𝐹 , 𝑥
When N = 2, 𝑉 x0 = 0
𝑟 𝑘𝑐 V x = 0.9

𝐹 , 𝑥 𝑥 𝐹 , 𝑥 𝐹 , 𝑥
𝑉
𝑟 𝑘𝑐 𝑘𝑐
𝑐 𝑐
𝑉 𝑉 𝑥 𝑐 𝑐 𝑐 𝑐 0.1
𝑐
F0,2CSTR ? 0.1F0,2CSTR
𝑐
𝑥 1 1 0.1 xA0 = 0 xA’ = ? xA = 0.9
𝑐 V V
𝑉 1 𝐹 ,
4.16 Two CSTRs in series can already increase productivity to > 4 times!
𝑉 𝑉 2 𝐹 ,
 38

Exercise (continued)
Method 2 (use equation for equal size CSTRs in series):
F0,1CSTR 0.1F0,1CSTR
If CSTRs are connected in series, from lecture notes Unit 4: x0 = 0 x = 0.9
V
1
𝑁 𝑐 𝑁 ……
𝜏 1
𝑘 𝑐
F0,1CSTR 0.1F0,1CSTR
1 9 x0 = 0
When N = 1, 𝜏 10 1 V x = 0.9
𝑘 𝑘
2 /
4.325
When N = 2, 𝜏 10 1
𝑘 𝑘
𝑉 𝑉
Note: 𝜏
F0,2CSTR ? 0.1F0,2CSTR
𝐹 , 𝑉 /𝜏 9/𝑘
2 x0 = 0 V x=? V x = 0.9
𝐹 , 𝑉 /𝜏 4.325/𝑘
4.16
Two CSTRs in series increase productivity to > 4 times!
 39

Exercise (continued)
Method 3 (graphical method):
If the 2 CSTRs are connected in series:
Method 3.1:
Using N = 1 and 1 − xA = 0.1, kτ1CSTR ≈ 9
Using N = 2 and 1 − xA = 0.1, kτ2CSTR ≈ 4.5
𝑘𝑉 2𝑘𝑉
Since 𝑘𝜏 and 𝑘𝜏 ,

𝐹 , 𝑣 2𝑉/𝜏 9
2× 4
𝐹 , 𝑣 𝑉/𝜏 4.5

Method 3.2:
Using N = 1 and 1 − xA = 0.1, ≈ 3.9

Using N = 2 and 1 − xA = 0.1, ≈ 1.9

𝑘𝑉 2𝑘𝑉
Since 𝑘𝜏 and 𝑘𝜏 ,

𝐹 , 𝑣 2𝑉/𝜏 3.9
2× 4.1
𝐹 , 𝑣 𝑉/𝜏 1.9
 40

Quiz 2
1. For a second order reaction, should a single CSTR or a series of multiple
CSTRs be chosen?
multiple, PFR if possible

2. For a negative order reaction, is a PFR operationally equivalent to an infinite

series of infinitesimally small CSTRs? yes, same logic as positive order
 41

PFRs in Series

FA0 FA1 FA2 FA(N−1) FAN

V1 V2 VN
xA0 = 0 xA1 xA2 xA(N−1) xAN
𝑑𝑥
𝑉 𝐹
0 𝑟
𝑑𝑥
𝑉 𝐹
𝑟
⋮
𝑑𝑥
𝑉 𝐹
𝑟
• Summing up:
𝑑𝑥
𝑉 𝑉 … 𝑉 𝐹
0 𝑟
 42

PFRs in Series
• The volume of a single PFR required to conduct the same reaction:
𝑑𝑥
𝑉 𝐹
0 𝑟
• Substitute into the previous equation:
𝑉 𝑉 𝑉 … 𝑉
• This relation always applies to PFRs in series.

okay to use multiple PFRs if it's too expensive to be built

 43

PFRs in Parallel
FA0 α1FA0 xA1 xAf
V1
xA0 = 0
α2FA0 xA2
V2

αNFA0 xAN
VN

• where α1 + α2 + … + αN = 1.

only CSTR in series has a positive effect on performance

 44

PFRs in Parallel
• Consider the case where xA1 = xA2 = … = xAN = xAf (all τ’s are equal):
𝑑𝑥
𝑉 𝛼 𝐹
0 𝑟
𝑑𝑥
𝑉 𝛼 𝐹
0 𝑟
⋮
𝑑𝑥
𝑉 𝛼 𝐹
0 𝑟
• Summing up:
𝑑𝑥
𝑉 𝑉 … 𝑉 𝐹
0 𝑟
• Comparing with the earlier expression for Vsingle PFR:
𝑉 𝑉 𝑉 … 𝑉
• This relation applies for PFRs in parallel as long as the conversion is the same
for all reactors.
 45

Rules of Thumb for CSTRs and PFRs

• For nth order reactions (n > 0), the reactors should be arranged in series:
• For n > 1, the reactant concentration should be kept as high as possible, i.e.
arrange in the order PFR(s) – small CSTR(s) – large CSTR(s).
• For n < 1, the reactant concentration should be kept as low as possible, i.e.
arrange in the order large CSTR(s) – small CSTR(s) – PFR(s).

• For rate-concentration curves with a turning point, there are no simple rules. A
close examination of the curve is a good way to determine the best
arrangement.
 46

Recycle Reactor
FA0 FA
V
xA0 = 0 xA

RFA
where R is the recycle ratio.
• The recycle reactor is a PFR with controlled back-mixing. Therefore, it may be
viewed as a hybrid of PFR and CSTR.
• The design equation is (details in Appendix):
𝑑𝑥
𝑉 𝑅 1 𝐹
𝑅 𝑟
𝑅 1
 47

Recycle Reactor
• Two limiting cases exist:
𝑑
1. As R → 0, 𝑉 → 𝐹 0
, i.e. a PFR
2. As R → ∞, A1 → 0, A1 + A2 → A2, 𝑉 → 𝐹 , i.e. a CSTR

• R determines the balance between “plug flow” (i.e. PFR) and “mixed flow” (i.e.
CSTR) properties.
 48

Quiz 3
1. For a negative order reaction, is the total volume required for a series of PFRs
equal to the volume required for a single PFR?

2. For a first order reaction, is the volume required for a recycle reactor larger or
smaller than that for a PFR?
 49

Autocatalytic Reactions
• Consider autocatalytic reaction:
• A→R k0 (uncatalysed)
• A+R→R+R k (catalysed)
Assume k >> k0, reaction only occurs in the presence of both A and R.
Assume first order kinetics for both A and R
rA = −kcAcR = −kcA0(1 − xA)cA0xA = −kcA02(1 − xA)xA

The curve exhibits a minimum point (maximum rate), suggesting a

mix of “positive order” and “negative order” behaviours.

The reactor of choice depends on xA:

If xA is to the left of the minimum point, a CSTR should be used.
If xA is to the right of the minimum point, a recycle PFR with the
optimal recycle ratio or a sequence of reactors consisting of a
leading CSTR should be used.
 50

Autocatalytic Reactions
Using a sequence of reactors consisting of a leading CSTR

CSTR CSTR

• For the arrangement on the right, the completion of the reaction depends
almost entirely on separation after reaction, i.e. the separator should recycle all
the unreacted reactant to the CSTR.
 51

Autocatalytic Reactions
Using a recycle PFR with the optimal recycle ratio
𝑑𝑥 1 𝑅𝑥
𝑥
𝑅 𝑟 𝑟 𝑅 1 Derivation provided in appendix
𝑅 1
𝑅
• Left hand sum is the AUC between and xA, while right hand sum is the area
𝑅 1
𝑅 1
of rectangle with length 𝑥 and width :
𝑅 1

1
𝑟

𝑅𝑥
xA
𝑅 1
 52

Appendix: Design Equation for Recycle Reactor

FA0 1
FA1 FA2 2 FA
V
xA0 = 0 xA1 xA xA

RFA, xA
• Mole balance around blue system boundary:
𝐹 𝐹 1 𝑥

• Mole balance around point (1):

𝑅𝑥
𝐹 𝐹 𝑅𝐹 𝐹 𝑅𝐹 1 𝑥 𝑅 1 𝐹 1
𝑅 1

• Mole balance around point (2):

𝐹 𝑅𝐹 𝐹 𝑅 1 𝐹 1 𝑥
 53

Appendix: Design Equation for Recycle Reactor

FA1 FA2
V
xA1 xA

• From earlier:
𝑅𝑥
𝐹 𝑅 1 𝐹 1
𝑅 1
𝐹 𝑅 1 𝐹 1 𝑥

• The PFR can hence be treated as having an initial flow rate of (R + 1)FA0, inlet
𝑅
conversion of and outlet conversion of xA:
𝑅 1
𝑑𝑥
𝑉 𝑅 1 𝐹
𝑅 𝑟
𝑅 1
 54

Appendix: Recycle Reactor

𝑑
• The integral 𝑅 can be approximately represented by rectangle A1:
𝑅 1

1
𝑟

𝑅𝑥
xA
𝑅 1
𝐴 𝐴 𝑥 0
𝑅 1
𝐴 𝑅𝑥
𝑥
𝑅 1
𝑑𝑥
∴𝐴 𝐴 𝑅 1 𝐴 𝑅 1
𝑅 𝑟
𝑅 1
 55

Appendix: Autocatalytic Reactions

Using a recycle PFR with the optimal recycle ratio
• Design equation:
𝑑𝑥
𝑉 𝑅 1 𝐹
𝑅 𝑟
𝑅 1
• To determine the optimal R value such that V is minimum, differentiate with
respect to R using the Leibniz rule and equate the derivative to zero:
1 𝑑𝑉 𝑑𝑥 1 𝑑 𝑅𝑥
𝑅 1 0 0
𝐹 𝑑𝑅 𝑅 𝑟 𝑟 𝑑𝑅 𝑅 1
𝑅 1
𝑅
• where 𝑟 is −rA evaluated at xA = .
𝑅 1
𝑑𝑥 𝑅 1 𝑥
0
𝑅 𝑟 𝑟 𝑅 1 Since 𝑅 𝑥
𝑅
:
𝑅 1 1 𝑅 1
𝑑𝑥 1 𝑥
𝑑𝑥 1 𝑅𝑥
𝑅 𝑟 𝑟 𝑅 1 𝑥
𝑅 1 𝑅 𝑟 𝑟 𝑅 1
𝑅 1