Professional Documents
Culture Documents
on
Attainable Region
by
Prof. Arun S Moharir
Production Support by
Satyanjay Sahoo
Anshu Shukla
Introduction
Attainable Region or AR is an important concept in design of reactor systems. In
any process, it is the reactor or a reactor network where value is created by
converting relatively low priced reactants into high priced products. The value
thus created is partly consumed in preparing the feed for the reactor, operating
the reactor itself, and processing the product from the reactor. All these
consumptions must be minimized while the value creation in the reactor
maximized to make the overall process optimally profitable. This, in a nutshell, is
the task of chemical process design. Chemical engineering curricula world over,
especially the undergraduate ones, aim at designing or creating the process
designers for future who will churn out newer process designs. Process design
thus must take a philosophical and holistic view rather than getting constrained
by individual design tasks such as designing a heat exchanger, a distillation
column, a reactor etc. Individual designs of unit operations and reactors are
covered in dedicated courses such as heat transfer, mass transfer, reactor
design, fluid mechanics etc. It is the process design course which must integrate
all these concepts to illuminate the path to that one final all important activity of
process flowsheet development and design. The course on process design is
thus the culmination of all the courses to finally build something whole and
complete. No wonder it is one of the final year, final semester courses in most
chemical engineering curricula. IITB, for whose final year undergraduate students
this note is prepared, is no exception.
The note deals with Attainable Region, AR, an extraordinary concept developed
by Prof. Glasser [1, 2] for reactor system design. It is also one of the more recent
philosophical ideas which has immensely enriched chemical process design task.
While the concept is well understood and further researched upon by teachers,
its teaching has been a challenge because it has been difficult to separate
complex mathematics from its basically simple philosophical content. It would not
be wrong to say that AR entered the research arena without entering the
textbooks of basic chemical engineering curricula. This note is an attempt to
Let us agree to some conventions for the rest of the note. An arrow like the one
used in representing the reaction as above indicates irreversible reaction.
Kinetics of the reaction can be either explicitly given or is easily inferable from
units of rate constant. For example, above reaction is first order as indicated by
the units of rate constant. Rate constant value will be temperature dependent.
The given value will be valid only at that temperature. Unless otherwise stated, it
is assumed that the isothermal reactor operates at this temperature.
With only two chemical species involved in the above case, the concentration
space is 2-Dimensional. Using a dominant component of the feed on X axis is a
preferred practice, although not necessary. In the present case, the other
component is on the Y axis.
CB (Kmol/m3)
0
0
0.5
CA (Kmol/m3)
to achieve starting with this feed. The straight line is thus itself the desired AR in
this case.
Being a straight line, the AR in this case can be said to be 1-Dimensional. Please
note that the concentration space was 2-Dimensional, while the AR is 1Dimensional.
Also worth noting is that we did not use any particular reactor type in developing
the AR. Also, we made no use of the reaction kinetics or rate constant explicitly.
All we used in arriving at the AR is stoichiometry, nature of reaction
(reversible/irreversible) to arrive at infinite time composition and the feed
composition.
With this first acquaintance with the concept of AR, let us look at some variations
of the above example to consolidate and expand our appreciation of AR.
Example 1A: Same as Example 1 as far as the kinetics and stoichiometry go,
but with the only difference that the feed is an equimolar mixture of A and B with
each at concentration 0.5 kmol/m3.
Figure 3: Attainable region for
CB (Kmol/m3)
0
0
0.5
CA (Kmol/m3)
Figure 2 shows the AR. The feed point is now (0.5, 0.5), infinite time product
point is (0,1) and the straight line joining these two points is the AR. Slope and
intercept of the line are the same as in Example 1.
All arguments put forth for Example 1 as regards feed composition, infinite time
product composition and the linear relation between concentrations of the two
components for any conversion are valid. The AR is thus the same as in Figure
1.
The kinetics does not seem to play any role and the AR is same for Example 1
and 1B although the kinetics was different. Neither the reaction order nor the rate
constant value had any bearing on AR which is a straight line, i.e. AR is 1Dimensional.
CB (Kmol/m3)
0.5
0
0
0.5
CA (Kmol/m3)
The feed composition is a point (1, 0) in the 2-D concentration space. The Infinite
time product concentration (i.e. product concentration achievable by employing a
reactor providing infinite space time) will now be (0.5, 0.5) because A and B will
CB (Kmol/m3)
0.5
0
0
0.5
CA (Kmol/m3)
If you compare the ARs developed by us so far, they are all part or whole of the
same straight line. We are not budging from this line in spite of changes in
reaction nature, reaction order, and feed composition. We still have a 1-D AR
and a 2-D concentration space. It is tempting to make a generalization and
proclaim Rule 3 stating that reaction kinetics and feed composition have no
bearing on the geometric nature of the AR, at least qualitatively speaking. Or
may be Rule 4 stating that dimensionality of AR is one less than the
dimensionality of the concentration space. Let is desist from doing that and
explore further. AR cannot be, after all, such a trivial concept!
The feed point is now (0.5, 0.5). The infinite time product point is also (0.5, 0.5)
given the equilibrium constant as 1.0. The AR is thus just a point in a 2Dimensional space. The AR is Zero-Dimensional so to say. Stated simply, the
composition remains same and cannot be changed. Whatever be the reactor
type and size, the feed emerges unchanged as a product. That is because the
feed is at equilibrium itself. The AR for the above system is shown in Figure 5.
CB (Kmol/m3)
0.5
0
0
0.5
CA (Kmol/m3)
This example at least gave us some deviation from something we were on the
verge of formulating as a rule. The dimensionality of AR is 1 in Examples 1, 1A,
1B and 1C and is 0 (Zero) for example 1D. The concentration space was 2-D in
all cases.
The 0-Dimensional AR, say the point AR, is still on the same lines which
emerged as ARs for the earlier cases.
All reactions so far were having same stoichiometry. Let us make some deviation
from the stoichiometry in the next example.
Example 1E: It is similar to Example 1 except that the reaction is 2A B + C.
There are now three species and the concentration space is 3-Dimensional.
What about the AR in this 3-D space?
In engineering, one invariably presents 3-D objects in their various 2-D views,
such as plan, elevation or profile views. The 3-D perspective is created by the
viewer in his mind from such views. We can try doing so in this case also and
show the AR by its projection on the A-B, A-C and B-C planes. These
representations are also shown in Figure 7. The AR is a straight line in all such
representations.
CC( Kmol/m3)
1
0.75
0.5
0.25
0
0
0.25
0.5
3
CA ( Kmol/m )
0.75
1 0
0.75 1
0.5
0.25
CB ( Kmol/m3)
Figure 7: Attainable region for 2A B+C; CA0 =1, CB0 = CC0 =0, k=1hr-1
The two dimensional views give the attainable concentrations of any two of the 3
components. The concentration of the remaining component can be deducted
from the overall mass balance which is CA + CB + CC = CA0 + CB0 + CC0. The feed
is pure A with concentration 1 kmol/m3 in this case. Therefore, CA + CB + CC = 1
irrespective of the conversion of A. The 2-D representations are thus adequate
and provide an idea of all attainable compositions.
0.5
CC (Kmol/m3)
CC (Kmol/m3)
CB (Kmol/m3)
0.5
0.5
0.5
CA
(Kmol/m3)
0.5
CA
(Kmol/m3)
0.5
CB
(Kmol/m3)
Figure 8: 2D Projection of attainable region for 2A B+C; CA0 =1, CB0 = CC0 =0,
k=1hr-1
Example 1F: Same as Example 1E but the feed is (0.5, 0.25, 0.25)
Example 1G: Same as Example 1E but the reaction is second order in A and
reversible with equilibrium constant 0.25
Figure 9 shows the graph between CB versus CA with feed as CA0=1 and
CB0=CC0=0.
Example 1H: Same as Example 1G but with the feed composition as (0.5, 0.25,
0.25): The representation in Figure 10 shows AR for Example 1H.
You get 2 ARs which are 1-D in whatever the representation you choose. In one
case, the AR is a point or is 1-D.
We thus got 0 and 1-D ARs in this 3-D concentration space.
You can increase the dimensionality of the concentration space by making the
reaction have 4 or more components. For example, try A B + C + D or A + B
C + D etc. Irreversible nature could then be converted to reversible nature of
reaction. If you play around a bit with feed concentration and equilibrium
constant, you will realize that the AR is still 0-D or 1-D. Representation of AR in
4-D concentration space is not conceivable and the best choice is to use a 2-D
space with selected pair of components. AR will be a straight line or a point in
such a representation.
What is stopping us from getting higher dimensional ARs, say a 2-D or 3-D AR,
such as a surface or a volume? We have played with almost everything except
that we have been considering only one reaction. Let us try multiple reactions for
a change and see what happens.
Example 2: Reaction A B C is carried out with pure A as feed. Feed is pure
A with concentration of A (CA0) is 1 kmol/m3. The rate constants are 1 hr-1 for
both the reactions. Construct an AR.
We have a series of two reactions, both irreversible, first order and with given
rate constant values. This is a reaction handled as the first encounter with
multiple reactions in any worthwhile book on CRE or Chemical Reaction
Engineering. CRE deals with two ideal reactor types, a CSTR and a PFR. Let us
see what product compositions one can achieve by employing a CSTR to begin
with. It can be of any size offering space time of any magnitude (0 to ).
Mass balance on species A and some jugglery gives the following relation
between concentration of A in CSTR product stream as a function of reactor
space time.
C 0A
CA =
1+ k 1
Similarly, mass balance on B gives:
CB =
c 0B + k 1 C A
1+ k 2
CB (Kmol/m3)
0.25
1
3
0.125
2
6
hr-1, in CSTR
0
0
0.5
CA (Kmol/m3)
Not really! AR is the set of all compositions attainable through any combination of
any type of reactors, and not just a single reactor of a particular type. So, let us
say, we are ready to have two CSTRs in parallel, one processing mass fraction x
of the feed and the other the remaining fraction of feed (1-x). Depending on the
size of individual reactors, the product from each reactor will be some point on
the CSTR performance curve we have generated. Consider points 1 and 2 on the
curve as one such pair. When a product of composition as represented by point 1
and with mass fraction x is mixed with the product of composition as represented
by point 2 and mass fraction (1-x), we will get a combined product of composition
as shown on the line joining points 1 and 2. The exact location of the point will
split the line in two parts, one of fractional length x towards point 2 and one of
fractional length (1-x) towards point 1. This can be appreciated by simple mass
balance. That means, by changing x from 0 to 1, any point on this line is
attainable. This is true also of any other pair of points on the reactor performance
line, such as points 3 and 4, or 5 and 6 etc. In fact, this is true of a line joining the
two ends of the performance line (1, 0) (feed point) and (0, 0) (the infinite time
product composition). The same logic holds if one point is the feed point and
another any point on the performance curve. The line joining these two points is
also attainable. In practice, one would achieve any composition on any such line
by passing a part of the feed through the reactor and mixing the remaining with
the product of the reactor by bypassing the reactor.
If all such possible lines are drawn and accepted as representing attainable
compositions, the overall AR that is attainable using none, one or two CSTRs
with or without bypass is as shown in Figure 9. The AR now is surface and not a
straight line. We got an AR which is two dimensional for the first time. It is a
surface in a 2-D plane. The composition of the third species (i.e. C) can be
obtained by overall balance as seen earlier.
CB (Kmol/m3)
0.25
Figure 10: AR for A B C ,CA0
=1, CB0 = CC0 =0 k1=k2=1 hr-1, in
0.125
CSTR
0
0
0.5
CA (Kmol/m3)
But is this then the AR for the present case?
Actually, we do not know. Whereas we have allowed more than 1 CSTRs while
arriving at attainable product compositions, we have not yet considered using
PFR instead of, or in addition to, the CSTR. Let us do it now.
Similar to the above treatment, one can develop a PFR performance curve in the
2-D concentration space. Mass balance on A and B for a PFR gives the following
relationships.
C A = C 0A e k1
CB = C e
0
B
k 2
k1 C 0A k1 k 2
+
e e
k 2 k1
CB (Kmol/m3)
0.375
0.125
CSTR
PFR
0
0
0.5
CA (Kmol/m3)
Figure 12: Performance curve for A B C ,CA0 =1, CB0 = CC0 =0, k1=k2=1 hr-1,
in both CSTR and PFR
Extending the logic used earlier (if any two compositions are attainable, then the
compositions lying on the line joining these two points are also attainable), we
can see the AR as the entire surface enclosed by the PFR line. This region
includes the region attainable using only CSTRs.
For the given feed and the reactions (stoichiometry, nature and kinetics), the AR
is thus possible to construct. For the series reaction considered above, the AR is
as shown in Figure 11. Composition outside this AR cannot be attained by any
series-parallel combination of PFR/CSTR with or without bypass from the given
feed.
scheme
in
terms
of
its
stoichiometry,
kinetics
and
thermodynamics.
CB (Kmol/m3)
0.375
0.25
0.125
CSTR
PFR
0
0
0.5
CA
(Kmol/m3)
Let us restrict at this time to all reactors operating isothermally and at same
temperature. Also, we do not consider restrictions on reactor sizes or constraints
on feed availability in terms of its quantity.
We have argued during above development that if any two points representing
two compositions are a part of AR, then the line joining these points must also be
a part of AR. Mathematically, this means that the geometrical shape of the AR
must be convex
In the above example, we constructed on a 2-D concentration space an AR for a
reaction scheme involving 3 species. The same could have been depicted in the
actual 3-D concentration space. Verify that it would still have been a region
marked on a plane surface. What we saw on the 2-D space was only a projection
of this actual AR in 3-D space on the chosen 2-D view. The AR could have been
similarly depicted on a CA-CC or CB-CC space. The looks could be quite different
and this is worth trying as an exercise. The expected AR looks in these
alternative choices of depiction are shown in Figure 12. Also shown are the
corresponding reactor lines. Whatever may be the preferred representation style,
the information content of an AR is the same. This content is very profound and
can be used to design the best suited reactor network for a given task as will be
seen later.
CSTR
PFR
0.5
CSTR
PFR
CC (Kmol/m3)
CC (Kmol/m3)
0.5
0.25
CB (Kmol/m3)
0.5
(a)
0.5
CA (Kmol/m3)
(b)
Figure 14: AR for A B C ,CA0 =1, CB0 = CC0 =0, k1=k2=1 hr-1, in both CSTR
and PFR in (a) CB = CC and (b) CA = CC plane
As of now, you could construct AR for the following variations of the above
example.
And so on. You can cook up your own examples and practice more.
Let us create a CSTR performance curve. Mass balance on A will give the
change in concentration of A as follows.
CA = CA0 k1
This is valid only for reactors providing space time from 0 to * where * is
CA0/k1. For larger reactors providing > *, CA will be zero.
Similarly, mass balance on B will give expression of CB in terms of . Till such
time A is available, concentration of B will build up in the reactor because
consumption rate of B is less than formation rate of B as can be seen from the
two rate constants. Once A is completely consumed, concentration of B will also
start dropping and eventually reach zero for reactor space time CA0/k2. C is
formed continuously at the rate of k2. The reactor performance curve is
comprised of two straight line sections in CA-CB space. The feed point is (1, 0). At
* = 1 hr, CA = 0, CB = 0.5 and CC = 0.5. The straight line joining (1, 0) to (0, 0.5)
is valid till *. Then onwards, B drops from 0.5 to 0.0. By time = 2 hr, all B is
consumed. This is point (0, 0) on the CA-CB space. The straight line joining (0,
0.5) and (0,0) is the second part of reactor line. In the actual 3-D concentration
space for (A, B, C), the corresponding points are (1, 0, 0), (0, 0.5, 0.5) and (0, 0,
1.0).
Using the earlier logic to construct a convex AR from reactor lines, the AR in A-B,
A-C, B-C and A-B-C space are as shown in Figure 13. The triangle is a convex
region. The third line of the triangle in each case was arrived at by joining the
feed point and the point corresponding to 2 hr space time when both A and B
deplete to zero.
This was done assuming CSTR as a reactor. PFR should also have been
included. But is PFR different from CSTR for zero order reactions? Think and get
convinced that the ARs in Figure 13 are the ARs in totality and in compliance
with the definition given earlier.
The zero order reactions simplified reaction mathematics and one could visualize
ARs with much less computation.
Consider two small variations of this example and construct ARs in various views
suitably
1
0.5
CC (Kmol/m3)
1
CC (Kmol/m3)
CB (Kmol/m3)
0.5
0.5
CA
(Kmol/m3)
0.5
0.5
CA
CB (Kmol/m3)
(a)
(b)
(Kmol/m3)
(C)
Figure 15:
1
CC (Kmol/m3)
0.5
AR for
reaction A B C;
CA0=1 CB0 =CC0=0, in
0.5
CA-CB-CC space
1
1
0
0.5
CB (Kmol/m3)
(d)
8 views, without label, are given in Figure 14. These include one 3-D view and
three 2-D views for each of the above two examples. Do your own development
and label these eight views of AR suitably with selections from following list.
(1) Example 3A, 3-D
Appreciate how the look and feel of the AR changes with the choice of 2-D
concentration space. Information content is of course the same. All ARs have
been represented with coordinates of vertices of the space clearly given. The
borders or edges of the AR were anyway straight lines and needed no equations
to be specifically mentioned. However, if the edges of AR are curves, it is good to
write the equations of all distinct curves. ARs with coordinates of vertices and
equations of edges mentioned become that much more readable and also usable
for reactor design. We will deal with reactor design using AR later.
You can try similar cases with parallel reactions: A B and A C and learn
more. Do not expect the ARs to be even remotely similar to those for series
reaction. The similarity between the problems is deceptive. Did you observe the
same thing whey you did similar thing earlier with reactions being first order?
ARs with zero order reactions are interesting. ARs with some reactions as zero
order and some as non-zero order are even more interesting. Let us try some.
0.5
CC (Kmol/m3)
CC(Kmol/m3)
CB (Kmol/m3)
0.5
0
0
0.5
0.5
CA
CA (Kmol/m3)
(a)
(c)
1
CC (Kmol/m3)
CC (Kmol/m3)
CB
0.5
0.5
0
0.5
1
3
CA (Kmol/m )
(d)
CB(Kmol/m3)
0.5
(Kmol/m3)
(b)
1
(Kmol/m3)
0.5
0.5
0.5
0.5
CA (Kmol/m3)
CB (Kmol/m3)
(e)
(f)
CC (Kmol/m )
0.5
(g)
0
1
0
0.5
0.5
3
CA (Kmol/m )
1 0
CB (Kmol/m )
CC (Kmol/m )
0.5
(h)
0
0
0
0.5
0.5
3
CB(Kmol/m )
1 1
CA(Kmol/m )
For a PFR or CSTR, the mass balances can be solved to get CA and CB as
functions of and pairs of CA and CB for same values can be plotted to get the
reactor (PFR, CSTR) curves.
This is true till A reacts out completely. This happens for CA0/ k1
After this CA0 stays 0 and only second reaction is active. For the given values,
this time is 1 hr. Concentration of A thus drops linearly with for one hour and
then stays 0.
Mass balance on B can be written separately for 1 and > 1.
For 1, concentration of B varies with space time as follows.
CB =
C 0B + k 1
1+ k 2
CB =
1/ 3
1 + k 2 ( -1)
C 0B + C 0A - C A
CB =
1 + k 2 (C 0A - C A ) / k 1
This is the equation of the line joining feed point (1, 1) to the point (0, 1/3).
Beyond this point, CB also drops to zero at infinite space time. That line is along
the ordinate in our 2-D representation. It is just a vertical line joining points (0,
1/3) to (0, 0). In any other representation (say CB-CC space) one would have to
get the equation of that line too by similar procedure. The CSTR performance
line is shown in Figure 15.
The procedure can be repeated for the PFR also.
C B = C 0B e k 2 +
k1
1 e k 2
k2
CB(Kmol/m3)
0.5
0
0
0.5
CA
(Kmol/m3)
AR has to be convex. Therefore, feed point (1, 1) must be joined with CSTR point
(1/3, 5/3) by a straight line. The concavity of the CSTR curve is bridged by this
line which is attainable by a CSTR with bypass stream.
There is also a concave region below the PFR curve. All points below the PFR
curve which can be attained by 2 PFRs in parallel or a PFR in parallel with CSTR
should be enclosed into the AR. This region is retrieved by drawing a tangent to
the PFR line from point (0, 0). Since the point at which this line meets the PFR
line is attainable and (0, 0) is also attainable. All points on this line are attainable.
Now, one has a convex AR which is shown in Figure 16. The equation of the
tangent and coordinates of the point where it touches the PFR line must be
evaluated. That is left to you as an exercise.
This is the first time we encountered reactor lines which have non-convexity on
both sides. It was bridged on one side by joining two prominent vertices while on
the other side, one had to draw a tangent. This is something new we saw by
conjuring up a series reaction with combination of zero and first order reactions.
It is suggested that you construct AR for this case in the other two choices of
views (in A-C and B-C space). The looks will be different but the information
content the same.
CB(Kmol/m3)
0
0
0.5
CA(Kmol/m3)
For zero order reactions, one has to realize that one or more reactants can be
completely consumed with concentration(s) dropping to zero. Once that happens,
that particular reaction is as good as not there. This should be kept in mind while
developing the reactor curves on way to development of ARs.
Since we are with reaction schemes with a sprinkle of zero order and first order
reactions, the following 2 examples would be interesting to attempt. If you do
these yourself, you would have revised all concepts we developed so far, without
much mathematical complications. .
Example 5: 10 different cases are listed below. These are different in the
reaction scheme and/or the feed specification. Identify for each case whether the
AR is 1-D, 2-D, 3-D or of higher dimension. Construct the AR only for cases
where AR is 1-D or 2-D. Select the x-y axes for your AR judiciously. Indicate on
the AR itself the equation of the edges and coordinates of the corners of the AR.
0
1
0
1
0
Reaction Scheme 1: A B C D E F
1
0
1
0 1
Reaction Scheme 2: A B C D E F
The integers above the reaction arrow are the orders of those reactions. For
example, the 5 reactions in scheme 1 are of order 0, 1, 0, 1, 0 respectively. For
reaction scheme 2, the orders of the 5 reactions involved are 1, 0, 1, 0, 1
respectively.
Case 1: Reaction Scheme:1, Feed: pure A with concentration 10 kmol/m3
Case 2: Reaction Scheme:1, Feed: pure B with concentration 10 kmol/m3
Case 3: Reaction Scheme:1, Feed: pure C with concentration 10 kmol/m3
Case 4: Reaction Scheme:1, Feed: pure D with concentration 10 kmol/m3
Case 5: Reaction Scheme:1, Feed: pure E with concentration 10 kmol/m3
Case 6: Reaction Scheme:2, Feed: pure A with concentration 10 kmol/m3
At first sight, the cases look formidable. With 6 species involved, the
concentration space is of a much larger dimension than we discussed so far.
ARs could thus also be of higher dimensions than we are comfortable with.
However, you are asked to only state the dimension of AR in each case and
construct only ARs of dimension 2 or less. As you think more, these cases are
not beyond your reach.
We will discuss the cases a bit more and then leave the rest to you once the
solution seems attainable.
The series reactions are alternately of zero and first order. Let us consider Case
1.
The first reaction is of zero order and feed is pure A. The rate of consumption of
A to form B is very high due to high value of the rate constant of the zero order
reaction. B will thus be formed rapidly and till A is present. B will simultaneously
react to C as per first order kinetics. B will not be consumed entirely at any time,
except in a reactor with infinite space time. Concentration of any species cannot
exceed the feed concentration of A for the given stoichiometry. Concentration of
C that is formed is thus always less than 10 kmol/m3. Rate of consumption of C
to form D by zero order reaction is more than rate of formation of C from B for the
given rate constant values. Therefore, C will not be there in the reaction mixture
at any time. The reaction C D is thus instantaneous for all practical purposes
Case 3 has pure C as feed. The first two reactions and species A and B are thus
irrelevant. The curtailed reaction is C D E F which further reduces to C
D F. The first reaction is zero order and the second first order. We have
handled AR for this series reaction previously, although for different values of
rate constant and different feed composition. You have to only do it for given rate
constant values and feed composition.
Case 4 has pure D as feed and the first three reactions and species A, B, C are
thus redundant. The effective reaction scheme is a single zero order reaction D
F. AR is 1-D and a straight line joining points (10,0) and (0,10) in D-F
concentration space.
Case 5 is anyways a single zero order reaction E F with similar 1-D AR in E-F
concentration space.
You thus essentially develop ARs for cases 2 and 3. Both are series reactions
and have been handled by us earlier. See if you can explore case 1 more.
Cases 6-10 can now be tackled successfully by you. You will surmise that the
ARs are respectively 3-D, 3-D, 2-D, 2-D and 1-D (Be careful). The 2-D and 3-D
ARs are similar to corresponding ARs for the earlier 5 cases.
The definition of AR given earlier is the most commonly used. One can however
extend it further by removing some restrictions one by one. For example, can we
develop AR for a case where more than one different feed compositions are
available? Similarly, can we develop AR for the case where a reactor of given
size is available and must be the only reactor to be used? We are basically trying
to find out what happens to the AR if there are constraints on resources such as
feed and reactor vessels. This is important because we ultimately want to use AR
for reactor design. There is no practical situation where there are no constraints
on resources.
On the A-B concentration space, the compositions attainable from the first feed is
a straight line joining (1,0) and (0,1) points. From the second feed, any
composition on line joining (1,0.2) and (0, 1.2) is attainable. For the individual
feeds, the ARs are 1-D as expected. But if both the feeds are available, the AR
will be a parallelogram bounded by these two straight lines (Figure 17). The AR
is thus 2-D. Any composition within the parallelogram is attainable by suitably
mixing the two feeds and processing the combined feed to a certain conversion
in a suitable reactor. It is also possible to process two feeds in two separate
reactors and then mix the products to achieve the desired composition.
If a restriction is put that the feeds should not be mixed at all prior to reaction, but
a feed could mix with product formed in reactor using another feed, what will be
AR? If an additional restriction is put that you can employ only one reactor, what
will be the AR? Think hard on this.
What is important to note is that the availability of alternative feeds has increased
the dimensionality of AR. 1-D AR for a single feed and for given reaction became
a 2-D AR if two feeds are available. So, what happens if we have 3, 4 or more
feeds available? What will happen if in the above case, we had another feed also
available with concentrations of A and B as 0.6 and 0.2 kmol/m3 respectively? Do
we get a 3-D AR?
CF (Kmol/m3)
1.2
Feed 1
Feed 2
0.8
0.4
0
0
0.5
CE (Kmol/m3)
That was of course a stupid question. The AR is 2-D in this case as you can
verify. It is not a parallelogram, but is a polygon with three vertices as three feed
compositions and other points obtained by infinite time composition with
individual feeds. The ARs with other restrictions on mixing and on number of
reactors could be different.
Example 7: Feed stream of pure A with concentration 8 kmol/m3 is available. A
CSTR of volume 25 m3 is also available and must be the only reactor used for
carrying out the following reaction. A B C. Both the reactions are zero order
with rate constants 16 and 8 kmol/m3/hr for the first and the second reaction
respectively. Construct an AR.
We have handled series zero order reactions earlier. The only new thing here is
that the reactor has to be a CSTR of given size. In any case, reactor type (PFR
or CSTR) makes no difference for zero order reactions. So, the only effective
restriction is the reactor size. However, by adjusting the feed rate through the
reactor, any space time can be achieved. Therefore, as far as AR is concerned, it
is no restriction. Therefore, AR can be constructed as earlier.
CB (Kmol/m3)
0
0
4
CA
(Kmol/m3)
Now let us consider a little variation in this example as follows and construct an
AR.
We are seeing a restriction on feed availability for the first time. This is not as
trivial a change as it appears. There is a devil in it. It would be nice if you mull
over this example for a day and then read ahead.
The AR without any restriction on feed availability was given in Figure 18. With
the given restriction on feed availability, the AR will be a part of this AR.
In the present case, there is only one reactor vessel. Therefore there is no
possibility of reactors in parallel. What is possible is only a bypass reactor. But,
there is a restriction on how much feed can be mixed with the reactor product
due to limitation on the total feed availability. Both the basic arguments used in
constructing AR are thus challenged in this example.
Let us see what part of the reactor line is attainable in this case out of the reactor
line comprising of a straight line joining (8,0) with (0,4) and another straight line
joining (0, 4) with (0,0) in Figure 36.
The minimum reactor space time that is achievable is when the entire feed
passes through the available reactor. With maximum feed availability as 50 m3/hr
and reactor size fixed at 25 m3/hr, the minimum space time that can be achieved
is 30 minutes. Reactor operation at space times from 0 to 30 minutes are thus
not feasible. This range was represented by the straight line portion joining (8,0)
to (0,4) in the previous case. The only portion of the reactor line that is attainable
by processing part or full feed through the available reactor is thus the line (0,4)
to (0,0) in Figure 19.
Now consider the reactor operating different flow rates to achieve different space
times from 30 minutes (all feed through reactor) to higher space times.
With 30 minutes, the only point attainable is (0,4). Let us operate the reactor at
40 minutes space time. A feed rate of 37.5 m3/hr will thus pass through the
reactor. The product will be a point (0, 8/3) in the A-B concentration space of
Figure 19.
This reactor product can be mixed with a bypass flow rate not exceeding the
balance available feed (12.5 m3/hr). If the entire balance (12.5 m3/hr with A, B, C
concentrations of 8, 0, 0 kmol/m3 is mixed with a reactor product of 37.5 m3/hr
with concentrations of A, B, C as 0, 8/3, 16/3 kmol/m3. the resultant stream will
CB (Kmol/m3)
0
0
4
CA(Kmol/m3)
If these arguments are used for other reactor space time possibilities, the
attainable region for a reactor with bypass seems to be the triangle joining
vertices (0,4), (0,0) and (4,0) on the A-B concentration space. Is this then the
attainable region? It is convex alright. But can AR exclude the feed point which is
always attainable?
operating at space times larger than 60 minutes (i.e. flow rates smaller than 25
m3/hr). If smaller flow rates are processed through the reactor, larger quantities
will be available for bypass. This will mean that we can attain points on the CA
axis to the right of (4,0) point also. For example, if we process only 12.5 m3/hr in
the reactor, we get a space time of 2 hr. All A and B would have reacted to give
C. The product will have concentrations of A, B and C as 0, 0, 8 in that case. This
will then be mixable with 37.5 m3/hr of feed to get a combined product of
concentrations (6, 0, 2). If lesser and lesser feed is processed through reactor
leaving larger and larger feed flow rates for bypass and mixing, we can attain
concentrations all the way up to the feed point on the X axis in Figure 19.
The Attainable compositions are thus captured by the AR as shown in Figure 19.
The AR is thus a triangle with a line attached to it. This region is not convex. And
still the triangle and the remaining line contain the only attainable product
compositions by employing a given CSTR with feed bypass.
For the first time, we are seeing an AR which is not convex (or did you get any
non-convex AR earlier?). This can happen when there are simultaneous
constraints on reactor sizes and feed availability.
The example has placed a question mark on our confident statement earlier that
AR must be convex. True, but only if the premises which led to the need for
convexity are satisfied. And these premises were the possibility of using more
than one reactors and also using a reactor with feed bypass with no limits on
feed availability.
Non-convex ARs are rarely talked about in the literature on AR. But keep these
restrictions in mind as the restrictions have a practicality about them.
A more challenging case will be the following variation of the above example.
Example 7B: Same as 7A except that both the reactions are first order with rate
constant 1 hr-1 for both the reactions.
The AR will not be as easy to develop as for zero order reactions. Resorting to
computer calculations will be called for. However, one would expect similar
observations. Develop this AR.
We have dealt with a case of two feeds earlier. We also dealt with a case of AR
with limitation on feed availability. Let us combine the two in the following
example, which is amenable to simpler calculations but will require excellent
analytical skills.
Example 8: For the following reversible reactions, develop AR for given feed
compositions, feed availability and desired production rates. The reactions are all
reversible and reach equilibrium as soon as appropriate conditions (temperature,
presence of catalyst etc.) are created.
Feed I:
Feed II:
Feed III:
Feed IV:
It is actually a trivial problem. It may be noted that all feeds have the same total
concentration (4 kmol/m3). The given reactions do not change the number of
moles. Therefore, any product obtained by mixing the available feeds before
and/or after reaction will also have the total concentration of 4 kmol/m3. Given the
concentration of any two components in any feed or product stream, the third
concentration is thus easily calculated. Representation on a 2-D concentration
space (such as given A-B space) is thus adequate.
For this choice, the four feeds are at 4 points (0,0), (1,0), (1,1) and (0,1) as
shown in Figure 20. All are available at a maximum rate of 12 m3/hr.
Equilibrium constants are given for the first two reactions. The same for the third
reaction can be deducted easily as 0.5.
Any feed or any mixture in any proportion of any number of feeds, if pushed
through a reactor reaches equilibrium instantaneously. The equilibrium
composition can also be deducted from the equilibrium constants as CA0 = 1, CB0
= 1, CC0 = 2. It is the same as Feed III corner in Figure 40, i.e. point (1,1) in the
A-B space. Any feed stream can thus be converted to a composition same as
that of Feed III by reaction.
Since, we must have a production rate of 48 m3/hr, we need to us all the four
feeds at their maximum availability. AR will be the region, any concentration in
which is attainable by reaction and or mixing.
reason. To generate AR, we thus do not need much calculations, but some
geometrical interpretation of the feeds occupying four corners of our
concentration space. Think along the following lines to get the AR.
If we decide not to employ any reactor and simply mix all the feeds available, we
will get a stream at 48 m3/hr with concentration represented by point (0.5,0.5).
That is, concentrations of A, B and C as 0.5, 0.5 and 3 kmol/m3. This is thus an
attainable point. Similarly, if we react Feed I and II and mix the product with Feed
III, we have a stream represented by (1,1) at 36 m3/hr. If this is mixed with Feed
IV at 12 m3/hr, we get 48 m3/hr of a stream represented by point (0.75, 1.0) on
the A-B concentration space. Similarly, composition (1, 0.75) is attainable. If we
react Feed II to equilibrium, we have 24 m3/hr of stream with composition
represented by (1,1). If we mix Feed I and IV, we get 24 m3/hr of stream with
composition represented by point (0,0.5). If we mix these two streams, we get 48
m3/hr of stream with composition (0.5, 0.75). Similarly point (0.75, 0.5) is
attainable. Thinking on these lines, you can arrive at the AR as shown in Figure
20.
You can check that no composition outside this AR is attainable by any scheme.
Using the above as a way to construct AR in this case, let us now look at some
variations of the problem. We only change the production rate that we want to
achieve.
CB (Kmol/m3)
0
0
0.5
CA (Kmol/m3)
Example 8A: Same as Example 8 except that the desired production rate is 36
m3/hr.
We thus have now surplus feed available. This will allow us more flexibility in
reaction and mixing and we expect the AR to be a larger area as compared to
AR for Example 8. Develop the AR and verify that it is as shown in Figure 21.
CB(Kmol/m3)
0
0
0.5
CA(Kmol/m3)
Example 8B: Same as Example 8 except that the desired production rate is 24
m3/hr.
Example 8C: Same as Example 8 except that the desired production rate is 12
m3/hr.
Example 8D: Same as Example 8 except that the desired production rate is 6
m3/hr.
CB (Kmol/m3)
0
0
0.5
CA (Kmol/m3)
Now let us make one small change to the above cases. So far, we have
developed AR for some reaction scheme or the other. What if the reactive
transformations are not possible. For example, what are the attainable
compositions if only mixing of streams is allowed and reactions are not possible.
In short what is the AR in the above 5 examples if reactive change is not possible
or disallowed?
The ARs for the case where production rates are 48, 36, 24, 12 and 6 m3/hr are
jumbled up in Figure 23. Identify which one belongs to which case.
1
CB(Kmol/m3)
0.5
0.25
0
0
0.25
0.5
0.75
CA(Kmol/m3)
are left with AR for the case where reaction must be resorted to or a reactor must
be employed. Note that these ARs are not convex. We thus got another example
of non-convex ARs.
We have so far played with almost all possibilities: single/multiple reactions (in
fact reaction and no reaction), irreversible/reversible reactions, different orders of
reaction, single/multiple feeds,
variable/fixed reactor sizes etc. This must give confidence that AR can be
developed although at times calculations may be involved. The examples also
took us through zero, first, second and higher dimensional ARs. With this feel for
ARs, one can now appreciate reaction schemes and ARs that have caught
attention of researchers. Most of these reactions are series-parallel, a
combination we have not considered explicitly. To create challenging problems
for research, authors have played with the structure of reaction schemes, orders,
types of reactions, feed compositions and rate constant values. This has given
rise to extraordinary examples, some of which inherit the names of the
developers. These reaction schemes are called model reactions, the famous
ones being van de Vusse, Denbigh, Tramboze reactions etc.
It is not the purpose of this primer to dwell on these examples. The objective of
this compilation was to prepare you to appreciate these higher complexity
examples, should you choose to work in reactor network domain. In any case,
can anyone do better than Prof. Glassers creation of van de Vusse reaction and
its AR? That must be read in original and appreciated as such.
launches into calculations. Let us understand this with some of the reaction
schemes we used in the examples discussed so far.
Example 1 had a simple irreversible reaction A B. To appreciate the
dimensionality of AR, one should simply write the net rate of formation of each
individual species from all the reactions. In the present case, we have two
species A and B. The rates of formation of A and B per unit volume are as
follows.
dC A
= k CA
dt
dC B
= k CA
dt
where k is the reaction rate constant. The dimensionality of the AR for a single
feed is the number of species whose concentrations are involved in some or all
the rate expressions for all the species together. In the above case, only
concentration of A is involved in the expressions and hence the AR is one
dimensional, i.e. a straight line. This is what we observed earlier also.
This holds true for Example 1A and 1B also. In Example 1C where the reaction
was second order, only the concentration of A will be raised to power 2 in both
the expressions. However, number of concentrations involved is still 1 and AR is
1-Dimensional.
dC A
= k1 C A + k 2 C B
dt
dC B
= k1 C A k 2 C B
dt
Two concentrations are involved on the right hand side of the rate expressions.
The AR should thus be 2-D. However, it should be noted that the stoichiometry
demands that the total concentration of A and B at any time must be the same as
total concentration of A and B in the feed. Therefore, concentration of B can be
expressed in terms of the feed concentration and the concentration of A.
Therefore, the rate expressions have only concentration of A on the right hand
side and the AR is 1-D as we found out earlier.
We also considered AR for the cases when there were more than one feeds. In
such cases, the dimensionality of AR could increase by one as was seen in some
examples. Except for these special cases where reversible reactions are involved
and feed is at equilibrium itself or where there are multiple feeds, the
dimensionality of AR can be deducted from the rate expressions for all the
species.
You can check this logic with so many other examples we considered.
Now let us see how the AR can be used for designing the reactor networks for a
given task. This is the main practical reason why one would develop AR.