Introduction to Packed Bed Reactors

(With Fixed Bed as Catalyst)

Topic 8
Ch.E. 422
Reference: ECRE by Fogler (pp. 170-187)

After this topic, you should be able to:

Describe the types and enumerate

some applications of a Packed Bed
Reactor (PBR);
Set up a mole balance for a steady
state PBR with the fixed bed as
catalyst;
Set up and apply pressure drop
equations across the same PBR.
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Packed Bed Reactor

Reactants are continuously
fed to a packed bed which
could be a catalyst or
another reactant. Reaction
takes place across the bed
and products exit at the
other end. The bed may be
stationary (fixed) or moving
(fluidized).

Fluidized Bed Reactor

Mole Balance for a steady state

PBR for a Product A

W = weight of catalyst

rA' in Mole A/weight catalyst-time

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Mole Balance for a steady state

PBR for a Product A

For A as reactant:

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Mole Balance for a steady state

PBR for a Product A in terms of XA

dFA FAo dX A

FA FAo (1 X A )

W1 FAo

X A1

dX A
rA '

Integral may be solved if rA may be expressed in

terms of XA or data of XA and rA is available.
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Summary of Reactor Mole Balances in

terms of Conversion, XA (For Finals)
Reactor

Batch

Differential

dX A
N A0
r AV
dt

PBR
8

Integral

t N A0

XA

XA

dX A
rAV

FA0 X A
V
rA

CSTR

PFR

Algebraic

dX A
FA0
rA
dV

dX A
FA0
rA
dW

V FA0

X Af

W1 FA0

dX A
rA

X A1

XA
dX A
rA

Volumetric Flow Relations

in a PBR and PFR
Applying Continuity Equation: mass flow rate = constant
m m0 = mass rate symbol

00 (mass rate = density x volumetric rate)

FT M FT 0M0 (mass rate = molal rate x Molecular Weight)

For Liquids, assume incompressible or =0 ; = 0

For Gases: assume ideal gas behavior

0
0

M0 FT

M FT 0

PM
RT

P0M0
RT0

P0 M0 T
P M T0

FT P0 T
FT 0 P T0
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Volumetric Flow Relations

in a PBR and PFR (Gas System)
FT P0 T
0
FT 0 P T0
Recall Batch Relation between Total Moles with Conversion, XA:

NT NT 0 (1 A X A )
For a Continuous Flow Reactor:

FT FT 0 (1 A X A )

FT
1 A X A
FT 0

0 (1 A X A )

P0 T
P T0
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Concentration Relations
Concentration for Flow System:

Gas Phase Flow System:

FA
CA

T P0
0 1 A X A
T0 P

FA0 1 X A
CA0 1 X A T0 P
CA

1 X T P0
1 A X A T P0

0
A
A
T0 P
FA

For: aA + bB -> R

b
b

FA0 B X A
C A 0 B X A
T0 P
FB
a
a

CB

P
T
1 X
1 A X A T P0
0

0
A
A
T0 P

CBo
B M
CAo

Pressure Drop in Packed Bed Reactors

Conducting a Gaseous Decomposition
Decomposition Reaction: a AB
Mole Balance:

Rate Equation:

dX A
FA0
rA
dW
n

rA kCA

Unit of k A : (Volume n /moln 1) / kg catalyst-time

Pressure Drop in Packed Bed Reactors

Conducting a Gaseous Decomposition
Stoichiometry:

Isothermal, T=T0

Combine:

CA

FA

CA0

1 X A

P T0
1 A X A P0 T

1 X A

P
CA CA0
1 A X A P0
dX A
kA

dW
FA0

1 X A P

CA0

X
P

A
A
0

Need to find (P/P0) as a function of W for Gas System

Pressure Drop in Packed Bed Reactors

Ergun Equation:

dP
G 1 1501
3

1
.75
G

dz g c D p
Dp
TURBULENT
LAMINAR

P = pressure (psf) varies with z

z = distance from reactor entrance
= porosity = volume of void/total bed volume = constant
1- = volume solids/total bed volume = constant
gc = 4.17 x 108 (lbm-ft/hr2/lbf)
Dp = particle diameter (ft) = constant
= gas viscosity (lbm/ft-hr) = f( T)
G = superficial mass velocity of gas (lbm/ft2-hr) = constant
= gas density (variable with T, P, FT)

Pressure Drop in Packed Bed Reactors

Ergun Equation:

0
0

dP
G 1 1501
3

1
.75
G

dz g c D p
Dp
TURBULENT
LAMINAR

FT P0 T
0
FT 0 P T0
1

0 FT P0 T

FT 0 P T0

1 FT P0 T
0 FT 0 P T0

P0 T FT
dP
G 1 1501
3

1.75G
dz 0g c D p
Dp
P T0 FT 0

Pressure Drop in Packed Bed Reactors

P0 T FT
dP
G 1 1501
3

1.75G
dz 0g c D p
Dp
P T0 FT 0

Let

G 1 150 1
0
1.75G
3
0 g c Dp
Dp

Unit of 0 : Pressure/length (e.g. kPa/m)

P T FT
dP
0 0
dz
P T0 FT 0

Relation Between W and z

Catalyst Weight W zAcb zAc 1 c
Ac cross sectional area
z = distance from reactor entrance

b bulk density of the solid (with void volume)

c = density of solid catalyst
= porosity or void volume fraction
1- = solids volume fraction
dW Ac (1 )c dz
dz

dW
Ac (1 )c

Relation Between P/Po and W

From the Ergun Equation:
P0 T FT
dP
0
dz
P T0 FT 0

dW
but: dz
Ac (1 )c

0
P0 T FT
dP

dW A c 1 c P T0 FT 0

Let

2 0
1
Ac 1 c P0

Unit of : 1/mass

dP P02 T FT

dW
2 P T0 FT 0

Pressure Drop in Packed Bed Reactors

dP P02 T FT

dW
2 P T0 FT 0
d P
P0 1 T FT
dW
2 P T0 FT 0
P0

But: FT FT 0 (1 A X A ) or

d P P0
dW

Let y =
0

FT
1 A X A
FT 0

1 T

1 A X A
2 P P0 T0

dy
T

1 A X A
dW
2y T0

Pressure Drop in Packed Bed Reactors

dy
T

1 A X A
dW
2y T0

Isothermal case:

dy

1 A X A
dW
2y

Pressure Drop in Packed Bed Reactors

Applied to a Gaseous Decomposition
dX A
k
A
dW
FA0

1 X A P

kA
C

A0

1 A X A P0 FA0

1 X A

y
CA0
1 A X A

dy

(1 A X A )
dW
2y

The two expressions are coupled ordinary differential

equations. We can only solve them simultaneously
using an ODE solver such as Polymath. For the special
case of isothermal operation and = 0, we can obtain
an analytical solution.

2
1

Polymath will combine the mole balance, rate law and

stoichiometry.

Special Case where A = 0

dy

(1 A X A )
dW
2y
For

A 0

dy

dW 2y
2y dy dW
When

W 0

2y dy

y 2 1 W
y (1 W )1/2

y 1

dW

Exercises:
1. Consider the elementary, isothermal gas phase decomposition:
2 A -> B +C taking place in a 20 m 1.5 Sch. 40 pipe packed with a
catalyst. The flow and packed bed conditions are as follows:
Po = 1013 kPa vo = 7.15 m3/hr
Solid catalyst density: 1923 kg/m3
Porosity = 0.45
Cross Sectional Area of Pipe: 0.0013 m2
Pressure Drop Parameter o = 25.8 kPa/m
Entering Concentration: 0.1 kmol/m3
Rate constant (k) : 12 m6/kmol-kg-cat-(hr)
a) Calculate the Final Conversion neglecting the pressure drop
b) Calculate the Final Conversion considering the pressure drop
c) Determine how Answer in (b) will change if Dp is doubled.

UST Ch.E. Department

Exercise 1
2AB +C

1) Mole Balance: dX rA
dW FA 0

1 X P
1 X
CA 0
CA CA 0
y
1 X P0
1 X
1 X 2
rA kC
y

1 X
2

2) Rate Law:

2
A0

Polymath Solution with y = 1

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Polymath Solution with y = 1

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Polymath Solution with y

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Polymath Solution with y

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Exercises:
2 . Consider the elementary, isothermal gas phase decomposition:
A + B -> 2C taking place in a fixed bed catalyst reactor under the
following conditions:
CAo = CBo = 0.2 M
FAo = 2 mols/min
Rate constant (k) : 1.5 dm6/mol-kg-cat-min
= 0.0099/kg
Weight of Catalyst = 100 kg

a) Calculate the Final Conversion and Final Pressure

b) Determine how Answer in (b) will change if Dp is doubled and
the entering pressure is reduced by 50%.

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Example 3: Gas Phase Reaction in

PBR for = 0
Gas Phase Reaction in PBR with = 0
(Polymath Solution)
A + B 2C
Repeat the previous one with
equimolar feed of A and B and
kA = 1.5dm6/mol/kg/min
= 0.0099 kg-1
Find X at 100 kg

3
0

Exercise 2: Gas Phase Reaction in

PBR for = 0
A + B 2C
dm 6
k 1.5
mol kg min

0.0099 kg 1

Case 1: W 100 kg

X?

Case 2: DP 2DP1

1
P02 P01
2

P?
X?

P?

Polymath Solution

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Polymath Solution

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Exercises:
3 . Consider the elementary, isothermal gas phase decomposition:
A + 2B -> 2C taking place in a fixed bed catalyst reactor under the
following conditions:
CAo = 0.2 M; CBo = 0.4 M
FAo = 2 mols/min
Po = 10 atm
Rate constant (k) : 6 dm9/mol2-kg-cat-min
= 0.02/kg
Weight of Catalyst = 100 kg
a) Calculate the Final Conversion and Final Pressure
b) Determine how Answer in (b) will change if Dp is doubled and
the entering pressure is reduced by 50%.

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Exercise 3: Gas Phase Reaction in

PBR for 0
Polymath Solution

A + 2B C
is carried out in a packed bed reactor in
which there is pressure drop.The feed is
stoichiometric in A and B.

Find the conversion and pressure ratio y =

P/P0 for a catalyst weight of 100 kg.

Additional Information
kA = 6dm9/mol2/kg/min
= 0.02 kg-1
3
5

Polymath Solution

UST Ch.E. Department

Polymath Solution

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Engineering Analysis

Engineering Analysis

Engineering Analysis