38

Fixed bed Reactors

Keywords: Void fraction, Pressure Drop, Axial Dispersion model

Catalytic reactions are generally carried out in fixed bed reactors, because of
simplicity of technology and operation. This simplicity is evident for adiabatic
reactors, but when important heat of reaction is involved, heat exchange may be
preferable, for optimum operation, to avoid runway and catalyst deactivation.
Thus heat transfer is very often the major problem encountered in design of
fixed bed reactors.
Three important classes of non adiabatic reactors are as follows:
Multiband adiabatic reactors with intermediate heat exchange leading to
non-sinusoidal waveform temperature profiles.
Reactors with internal multitublar heat exchangers.
Multitublar reactors.
The last two are generally preferred to the multibed adiabatic reactor when
highly exothermic or endothermic reactions take place, or when an optimum
temperature profile is desirable.
Another aspect is the pressure drop through the bed. In order to limit it, larger
catalyst particle may be used, but diffusion limitations will also increase.
Classification of models:
Fixed bed reactors are essentially described by continuum type model, but cell
models have been developed to account for the two phase structure of the
reactor. Most catalytic reactions are classic axial flow reactions, the most
reliable model are classic continuum model.
According to Froment & Bischoff, these continuum model may be classified in
two general categories depending on the direction is made between the fluid and
solid phases.
Pseudo-homogeneous model(PH)
[Temperature and concentrations are supported to be identical in both
phases at a given position in the reactor].
Heterogeneous model(HT)
[Account for temperature and concentrations gradients inside and around
the catalyst particle].
Each category is classified in different types of model based on more and more
sophistication involved in description of flow & transfer phenomenon.
Pseudo-Homogeneous Models:
The basic one dimensional model
In the one dimensional model, uniformly is assumed in a cross section of the
reactors.

u + r =0 ...38.1
( )
u C +4 r (H) = 0 ...38.2

= u f/gd ...38.3

With given entrance conditions at

z 0, c = c ,T = T , P = P
These coupled equations can be easily solved by the Runga-Kutta method. The
only characteristic parameter is , the heat transfer coefficient between the bed
and the internal wall. An accurate estimation has been given by De Wasch and
Froment.

= + 0.033 ...38.4

Where a static heat transfer coefficient is introduced:

 /
= 2.44 /d ...38.5
Where is the static contribution to the effective radial conductivity, to be
discussed in the two dimensional pseudo-homogeneous model.
The friction factor f, involved in the pressure drop equation may be evaluated
by the Ergun equation modified by Mc Donald et.al.
f 1 1 . 8 1 8 0 (1 ) / R e
...38.6

This relation derived with spherical particles, is still valid for other shapes
provided that void fraction does not exceed 0.5 and using the equivalent
diameter.

d =6 ...38.7

Void age of bed

V =Volume of catalyst pellet,m3
P
S =Extended surface area of catalyst pellet, m3
P
a Bed to wall heat transfer coefficient, W/(m2-K)
t
d Tube diameter, m
t
=Catalyst bulk density, kg/m3
=Density of gas, kg/m3
d = Particle diameter, m
p
U Superficial velocity of gas, m/s
= Conductivity of gas, W/ (m-K)

Axial dispersion model

A diffusional term is added in the mass and heat transfer equations, involving
effective axial transport Dea and ea
D u r =0 ...38.8

d 2t dT
u C u (T T ) / d r (H ) 0 ...38.9
ea dz 2 G p dz t w t ma
The pressure drop equation of Eq. (38.1) is not modified.
Boundary conditions for a closed diffusion reactor are
Atz 0,

u(c c) = D ...38.10

u C (T T) = ...38.11
Atz L ;
R

=0 ...38.12

=0 ...38.13

The solution of equation (38.1) to (38.6) can predict possible multiple steady
states in very shallow beds when very exothermic reactions with high activation
energy are carried out.
According to Young and Finlayson, axial dispersion may be neglected when

( ) Pe

...38.14
And
[(H)r d /u C (T T )] Pe
These conditions are valid only when the reaction rate is maximum at the inlet.
If not they are changed to:

Pe dx d(z/d ) ...38.15a

d(TT )
Pe d(z/d ) ...38.15b
Pe = Peclet number.

Two dimensional models with the velocity profile:

In this model the hypothesis of uniform concentrations and temperature in a
cross section is no longer verified when very exothermic reaction are carried
out, due to the finite radial heat and mass transfer inside the bed. The radial
flumes are expressed in terms of effective radial transport parameter
and D . These overall coefficients lump together several contributions,
molecular and turbulent motion, and deviation due to particles.

Heat transfer is even more complex, because of the solid phase and various
radiation effects
= + ...38.16
The dynamic contribution has been correlated by De Wasch and Froment
(1972) as

= 0.0029 /[(1 + 46( )) ] ...38.17

The static contribution has been described by a complex model due to Kunii &
Smith on the basis of electrical energy.
Transfer through the fluid in the voids
a) Conduction
b) Radiation from void to void
Transfer involving the solid phase:
a) Conduction through the particles
b) Conduction through the contact surface between the particles
c) Conduction through the film near the contact surface
d) Radiation from particle to particle
Another complication in the use of 2D model is the supposed decrease of
near the wall owing to fixed bed structure. Thus a supplementary wall interface
heat transfer is introduced, by a wall coefficient so that

= (T T) ...38.18

At = 2

The overall coefficient of 1 Dimensional models include wall resistance are

radial diffusion through the bed. The two heat transfer coefficient are thus
related by

= + ...38.19

In the case where volume change, pressure drop and axial dispersion may be
neglected, the steady state model equations are:

+ =0 ...38.20

+ ( ) = 0 ...38.21

Atz 0; c c ,T T r 0;
o o

r 0; = =0