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METZNER
University of Delaware, Newark, Del.
Reaction Rates in . .
Nonisothermal Catalysts
Temperature gradients within a catalyst particle can be important factors
in a chemical reaction. “Effectiveness factors” for nonisothermal catalyst
particles will be useful in achieving optimum reactor design and operation
I N THE DESIGN AND OPERATION Of as only a few sample calculations were sures of about 10 atm. (77) ; as similar
chemical reactors using porous catalyst made, no general design criteria were conditions of pore size prevail in most
pellets, rates of both mass transfer and developed. Pigford and Tinkler (9) good catalysts this mechanism is one
of some generality, and it is for this
chemical reaction must be considered. considered the case in which the tem-
case that the assumed temperature and
Because of resistance to mass transfer perature difference across the pellet is concentration independence of the
within the catalyst structure, diffusion of small but not negligible. By means of a diffLisivity is either a good approxirna-
reactants and products into and out of perturbation technique, they developed tion or a well established fact, re-
the pellet is often the slow or rate-control- a simple extension of Thiele’s result to spectively. Transport by thermal dif-
ling step. As a result, the reaction rate account for heat generation in the case of fusion and by surface migration of
may be much smaller than it would be a first-order, irreversible reaction inside physically adsorbed layers is ignored
if a diffusional resistance were not a spherical pellet. in this work. The latter may not be
present, I n the work reported here the non- small under low temperature con-
ditions, but as neither its importance
The effectiveness factor, first used by linear differential equations expressing nor mechanism is well defined at
Thiele (74) in 1939, is defined as the conservation of mass and energy for the present time no alternative as-
ratio of actual conversion rate to the reactions in nonisothermal particles sumption is possible.
rate which would occur if reactant were considered. Solutions were ob- .Heat transfer within the particle
concentrations everywhere inside the tained for first- and second-order ir- occurs by conduction through the
pellet were the same as a t the surface. reversible reactions taking place in spheri- solid portion of the pellet only.
Equations for the effectiveness factor cal catalyst pellets. Calculations were Simple calculations show that the
have been derived by Thiele and by also made for a first-order reaction tak- additional enthalpy transport of the
Wheeler (77, 78). However, in both ing place in a “flat-plate,” to obtain gases is negligible unless heat capacities
of reaction products differ enormously
cases it was assumed that the catalyst some insight into the effect of particle from those of the reactants. This
particle is isothermal and, therefore, geometry. The reader may compare the would require that the heat of reaction
that the reaction rate constant does not present results with those obtained in- be a much stronger function of tem-
vary with position. dependently and approximately simul- perature than for any catalytic reac-
Prater (10) has pointed out that a taneously by Carberry (6) and Weisz tion known a t the present time.
significant temperature difference may (76)* .Constant values of the thermal con-
exist between the interior and the ductivity and heat of reaction are
surface of the pellet because of the heat used. These approximations are ex-
of reaction. For instance, in dehydro- Working Equations pected to be excellent under the con-
ditions encountered.
genating cyclohexane on a platinum-
Derivations of the differential equa-
.The temperature dependence of the
alumina reforming catalyst, Prater esti- reaction rate constant is expressed
mated that the center temperature may tions are based upon the following as- by the Arrhenius equation.
be 53’ C. lower than that of the sur- sumptions : .Specific reaction rate and stoichio-
rounding fluid. Obviously, the assump- metric expressions must be chosen.
tion of no temperature gradients within 0 Catalyst particles have a porous, The problems analyzed herein are for
the pellet is not valid here. Thus, homogeneous structure in which the first- and second-order reactions
a theory which accounts for heat as catalytic activity per unit area is whose stoichiometry and mechanism
independent of position in the par- are both given by:
well as mass transfer is needed. The ticle.
nonisothermal effectiveness factor is 0 Surface concentrations of reactants
defined as the ratio of conversion rate and surface temperature are known.
to the rate which would occur if both If external resistances to mass and
reactant concentrations and temperature heat transfer exist, the surface con- Since the common application of
were the same everywhere inside the ditions may be calculated by means of these equations is in catalysis of gaseous
pellet as a t the surface. transfer coefficient correlations pre- reactants, concentration terms are ex-
Schilson ( 7 7 ) calculated the effective- sented in a variety of standard ref- pressed in terms of partial pressures for
ness factor, as well as intraparticle erences and recent reports (3,5,8,73). convenience of application. However,
0 Mass transfer within the pellet no restriction to gaseous reactants or
temperature and concentration profiles, occurs by diffusion only and may be
by solving an integral equation by the expressed by means of a constant products is either intended or necessary,
method of successive approximations. diffusion coefficient. I n many com- and the results may be directly applied
This approach clearly illustrates the mercial silica-alumina catalysts, Knud- to liquids by making self-evident and
magnitude of the effects involved, but sen diffusion prevails up to gas pres- consistent changes in the concentra-
v = -3(d6jdp),=1.0 (16)
Equation 10 becomes
in which (dO,'dp),= 1.0as evaluated from
1 d Equations 13 or 14 will be a function
of cy and p.
(where f; is the rate of formaiion of (11) The classical result of Thiele ( 7 4 ) is a
component i caused by reaction per special case of these equations cor-
unit volume and v i is the whole number where 01 = R2k, P.4z-1/DA, a dimen-
responding to 0 = 0. Thus, for the
stoichiometric coefficient of component sionless parameter. The ratio of rcac.ion-
rate constants may be expressed as a first-order case, integration of Equation
i in the general chemical reaction, 13 produces :
Zv,Mi = 0 ; vi is positive for products, function of dimensionless temperature
negative for reactants. The value of by means of the Arrhenius equation: e = sinh d i p 1
(17)
the ratio, fi/vi, is the same for all com- ap sinh +
nA+B n = l , 2 (6) is a function of only two parameters, 1 and 2 for the case of spherical ge-
then fB = k P.kn v.t, = --n vg = +1 a and 0. (If the simplifying assumption
employed in Equation 12 were not used,
ometry :
(7) a third parameter would necessarily
Substitution of these relationships appear.)
into Equations 2 and 5 gives: The effectiveness factor of the catalyst
particle is given as:
1.00 I .oo
F F
0 IO 0.10
\I \
EAHPA, DA Y.
1111 I i i I
mTe2X
BROKEN LINES INDICATE
BROKEN LINES LNDICATE EXTRAPOLATED REGION
EXTRAPOLATED REGION
I
0.01
0.2 I .o 10.0
Figure 1. Values of a and E determine magnitude of Figure 2. For a second-order reaction within a spherical
effectiveness factor for first-order reaction within a spherical pellet, the effectiveness factor curves change shape
pellet
iManipulations similar to those used in ever, accuracy must be examined iiide- reduced to a small fraction. Throughout
the case of spherical geometry give, in pendently because it is a function of the this range analytical and analog solutions
dimensionless form : type of equation being solved, electronic agree very well.
circuit used, and transformation scale To illustrate his numerical procedure,
factors, as well as being dependent Schilson worked several sample hypo-
on the approximation introduced by thetical problems using fictitious nu-
Equation 12. Analog computer solu- merical values. Only two of his prob-
tions are compared with the analytic lems are within the range of variables
solutions of Thiele (74) and two numeri- likely to be encountered in practice and,
Again, for the special case /3 = 0 the cal solutions of Schilson ( 7 7) in the table therefore, included in the present cal-
equations may be solved analytically, for spherical pellets and for first- and culations. The results are presented
and one obtains Thiele's result: second-order, irreversible reactions. as cases 5 and 6 in the table. For
I n cases 1 through 4, cy values extend case 5 , in which Schilson considered
17 =
tanh
~-
l/o( (23)
from the kinetically controlled region, in the temperature dependence of the Knud-
6- which the effectiveness factor is approxi- sen diffusion coefficient, the coefficient
mately unity, to the diffusion-controlled evaluated at the surface temperature is
Results region, in which the effectiveness factor is used in calculating cy.
I O 0
F
aio
0 IO
0.10
I E-
EAHPAs Dn
I BROKEN L I N E S INDICATE
, 1
1 I
0.01
0.2
' E X T R A P O L A T E D REGION
I .o
I I
~ ~ I ' I
! I l l
10.0
~
1 1
~
' 1
0.01
0.2 I O IO 0
f i = R T f i
Figure 3. Effectiveness factors for first-order reaction Figure 4. Temperature a t the center of a spherical pellet
within a "flat plate" differ from those for spherical geom- for first-order reaction i s determined b y vclucs of Q and e
etry, except when E lies between - 2 and $2
I n cases 5 and 6, differences between T h e characteristic dimension in this second-cm.-atm. The thermal conduc-
analog computer solutions and numerical modulus was taken as equal to R for tivity of silica-alumina cracking catalysts,
solutions are due not only to machine the spherical pellet and as 3L for the as determined experimentally by Sehr
error but also to the approximation flat plate solution, as suggested by Aris (72),is 4 X lop3cal. per second-cm.-' C.
introduced into Equation 12 for the (2). He noted that in the "isothermal" A heat of reaction of +10 kcal. per
ratio of rate constants. This approxi- case, the effectiveness factor is nearly gram mole and an activation energy of
mation is very good for small activation independent of particle shape if the 40 kcal. per gram mole give E = 0.017.
energies and/or small temperature dif- characteristic dimension of the particle is Love and Emmett (7) studied am-
ferences across the pellet, but for the large defined as 3Vp/Sp, where V,, and S, monia decomposition on an iron am-
differences in temperature combined are volume and external surface area, monia synthesis catalyst at 387' C.
with high activation energies as en- respectively, of a single particle. and atmospheric pressure. For one
countered in these examples (AT = The introduction of a new parameter catalyst. calculated activation energy
40' C., E = 30, and 18 kcal., respec- defined as: was 31.7 kcal. per gram-mole. Using
tively), the approximation is not partic- a diffusion coefficient of 6.5 X 10-7
ularly good, and percentage error in gram-mole per second-cm.-atm., a ther-
the effectiveness factor exceeds 5%. mal conductivity of cal. per second-
However, even this is not excessive in cm.-O C., and heat of reaction of +11
view of other uncertainties generally is made so that the particle dimension kcal. per gram mole of ammonia one
involved in reactor design. appears in only one of the two param- obtains E = 0.26.
I n general, the present calculations eters required to describe the physical The vapor-phase hydrogenation of
may be assumed accurate whenever the situation. This parameter may be called benzene at 112' C. and 1 atm. on an
effectiveness factor does not exceed that a heat generation parameter, since it alumina-supported platinum catalyst was
for isothermal conditions by more than a includes the activation energy, heat of studied by Amano and Parravano ( 7 )
factor of about 2.0. At higher values, reaction, pellet thermal conductivity, who found the activation energy to be
the simplifying assumption of Equarion and surface temperature; it is negative 12 kcal. per gram-mole. The heat of
12 is no longer quantitatively valid for exothermic reactions and positive reaction, -50 kcal. per gram-mole, is
because of the large temperature dif- for endothermk reactions. To deter- unusually large. At 112' C. and for a
ferences in the pellet under these condi- mine the range of parameter values pore radius of 30 A., the effective
tions. There is no such limitation on which should be included in the calcula- Knudsen-diffusion coefficient of hydro-
the present calculations in the endo- tions to cover essentially all reactions of gen is 3.1 X 10-7 gram-mole per second-
thermic region, as the central portions of practical interest, consider the numeri- cm.-atm. Since the catalyst support is
the catalyst contribute negligibly to cal values arising in three typical kinds of alumina, the value of the thermal
over-all reaction rate under conditions reactions. conductivity for silica-alumina cracking
of a large temperature drop. M'heeler (77) considered a gas-phase catalysts may be used here. A value of
Ranges Covered. T h e Thiele modu- cracking reaction at 500' C. and atmos- B = 1.9 results.
lus, which is identical to &, was varied pheric pressure. For a molecule like I n these three examples, the absolute
over a wide range, extending from the cetane (C16H34)and a mean pore radius value of E changed by two orders of
completely kinetically controlled region of 30 A., the effective Knudsen-diffusion magnitude. For most practical cases,
well into the diffusion-controlled region. coefficient is 2 X 10-8 gram mole per the absolute magnitude of E will not
6 = R m
Figure 5. Center temperature and maximum temperature Figure 6. Midplane temperature for first-order reaction
rise for second-order reaction within a spherical pellet are within a “flat plate”
obtained from these curves