Chemical reactor

selection and design

Rajesh Kumar Bhagat

B.E.(CHE) 4th year

Introduction
Almost all chemical engineering
process contains three operations.
Unit
Raw
operation
material
(cleaning )

Chemical
reactor

Unit
operation
(separatio
n)

What does chemical reactor design

means ?

Product

Reactor System

Homogenous
Heterogeneous

Types of reactors
1.Batch- uniform composition
everywhere in reactor but
changes with time
2. Semi batch- in semi-batch
one reactant will be added
when reaction will proceed
3. Continuous reactor
a. Mixed flow- this is uniformly
mixed , same composition
everywhere, within the
reactor and at exit
b. Plug flow- flow of fluid
through reactor with order so
that only lateral mixing is
possible.

Reactor design parameter

Reactor design basically means which type
and size of reactor and method of operation
we should employ for a given conversation
Parameters

Volume of reactor
Flow rate
Concentration of feed
Reaction kinetic
Temperature
pressure

Isothermal reactor design

algorithm

Plug flow and mixed flow

reactor design
Mixed flow reactor
design
Applying mass balance
performance equation for
mixed flow reactor

Plug flow reactor

design
Performance equation for plug
flow reactor

Performance equation

Plug flow vs CSTR

For any particular duty and for all

positive reaction order the volume
of mixed flow reactor will always be
grater then plug flow
Area under curve in figure is very
small for plug flow as compared to
mixed flow so volume is small for
plug flow.
When conversion is small, the
reactor performance is only slightly
affected by flow type. the
perforation ratio very rapidly at
high conversion.
Density variation during reaction
affects design, however it is
normally of secondary importance
compared to the difference in flow
type.

Multiple reactor system

Number of plug flow reactor
in series are theoretically
same as equivalent volume
of a single plug flow reactor.
Number of mixed flow
reactor of equal size in series
may be used when we need
high conversion and cant
perform in a single reactor.
From the given graph, for
first order reaction,
conversion for series of equal
size reactor can be find

Mixed flow reactor of different

size in series

From the fig it is clear that for plug

flow reactor volume can be find by
dashed area and for mixed flow whole
area.
When we are have to use mixed flow
reactor, then we can use different size
mixed flow reactor so, that over all
volume would be small
To optimized or to find how different
size of mixed flow reactor should used
we have to maximized lower dashed
rectangle.
This optimization gives the slope of
diagonal of the rectangle should be
equal to slope of curve at intersection
of these two reactor.
Levenspiel , has proved that after
overall economic consideration equal
size reactors in series are economical.

Autocatalytic reactor

When a product will act like a catalyst

then it is called auto catalytic reaction.
In mixed flow reactor at fixed product
concentration for high yield, efficiency
of reactor will be very low.
For no recycle for low product
concentration mixed flow reactor will
be preferred and for high conversion
plug flow .
For optimum efficiency we can use a
recycle or back mixing plug flow
reactors.
For a particular exit concentration a
particular optimum recycle ratio
should be used.
Optimum recycle ratio introduced to
the reactor feeds 1/(-r) value should
be equal to average 1/(-r) value for
whole reactor.

Fig-1 Plug flow

reactor with recycle

Fig-2

Fig-3

Fig-4

Design for parallel

reaction

When a reactant gives two product

(desired, and
undesired)simultaneously with
different rate constant then this is
called a parallel reaction.
To keep maximum amount of desired
product we can take following steps.
Ifa1>a2 or the desired reaction is of
higher order then keep reactant
concentration high for high product
concentration.
If a1<a2 than for desired reaction
keep reactant concentration low.
For a1=a2 change in reactant
concentration will not affect the
product then, because rate constant
k1 and k2 are different at different
temperature so, we can keep our
temperature such that desired
product will be high or use of catalyst
would be a option which are selective
in nature.

Reactor design for

multiple reaction

In multiple reaction reactor design contacting pattern is most important

factor to get a particular product.
In irreversible reaction in series like
the mixing of fluid of different composition is the key to formation of
intermediate. The maximum possible amount of intermediate is obtained if
fluid of different composition and different stage of conversation are not
allowed to mixed.
In series of reaction if intermediate reactant is our desired product than semi
batch reactor will be used.

Irreversible series-parallel
reaction

Multiple reaction that consist of

steps in series and steps in
parallel reaction.
In these reaction proper
contacting pattern is very
important.
The general representation of
these reaction are

Here the reaction is parallel with

respect to reactant B and in series
with A.

Halogenations of alkane is a
example of this kind of
reaction where reaction is
parallel with respect to
halogen

Case study Product distribution

with respect to contacting pattern

We will discuss simpler example of

CASE-1 Add A slowly to B

By contacting A slowly in a beaker
containing B and stirring to consume
all A added , the mixer with very high
concentration in S can be find.
CASE-2 Add B slowly to A
Now by contacting B slowly to a
beaker containing A, the
concentration of R will be build up
inside then after reaching a maxima
R will convert in to S and the process
will be gradual.
CASE-3 Add A and B rapidly
In this case it will give the behavior of
series reaction , R will increase first
and after reaching a maxima it will
diminish and concentration of S will
increase.

Residence Time
Distribution

RTD is important factor from the point of

view of real equipment .
Element of fluid will take different route
through the reactor and may take different
length of time to pass through the reactor.
Ideal reactor design are made by
considering volume of reactor or time
spend by all the reactant will be same
inside reactor.
Completion of reaction will depend on
time of exposure inside the reactor.
The distribution of time inside the reactor
is called exit age distribution E, have unite
time-1.
According to RTD fraction of exit stream of
age between t and t+dt is E dt.

Residence time distribution

determination

RTD can be determined by two

experimental method.(Pulse input
experiment, and step input
experiment )
In pulse experimental method in a
steady state system we will put a pulse
input of tracer and will plot the graph
of this tracer concentration with time at
output.
This graph will show time variation or
age distribution of tracer concentration
with time.
Another method of determination of
RTD is by putting a step input
(Preferably unite step input) of tracer.
Then we can plot the graph between
the concentration versus time graph of
tracer.
The slope versus time graph of this
system will give us residence time
distribution .
Step input method is more accurate
than pulse input method although
impulse input would give the perfect
distribution.

Holding time and residence

time

Holding time is defined as time

needed to treat one reactor
volume.
Residence time or mean residence
time space time is defined as mean
residence time of flowing material
in the reactor.
From fig when inside popcorn
popper, when popping occurs at
back end of popper then holding
time and residence time will be
same.
When popping occurs in midway or
every where inside the popper then
the two time will be different.
For unchanging density system
holding time and residence time
will be equal.

Heterogeneous system
heterogeneous systems are those which consist of two or
more than two phase
Apart from temperature pressure and concentration, heat and mass
transfer are important

Catalytic systems
Non-catalytic system

Catalytic system
plug flow Reactor
Differential reactor

Integral reactor

mixed flow type

(Fluidized bed reactor)

Performance
equation

Catalytic reactor selection parameter

and design

Reaction type
Reactor type
Economics
Rate of
deactivation
Other process
requirement

Reaction type
Chemical kinetics of reaction can be known by
knowing the type of reaction
For reactor selection reaction type will tell us about
heat of reaction either reaction is endothermic or
exothermic.
Selectivity is defined as reaction rate ratio for two
parallel reaction.
Catalyst are used to increase reaction rate and
selectivity for a specific reaction.
We can determine what type of catalyst will be used.
Reaction temperature range will be determined.

Reactor type
Reactor may be a plug flow or mixed
flow or batch flow reactor or other.
Contacting pattern of reaction will be
known.
In case of expensive catalyst and high
heat transfer rate required, mixed
flow(fludized bed) reactor are used.
For high mass transfer plug flow
(packed bed) reactor will be used.

Economics
For reactor design overall economics
should be considered.
Like instead of different size of mixed
flow reactor in series, equal size mixed
flow reactor are economically good.
If catalyst is not very expensive then
we may opt to non-regeneration but
for expensive regeneration must be
considered.

Packed bed

Solid fluid contact will be most efficient

High amount of catalyst will be used
Heat transfer will be difficult
Pressure drop will be high
Effective for mass transfer control system
With increase in temperature side reaction
will be a problem and less selectivity
Sintering of catalyst may happen

Fluidized bed

Industrially most widely used

Heat transfer are very good
Pressure drop is low
Catalyst can easily replaced for
regeneration
Amount of catalyst necessary is less
Surface area per unite mass of
catalyst will be large

Fluidized bed catalytic

reactor design
Types of fluidized bed catalytic
reactor
Bubbling fluidized bed(BFB)industrial solid catalyzed reactor
generally works as bubbling fluidized
bed reactor. Calculation of conversion
for bubbling flow varies between plug
flow to mixed flow.
Turbulent fluidized bed
reactor(TFB)- at high gas velocity
BFB transform in to TFB in this case
no distinct bubble of gas will flow and
solid movement will be violent.
Fast fluidized bed- transition from
TFB with very high speed of gas this
FFB will formed.
Pneumatic conveying bed- highest
gas velocity for fluidization are
choking velocity and after that it will
converted into pneumatic bed and
this reactor pneumatic conveying
fluidized bed reactor.
In all three model TFB, BFB, PCB
solid entrain out of bed regularly.

Bubbling fluidized bed

Model for bubbling
fluidization
Dispersion and tank
series model
Hydrodynamic flow model
K-L model for BFB
RTD Model
Contact time distribution
model

Bubbling fluidized bed seems like

boiling of liquid and gas bubbles
are moving up with faster velocity
then dispersed gas.

Contact time distribution

model

In BFB faster gas stayed mainly in bubbles and slow moving

gas in emulsion, according to this model effective rate
constant depend on length of stay of element of gas in bed.
K= K0tm
here m is a parameter

for first order constant density system concentration at exit will

be

Non-catalytic system
Heterogeneous fluid-fluid or solid-gas
system with two or more phase
heat transfer and mass transfer are
important factor for this model
Heat may be a product of this model
Contacting scheme is very important
Equilibrium solubility (if liquid-liquid
system)
Overall rate scheme
Many method like shrinking core method of
analysis may be used

Reactor selection & design for

burning of coal
Reaction type
Burning of coal is a exothermic reaction
C + O2 = CO2 + heat
Reactor selection
For burning of coal contact of air and coal is very important
Resistance to mass transfer will be
1. film above the coal
2. Ash layer with burning of coal
3. Resistance due to chemical reaction
So, very high mass transfer resistance

conti

Ignition temperature
For burning of coal
minimum ignition required
so, heat should be recycled
Plug flow reactor with
recycle will be most suitable
reactor for this system
Mass Transfer resistance
and rate equation
Total resistance = film
resistance + ash resistance
+ reaction resistance

Plug flow reactor

 Know as we know the rate of reaction

by knowing all resistance
We know the flow type and reactor
type is plug flow
We know feed rate from heat balance
of burning of coal
From performance equation we will
get the volume of reactor

References
Chemical reaction engineering
(octave levinspeil)
Element of chemical reaction engineering
(H. scott fogler)
Chemical reaction design
(Peter harriott)
http://highwire.stanford.edu
http://ocw.mit.com

Thank you