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Iv-6 - Design of Chemical Reactors
Iv-6 - Design of Chemical Reactors
A q Q, rA k C An , V ct
k
X Af
dX A taux high CSTR
VBR
taux C A0 rA X A
0
VCSTR X Af
C A0
rA X Af XAf high BR
A q Q, rA k C An , V ct
k
A q Q, rA k C An , V ct
k
X Af
VCSTR rA X Af , 1 X Af
X Af
VPFR dX A
0
rA X A ,
(F’A0 )
Plug flow
FA1
XA1
FA0 XA2 (β+1)Fvf Fvf
K Fv 1
Fv0 V
L
XAf
XA0 = 0
Fv r = βFvf
The flow entering the reactor includes both fresh feed and the
recycle stream. The recycled flow is measured at the split
point L
A which would enter in an A entering in
FA0 FA0 FA0 1 FA0
unconverted recycle stream fresh feed
1 C A1 / C A 0 FA1 FA 0 FAr 1 X A f
X A1 C A1 CA0
1 C A1 / C A0 FV 1 FV 0 FVf 1 X A f
X A1 X A f
1
0
X Af
V dX A V X Af
FA 0
0
rA
PFR
FA 0 rAf X Af
CSTR
C A0, XA0 = 0 C A1, XA1 C A2, XA2 CAi-1, XAi-1 C Ai, X Ai C AN-1 , XAN-1
FA0
1 2 i CAN , XAN
N
N C 1N N 1 C A0
R N R 0 A0 1 D ln
k C AN k CA
k= 50
10 20
10
=
N=2
τRN
5
τRN =
N=3
=
N=4 2
τD
τRN
N=6 k= 1
N = 10
1 N=
C A0
Plug flow solution: 1 C A0 k D
CA
June 5, 2008 FILS – Chemical Reactors 25
Design of Chemical Reactors
Design of Chemical Reactors
Single Reaction Case
100
(CA02 V / FA0) D
(CA02 V / FA0)N
N =1
Second order reaction
kC A0τR = 1000
=
500
(τCA0)N
(τCA0)D
200
100
10
50
N=2
20
N=3 10
5
N=4
2
N=6
1
N = 10
1 N= (plug flow)
C A0, XA0 = 0 C A1, XA1 C A2, XA2 CAi-1, XAi-1 C Ai, X Ai C AN-1 , XAN-1
FA0
1 2 i CAN , XAN
N
Rate versus
concentration M
rA
curve
r A(C A1) 1
Slope =
cA1-cA0= τR1
P
rA(C A2) 1
Slope = =
cA2-cA1 τR2
N L
C A3 CA2 CA1 CA0
Reactant concentration
June 5, 2008 FILS – Chemical Reactors 28
Design of Chemical Reactors
Design of Chemical Reactors
Single Reaction Case
Unequal-size CSTRs in Series
Determining the Best System for a Given Performance
1 Arbitrary
r curve
K L K L
N M Of second unit
Diagonal of
1 rectangle
rA
K L
Maximum
area
Slope of
curve at M
N M
Second
First reactor reactor
area area
0 XA1 XA2 XA
June 5, 2008 FILS – Chemical Reactors 30
Design of Chemical Reactors
Design of Chemical Reactors
Single Reaction Case
Reactors of Different Types in Series
F A0
C A0 X A1 X A2 X A3
V2
X A0 = 0 V1 V3
V1 X X A0
A1
FA0 rA X A1
1
rA Rate conversion
dependent curve
X A2
V2 dX A
FA0
r XA
X A1 A
V3
V3 X X A2 V2 FA0
A3 V1
FA0 rA X A3 FA0
FA0
X2
June 5, 2008 FILS – Chemical Reactors 31
Design of Chemical Reactors
Design of Chemical Reactors
Single Reaction Case
Best Arrangement of a Set of Ideal Reactors
1) For a reaction whose rate-concentration curve rises monotonically (any
nth-order reaction, n > 0) the reactors should be connected in series.
They should be ordered so as to keep the concentration of reactant as
high as possible if the rate-concentration curve is concave (n > 1), as
low as possible if the curve is convex (n < 1). For the previous case, the
ordering of units should be PFR, small CSTR, large CSTR; the reverse
ordering should be used when n < 1.
2) For reactions where the rate-concentration curve passes through a
maximum or minimum the arrangement of units depends on the actual
shape of curve, the conversion level desired, and the units available. No
simple rules can be suggested.
3) Whatever may be the kinetics and the reactor system, an examination of
the 1/rA versus CA curve is a good way to find the best arrangement of
units.
Point of
No R maximum
in feed rate
Progress
of reaction
Progress
of reaction
CA XA
Average Average
rate rate
P
K P
L L L
XA0 XAi XAf Q XA0 XAi XAf Q XA0 X Ai XAf Q
X Ai
1
b
dF f X A, db da
dX A f b, f a,
d a d d
d RR / C A 0 X Af
dX A 1 dX Ai 1. For conversions smaller
d
0 rA X A
0
rA X { d
than the point of maximum
X Ai Ai rate the CSTR performs better
X Af
1 2
than any RR.
X Af
dX A 2. For conversions higher than
1
rA X A
the point of maximum rate the
X Ai
RR with the proper β is better
rA X Ai
X Af X Ai to either PFR or CSTR
June 5, 2008 FILS – Chemical Reactors 36
Design of Chemical Reactors
Design of Chemical Reactors
PFR
C Af
CSTR
1
D
C A C A 0
dC A
R evaluated at C Af
C Af
d PFR 1
C A CA 0
CSTR & PFR CSTR dC A
dC A at C Af
CRf CR 0 C A0 C Af
Plug flow Mixed
Staged reactors
flow
η’ CRf C Rf CRf
CR,CSTR
CR, total
k2 / k2 k1
CR , max k ln k2 / k1
1 opt
C A0 k2 k2 k1
1 1
CA A R S CA
CA 0
0.8 CA0 Plug flow
0.1
CB k2 CS
0.6
CA0
for
k1
=0 0.1
C/CA0
C A0
k2
0.4 Locus of CR, max =1
k1
0.2 CR
1 C A0
10 10
0 0
0 1 2 3 4 5 0 1
k1τ XA = 1 - CA/CA0
Writing the mass balance for each species of interest, for the whole
CSTR, their dependencies upon residence time are found.
CA 1 CR k1 CSTR CS k1k2 CSTR
2
C A0 1 k1 CSTR C A0 1 k1 CSTR 1 k2 CSTR C A0 1 k1 CSTR 1 k2 CSTR
CR ,max 1 1
2 opt
C A0 k2 / k1 1/ 2 1 k1k2
1 1
CA k2
CA for =0 A R S
CA0 k1 Mixed flow CA
0.8 CA0 C A0
Parallel reactions
Homework!
rA k C An
FV, XAR β∙FV, FV,
m
Steps in design:
CA0 α∙V XAR XA
2. Apply CSTR characteristic
Active Zone equation to the active zone
3. Take the mass balance in
the mixing point, m
Dead Zone
4. Write the residence time
with respect to the reactor
performance
June 5, 2008 FILS – Chemical Reactors 50
Design of Chemical Reactors
Design of Chemical Reactors
Non-ideal Flow: Micro-mixing (microfluid)
Apply CSTR characteristic equation to the active zone
VR X AR X Ain X AR 1 X AR
R C A0 C A0
FVR rA X AR k C An 0 1 X AR
n
k C An 01 1 X AR n
V 1 X AR
FV k C An 01 1 X AR n
Take the mass balance in the mixing point, m
1 FV C A0 FV C A0 1 X AR FV C A0 1 X A
X
X AR A
Write the residence time with respect to the reactor performance
V 1 XA
FV k C An 01 XA
n
1
June 5, 2008 FILS – Chemical Reactors 51
Design of Chemical Reactors
Design of Chemical Reactors
Non-ideal Flow: Micro-mixing (microfluid)
Axial Dispersion Model
rA k C An
Steps in design:
2. Write the mass balance for
dispersion zone, taking into
Change in flow pattern at
boundaries account the chemical process
3. Write the boundary conditions
4. Solve analytically or numerically
the model
A entering by A leaving by
bulk flow bulk flow
A entering by A leaving by
dispersion dispersion
Accumulation of A
Cross - sectional (= 0 for steady state )
area = S
Disappearance of A
dN A dC A
entering by axial dispersion DL S
dt dl l
dN A dC A
leaving by axial dispersion DL S
dt dl l l
dissapearance by reaction rA V rA S l
Note the inclusion of two dispersion terms, because material enters and leaves
the differential section not only by bulk flow but by dispersion as well
dC A dC A
u
C A,l l C A ,l
DL
dl
l l dl l
rA 0
l l
Taking the limits as ∆l→0 reads:
d 2C A dC A
DL 2
u kC A 0
n
dl dl
The dimensionless form is:
DL d 2 X A dX A z l L
k C A 0 1 X A 0
n 1 n
dz 1 2 3 L u V FV
2
uL dz
{ *
Dg
m1,2
1
2 Dg
1 1 4 * Dg
1
2 Dg
1 a
1 a z 1 a z
X A 1 A1 e 2 Dg
A2 e 2 Dg
4 a e 2 Dg
1 X A z 1
a a
1 a 1 a e
2 2 Dg 2 2 Dg
e
June 5, 2008 FILS – Chemical Reactors 57
Design of Chemical Reactors
Design of Chemical Reactors
Non-ideal Flow: Micro-mixing (microfluid)