Chemical reactor

selection and design

Rajesh Kumar
Bhagat
B.E.(CHE) 4th year
 Introduction
Almost all chemical engineering
process contains three operations.

Unit Unit Product

Raw Chemical
operation operation
material reactor
(cleaning ) (separatio
n)

What does chemical reactor design

means ?
 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 can’t
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
Fig-1 Plug flow
• When a product will act like a catalyst then it reactor with recycle
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 Fig-2
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 feed’s 1/(-r) value should be equal to
average 1/(-r) value for whole reactor.
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
Halogenations of alkane is a
steps in series and steps in
example of this kind of
parallel reaction.
reaction where reaction is
• In these reaction proper parallel with respect to
contacting pattern is very halogen
important.
• The general representation of
these reaction are

• Here the reaction is parallel with

respect to reactant B and in series
with A.
 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
Performance
plug flow Reactor equation
Differential reactor

Integral reactor

mixed flow type

(Fluidized bed reactor)
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

Bubbling fluidized bed seems like
boiling of liquid and gas bubbles
• K-L model for BFB are moving up with faster velocity
then dispersed gas.

• RTD Model

• Contact time distribution

model
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