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:
R
P1
= 2u
/
j
f
/
@f
@x
j
= 2D
T
@f
@x
j
_ _
2
(4)
and dissipated due to the inertial-convective reduction of the
scale of inhomogeneity, producing r
2
2
R
D1
= R
P2
=
r
2
1
s
S
; s
S
=
1
R
k
e
(5)
r
2
2
, decays due to viscous-convective shrinking of compo-
nent slabs, producing r
2
3
R
D2
= R
P3
= Er
2
2
; E = 0:058
e
m
_ _1=2
(6)
r
2
3
, is dissipated due to molecular diffusion in deforming,
shrinking slabs
R
D3
= Gr
2
3
; G = E 0:303
17050
Sc
_ _
(7)
Once the spatial distributions of f
and r
2
S
are known, one
expresses the local value of the probability density of f using
the Beta probability distribution
U(f; x
*
; t) =
f
v1
(1f)
w1
_
1
0
y
v1
(1y)
w1
dy
(8)
with
v = f
f 1f
_ _
r
2
S
1
_ _
; w =
1f
_ _
f
_ _
v (9)
andcalculates the local values of the average reactionrate. For
example, the average reaction rate between the ester C and
the base A is given by
r
2
= k
2
c
A
c
B
= k
2
_
1
0
c
A
(f)c
C
(f)U(f)df (10)
226 2004 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim http://www.cet-journal.de Chem. Eng. Technol. 2004, 27, No. 3
0.8 1 1.2 1.4 1.6
-1.6
-1.2
-0.8
-0.4
0
0.4
z
tip
0.8 1 1.2 1.4 1.6
-0.08
-0.04
0
0.04
0.08
2r/D
2r/D
z
tip
2r/D
0.8 1 1.2 1.4 1.6
0
0.04
0.08
0.12
0.16
2r/D
z/T = 0.300
z/T = 0.366 z/T = 0.333
z/T = 0.266
0.8 1 1.2 1.4 1.6
-0.15
-0.1
-0.05
0
0.05
0.1
experimental
predicted (model k - )
Figure 2. Variation of the mean axial velocity close to the feed pipe;
N = 106 rpm, t
f
= 20 min.
_
+
E s
1
S
_ _
)=2. Results of computation of effects of mixing on
the course of parallel chemical reactions are compared with
predictions of both models in Fig. 3 and 4. Experimental
results are taken from Ref. [1]. Fig. 3 shows that both models
well predict trends of influenceof the meanresidence timeand
mixing rate on the reaction selectivity defined by equation
(13). Model IIa overestimates experimental data. There can
be several reasons for this effect. The first reason can be a too
Chem. Eng. Technol. 2004, 27, No. 3 http://www.cet-journal.de 2004 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim 227
0
0.04
0.08
0.12
0.16
0.2
experimental
106 rpm
214 rpm
Model I
106 rpm
214 rpm
Model II, case a
106 rpm
214 rpm
f
/
is calculated;
The mixture fraction, is interpreted in the case of the
semibatch reactor as a mass fraction of the fresh feed that is
diluted by the older bulk fluid. To determine distribution of
f
/
two methods are used. The first one is based on CFD
simulations of the conversion of chemical reactions of order
zero for various initial reactant concentrations c
Y
. The
reactant of the zero-order reaction is fed into the system by
the A-inlet. As the rateof consumptionof the reactant of the
zero-order chemical reaction is independent of the feed
concentration, the dilution effect determines
f
/
.
228 2004 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim http://www.cet-journal.de Chem. Eng. Technol. 2004, 27, No. 3
experimental
Model I
Model II, case a
Model II, case b
[m
2
s
-3
]
Figure 4. Influence of the energy dissipationratee onthe selectivity X
S
observed
inthe continuous-flowstirredtankreactor; s = 20 min; c
B0
= c
C0
= 20 mol m
3
;
c
A0
= 1000 mol m
3
.
Full Paper
f
/
= c
Y2
c
Y1
_ _
= c
Y02
c
Y01
_ _
(15)
The second method is simpler but less exact. It is based on
renormalization of the mixture fraction, which in the case of
semibatch feeding reads:
f
/
= f f
b
_ _
= 1 f
b
_ _
; f
b
= Q
A
t= V
B0
Q
A
t
_ _
(16)
Both methods give almost identical results, so the second
one is recommended as easier to use.
distributions of variances r
2
1
; r
2
2
; r
2
3
are calculated from eqs
(3)(7);
a closure based on Beta distribution is used to compute
concentration distributions and the final selectivity value.
For comparison we also have performed computations
using the model that neglects concentration fluctuations of
reactants and is based on local average reactant concentra-
tions with k
2
c
A
c
C
replaced by k
2
c
A
c
C
. In the following,
this model is called Model III. Fig. 5 and 6 show comparisons
of experimental data with predictions of Models I and III. It
can be clearly seen fromexperimental data that an increase of
both the stirrer speed and the feed time decreases production
of the byproduct and thus decreases X
S
. Both models predict
these tendencies, however, neglecting effects of concentration
fluctuations (Model III) results in much smaller X
S
values
than observed in experiments. Hence, Model III is not
recommended. Results of Model I (r = 10) are in good
agreement with experimental data. It has been checked
whether sensitivity of the selectivity to the feed discretization
is small; increasing r from 10 to 30 results in increase of X
S
by
not more than 3.5%. Fig. 7 compares experimental results and
model predictions obtained in the semibatch reactor with
those for the CSTR. One cansee that the effect of the changing
operationmode is well predictedby the model. Fig. 8 shows an
example of computer visualization of reaction plumes
computed with Model I. The reaction zone presented in the
figure is equivalent to the zone of basic solution (c
A
>10
7
mol/
dm
3
). Results show a significant increase of the reaction zone
with time. The reaction zone is localized very close to the
feeding point at early stages of the process and spreads out
towards the end of the process. Hence application of the test
reaction systemto determine local values of the rate of energy
Chem. Eng. Technol. 2004, 27, No. 3 http://www.cet-journal.de 2004 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim 229
0 0.04 0.08 0.12
0
0.02
0.04
0.06
0.08
0.1
0.12
t
f
=15 min
experimental
Model I
Model III
S
0 0.04 0.08 0.12
0
0.02
0.04
0.06
0.08
0.1
0.12
t
f
=20 min
experimental
Model I
Model III
S
[m
2
s
-3
]
[m
2
s
-3
]
Figure 5. Influence of the energy dissipationratee onthe selectivity X
S
observed
in the semibatch stirred tank reactor for different feed time values t
f
;
c
B0
= c
C0
= 40 mol m
3
; c
A0
= 2000 mol m
3
.
Figure 6. Influence of the feed time t
f
on the selectivity X
S
observed in the
semibatch stirred tank reactor; N = 214 rpm; c
B0
= c
C0
= 40 mol m
3
; c
A0
=
2000 mol m
3
.
0 0.04 0.08 0.12
0
0.02
0.04
0.06
0.08
0.1
Experimental
= 20 - CSTR
t
f
= 20 - SBR
Predicted - Model I
= 20 - CSTR
t
f
= 20 - SBR
X
s
[m
2
s
-3
]
Figure 7. Influence of the energy dissipation e on the selectivity X
S
observed in
the continuous-flowstirred tank reactor and the semibatch stirred tank reactor;
s = t
f
= 20 min; c
B0
= c
C0
= 20 mol m
3
; c
A0
= 1000 mol m
3
.
Full Paper
dissipation from the reaction product distribution X
S
yields
only a crude estimate of e.
6 Discussion and conclusions
I. TheCFDbasedmodels well predict experimental data for
parallel chemical reactions carried out in stirred tank
reactors provided that modelling of micromixing and
relaxation of the concentration spectrum are included
(models I and IIb in this paper). This conclusion seems
not to agree with observations of Brucato et al. [9] that
effects of micromixing phenomena in stirred tanks are
negligible. However, there is a simple explanation for this
discrepancy: for fast injection applied by Brucato et al. [9]
(batch system) effects of micromixing are small, whereas
for slow, controlled addition they determine product
distribution. This phenomenon can be explained using
time constant analysis, see [3], pages 606608.
II. The finite-mode model requires using a large number of
environments for high values of the concentration ratio;
the performance of the model may be improved by
correcting for the effects of spurious scalar dissipation.
III. The presented approach to modelling has been validated
using experimental data from the stirred tank reactor of
diameter T = 0.3 m. However, completeness of the
model enables us to predict consequences of scale-up to
the large industrial scale. For example when using a
common scale-up criterion based on constant power per
unit mass during scale-up, one gets the same time
constants for the viscous-convective andviscous-diffusive
mixing in both systems, but the rate of turbulent diffusion
increases with increasing the scale, D
T
~ k
2
=e ~ e
1=3
L
4=3
,
whilst the rate of inertial-convective mixing decreases,
s
S
~ k=e ~ L
2=3
=e
1=3
(time constant increases). Conse-
quently, the decay of concentration fluctuations is slower
in large-scale systems and selectivity X
S
is higher.
Moreover at not too high power input the controlling
mechanism can change during scale-up from the viscous-
convective to inertial-convective. Hence, scale-up based
on e = const. is not recommended.
Received: December 1, 2003 [CET1992]
References
[1] J. Badyga, M. Henczka, . Makowski, Trans. IChemE 2001, 79(A), 895.
[2] J. Badyga, Chem. Eng. Sci. 1989, 44, 1175.
[3] J. Badyga, J. R. Bourne, Turbulent Mixing and Chemical Reactions,
Wiley, Chichester, 1999.
[4] R. O. Fox, Chem. Eng. Process. 1998, 37, 521.
[5] S. Heinz, D. Roekaerts, Chem. Eng. Sci., 2001, 56, 3197.
[6] J. Badyga, M. Jasinska, Inz. i Ap. Chem. 2002, 41, 24.
[7] J. R. Bourne, S. Yu, Ind. Eng. Chem. Res. 1989, 33, 41.
[8] G. K. Patterson, J. Randick, Proceedings of the Tenth European
Conference on Mixing, Elsevier, Delft, 1989, 53.
[9] A. Brucato, M. Ciofalo, F. Grisa, R. Tocco, Chem. Eng. Sci. 1989, 55,
291.
Symbols used
c
i
[mol dm
3
] concentration of substance i
c
i
[mol dm
3
] concentration of reactant of
instantaneous reaction
c
0
i
[mol dm
3
] concentration of nonreacting tracer
D
m
[m
2
s
1
] molecular diffusivity
D
T
[m
2
s
1
] turbulent diffusivity
E [s
1
] engulfment parameter
F [] dimensionless concentration of
nonreacting tracer
G [s
1
] molecular diffusion parameter
K [m
2
s
2
] kinetic energy of turbulence
k
1
, k
2
[dm
3
mol
1
s
1
] second order rate constant
L [m] integral scale of turbulence
N [rpm] stirrer speed
p
i
[] probability
t
f
[s] feeding time
u [m s
1
] local average velocity
u
tip
[m s
1
] tip velocity
X
S
[] product distribution
V
i
[m
3
] volume
e [m
2
s
3
] local average value of the rate of energy
dissipation
e [m
2
s
3
] average rate of energy dissipationinthe
tank
230 2004 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim http://www.cet-journal.de Chem. Eng. Technol. 2004, 27, No. 3
Figure 8. Visualization of the reaction plume observed in the semibatch stirred
tank reactor: N = 174 rpm, t
f
= 8 min, c
B0
= c
C0
= 40 mol/m
3
, c
A0
= 2000 mol/
m
3
; a) after 48 s, b) after 240 s, c) after 480 s.
Full Paper
c [s
1
] micromixing parameter
m [m s
2
] kinematic viscosity
r [] feed discretization
r
2
S
, r
2
i
[] dimensionless concentration variances
s [s] mean residence time
s
s
[s] time scale for the inertial-convective
mixing
Abbreviations
CFD computational fluid dynamics
CSTR continuous-flow stirred tank reactor
LDA laser Doppler anemometry
PDF probability density function
SBR semibatch stirred tank reactor
______________________
Chem. Eng. Technol. 2004, 27, No. 3 http://www.cet-journal.de 2004 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim 231
Full Paper