Wilcox home ChE design home Profession General Properties Equipment Separation Aspen +

HYSYS & niSim Costs Safet! Case studies Excel "A#$A% Experiment &esign
Simulation of a fluidi'ed (ed reactor
See Chapter )* in Perr!+s, the -luidi'ation chapter in .ir/01thmer, and -luidi'ation,
Solids Handling, and Processing2
#he pro(lem 3ith fluidi'ed (ed reactors is that the! do not correspond to an! of the easil!0
modeled ideal reactors2 While most of the gas flo3s up3ard through the liquid0li/e
suspended particles, some passes through in (u((les 3ith scant contact 3ith an! catal!st
particles2 4n addition, there is generall! some circulation and tur(ulent (ac/0mixing2
Since process simulators are not set up to model this, one must use one of the approximate
methods indicated (elo32 You can model a fluidi'ed0(ed reactor as a5
Plug flo3 reactor 3ith a non0reacting (!pass stream to account for (u((les and
circulation2 64f the o7erall reactor con7ersion efficienc! is /no3n, determine the
required 7olume for a plug flo3 reactor and di7ide (! this efficienc!28 A step0(!0step
example is gi7en (elo3 for HYSYS & niSim, 3ith other simulators such as Aspen Plus
(eing 7er! similar2 se the Plug -lo3 9eactor unit2 suall! assume the inlet and outlet
# are the same, i2e2 isothermal conditions2 #his is a good approximation (ecause the
7olumetric heat capacit! of the circulating particles is so much larger than that of the
gas, and (ecause of the 7er! high heat transfer coefficient to heating or cooling surfaces2
Set &esign Parameters &elta P to ser Specified 6not :8 and Cooling &irect ; <alue,
enter temperatures in Wor/sheet Conditions2 <ar! #, P and 9ating #otal <olume until
!ou get the (est performance, as indicated in Performance Plots for # and
Compositions2 9ecord the calculated ;r 6=: for exothermic reaction8 for use later to
calculate the required flo3 of coolant, and the heat exchange area inside the reactor2
#he outlet pressure must (e less than the inlet pressure2 #he pressure drop is
approximatel! the 3eight of catal!st per cross sectional area2 4n a real reactor, the inlet
gas temperature 3ill (e different from the outlet temperature, (ut it 3ill (e rapidl!
heated to the outlet # (! the circulating particles2 1ne must add a fictitious heater to
(ring the feed stream up to the reactor # >ust prior to the fictitious split off of the
(!pass stream, 3hich recom(ines 3ith the reactor effluent2 9ecord the ;fh 6?: for
heating of the feed8 in order to calculate the heat exchange dut! inside the reactor 6;r +
;fh82 #he fictitious heat exchanger, plug flo3 reactor, and (!pass stream constitute the
actual reactor2
Series of stirred0tan/ reactors 6CS#9s8, e2g2 fluidi'ed0(ed catal!tic crac/er 6-CC8
Series of parallel plug flo3 reactors and stirred tan/ reactors 6see Simulation of a
fluidi'ed0(ed steam reformer82 %! @emulsion phaseA in this and other papers on
fluidi'ed0(ed reactors is meant the portions containing large amounts of suspended
particlesB these portions (eha7e as a liquid2
Computational fluid mechanics5 &etailed numerical computations can (e carried out
for fluid mechanics, particle motion, reaction /inetics, heat and mass transport, etc2
While research papers ha7e (een pu(lished illustrating this, and 3hile companies are
no dou(t pursuing it, thus far it remains (e!ond read! use (! students2
1
Example5 Production of maleic anh!dride (! partial oxidation
of n0(utane using air 3ith a 7anadium phosphate catal!st2
Selected references for the A$"A process5
1. G. Stefani, F. Budi, C. Fumagalli, G.D. Suciu, Fluidized bed oxidation of n-butane: a new
commercial roce!! for maleic an"#dride,$ in %ew De&eloment! in Selecti&e 'xidation,
edited b# G. Centi and F. (rifir) *+l!e&ier, ,m!terdam 1--./ 012 - 003.
3. S.C. ,rnold, G.D. Sucium, 4. 5erde, ,. %eri, 6!e fluid bed reactor for maleic an"#dride
from butane,$ 7#drocarbon 8roce!!ing *Setember 1-90/ 131-13:.
1. G. Stefani, F. Budi, C. Fumagalli, G.D. Suciu, Fluidized bed oxidation of n-butane: a new
commercial roce!! for maleic an"#dride,$ C"imica ; <ndu!tria *=ilano/ 23 *1--./ :.>-
:.-.
("e ad&antage! of a fluidized-bed reactor o&er a ac?ed bed are claimed to be t"e following:
1. ,&oid! "ot !ot!. *Fluidized bed! are nearl# i!ot"ermal becau!e t"e "eat caacit# of t"e !olid
catal#!t article! far exceed! t"at of t"e ga!, and becau!e t"e !olid! circulate./
3. +nable! u!e of !earate feed !tream! for n-butane and air, !o t"at one can oerate o&erall
wit"in t"e combu!tible range. *,gain, t"i! i! becau!e t"e "ig" "eat caacit# of t"e ga!
article! would re&ent a flame from roagating, i.e. deflagration.$ <n addition, t"e "eat
tran!fer coefficient to t"e cooled wall or tube! i! extremel# "ig"./ ("i! reduce! t"e air
re@uirement, t"e comre!!or !ize and ower, t"e reactor !ize, and t"e !ize of t"e down!tream
!earation e@uiment, and ermit! u!e of an incinerator for t"e wa!te ga! wit" roduction of
&aluable !team.
1. Co!t i! muc" lower t"an for tubular reactor! cooled b# a molten !alt.
>. ("e !ize can be muc" larger. From reference 3, ("e maximum caacit# wit" a !ingle
reactor &e!!el i! 3.-30,... metric ton! er #ear. Suc" a reactor &e!!el "a! o&er 30,... tube!
w"ic" mu!t be filled wit" reci!ion eac" time a new catal#!t c"arge i! loaded.$
0. +a!# to load and unload.
:. Can generate &aluable !team w"ile cooling t"e reactor.
Aeference 1 abo&e indicate! t"at t"e catal#!t article! u!ed in t"e ,4=, fluidized bed are t#e ,
*Geldart cla!!ification/, and are &er# nearl# !"erical. Be a!!ume t"at t"e!e article! are mo!tl#
!ilicon oxide *for abra!ion re!i!tance/, incororating or coated wit" &anadium "o!"ate. Be
fir!t determine t"e aroximate oerating arameter! of a fluidized-bed reactor for maleic
an"#dride, u!ing t"e material, articularl# t"e figure!, in Cir?-'t"merD! !ection on fluidization.
1. Determine a rea!onable den!it# for t"e catal#!t article!, in ?gEm
1
. Determine a rea!onable
article !ize, in mm, u!ing Figure > of C-'.
3. Determine a rea!onable &oid fraction */ from Figure! 2 and 1. wit" turbulent flow.
1. Determine a rea!onable range for t"e !uerficial ga! &elocit# 6 *&elocit# a! if t"ere were no
article! re!ent, i.e. t"e &olumetric flow rate of t"e ga! di&ided b# t"e cro!!-!ectional area/,
in mE!. *6!e Figure! 9b and 1., for examle./
>. From Figure 11a, find a rea!onable "eat tran!fer coefficient at 3.. ?8a between t"e bed and
t"e wall or immer!ed tube!, in wEm
3
.C.
0. Find a rea!onable &alue for t"e (ran!ort Di!engaging 7eig"t *(D7/ and t"e reactor
diameter, from Figure 12.
:. Determine a rea!onable den!it# for t"e catal#!t article!, in ?gEm
1
. Determine a rea!onable
article !ize, in mm, u!ing Figure > of C-'.
2. Determine a rea!onable &oid fraction */ be, from Figure! 2 and 1. wit" turbulent flow.
3
9. Determine a rea!onable range for t"e !uerficial ga! &elocit# 6 *&elocit# a! if t"ere were no
article! re!ent, i.e. t"e &olumetric flow rate of t"e ga! di&ided b# t"e cro!!-!ectional area/,
in mE!. *6!e Figure! 9b and 1., for examle./
-. From Figure 11a, find a rea!onable "eat tran!fer coefficient at 3.. ?8a between t"e bed and
t"e wall or immer!ed tube!, in wEm
3
.C.
1.. Find a rea!onable &alue for t"e (ran!ort Di!engaging 7eig"t *(D7/ and t"e reactor
diameter, from Figure 12.
Following i! aroximatel# w"at a !uitable 8FD !"ould be in 7FSFS ; 6niSim, wit"out t"e
w"ite rectangle, w"ic" rere!ent! t"e actual reactor.
("e butane and t"e air are to be fed !earatel# into t"e reactor, w"ic" can be con!idered
i!ot"ermal. Fou will !imulate it b# a lug-flow reactor wit" 1.G b#a!! to account for bac?-
mixing and bubbling. Fou will u!e !e&eral fictitiou! unit! to !imulate t"e actual reactor. Carr#
out t"e following !te!:
1. <n t"e Ba!i! +n&ironment enter t"e comonent! for air and n-butane, and !elect a !uitable
t"ermod#namic! ac?age.
3. Find a !ource for reaction ?inetic!, e.g. G. Centi, G. Forna!ari and F. (rifirH, n-Butane
'xidation to =aleic ,n"#dride on 5anadium-8"o!"oru! 'xide!: Cinetic ,nal#!i! wit" a
(ubular Flow Stac?ed-8ellet Aeactor,$ <nd. +ng. C"em. 8rod. Ae!. De&. 3> *1-90/ 13-12.
From t"i!, determine t"e ?inetic! con!tant! !uitable for u!e in t"e !oftware. %ote t"at
7FSFS ; 6niSim a!!ume t"at t"e reaction! all ta?e lace in t"e ga! "a!e, e&en t"oug" in
t"i! ca!e t"e# all occur on t"e !urface of t"e catal#!t article! *i.e., "eterogeneou! catal#!i!/.
("u! t"e ?inetic! exre!!ion! *actuall# t"e re-exonential , &alue! in t"e numerator!/
deend on t"e &oid fraction , article !ize and oro!it#. +nter aroriate con!tant! into t"e
Ba!i!.
1. Create a !econd ba!i! for water wit" eit"er t"e ,S=+ !team or %BS !team ac?age.
1
Actual reactor
>. Go to t"e Simulation +n&ironment. Set t"e n-butane flow rate to corre!ond to t"at re@uired
for t"e de!ired maleic an"#dride roduction rate a!!uming a rea!onable o&erall #ield for t"e
lant. ,!!ume room ( and 1.0 atm.
0. C"ange t"e air flow rate !uc" t"at if t"e butane and air !tream! were mixed t"ere would be
>G butane in t"e mixed ga!. *See t"e reference! abo&e./
:. <n!ert a um for t"e butane and a comre!!or for t"e air. Secif# t"e outlet re!!ure onl#
for t"e um, from 3.. to 0.. ?8a.
2. <n!ert a Set unit and ma?e t"e comre!!or outlet re!!ure e@ual to t"e butane um outlet
re!!ure. <n t"i! wa# #ou can c"ange t"e re!!ure to t"e reactor wit"out "a&ing to c"ange t"e
outlet re!!ure! for bot" comre!!or and um.
9. ,dd a "eat exc"anger for t"e butane to increa!e it! temerature a! "ig" a! o!!ible u!ing "ig"
re!!ure !team. *Follow alicable "euri!tic!./ 8rint a lot of temerature *F/ &er!u! "eat
flow *I/. ("ere !"ould be at lea!t 3. oint! for t"e butane *tube/ !ide.
-. ,dd a "eat exc"anger for t"e air u!ing "ig" re!!ure !team. 6!e a Set unit to ma?e t"e exit
temerature e@ual to t"at for t"e butane "eat exc"anger. 8rint out a lot of temerature
&er!u! "eat flow.
1.. ,dd a fictitiou! mixer to combine t"e butane and air !tream!. *("e!e would be fed !earatel#
into t"e real reactor, a! de!cribed in t"e ,4=, reference! abo&e./
11. ,dd a fictitiou! "eater *not a "eat exc"anger/. For now, lea&e it! exit temerature blan?.
*4ater it will be !et e@ual to t"e reactor exit temerature, !ince t"e reactor i! a!!umed
i!ot"ermal. <n t"e actual reactor, t"e feed !tream! are raidl# "eated b# t"e circulating
catal#!t article!./
13. ,dd a fictitiou! !litter, wit" 1.G of t"e !tream going to t"e b#a!!.
11. <n!ert a lug-flow reactor wit" t"e following !ecification!:
a. De!ign 8arameter! age. From t"e Cir?-'t"mer fluidization !ection, t"e Delta 8 in a
fluidized bed i! aroximatel# t"e weig"t of t"e catal#!t di&ided b# t"e cro!!-!ectional
area, or catal#!tg". 6!e #our &alue for t"e catal#!t den!it# and a!!ume a rea!onable &alue
for bed "eig"t ". For Dut# 8arameter!, clic? Cooling and Direct J 5alue. *Fou want
7FSFSE6niSim to calculate t"e dut# !o t"at #ou can e!timate "ow muc" !team will be
roduced b# t"e reactor. Since #ouDre a!!uming i!ot"ermal condition!, #ou donDt want to
calculate "eat tran!fer for t"i! fictitiou! reactor./
b. De!ign 7eat (ran!fer. Direct J 5alue. %ame t"e +nerg# Stream w"ate&er #ou wantK
#ouDll be generating !team from boiler feed water in t"e real reactor.
c. Aating. Set 1 tube, a! t"e water-!team will be in!ide t"e tube! w"ile t"e catal#!t and
roce!! ga! will be on t"e !"ell !ide. Gue!! a 5olume. ("e 4engt" and 5oid Fraction
!"ould be t"e &alue! u!ed in 11.a abo&e.
d. Set t"e fictitiou! "eater temerature e@ual to t"e reactor effluent temerature.
e. 'n t"e reactor Bor?!"eet age, gue!! an effluent temerature. <f t"e green run icon i!
dere!!ed, t"e reactor !"ould con&erge.
f. 8erformance Como!ition! 8lot. Select butane, =, and carbon dioxide a! t"e
comonent!. C"ange t"e Comonent Ba!i! to =olar Flow. From t"e lot, e!timate t"e
#ield of =,. 8la# around wit" (, 8, &olume, lengt" until #ou get a #ield greater t"an
0.G *ba!ed on t"e butane feed !tream, !ince in actualit# all of t"i! enter! t"e reactor ---
t"e b#a!! i! fictional/.
g. <f nece!!ar#, redo !te a *reactor re!!ure dro/.
1>. C"ec? t"e !uerficial ga! &elocit# at t"e entrance and exit of t"e reactor, u!ing !tream! 9 and
13 to get t"e actual &olumetric flow rate of t"e ga!. *B"# are t"e!e !ignificantl# differentL/
=a?e certain t"e!e are wit"in t"e range #ou found abo&e. <f not adMu!t or t"e reactor cro!!-
!ectional area until all i! o?a#.
>
10. Calculate t"e amount of !team roduced b# t"e reactor. Fir!t !ubtract t"e dut# of t"e
fictitiou! "eater from t"e reactor dut# --- t"i! gi&e! t"e actual dut# of t"e actual reactor. ("en
di&ide t"i! b# t"e latent "eat of e&aoration of t"e !team to be roduced *difference between
!ecific ent"al# of !aturated &aor and li@uid at t"e c"o!en re!!ure/.
1:. +!timate t"e "eat tran!fer area re@uired for t"e real reactor. +!timate t"e o&erall 6 from t"e "
found in 4-1> for t"e bed !ide and from "euri!tic! for t"e boiling water !ide.
12. From t"e area in 12, a!!ume a tube diameter and calculate "ow man# &ertical tube! would
"a&e to be in!erted in t"e bed to cool it b# generating !team.
19. From Cir?-'t"mer, ic? a rea!onable &alue for t"e (ran!ort Di!engaging 7eig"t.
1-. Determine t"e o&erall &olume of t"e reactor b# adding t"e &olume u!ed in #our reactor
calculation!, t"e &olume occuied b# t"e !team tube!, and t"e &olume occuied b# t"e
(ran!ort Di!engaging 7eig"t.
3.. =a?e certain t"e diameter and "eig"t conform to t"e alicable "euri!tic for a &e!!el. <f not,
ma?e t"e aroriate c"ange! in #our de!ign.
31. 4ater, in C,8C'S(, co!t t"e reactor bot" a! a &e!!el *b# &olume/ and "eat exc"anger *b#
"eat exc"ange area/, Mu!t a! for a ac?ed bed reactor wit" "eat tran!fer.
Created June 21, 2007; last modified December 10, 2009. Please submit all questions,
comments and suggestions to W.. Wilco!
Disclaimer: The material on these pages is intended for instructional purposes by Clarkson
University students only. Neither Clarkson University nor Professor Wilco is responsible for
problems caused by using this information.
Wilcox home ChE design home Profession General Properties Equipment Separation Aspen +
HYSYS & niSim Costs Safet! Case studies Excel "A#$A% Experiment &esign
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