M4_Other design factors

M4-1
This session

Recycle PFR
Recycle
l ratio
i
Design equation
Relationship between recycle PFR
PFR, MFR and PFR
Optimum recycle ratio

M4-2
 Recycle PFR
Consider a recycle PFR
FA1 ( FA' 0 )
FA0 X Af
K X A1 L
0
X A0 0
1 f
C A0
C A1
3 R f FA3 C Af

Recycle
y ratio R
Volume of fluid returned v3
R
Volume leavingg system
y vf

Across the PFR, what is design equation?

M4-3
 FA1 dV
FA0 X Af
K X A1 L
0 CA CA+dCA
X A0 0
1 f
C A0
C A1
3 R f FA3 C Af

when A 0 v0 v f
Material balance:

I t = output
Input t t + disappearance
di by
b reaction
ti + accumulation
l ti

v1 C A v1 (C A dC A ) ( rA )dV 0
As v1 v0 v3 v0 Rv f (1 R )v0

(1 R )v0 C A (1 R )v0 (C A dC A ) ( rA )dV

(1 R )v0dC A ( rA )dV
 (1 R )v0dC A
dV
( rA )
V C Af dC A
0
dV (1 R )v0
C A1 ( rA )
V C Af dC
(1 R ) A
v0 C A1 ( r )
A
C A1 dC A
(1 R )
C Af ( rA )

DE for recycle PF

M4-5
 RPF DE Based on XA
C A1 dC A
(1 R )
C Af ( rA )
V 1 C A1 dC
(1 R ) A
FA0 C A0 C A0 C Af ( r )
A

1 X A1 ( C dX ) X A1 dX
(1 R ) A0 A
(1 R ) A
C A0 X Af ( rA ) X Af ( r )
A

V X Af dX
(1 R ) A
FA0 X A1 ( r )
A

M4-6
XA1=? CA1=? FAf FA0 (1 X Af ) FA3 RFAf RFA0 (1 X Af ) A 0

FA1 FA0 FA3 FA0 RFA0 (1 X A f )

C A1
1 0 R f 0 R 0
C Af
1 R R (1 )
FA0 1 R(1 X A f ) C A0
C A0
0 1 R 1 R
C A0 RC
C Af
C A1
1 R

C A1 1 C A0 RC Af 1 R (1 X Af )
Also X A1 1 1 1
C A0 C A0 1 R 1 R
R
X A1 X Af
R 1

M4-7
 X Af
V dX A
FA0
( R 1)

rA
R
X A f
R 1)

1
AVGE HT.
AVGE. HT
r

X A1 X A f
R
R+1
M4-8
 Graphically

1 1

r r

0 0
X Ai X A f C Af C Ai C A0
R R
R+1
R+1

M4-9
 1 1

r r

0 0
X Ai X A f C Af C Ai C A0
R R
R+1
R+1

C A0 RC Af
R
C Ai
X A1 X Af 1 R
R 1 Rearrange to :
X A1 R
C A0 C Ai R
X A f R 11
C A0 C A f 1 R
M4-10
 Class example
For a recycle PF,
PF if we have XAf=0.9,
=0 9
XAi =0.45, what is recycle ratio R?

M4-11
 X Af
V dX A
FA0
( R 1)

rA
R
X A f
R 1)

1
AVGE HT.
AVGE. HT
r
V
Area
FA0
X A f (AV.HT.)

X A1 X A f
R 1
R+1
M4-12
 Av.H ( X to X Af )
Ai
1

r Av.H ( 0 to X )
Af

1 2

X Af
dX A
X A1 X A f Area 2 rA
Av.H ( X A1 to X Af )
( X Af X A1 )
R X A1

X Af

R 1
R+1 ( R 1)
dX A
( R 1) Av.H ( X Af X A1 )
X A1
rA ( X A1 to X Af )

X Af
dX
X ( R 1) ( R 1) A
Av.H X
r ( X A 1 to X Af ) Af
Af X A1

X X
A

Af
1 A1 Area 1 Area 2
( R 1)( X X ) X V
Af A1 Af

F A0

M4-13
 C Ai dC A
(1 R )
C Aff ( rA )

1

r
What Area? AH

2 1
0
C Af C Ai C A0
R
R+1
M4-14
 Limits of recycle equation
X Af
V dX A

FA0 C A0
( R 1)

rA
R
X A f
R 1)

R0 ( Plugg)) R ( MFR)
X Af V X A ff
V dX A
FA0

0
rA
FA0 rA ff

1 Small R
1 Large R
r r

0 0
R 1 X Af R 1M4-15X A f
 Integration of recycle equation
1st Order (A= 0)

rA kC A
dC A R 1
ln C A C Af
C A1
R (1 R )
C A1
C Af kC A k
R 1 C A1 R 1 1 C A0 RC Af
R ln ln
k C Af k C Af 1 R

R 1 C A0 RC A f
R ln
k ( R 1)C A f
 Compare ( st order))
p to PF (1
R 1 C A0 RC A f R 1 C A RC A (1 X Af ) 1 R (1 X Af )
ln ln 0 0
ln
R

k ( R 1)C A f

k ( R 1)C A0 (1 X Af
) C ( R 1) ( R 1)(1 X Af )
P 1 1 1 1
A0
1
ln ln ln
k 1 X Af k 1 X Af 1 X Af

g p
graphically
y
R 30
p
10 As R
c eases,
increases,
move from
PFR MFR
1 R=0 (PFR)
1-XAf
0.01 0.01 1.0 M4-17
 XA
k `m
1 X A

R 1 C A0 RC A f
R ln
k ( R 1)C A f

1
k p ln
1 X A

M4-18
Similarly for 2nd order

XA
k mC A0
1 X A 2

XA
k p C A0
1 X A

M4-19
 Optimum recycle ratio
Differentiate with respect to R and set to zero

d

X Af
CA
dX A 0 0
C A0

R
( R 1)
rA
need
dR
X Ai X A f
R 1)

When XAf has a fixed value, optimum R

occurs where:
X Af
dX A
1

X Ai
rA

rA X Ai
X A f X Ai
M4-20
 At optimum R: 1/(-rA) at the entry to X Af
the reactor is equal
q to the average
g 1/(-( dX A
rA) in the reactor as a whole. 1

X Ai
rA
Graphically:
p y
rA X Ai
X A f X Ai

KL < PQ KL = PQ at ROPT KL > PQM4-21

 From XA CA
X Af C Ai
dX A dC A
1

X Ai
rA 1
rA

C Af

rA X Ai
X A f X Ai rA C C Ai C A f
Ai

Graphically: 1

r

0
CAf C Ai C A 0
R
R+1 M4-22
 X Af C Ai
dX A dC A
1
rA rA
X Ai 1

C Af

rA X Ai
X A f X Ai rA C C Ai C A f
Ai

1

r

0
CAf C Ai C A 0
R
R+1
M4-23
 Class Problem 1
IIn the
h presence off a specific
ifi enzyme E,
E which
hi h acts as a
homogeneous catalyst, a harmful organic A present in
industrial waste water degrades into harmless chemicals.
chemicals
At a given enzyme concentration CE test in a laboratory
mixed flow reactor give the following results:
CA0, mmol/m3 2 5 6 6 11 14 16 24
CA, mmol/m3 0.5 3 1 2 6 10 8 4
, min 30 1 50 8 4 20 20 4
0 1 m3/min of this waste water having CA0 = 10
We wish to treat 0.1
mmol/m3 to 90% conversion with this enzyme at concentration
CE. One possibility is to use a long tubular reactor (assume PF)
with possible recycle of exit fluid. What design do you
recommend? Give the size of the reactor and tell if it should be
used with recycle. If so, determine the recycle flow rate in
m3/min. sketch your recommended design. M4-24
 Solution CA0, mmol/m3 2 5 6 6 11 14 16 24
v=0.1 m3/min CA, mmol/m3 05
0.5 3 1 2 6 10 8 4
CA0=10 mmol/m3 , min 30 1 50 8 4 20 20 4
1 m 3 / min
i
, 20 0.5 10 2 0.8 5 2.5 0.2
rA C A 0 C A mmol

For graph,
F h we fi
find
d th
the optimum
ti
25
position: CAi = 6.6
20 R 10 6.6
0.607
15
1 6 .6 1
-(1/rA)

A
Area 1.2 (10 1)
10.8(min)
10

5 V 10.8 0.1
0

1.08(m ) 3

0
0 2 4 6 8 10 12
R 0.1 0.607
R 0

1 CA R 0.0607(m / min) 3

M4-25
Lastt session
L i
Recycle PFR
Recycle
Recycle ratio
Design equation
Relationship between recycle PFR, MFR and PFR
Optimum recycle ratio

Next session
Temp effects
ff
On k/rate
Reactor design procedure
Opt. temp progression

M4-26
 Temperature effects
Several questions arise for reversible
reaction:
How does equilibrium, rate and product
distribution change with T?
What is the optimum temperature progression?
How will heat have effects on change of the
reactors temperature?
What is the most favourable reactor system?

M4-27
 Primarily investigated in
Conversion
Reactor stability X Ae
ENDO
Size of reactor 1
Thermodynamics enables
us to determine heat of
reaction and maximum EXO

conversion 0
T
Equilibrium constant is
affected by temperature

M4-28
 Graphical reactor design procedure
1) r = f (T,C) C
r3
r2
r1
T
2) XA vs. T (plot)
XA XA

1
10 1
10
100
100
T T

Reversible EXO Reversible ENDO M4-29

M4-30
 The Method
Size of reactor for a given XA and temperature
progressioni can beb found
f d as follows:
f ll
((1)) Draw reaction ppath on XA vs. T diagram
g
(operation line)
(2) Find rate at various XA values along this
path
(3) Plot (1/-rA) vs. XA for this path
(4) Find area under curve to give V/FA0 for PFR

M4-31
 Examples
p
(1) Consider path AB for PFR and arbitrary
temperature profile
1
XA V
r FA0
1 C2
08
0.8 B -rr = 0.01
0 01 100
0.5 0.02
C3
C2 500
0.3 0.05 C1
C3

20
C1 A T
T1 0.3 0.5 0.8 1
XA
M4-32
 (2) Consider path CD,
CD non
non-isothermal
isothermal PFR
with 50% recycle
1
XA
r
1 D
0.8 100
1
R+1
K
C
0.4 0.05 50
1
R 00.02
02
K
-r = 0.01 T V
T1 R R+1 04
0.4 08
0.8 1
FA0
R XA
1
R+1
 (3) Consider point E for mixed flow

1
XA V
r FA0
E Point E
0.7

T
T1 0.7 1
XA

M4-34
 Optimum Temperature progression
Minimises V/FA0 for g given
XA XA Best path is
isothermal
Aim
Ai to t always
l have
h system
t
at T where rate is maximum 0.7

The path of maximum rates

is found by examining the r,r
1
T, XA curves 10 100
T
Endothermic
d h i reactions,
i usedd
highest allowable T Tmax allowable

M4-35
 Exothermic reactions
Where system is far
Path
P h off f
from m use high
hi h T
XA maximum rate
As m is approached,
approached
1 use low T to shift rate to
10
a more favourable
fa o rable value
al e
100
T Optimum path?
Tmax allowable Highest
g allowable
starting T follow path
of maximum rate on
rate curves M4-36
M4-37
Last session

Temp effects
On k/rate
Reactor design procedure
Opt. temp progression
Opt.

This session
Adiabatic operations
Energy
E balance
b l
Operating line
Optimum
Optimum size of reactor?
Best reactor type.
Non-adiabatic operations

M4-38
Thermo review

M4-39
In a reactor system

M4-40
Heat effects (adiabatic operations)
X A0 0
T1 Heat absorbed or
released

X A , T2
Insulated
Let CP, CP = mean specific heat of unreacted
feed and completely converted product per mole of
component
Let H
H, H
H = enthalpy of unreacted feed stream
and completely converted product per mole of
component.
Let Hr = heat of reaction per mole of reactant A
M4-41
 Using T1 as reference (under 1mol of A)
Enthalpy of feed H1' C p' (T1 T1 ) 0
(A)
E h l off leaving
Enthalpy l i stream
H 2'' X A H 2' (1 X A ) CP'' (T2 T1 ) X A CP' (T2 T1 )(1 X A )
(P) (A)
Energy absorbed by reaction: Hr1 XA
Substitution into energy balance
accum. disapperan
di ce
input output
0 by reaction
At steady state
0 CP'' (T2 T1 ) X A CP' (T2 T1 )(1 X A ) H r1 X A
M4-42
 Rearrange
C P' (T2 T1 ) C P' T
XA
H r1 (C P C P )(T2 T1 ) H r1 (C P'' C P' )T
'' '

heat needed to raise

C P T feed stream to T2
'
XA
H r2 heat released by

reaction at T2
On a plot of XA versus T,
T slope of adiabatic
operating line is
'
C P
H r2
M4-43
 C P' T
XA when X A 1 H r 2 C P' T
H r 2
Graphically
Graphically adiabatic operating lines
ENDO
XA
EXO

T
T1 = feed temperature
PFR fluid temperature moves
progressively along line
MFR T, XA jumps to final value
M4-44
 Size of reactor?
PFR tabulate (rA) for various XA along
adiabatic operating line
MFR use rate at conditions within reactor
Graphically: 1
Along AB
XA r
B 1 1.0
2 3
V
0.6 4 FA0
1
4
T
A 0.6
XA
M4-45
Endo, Plug Flow
Best adiabatic operation for single PFR?
Shift operating line to where rates have
hi h t mean
highest
For exothermic in single
g PFR straddle locus
of maximum rates
XA
XA required
Locus of
maximum
rates
T

low high
Correct inlet T to minimise V/FAo M4-46
Best adiabatic operation for single MFR?
Find point at locus line cross conversion

XA
XA required
Locus of
maximum
rates
T

low high
Correct inlet T to minimise V/FAo

M4-47
 Best reactor type?
Find directly from XA versus T plot
If rate
t decreases
d with
ith XA use PFR
(endothermic) 1
Along AB
XA r
B 1 1.0
2 3

0.6 4
1
4
T XA
A 0.6

Area under curve < for MFR

M4-48
 Exothermic reactions?
Two limiting situations determined by slope
of CP//-Hr
1

(a) small CP/-Hr (recycle or MFR) r

/ Hr (PFR bbest)
(b) llarge CP/- t)
XA XA
'
1

r
Large CP//-Hr
'
XA
(use PFR)
''
XA
0 ''
XA
T

Small CP/-Hr (use large recycle

M4-49
or MFR)
M4-50
 Class Problem 2
We have a 1st order aqueous reaction:
A R
CpA=250 cal (mol A)-1 K-1, Hr=-18000 cal (mol A)-1
If the reaction is going to be performed in a MF
reactor to achieve 80% conversion, a) what size
of reactor is needed and what is the operation
temperature? b) what is the heat duty if feed
enter at 250C and product is to be withdraw at
p
this temp?
Feed condition:
CA0=4 mol/litre
mol/litre, FA0=1000 mol/min
(Fig E9.3 can be used
M4-51 )
Solution: As it is a MF, for XA=0.8 we have C point where rate
(a) is maximum: -rrA = 0.1 mol/L min and T=62 0C
0 1 mol/L.min
Also due to CA0=4 mol/L,
the real rA = 0.4 mol/L.min

The MF will operate at 62 0C

mol
1000 0.80
F X
V A0 A min
i
2000 L
rA mol
0.4
min L

M4-52
C

M4-53
Solution: As it is a MF, for XA=0.8 we have C point where rate
(a) is maximum: -rrA = 0.1 mol/L min and T=62 0C
0 1 mol/L.min
Also due to CA0=4 mol/L,
the real rA = 0.4 mol/L.min

The MF will operate at 62 0C

mol
1000 0.80
F X
V A0 A min
i
2000 L
rA mol
0.4
min L
(b)
call
250 0.8 1
Cp molA K 1 1 T 5 C 0

slope K 62 T 72
in

Hr cal 72 in
18000
molA
M4-54
 D
C

B A
M4-55
 If we make (XA=0, T=50C) as B point,
A point : (XA=0, T=25 0C)
D Point: (XA=00.8,
8 T 25 0C)
T=25
Pre-cooler:

cal molA
Q 250 (25 5)( K ) 1000
molA K min
A B

cal
5,000,000 348.7kw
min
Post-cooler:
cal molA
Q 250
2 0 (62 25
2 )( K ) 1000
molA K min
C D

cal
9,250,000 645.0kw
min M4-56
 Class Problem 3
We have a 1st order aqueous reaction:
A R
CpA=250 cal (mol A)-1 K-1, Hr=-18000 cal (mol A)-1
If the reaction is going to be performed in a PF
reactor with exit temperature at 62oC to achieve
80% conversion and the reactor follows an
adiabatic operation, a) what size of reactor is
needed?
Feed condition:
CA0=4 mol/litre, FA0=1000 mol/min
(Fi E9
(Fig E9.33 can be
b usedd )
M4-57
Solution: As adiabatic, following the operation line with a
slope
l off 1/72 K-11.
Reading from the operation line we have the
following data:
Xa
(-rA/4)
1/-rA
 C

B
M4-59
Solution: As adiabatic, following the operation line with a
slope
l off 1/72 K-11.
Reading from the operation line we have the
following data:
Xa 0.00 0.06 0.21 0.35 0.42 0.60 0.70 0.80
(-rA/4) 0.02 0.03 0.05 0.08 0.10 0.15 0.15 0.10
1/-rA 12.50 8.33 5.00 3.13 2.50 1.67 1.67 2.50
Ai 0.63 1.00 0.57 0.20 0.38 0.17 0.21 sum= 3.14

14.00
0.8
dX A
V FA0
12.00

rA
10.00

8.00 0
1/-rA

6.00 mol L min

4.00 1000( ) 3.14( )
2.00
min mol
0.00 3140( L)
0.00 0.20 0.40 0.60 0.80 1.00
Xa

M4-60
 Non-adiabatic operations
Consider MFR
Heat exch.

T1

X A , T2

Losses

Q = total heat added per mole of A
entering (including heat losses to
surroundings) M4-61
 Heat balance becomes
input output disapperance
Q [ C ( T T ) X C ( T T )( 1 X )] H X
''
P 2 1 A
'
P 2 1 A r1 A

C T Q
'

Assume C C , Rearrange
' ''
X P

H
P P A

r2

Graphically

XA Heat
removal
Summary

Adiabatic operations
Energy balance
p
Operatingg line
Optimum size of reactor?
Best reactor type.
Best type

Non-adiabatic operations

M4-63