Basics of

Reactor Design & Selection

Mechanically Agitated Contactors

Prof. A. B. Pandit
Institute of Chemical Technology
University of Mumbai
 Design Variables
Independent Variables
1. Reactor Geometry : Diameter, Height
2. Impeller type
3. Impeller diameter
4. Impeller Position
5. Impeller rotational speed

Minor Variables

6. No. of baffles / baffle width

7. No. of nozzles / nozzle diameters
8. Other reactor internals :
coil, sampling point, foam breaker etc
 Function of Impeller

1. Mixing of liquid / liquids

2. Disperse gas / vapors
3. Suspend solid particles
4. Achieve certain heat transfer
 Dependent Variables
Parameters defining them:

1) Power
Important design variable; decides the operating cost

P = Power (watts) = NP  N3 D5

NP – power number, function of impeller type and a weak function of

geometry of vessel, strong function of Reynolds number, Re
for Re< 104

– density of fluid, kg/m3 N – speed of rotation, rev/sec

D – diameter of impeller, m
P
Power/unit volume =
π T 2H
4
• Good overall criteria for heat transfer, solid suspension and gas dispersion
• Not so good for mixing, except shear sensitive material
 Dependent Variables

2) Torque
Useful for drive consideration / selection

Power N P
Torque = τ = = ρN 3D5
2πN 2π

• Also useful for selection of gear box, sizing of shaft

• Good criteria for flow velocity sensitive operations
 Dimensionless Numbers
P
1) Power Number : N P =
ρ L N 3 D5
ND 2ρ Inertial forces
2) Reynolds Number : Re = 
 Viscous forces
 – viscosity of fluid at operating conditions, kg/m s, mPas
1 cp = 1mPas = 0.001 kg/m s

Relation between NP & Re

100

Different impeller type NP independent of

10
NP =
P Re for Re  104
ρ L N3 D5

1
ND 2ρ
Re =

10 100 1000 104 105
 Dimensionless Numbers
N 2 D Acceleration due to impeller
3) Froude No. : 
g Acceleration due to gravity

Useful in mixing of different density liquids

N 2 D3  inertial forces
4) Weber Number : 
 surface tension forces
 – surface / interfacial tension, N/m

Useful in deciding gas dispersion or liquid emulsion

5) Blend Number : NB = N

N – speed of agitation, rev/sec
 – mixing time to achieve specific homogeneity
 Dimensionless Numbers
Q
4) Pumping Number / coefficient : NQ =
ND3

Useful in correlating pumping capacity of various impellers

D
Experimental observations : N Q 
T

 T
0.5
Q D
NQ  Q – pumping rate, m3/s
ND3
Concept of turnover

4) Richardson Number :
Δρ ρ L g H
Ri =
ρL N 2D2
 Certain Critical Impeller Speeds

1) Minimum impeller speed for gas dispersion :

NC D 2 Constant as a function of type

1.25 Qg
T
2) Minimum impeller speed for surface aeration :

 
0.45
N JS = S υ0.1 d P 0.2 gΔρ X 0.11 D-0.85
ρ
S – function of impeller type

3) Minimum impeller speed for solids suspension :

0.19
NS D 1.98
 g 
 1.34  
T 1.1   
 Geometric Consideration
1) D/T ratio : 0.2 ≤D/T ≤0.5
Low D/T : low purchase price
low power
high shear/ low pumping
B
H High D/T : Higher operating costs
Higher price
Low price / High pumping
C
2) H/T ratio : 0.5 ≤H/T ≤1.0
D Multiple impellers for H/T ≥ 1.0

T
3) C/T ratio : 0.1 ≤C/T ≤0.3
Solid suspension, low C/T etc.

4) B = Baffles, 4 in No. diametrically

opposite
B/T  1/10 to 1/12
 Heat Transfer
Correlation for Reactor side HTC : x
km
-0.14
hRT 0.33  μ wall 
=1.35  Re   N Pr    N Fr 
0.59 -0.1

k μ
 bulk  hR
ho
…..For jacket heating / cooling
fluid
-0.14
hRT 0.33  μ wall 
= 0.87  Re   N Pr    N Fr 
0.64 -0.1

k μ
 bulk 
…..For coil
wall
limpet
Overall heat transfer coefficient ‘U’ :
1 1 x 1
= + +
U hR km ho x – metal thickness
Km – metal conductivity
ho – outside heat transfer coeff. (k.cal/hr m2 OC)
 Typical Processes

Equal fluid Motion by far the most common actual mixing

requirement: Adequate for heat transfer and solid suspension or
gas dispersion.

Equal fluid Motion

1. Most common mixing requirement
2. Constant torque per unit volume
3. Ensure motion throughout the tank
4. Solid suspension application
5. Blend time increases with increase in the reactor diameter
6. Flow velocity sensitivity operations e.g. heat transfer
 Typical Processes
Dispersion
1. Constant P/V
2. Usually high shear , radial turbine
3. Gas dispersion
4. Emulsification
5. Shear sensitivity operations

Solid Suspension
1. Scale-up rules can vary
2. P/V decreases with increase in tank diameter
3. T/V can be constant

Surface Effects
1. Vortex formulation
2. Dry solids drawdown
3. Foam breading / non-wetting nature
 High Viscosity Special Cases
Special Impellers : Close wall clearance
Anchors, Helical ribbons, screws / draft tubes
Range of applications :
Anchor : 10,000 cp – 1,50,000 cp
Ribbon : 30,000 cp – 1,50,000 cp

Power response can be calculated from

NP x Re = Constant
NP
constant
P= ρ N3 D5
Re
Re
Blend time can be roughly estimated from
N = 50
 Scale up techniques
Criteria for scale-up
N = constant. or constant tip velocity

Scale up criteria Validity of operation

1. Dimensionless Number (hT/K) Good for heat transfer

2. Impeller rotational speed (N) Good for mixing time

3. Power (P/V) Fluid motion, dispersion

(but not solids suspension)

4. Torque Fluid motion

(including suspension)
 Impeller type & flow patterns
1) Radial flow : Turbine, paddles

Two loops with exchange at impeller plane

 Impeller type & flow patterns
2) Axial flow : Propeller, Hydrofoil (fans)

Single loop : Low velocity

 Impeller type & flow patterns
3) Mixed Flow : 4) Complex Flow :
Pitched blade turbines Ribbons / screw

Two superimposed No loop : no mixing

loops with greater
exchange
 Utility of the relations in design
Problem Statement : Dehydration and esterification of long / medium oil is
to be carried out as per the recipe.
Process Conditions : Max temp. 260oC
Reactor charge : 3235 kgs of oil
Starting temp. of oil : 30oC
Solvent used : Xylene (100 kgs)
Other raw materials : Penta, pthalic in solid form

Neglecting reaction kinetics and assuming no heat effects associated with

the reaction.

The Reactor is expected to carry out the following physical operations

1. Mixing of solid / liquid raw material
2. Mixing of xylene for the removal of water of dehydration and or reaction
3. Supply of heat with thermic fluid to achieve temperature as per recipe.
 Utility of the relations in design
Now let us assign some time frame to the above operations

Operation Alloted time (sec) Why this time

1. Heating oil to 150oC 1 hr Could be reduced

2. Heating to M. G. 1 hr / 1 hr 15 min Thermic fluid as

temp. 245oC limiting temp
3. Cooling to 170oC 30 min Cooling media temp

4. Heating to 170oC 30 min Phthalic reactions

(not too fast)
5. Esterification 6 to 7 hrs Reported O. K.
 Utility of the relations in design
A) Selection of Geometry :
Total occupancy : 6o% of the geometric volume
 Geometric volume = (3235+100)/0.6 = 5.56 K. L.
Let H/T  1.0  H = T = 1.92 m
Dished ends : Ease of drainage / discharging
Actual diameter to be selected in consultation with the fabricator :
Available plate size, no waste

Let T = 2.0 m, Hence rough geometry

4 in no. (0.2m) 2.0 m

2.0 m
 Utility of the relations in design

B) Selection of heating surface /form/cooling :

1. Limpet coli 2. Jacket
Form of heating : steam or Thermic fluid

Max. temp. 260oC and hence hot fluid temp. 200oC very high steam pressure,
increase in reactor wall thickness expensive

Thus : Thermic fluid : due to high viscosity it requires good velocities :

not possible in jacket due to large flow areas
and hence Limpet coils.

Cooling : Cooling oil or cold fluid through limpet coil.

 Utility of the relations in design
C) Selection of Impeller :
Properties of fluid required for the same
 - viscosity at operating temperature or range of viscosities or max.  300
cp  3 poise 200oC
 - density of fluid  900 kg/m3

Functions expected of impeller

Generate sufficient liquid motion : well directed to give
1) good mixing
2) good heat transfer
3) good solid suspension
4) good nitrogen dispersion (blanketing)

For the range of viscosities & densities encountered

Anchor and / or ribbons are not required
 Utility of the relations in design
Impeller type Its best usefulness

1. Radial flow Gas dispersion and heat

transfer
2. Axial flow Good for mixing, good solid
suspension
3. Mixed flow Multipurpose impeller

Better designs are available enhancing any of the above 4 functions

Radial flow : higher power consumptions

Axial flow : lower power but not good for dispersion

Thus MIXED FLOW IMPELLER IS SELECTED

Various designs are available : by varying pitch axial or radial component can
be altered, by making it profiled, it could alter shear and flow levels etc.

Due to slightly higher viscosities D/T ratio used  0.5 and two
impellers on the same shaft can be used
The final geometric design

Parameter selection

The only parameter remains to be selected

1 is ‘ impeller speed’
We have number of choices
2.0 m
0.75
1. Impeller speed required for heat transfer
Largest heat duty : during esterification
0.75
Alloted time 6 hrs.
2.0 m
This time includes
1) 170 to dehydration temp
2) dehydration
3) esterification
 The final design
Heat duty for each operation
1. m CpT = 3235 x 0.5 x (260-170) = 144575 kcal

2. Dehydration = water removed  80 kg

= 43200 kcal

3. Esterification = water removed  120 kg

= 64800 kcal

For 2 & 3 xylene is also evaporated

200 kgs of water is removed in 5 hrs.  40 kgs of water removed/

hr (if removed)

If less then accordingly : 100 kgs of xylene present

Based on the azeotropic concentration 1 kg of water is associated
with 18kg of xylene
 The final design
4. Heat duty required for xylene evaporation = 720 x 95 x 5 = 34200 kcal
Thus, total heat duty in 6 hrs is Q = 1 + 2 + 3 + 4  595000 kcal
 1,00000 kcal/hrs

Total heat transfer area is 15.0 m2 of limpet coil

 285-170 -  285-260 =
Average temp. gradient = 115
 ΔT  =59oC
ln
25

Thermic fluid temp. is assumed to 285 oC

Q 1,00000
Hence the required HTC = =
A . ΔT 15.0×59

kcal
U =113
hrm2oC
 The final design
Impeller speed required is calculated as follows

1 1 x 1 1 1 1 0.006
= + +  = + +
U hR km ho 113 h R 800 km

kcal
hR 226
hr m2 oC

23 13 0.24
hR T  ND ρ 
2
  CP   μw 
=0.485    k    T =2.0 m;k o =0.163
kcal
ko  μ     μ  hrm2oC

kcal
D=1.0 m;hR =226
hrm2oC
N = 1.52 r/s  91 rpm (90 rpm) kg kg
 =3 poise=0.3  1080
ms mm
Now check whether this impeller speed CP =0.5
kcal
;   900kg m3
satisfies the other operational o
kg C
requirements
 The final design
Heating to 150oC in 1 hr.

Heat duty = m Cp T
= 3235 x 0.5 x (150-30) = 194000 kcal
Heat flux obtainable = U A T
= 113 x 15 x [(285-30)-(285-150)]/ln(255/135)
= 319816 kcal / hr.
Expected time of heating = 194000/319816 = 0.6 hrs  37 min.

Other parameters can also be checked

Cooling requirement also appear to be adequate if the thermic fluid is

available at a temp. of 100oC or below
 The final design
Mixing time calculations :

length of longest loop

θ= ×5
Avg. circulation Velocity
4 mt. 4×5
= ×5= 21sec
0.1×2 ND 0.942

Final mixing depends upon the exchange between the two loops which is  35 %.

21
θmix   60 sec 1min
0.35
GOAL ACHIEVED

Process Reactor design is complete

 Impeller drive selection
Parameter known : D = 1m, N = 1.5 rev/sec
Impeller type : Mixed flow, NP = 1.0 for Re > 104

1.5×  1 ×900
2
2
ND ρ
Reynolds Number = = = 4500
μ 0.3
Thus, you can
• Expect NP to increase to about 1.1
• Actual power curve is necessary

Power, P = NP  N3 D5 = 1.1 x 900 x (1.5)3 x (1)5 = 3341 watts

Now two such impellers
 Total power = 1.9 x 3341 = 6348 watts = 8.5 HP

Thus with the knowledge of gear efficiency 10 HP motor should be

adequate giving
P {Normal Range is 1 to 5 kw/m3}
=1.81Kw m3
V
Thus quite satisfactory.
Additional Process Calculations
• Separator design
• Nozzle selection
• Nozzle location

3
D ×RPM
HP= C = 50, for only torsional

C = 80, for torsional + bending

= 130 for

Mechanical design i.e. shaft diameter, critical speed

in consultation with the fabricator.
 Selection and design of accessories

Basic Reactor Configuration:

C
A
A – Reactor
B – Condenser for reflux
C – Separator for xylene return
& water removal

A – Reactor design has been complete

 Condenser Design
B – Design of condenser :

Maximum heat duty of condenser = Maximum heat supplied to the reactor

= Q = 100000 kcal/hr

Let it be a Shell and Tube Heat Exchanger

Cooling media = water at 30oC
Let the vapors be condensed and cooled at 30 oC

Vapors might be cooled due to atmospheric heat losses by the time they
come to the condenser

Let the vapor temperature be 150oC ( as against 260oC)

 Condenser Design
150oC
LMTD =
 150 -37  -  80-30 
150-30
37 C
o ln
80-30
= 77 o C
For water on shell side and vapors (condensing)
30oC
on tube side, overall heat transfer coefficient (U)
can be assumed to be  500 kcal / hr m2 oC
Q 100000
80oC Condenser Area, A = 
U  LMTD 500  77

 2.58 3m 2
Due to pthalic evaporation, considerable fouling is observed,
Thus, Let A  10m2
Mounted Vertical : Washing of vapors and preheating of returned
liquid
Fouling : Tube dia ≥ ¾”, periodic clearing
 Cooling water requirement
Total heat removed = 1,00, 000 kcal/hr

(T)water = 37-30 = 7oC

Q = m CP T

1, 00, 00 = m x 1 x 7

m = 14285 kgs/hr  15 m2/hr

Pump required with  of 50%

Power = h  g Q = [30 x 1000 x 9.81 x (15/3600)]/0.5

= 3.3 HP  3.5 HP  3KW

Conclusions
Condenser type = Shell & Tube Cooling water : 15 m3/hr
Tube size 3/4” at 3 kg/cm2 head
Area  10 m2  3 KW motor
Vertical Mounting
 Design of Separator
Options : Horizontal (larger space)
Vertical (less efficient)

Design information required

A. Time of separation of xylene / water
B. Reflux rate of xylene

A.  4 to 5 seconds : Lab experiments

B.  720 + 40 (xylene + water) : 760 kgs / hr
 950 lits / hr  265 ccs/s

Mean residence time of mixture  10 times of separation

 60 seconds or 1 min

Volume of the separator = 265 x 60 = 15900 cm3  16 lits

 Design of Separator

Separation is taking place with continual agitation due to falling liquid

Net liquid velocity  10 mm/s

 C/s area of separator = 265/1 (cm3/s)/(cm/s) = 265 cm2

 Diameter of separator  20 cm

 Height or length = 50 cm
 Separator Arrangements
A
B

xylene
vapors

vap

liquid
water

vapors
C
Xylene to
reactor

water
 Other Utilities

1) Thermic fluid boiler – 2, 00, 000 kcal/hr

Hytherm 600 – max. operating temp. 300 oC

2) Cooling water

3) Electricity : Flame – proof connection

 Design Problem
Problem Statement : To design a reactor for emulsion polymerization

Important Criteria
1) Size of the droplets
2) Heat of reaction to be removed
3) Controlling the molecular wt. distribution

Experimental work in the lab should provide the following information

1) Reaction kinetics : Rate of consumption of monomer as a function of
reaction conditions, monomer concentration and the
form (droplet surface area)
2) Heat effects associated with it
3) Effect of speed of agitation (shear) on the emulsion quality :

Droplet size distribution

 Design Problem
Interpretation of lab results

Formulation of mathematical model

Material Balance : Reaction R A = k1 CAm

 Ci  ki  Vi   ti  C1
 e-k1t1
 Ci -ki Vi Co

 - flow rate, m3/s Vi – initial volume, m3

k1 – rate constant 1/s Ci – molar conc. in inlet flow (gmoles/m3)
C - initial conc. gmole/m3 C1 – conc. at time, t1
 Design Problem

Heat Balance : Including the heat of reaction

Enthalpy in – enthalpy out + enthalpy generated = Accumulation of enthalpy

m CP Ti – (Atm. losses + heat removal) + R . HR = CPR T d/dt (mR) (1)

m – mass of monomer + water input, kgs/s

CPi – sp. Heat of entering mass, k.cal/kg oC
Ti - inlet temp. oC
R – rate of reaction, gm/s
HR – Heat of polymerisation, k.cal/gm
CPR – sp. Heat of reaction mass, k.cal/ kg oC
TR – temp. of reactor, oC
mR – reactor mass, kg
 Design Problem

Neglect atmospheric losses

Over a period of specified time period

t t
m CPi Ti  dt - QL CP Z ΔT ×t +R HR  dt
0 0

 t

=CPR TR  mi +m  dt  (2)
 0 

where QL CP  ΔT .t =totalheat removedby cooling water

From equation (1) and (2) total kinetic information can be obtained
 Design Problem
Process parameter selection
Geometrical consideration : Same as before
1) Mixing 2 ) Heat transfer 3) Effect of agitation on product quality

Factor 3 will affect the impeller selection in the following way

1) High shear impeller: low D/T, high speed, smaller drops, large shear
gradients, poor heat transfer at wall but good at
interface
2) Low shear impeller : High D/T, low speed, larger drops, lesser shear
gradient (less wide drop size distribution) good
heat transfer at wall but poor at interface

Thus, unless these effects on product quality are assessed in labs.

“Impeller selection is difficult”
Say we generate this information in labs, the design procedure is identical
σ 0.6
Additional Impeller
 V  ρC 
0.4 0.2
P
speed criteria d32 =a -0.1
 μc 
 μd 
 
 Design Problem
We require, one impeller speed for good mixing
second for good heat transfer
Third for good dispersion (emulsion)
fourth for particular drop size distribution

Now, all these impeller speeds are function of the following additional
parameters
1. Physical properties of system
2. Type and size of impeller
3. Required production rate (also dependent on temp. & catalyst conc.)
Thus number of combinations need to be tried for an optimum design
Again : parameter might be different for different recipes
Thus finding a compromise, suitable for all recipies

These are the general consideration in Reactor Design, many specific

are related to individual processes
 Mechanical Aspects
Material of Construction

Type of Services
• Continuous – Slow speed
• Otherwise – high speed
• Future changes / Experiments (built in flexibility)
• variable speed
 Power for agitator
Absorbed for agitator
Add for baffles and fittings
Dip pipes (10%) and thermo wells (40%)

Transmission Losses
Worm wheel < 85%
Helical gears > 90%
Planetary gears > 96%
V belts 90 to 95 %

Gland Losses
Higher of ½ HP or 10%

Motor Aspects
Oversize for start up
oversize for settling solids
next higher standard size
 Mechanical Aspects

Shaft diameter / size

• Slow speed : have design for (1.5 x full load motor torque)
• high speed : have design for (2.5 x full load motor torque)

Concerns
• Jamming
• Fatigue Failure
• Pitting / corrosion
• Deflection
 Mechanical Aspects
Shaft diameter
3300×12×HP
Tm = 2.5 Tc ton.in Tc =
2 n×2240
S
Tm
Force, Fm = ton
0.75r
dt
L Moment Mm = Fm x L ton.in
0.75 r
32 Mm
Stress, fy =
  dt 
3

2r

Shaft deflection
448 Fm L3
x x= =
0.75 r 9  D4 E
 Mechanical Aspect
Critical Speed

If ‘x’ is the critical speed we must not work at (0.7 x) RPM to (1.3 x) RPM

EI
x=k Rev / min.
Ws l4

E : Young’s Modulus
I : Moment of Intertia k
Ws : Weight of shaft
K : from graph

= L/S
= length / distance from
bearing
 Mixing
Types
• Liquid – Liquid (most common) a) density difference b) viscosity difference
• Solid – Liquid a) slurry b) suspension c) dissolution
• Gas – Liquid a) dispersion
• Liquid – Liquid (immiscible) a) emulsion / dispersion

Requirement
Energy to be supplied for moving the different phases
a) Supplied internally : e.g. Mechanically Agitated Contactors
b) Supplied externally : e.g. use of pumps, compressors, blowers

Devices Used
a) Stirred vessels
b) jet mixing
c) static mixing / mixers

Usually mixing is accompanied by other operations

 Jet Mixing

a) liquid jet : low to medium viscosity liquids

Liquid velocity generated

through the external pump

Z1L 2 T
Mixing time = θ =
 νido 
16 46
Re g1 6
 Jet Mixing

b) gas jet : medium to high viscosity liquids

Use of external compressor : different fluid

Multipoint Single point

 Static Mixers
Number of different designs are available
Simplest : baffle in heat exchanger shells
Job : divert the flow by putting an obstacle in its path

Energy associated with the moving fluid is used for mixing, i.e. if fluid is
made to go everywhere in the reactor / vessel uniformity (mixing) will be
achieved.

Common Examples

a) Kenics Twisted stripe

b) Sulzer SMXL / SMX

Inserted in pipes
Flow bifurcation takes place and
the direction is changed
 Energy for mixing
Stirred Vessel

P x mix = NP  N3 D5 x mix joules

Typical  = 0.2 to 0.4 %

Jet mixing

(Vg L g x volume) x  mix

Typical  = 0.03 to 0.8 % Due to pump or compressor 

Static mixing

(P x volumetric flow rate) x (L/velocity)

Typical  = 1 to 10 %

One of the most energy “Inefficient” operations

“Considerable Scope for improvement”

 Problem Statement

1) To carry out blending of two liquids

2) To transfer O2 in the fermenter liquid by air sparging

3) To suspend the catalyst particle in a liquid – uniform suspension

4) To control the temperature of the reactor

5) Hydrogenation of fatty oils to saturated oils

a) Suspend Raney-Nickle catalyst

b) Sparge and distribute hydrogen

c) Control the hydrogenation temperature

 Problem statement
1) Blending of Two miscible liquids
e.g. Std. geometry, disk turbine
Estimation of ‘N’ (dimensionless mixing time)

Requirement

C
1) Length of loop, longest
D
2) Average velocity
3) No. of circulations
B E
A
1) Length of the longest loop ‘ABCDE’
2) Average velocity Vrw = 0.53 (D/w) ND (D/T)7/6
3) No. of circulations  5 for 95% mixing

4) mix = 5 x circulation time

 aH+ T  T
   w d
13/6
Nθ=9.43  
 T  D
Thus, loop length and average velocity
 Problem Statement
2) To transfer O2 in fermenter :
Requirement : 1) Good gas dispersion
2) Generate interfacial area
Rate of O2 transfer, gms/s = KLa x C* x V (1/s x gm/m3 x m3)

And
KL a = 0.025 (P/V)0.59 (VG)0.5

P/V – watts/m3, VG = superficial gas velocity, (m/s)

N
PG = NPG L N3 D5
NPG/NP

Can be obtained by changing P/V or VG

QG/ND3 Typical P/V – 1000 to 5000 watts / m3

VG  30 to 40 mm/s

P/V =  g VG
 Problem Statement
3) To suspend catalyst particles
0.45
 gΔρ 
Njs =S  0.1 dp0.2   x0.11 D-0.85
 ρ 

S – function of impeller type, location & geometry

b
 QG 
NjsG =NjsG  x  3 
 ND 
x – type of sparger / location and regime
b – extent of reduction in NPG

Thus knowing dp, , x & S. Select either Njs for a fixed D or select D for a

fixed Njs.

Now, Power  N3 & D5. OPTIMISE / SCALE EFFECT

 Problem Statement
4) To control reactor temperature
Know heat flux Q = U A T
Know ‘A’ from reactor geometry
Know T from heat transfer medium conditions
Estimate U.

1 1 x 1
Now, = + +
U hR k m ho
Jacket -0.14
hR T 0.33  μwall 
=1.35  Re   Pr  
0.59
N 
k μ
 bulk 

0.64 0.33 0.14

Coil hR T  ND2ρ    CP   μw 
=0.87    k   
ko  μ     μ 

Optimise ‘ N & D’ in Re to get required ‘h R’

 Problem Statement
5) To control reactor temperature
a) Estimate Njs for the catalyst loading (Na)

typically, dp  5.0 x 10-6 m

x=5%
b) Estimate Required KL a (Nb)
i) Calculate NS = 1.25 QG 0.25 (T/D2)

ii) Estimate KL a or P/V (N) & VG to get the desired KL a

iii) Estimate H2 transfer rate

Estimate Njs again

c) Estimate N for the required heat transfer coefficient (Nc)

Select the higher of Na, Nb & Nc to satisfy all the requirement

Mixing time measurement methods