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    CHEE 321: Chemical Reaction Engineering: Module 3: Isothermal Reactor Design

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    Pranav Nakhate
    This document provides an overview of Module 3a: Isothermal Reactor Design for the course CHEE 321: Chemical Reaction Engineering. It introduces the 4-step algorithm for solving reactor design problems for CSTRs and PFRs. Examples are provided for solving problems for batch, CSTR, and PFR reactors. It also discusses CSTRs in series, Damkohler numbers, and reactor configurations like parallel vs. series setups. The module focuses on ideal isothermal reactors and single reactions.

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    CHEE 321: Chemical Reaction Engineering: Module 3: Isothermal Reactor Design

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    Pranav Nakhate
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    This document provides an overview of Module 3a: Isothermal Reactor Design for the course CHEE 321: Chemical Reaction Engineering. It introduces the 4-step algorithm for solving reactor design problems for CSTRs and PFRs. Examples are provided for solving problems for batch, CSTR, and PFR reactors. It also discusses CSTRs in series, Damkohler numbers, and reactor configurations like parallel vs. series setups. The module focuses on ideal isothermal reactors and single reactions.

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    This document provides an overview of Module 3a: Isothermal Reactor Design for the course CHEE 321: Chemical Reaction Engineering. It introduces the 4-step algorithm for solving reactor design problems for CSTRs and PFRs. Examples are provided for solving problems for batch, CSTR, and PFR reactors. It also discusses CSTRs in series, Damkohler numbers, and reactor configurations like parallel vs. series setups. The module focuses on ideal isothermal reactors and single reactions.

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    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    140 views16 pages

    CHEE 321: Chemical Reaction Engineering: Module 3: Isothermal Reactor Design

    Uploaded by

    Pranav Nakhate
    This document provides an overview of Module 3a: Isothermal Reactor Design for the course CHEE 321: Chemical Reaction Engineering. It introduces the 4-step algorithm for solving reactor design problems for CSTRs and PFRs. Examples are provided for solving problems for batch, CSTR, and PFR reactors. It also discusses CSTRs in series, Damkohler numbers, and reactor configurations like parallel vs. series setups. The module focuses on ideal isothermal reactors and single reactions.

    Copyright:

    Attribution Non-Commercial (BY-NC)
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    of 16

    CHEE 321: Chemical Reaction Engineering

    Module 3: Isothermal Reactor Design

    3a: Solving Reactor Design Problems (Single Reaction in batch, CSTR, PFR) Chapter 4.1-4.4, Fogler

    Module 3a: Isothermal Reactor Design


    Topics to be covered in this module
    4-Step Algorithm for solving reactor design problem CSTR in-series
    Damkohler Number (Application to design of CSTR-in-series)

    Still working with ideal reactors and single reactions

    In perhaps no area of engineering is mere formula plugging more hazardous; the number of physical conditions that can arise appear infinite, and the chances of a simple formula being sufficient for the adequate design of a real reactor are vanishingly small.
    From Fogler, Ch 4 intro

    General Algorithm for Solving Isothermal Reactor Problems


    1. 2.

    General Mole Balance Equation (GMBE) Rate Laws


    Write down rate law in terms of limiting reactant

    3.

    Stoichiometry
    relate concentration to volume and number of moles (for batch reactors) or to volumetric flow rate and molar flow rate (for flow reactor) Relate volume or volumetric flow rate to conversion, pressure and temperature

    4.

    Combine and Solve


    Substitute rate law and stoichiometry in to the GMBE

    See Fogler Figure 4.1

    General Algorithm (Fogler, Figure 4-2)

    Reactor Design (Single Reaction)


    Constant volume (or volumetric flow) systems
    Generally easier to set up and solve Liquid-phase or gas phase systems with no change in moles

    Example 1: Batch Reactor Example 2: Gas-Phase PFR with reversible reaction

    Systems with changing volume (or volumetric flow)


    Gas phase systems with change in moles due to reaction

    Example 3: Gas-Phase reaction in a PFR Example 4: Gas-Phase reaction in a CSTR

    Example 1
    Constant volume batch reactor with reaction A B and 2nd order reaction GMBE: Rate Law: Stoichiometry: Combine:
    dN A = rAV ; N A = N A0 at t = 0 dt
    2 rA = kC A

    C A = C A0 (1 X A )
    N A = C AV ; dN A dC A dX =V = VC A0 A dt dt dt

    2 2 2 rA = kC A = kC A 0 (1 X A )

    dX A = kC A0 (1 X A ) 2 dt

    Integrate and Solve:

    t=

    1 XA kC A0 1 X A

    Example 1 (contd): constant volume batch reactor


    For 2nd order reaction order reaction
    t= 1 XA kC A0 1 X A

    For a

    1st

    1 1 t = ln k 1 X A

    (see Fogler Ex. 4.1)

    Time to reach 90% conversion can vary from hours to less than a second, depending on the magnitude of k (or kCA0 ) [See Table 4.2 in Fogler] 1st order: if k=10-4 s-1, 6.4 h to reach 90% conversion 2nd order: if kCA0=10-4 L/(mol-s), 25 h to reach 90% conversion Practical issues with batch reactors: - Table 4.3 in Fogler - Can you think of others?

    Example 2 (CSTR, constant volumetric flow)


    The elementary liquid-phase reaction
    k1 R +S A + B k2

    is to take place in a 120 L steady-state mixed reactor. Two feed streams, one containing 2.8 mol-A/L and the other containing 1.6 mol-B/L, are to be introduced in equal volumes into the reactor, and 75% conversion of the limiting component is desired. What should be the flow rate of each stream? Assume a constant density throughout, with k1= 7 Lmol-1min-1 and k2= 3 Lmol-1min-1 .

    CSTR in series
    CA0 X=0 v0 CA1 CA2 X=X2

    V1 ; k1

    X=X1

    V2 ; k2

    Liquid-phase (v = v0), first-order reaction

    Mole Balance on CSTR-1


    FA0 FA v [C C A1 ] V1 = = 0 A0 k1C A1 (rA ) at X = X 1

    Mole Balance on CSTR-2


    V2 = v [C C A 2 ] FA1 FA 2 = 0 A1 k 2C A 2 (rA ) at X = X 2
    [C A1 C A 2 ] C A1 = 1 C A2 C A2 C A2 = C A2 = C A1 1 + 2k2

    1k1 =

    [C A0 C A1 ] C A0 = 1 C A1 C A1

    2 k2 =

    C A1 =

    C A0 1 + 1k1

    C A0 [1 + 1k1 ][1 + 2 k 2 ]

    n-Equal Sized CSTR in series


    CA0 X=0 v0 CAn CA n-1

    X=Xn-1

    X=Xn

    V = v0 C A1 = C A0 1+ k C A2 =

    All CSTRs are operated at same temperature [ k is same in all reactors]


    C A1 1+ k C A3 = C A2 1+ k C An = C An 1 1+ k

    C An

    C A0 C A0 = = n n (1 + k ) (1 + Da)

    CSTRs: Damkohler Number (Da)


    Da is a dimensionless number that can provide a quick estimate of the degree of conversion in continuous flow reactors.
    ( rA0 ) V Da = FA0
    Note: rate is calculated at inlet conditions

    First-order reaction
    rA0 V V (kC A0 ) Da = = = k FA0 v0C A0

    Second-order reaction
    2 rA0 V V (kC A 0) Da = = = k C A0 FA0 v0C A0

    Da 0.1 usually results in conversion less than 10% Da 10 usually results in conversion greater than 90%

    n-Equal Sized CSTR in series

    n Equal-sized CSTRs - Which is a better configuration? Parallel or Series


    v0/n
    V
    CA1 X=X1

    v0/n
    CA0 X=0 v0 CA2 X=X2

    If you had n-equal sized reactors available and had the option of setting them in series or parallel, which configuration would you choose to achieve maximum conversion for a first-order reaction occurring in liquid phase?

    v0/n
    CA3

    X = Xmix -See Fogler 4.3, Ex. 4-2 -Remember your Levenspiel plots

    X=X3

    v0/n
    V

    CAn X=Xn

    Why run reactors in parallel?

    Example 3 (PFR, variable flow)


    Estimate the volume of a plug-flow reactor (in m3) required for production of ethylene from ethane (C2H6 C2H4 + H2) based on the following data and assumptions: a. The feed is pure ethane at 1 kg s-1, 1000K and 2 bar (abs). b. The reaction is first-order and irreversible at low conversion, with k = 0.254 s-1 at 1000 K. c. The reactor is operated isothermally and isobarically. d. Conversion of ethane is 20% at the outlet.

    (Similar to Fogler Ex. 4.3)


    Effect of changing NT: Examine Fogler Fig 4.7 and 4.8)

    Example 3.4 (CSTR, variable flow)


    It is being considered that the following gas-phase reaction be carried out in a CSTR: A + 2B 4C The reactor will be operated isobarically and isothermally. The rate law for the reaction is given as: (-rA)=k CACB where, k = 8 L/mol-min at the operating temperature. The total feed volumetric flow rate to the reactor at operating temperature and pressure is 10 L/min. The feed consists of A, B and an inert (I). The feed molar flow rates are FA0= FB0= 1 mol/s and FI0=2 mol/s. a) Calculate the volume of reactor required to achieve 80% conversion of the limiting reactant.

    b) If all other conditions are kept constant (including total volumetric flow rate) but no inert is present in the feed, calculate the reactor volume required to achieve 80% conversion of limiting reactant

    Week 5: Design Week


    Special lectures by design team (see topics at
    http://www.chemeng.queensu.ca/courses/integratedDesign/ )

    Intro to UNISIM software in tutorial(s)

    Work on CHEE 321 Design Assignment 1


    Design TAs Raul Moraes and Devon Lehrer Dr. Hutchinson will be back on Wed 15Oct
    Im giving Polymer Reaction Engineering talks in Germany (2) and in Chicago

    Happy Thanksgiving!

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