Unit1 Bioprocess PDF

18BT202J – BIOPROCESS ENGINEERING
UNIT – I – DESIGN AND ANALYSIS OF BIOREACTORS I
Session 1: Introduction to ideal and non-ideal reactors
Session Learning Objective (SLOs) - 1

Outline of SLO1
•Introduction
•Ideal reactors (e.g.)
•Non ideal reactors
Ideal reactors
A reactor is a system (volume) with boundaries. Mass may enter and leave across boundary.
Characteristics: System:
1. Closed or intermittent: no mass enters or leaves during reaction(s) are batch or semi-batch reactors
2. Open (control volume): mass enters/leaves during reaction(s) are continuous flow reactors
Mixing:
1.Completely mixed: mass is homogeneous throughout system
◦ Batch/Semi-batch
◦ Continuous: Continuous stirred tank reactor (CSTR)
2.Completely segregated: mass does not mix, no dispersion with heterogeneous conditions
◦ Plug flow reactor (PFR)
In the tubular reactor, no attempt is made to induce mixing and the flow
characteristics depend largely on the properties of the fluid and the dimensions of
the reactor.
In the continuous stirred tank, efficient stirring ensures that the composition and
temperature of the reacting mixture are constant throughout the mixture. While in
the tubular reactor, the properties of the mixture change along the length of the
reactor.
Ideal reactors are model systems for which the transport and mixing processes
are exactly defined. They serve as abstract analogs of effective reactors. Their
properties are chosen such that they can easily be described in mathematical
terms.
IDEAL REACTOR TYPES
Non-ideal reactors
Reactors do not meet ideal conditions of flow and mixing
due to:
◦Dispersion deviates from ideal plug flow conditions
◦Short-circuiting and dead spaces deviate from ideal mixing
and plug flow conditions
◦Filling and drawing deviate from ideal batch conditions
Ideal vs. non-ideal reactor
IDEAL REACTOR NON-IDEAL REACTOR
Uniform flow distribution Non uniform flow
Uniform mixing Inefficient mixing, unmixed
Ideal mixing Design equation changes
Ideal design equations Different flow effects can occur e.g. laminar or
No flow effects turbulent
No bypass Bypass
No radial variation in concentration Affect the reactor design, the yield or

temperature development of a chemical
No hotspots process
Ideal Reactor Types
0% Backmixing (PFR)
Three ideal reactors: (a) Batch Reactor (BR); (b) Plug Flow Reactor (PFR); (c) Mixed Flow Reactor, or MFR.
Ideal Bioreactors
1.It has neither inflow nor outflow of reactants or products which the reaction is being carried out.
2.Perfectly mixed.
3.No variation in the rate of reaction throughout the reactor volume.
4.Normally run at steady state.
5.Generally modelled as having no spatial variations in concentration, temperature, or reaction
rate throughout the vessel.
100% Back mixing (CSTR)

Batch Reactor
Perfectly mixed
No flow in or out
Continuous Stirred Tank Reactor – CSTR or
backmix reactor
Perfectly mixed
Steady state
Plug Flow Reactor - PFR
No radial gradients – only axial

No radial variations in velocity,
concentration, temperature or reaction rate
Steady state
Multiple choice questions
1. A reactor is generally termed as an autoclave, when it is a

a. High pressure batch reactor.
b. Atmospheric pressure tank reactor.
c. High pressure tubular reactor.
d. Atmospheric pressure CSTR.
2. The batch reactor has the disadvantage(s) of

a. High labour and handling cost
b. Poorer quality control of the product
c. Considerable shutdown time to empty, clean out and refill
d. All of the above
3. A batch reactor is suitable for

a. Large scale gaseous phase reactions.
b. Liquid phase reactions.
c. Achieving cent percent conversion of reactants into products.
d. Obtaining uniform polymerisation products in highly exothermic reactions.
4. The most unsuitable reactor for carrying out reactions in which high reactant concentration
favours high yields is
a. Series of CSTR
b. Backmix reactor
c. Plug flow reactor
d. PFR in series
15BT305 – BIOPROCESS ENGINEERING
Session 1: Introduction to ideal reactors: performance equations

Outline of SLO2
• Batch Vs Continuous Operation
• Introduction- Basics of Biochemical Engineering
• Ideal Reactors
• General Mole Balance
Batch vs. Continuous
BATCH CONTINUOUS
1) Time variant conditions 1. Continuous production
2) Discontinuous production 2. Steady state after start-up period (usually)

3. No variation of concentrations with time
3) Downtime for cleaning and filling
4. Constant reaction rate
4) Flexibility
5. Ease of balancing to determine kinetics
6. No down-time for cleaning, filling, etc.
Comparison of batch and continuous operation
(A- advantage; D- disadvantage)
BATCH OPERATION CONTINUOUS OPERATION
Usually better for small-volume production (A). Better for indefinitely long production runs of one product
or set of products (A).
More flexible for multi-product (multipurpose)
operation (A) Flexibility usually low (D)
Capital cost usually relatively low (A) Capital cost usually relatively high (D)
Easy to shut down and clean for fouling service (A) Shut down for cleaning very demanding and costly (D)
Inherent down-time between batches (D) No down-time except for scheduled and emergency
Unsteady-state operation means process control and maintenance (A); but loss of production in lengthy
obtaining uniformity of product is more difficult (D) stoppages can be costly (D)
Process control and obtaining uniform product quality Operating cost relatively low (A)
more difficult because of unsteady-state operation (D)
Process control and obtaining uniformity of product easier
Coupling with continuous down-stream processing because of steady-state operation (A)
requires buffering tanks (D)
Steady-state operation allows easy coupling with
continuous down-stream operation (A)
Basics of Biochemical Reaction Engineering
• Chemical Identity : A chemical species is said to have reacted when it has lost its chemical identity. The identity of a
chemical species is determined by the kind, number, and configuration of that species’ atoms.
1. Decomposition
2. Combination
3. Isomerization
• Reaction Rate: The reaction rate is the rate at which a species looses its chemical identity per unit volume. The rate of a
reaction (mol/dm3/s) can be expressed as either
the rate of Disappearance: -rA
or as
the rate of Formation (Generation): rA
Consider the isomerization A B
rA = the rate of formation of species A per unit volume
-rA = the rate of a disappearance of species A per unit volume
rB = the rate of formation of species B per unit volume
EXAMPLE: A B
If Species B is being formed at a rate of 0.2 moles per decimeter cubed per second, i.e.,
rB = 0.2 mole/dm3/s.
Then A is disappearing at the same rate: -rA = 0.2 mole/dm3/s
The rate of formation (generation of A) is rA = - 0.2 mole/dm3/s
For a catalytic reaction, we refer to -rA', which is the rate of disappearance of species A on a per mass of catalyst basis.
(mol/gcat/s)
NOTE: dCA/dt is not the rate of reaction

Ideal Reactor
Batch Reactor - Mole Balance
1. A Catalyst
a. Lowers the activation energy of reacting molecules.
b. Initiates a reaction.
c. Cannot be recovered chemically unchanged at the end of a chemical reaction.
d. Is capable of reacting with any one of the reactants.
2. From among the following, choose one which is not an exothermic process.
a. Oxidation of sulphur
b. Catalytic cracking
c. Ammonia synthesis
d. Methanol synthesis
3. A reversible liquid phase endothermic reaction is to be carried out in a plug flow reactor.
For minimum reactor volume, it should be operated such that the temperature along the length
a. Decreases
b. Increases
c. First increases and then decreases.
d. Is at the highest allowable temperature throughout.
4. In an exothermic chemical reaction, the reactants compared to the products have

a. Higher temperature
b. More energy
c. Less energy
d. Same energy.
5. __________ explains the mechanism of catalysis.

a. None of these
b. Activated complex theory
c. Collision theory
d. Thermodynamics
6. For every 10°C rise in temperature, the rate of chemical reaction doubles. When the
temperature is increased from 30 to 70°C, the rate of reaction increases __________ times.
a. 32
b. 8
c. 12
d. 16
7. With decrease in temperature, the equilibrium conversion of a reversible endothermic

reaction
a. Increases
b. Decreases
c. Remains unaffected
d. Increases linearly with temperature
8. The rate constant of a chemical reaction decreases by decreasing the

a. Concentration of reactants
b. Temperature
c. Duration of reaction
d. Pressure
Session 2: Ideal reactors - Equations

Outline of SLO3
• Batch Reactors – Mole Balance
Ideal batch reactor
CAo - Initial concentration of A

CA - Final concentration of A
CBo - Initial concentration of B
CB - Final concentration of B
A B
Conditions:
Constant volume
Input=0 ; Output=0
Material balance for component A:
I/P=0 ; O/P=0
I/P = O/P + accumulation + disappearance
Hence,
Rate of loss of reactant A = rate of accumulation of reactant A (1)
Disappearance: moles of A /time = ( - rA) V = [moles of A reacting /(time x volume of fluid)] (volume of fluid)
Disappearance = ( - rA) V
Accumulation: moles of A /time = dNA/dt = d [NAo (1- XA)] /dt = - NAo dXA/dt
Accumulation = - NAo dXA/dt
By replacing the terms of equation 1:
(rA) V = - NAo dXA/dt

(rA) dt= - NAo dXA/V
(rA) t ∫ dt= - (NAo /V)X∫AdXA

0
(rA) [t] = - (NAo /V)XAO
[XA]
rA.t = - CAo .XA
t= - (NAo) X∫A dXA / (rA V) (2)

0
t= - (NAo) / rA V
t= - (CAo) X∫AdXA / rA (3)

0
XA = - rA t / CAo
1. A reactor is generally termed as an autoclave, when it is a

a. High pressure batch reactor.
b. Atmospheric pressure tank reactor.
c. High pressure tubular reactor.
d. Atmospheric pressure CSTR.
2. The batch reactor has the disadvantage(s) of

a. High labour and handling cost
b. Poorer quality control of the product
c. Considerable shutdown time to empty, clean out and refill
d. All of the above
3. A batch reactor is suitable for

a. Large scale gaseous phase reactions.
b. Liquid phase reactions.
c. Achieving cent percent conversion of reactants into products.
d. Obtaining uniform polymerisation products in highly exothermic reactions.
4. The most unsuitable reactor for carrying out reactions in which high reactant concentration
favours high yields is
a. Series of CSTR
b. Backmix reactor
c. Plug flow reactor
d. PFR in series

Outline of SLO4
• CSTR – Mole Balance
Continuous Stirred Tank Reactor - Mole
Balance
FA feed rate
Mixed flow reactor
Residence time (t) : Time spent by a molecule in the reactor
CAo= 0 CAf=CA
Space time (Ʈ) : Time taken to process one (batch) reactor
XAo= 0 XAf=XA
vo vA Space time or mean residence time or holding time, Ʈ = V/vo =
FAo (-rAf)=(-rA)
FA reactor volume/ volumetric feed rate entering the reactor
Space velocity (s) : Number of reactor volumes processed per unit time
s= v0/V = 1/ Ʈ
V, XA, CA 1/ s = Ʈ = CAoV/FAo
(r )
, A
= (moles of A entering/feed volume) x Reactor volume/(moles of A entering/time)
We know that : XA = 1- CA /CAo
By differentiating: dXA = 0- dCA /CAo
∫dXA= ∫dCXAaf Caf
XAo CAo
Input = output + disappearance + accumulation
[ If X = 0, it is FAo (XA) but if there is some value, it becomes FAo (1- XA)]
FAo (1- XAo) = FA + (-rA V)
For zero conversion of feed : XAo = 0
Now, FAo (1- XAo) = FAo (1- XA) + (-rA V)
FAo = FAo (1- XA) - rA V
XA /-rA = V/FAo Basic performance equation of
Mixed Flow Reactor (MFR)

Ʈ / CAo = V/FAo also, Ʈ FAo = CAo V
Ʈ = 1/ s = (CAo - CA)/(- rA )
Ʈ = 1/ s = CAo V/FAo = (XA CAo )/(- rA )
= (CAo - CA) CAo /(- rA CAo ) [since, XA = (CAo - CA) / CAo ]
Ʈ= (CAo - CA) /(- rA)
For space velocity:
1/ (s CAo ) = XA/(- rA )
V/FAo= ∆XA/(- rA)f = (XA final – XA initial)/(- rA ) f
Ʈ = CAo V/FAo = CAo(XA final – XA initial)/(- rA ) f

1. In an ideal mixed reactor at steady-state

a. The composition throughout the reactor remains same
b. The exit stream has the same composition as the fluid within the reactor
c. The space-time is equivalent to holding time for constant density systems
d. All of these answers.
2. A first-order reaction is to be treated in a series of two mixed reactors. The total volume of
the two reactors is
a. Minimum when the reactors are of different sizes
b. Maximum when the reactors are equal in size
c. Minimum when the reactors are equal in size.
3. A first order reaction requires two unequal sized CSTR. Which of the following gives higher
yield?
a. Large reactor followed by smaller one.
b. Smaller reactor followed by larger one.
c. Either of the arrangement (a) or (b) will give the same yield.
d. Data insufficient, can't be predicted.
4. A first order reaction requires two equal sized CSTR. The conversion is
a. More when they are connected in series.
b. More when they are connected in parallel.
c. Less when they are connected in series.
d. Same whether they are connected in series or in parallel.

Outline of SLO5
• Plug Flow Reactors – Mole Balance
• Reactor – Mole Balance - Summary
Plug Flow Reactor (PFR)
No radial gradients – only axial

Steady state
In fluid mechanics, plug flow is a simple model of the
velocity profile of a fluid flowing in a pipe.
In plug flow, the velocity of the fluid is assumed to be
constant across any cross-section of the pipe
perpendicular to the axis of the pipe.
Plug Flow Reactor - Mole Balance
PFR:
The integral form is:
This is the volume necessary to reduce the entering molar flow rate (mol/s) from FA0 to the exit molar flow rate of FA.
PLUG FLOW REACTOR
XAo, FAo, CAo XAf, FAf, CAf

F FA +dFA
Vo, t=o A Vf
dX
VARIABLES: velocity and space time (gives conversion)
•Uniform diameter, narrow, hollow (tubular structure)
•Diameter is constant (but can be varied)
•Conversion is directly proportional to length of the reactor

Input = Output + accumulation + disappearance by reaction
Input of A, mole/time,FA = (FA + dFA) + 0 + (-rA)dV
rA= dFA/dV
We know that FA = FAo (1 - XA)
Hence rA = [FAo (1 - XA)] /dV
= -FAo (dXA) /dV
∫ dV/ FAo = -∫ dXA / rA
Now we can consider the entire volume; applying limits from Vo to Vf and
XAo to XAf
∫ dV/ FAoVf = ∫ dXA /-

XAfrA
Vo XAo
Vf / FAo = ∫dXA X/-AfrA = Ʈ/ CAo
XAo
For determination of reactor size for a given feed rate and required conversion.
Reactor Mole Balance - Summary
1. A reversible liquid phase endothermic reaction is to be carried out in a plug flow reactor.
For minimum reactor volume, it should be operated such that the temperature along the length
a. Decreases
b. Increases
c. First increases and then decreases.
d. Is at the highest allowable temperature throughout.
2. Which of the following is the most suitable for very high pressure gas phase reaction ?
a. Tubular flow reactor
b. Batch reactor
c. Stirred tank reactor
d. Fluidised bed reactor
3.
3. NN plug
plug flow
flow reactors
reactors in
in series
series with
with aa total
total volume
volume VV gives
gives the
the same
same conversion
conversion as
as aa single
single
plug
plugflow
flowreactor
reactorofofvolume
volumeV. V.The
Theabove
abovestatement
statementisistrue
truefor
for
a. Zero-order reactions only
b. First-order reactions only
c. Second-order reactions only
d. All reaction orders.
4. For identical feed compostion and flow rate, N plug flow reactors in series with a total
volume V gives the same conversion as a single
a. Plug flow reactor of volume V
b. CSTR of volume V
c. Plug flow reactor of volume V/N
d. Plug flow reactor of volume NV
5. In an ideal plug flow reactor at steady state

a. There may be diffusion along the flow path
b. There must be lateral mixing of fluid
c. The composition of the reactant remains constant along a flow path
d. The fractional conversion of the reactant varies from point to point along a flow path
6. In flow reactors, the performance equations interrelate the rate of reaction to the
a. Feed rate
b. Reactor volume
c. Extent of reaction
d. All (a), (b) and (c)
7. For identical feed composition, flow rate, conversion and for all positive reaction orders the
ratio of the volume of mixed reactor to the volume of plug flow reactor
a. Is independent of the order of reaction
b. Increases with increase in the order of reaction
c. Decreases with increase in the order of reaction
d. Increases linearly with increase in the order of reaction.
8. For identical feed composition, flow rate, conversion and for zero-order reactions the ratio of
the volume of mixed reactor to the volume of plug flow reactor is
a. 0
b. 1
c. < 1
d. > 1
9. A plug-flow reactor is characterized by

a. High capacity
b. Presence of axial mixing
c. Presence of lateral mixing
d. Constant composition and temperature of reaction mixture
10. Three plug flow reactors (PFR's) of 4, 5 & 6 m3 volumes are arranged in two branches as
shown below in the figure. If the total feed rate is 300 tons/hr, then for the same conversion in
each branch, the feed rate through branch II should be __________ tons/hr.
a. 100
b. 150
c. 200
d. 225
Session 3: Non ideal reactors

Outline of SLO6
• Non - Ideal Reactors
• Residence Time Distribution
Non-Ideal Reactors
Ideal Reactors
1.PFR (no-axial mixing)
2.MFR (complete mixing)
•So far, the reactors we have considered ideal flow patterns

• Residence time of all molecules are identical
• Perfectly mixed CSTRs & batch reactors
• No radial diffusion in a PFR/PBR
Non-ideal reactors (real reactors) - The reactors always deviate some degree from these ideal behaviors called real
reactors.
Non-Ideal Flow - CSTR
The deviation from ideal flow patterns may be caused by Short Circuiting
1.Stagnant regions in the vessel (dead zone) Dead Zone
2.Bypassing or short-circuiting of the fluid
3.Channeling
4.Recycling of fluid
5.Due to vortices and turbulences at inlet and outlet
• Ideal CSTR: uniform reactant concentration throughout the vessel

Dead Zone
• Real stirred tank
• Relatively high reactant concentration at the feed entrance
• Relatively low concentration in the stagnant regions, called dead zones (usually corners and behind baffles)
Non-ideal Flow in a PBR
• Ideal plug flow reactor: all reactant and product molecules at any given axial position move
at same rate in the direction of the bulk fluid flow
• Real plug flow reactor: fluid velocity profiles, turbulent mixing, & molecular diffusion cause
molecules to move with changing speeds and in different directions
Channeling
Dead zones
Non-Ideal Flow Patterns which may exist in process
equipment
Factors that make up the contacting or flow pattern are:

1.The RTD – residence time distribution of fluid flowing through the vessel.
2.The state of aggregation of fluid and
3.The earliness and lateness of fluid mixing in the vessel
RTD ≡ E(t) ≡ “residence time distribution” function
“Residence Time Distribution” (RTD) Function

Flow through a reactor is characterized by:
• The amount of time molecules spend in the reactor, called the RTD (or) The time it takes a molecule to pass through a reactor is
called the residence time of the molecule in the reactor.
• Quality of mixing
Chemical Engineering use the RTD to characterize the mixing and flow within reactors and to compare the behavior of real
reactors to their ideal models. This is useful, not only for troubleshooting existing reactors, but in estimating the yield of a given
reaction and designing future reactors.
It is clear that elements of fluid taking different routes through the reactor may take different lengths of time to pass through it. So
there is a distribution of residence time of the fluid material within the reactor.
The distribution of these times for the stream of fluid leaving the vessel is called the exit age distribution, E, or the RTD of fluid.
UNIT of E is time-1
•In an ideal PFR – all the molecules within the reactor having the same length of time.
•In an ideal batch reactor - all the molecules within the reactor having the same length of time
•The ideal PFR and BR are the only reactors in which all the fluid elements in the reactors have the same residence
time.
•In all other reactors, the various molecules spend different times inside the reactor, Ex: MFR
•The feed introduced into the MFR at any given time completely mixed with the material already in the reactor.
Some of the molecules entering the MFR leave it almost immediately, because the material is continuously
removed from the reactor, other molecules remain in the reactor almost forever because all the material is never
withdrawn at one time from the reactor. Many of the molecules leave the reactor after spending a period of time
which is somewhere close to the mean residence time.
The distribution of residence time can significantly affects the performance of reactor.
The RTD of a reactor is a characteristic of the mixing that occurs in the reactor.
Session 4: Non ideal reactors

Outline of SLO7
• Residence Time Distribution
• RTD Measurement
RTD Measurement
The RTD is determined experimentally by using an inert chemical, molecule or atom is
called a tracer (dyes and radioactive materials).
Characteristics of chemical tracer:

1.It should be non-reactive
2.It should be completely soluble in the system fluid

3.It should be easily detectable
4.Physical properties of the tracer should be similar to those of the system and
5.It should not adsorb on the walls or others surfaces in the vessel.
Experimental Methods for Finding E
1. Pulse input
2. Step input
3. Periodic input
4. Random input
Residence Time Distribution (RTD)
•RTD is measured experimentally by injecting an inert “tracer” at t=0 and measuring the tracer concentration C(t) at the
exit as a function of time
•Tracer should be easy to detect & have physical properties similar to the reactant
Measurement of RTD
This plot would have the same

(PBR or PFR) shape as the pulse injection if the
reactor had perfect plug flow
Pulse injection Detection
RTD Profiles & Cum RTD Function F(t)
Tracer Conc
Tracer Conc
Tracer Conc
Tracer Conc
τ t τ t
t t
Nearly ideal Nearly ideal PBR w/ channeling & CSTR with dead
PFR CSTR dead zones zones
Calculation of RTD
The C curve
• RTD ≡ E(t) ≡ “residence time distribution” function
C(t) • RTD describes the amount of time molecules have spent in the reactor
Fraction of material leaving the reactor that has resided in the reactor for a
time between t1 & t2
E(t)=0 for t<0 since no fluid can exit before it enters

E(t)≥0 for t>0 since mass fractions are always positive
Fraction of fluid element in the exit stream with age less than t1 is:
1. The exit age distribution of fluid leaving a vessel is used

a. To study the reaction mechanism
b. To study the extent of non-ideal flow in the vessel
c. To know the reaction rate constants
d. To know the activation energies of a reaction.
2. Stimulus-response techniques are commonly used to characterize the extent of non-ideal flow
in vessels. Tracer input signal is used as stimulus. Any material can be used
a. As tracer if it can disturb the flow pattern in the vessel
b. As tracer if it does not disturb the flow pattern in the vessel and it can be detected.
c. As tracer if it follows ideal flow patterns
d. As tracer.
3. Which of the following types of tracer input signal can be used to study the extent of non-ideal
flow?
a. Periodical signal
b. Step signal
c. Pulse signal
d. All of the above
4. The exit age distribution of a fluid leaving a vessel (denoted by E) is used to study the extent
of non-ideal flow in the vessel. The value of is
a. 0
b. 1
c. ∞
d. 2π
5. The 'E' curve for a non-ideal reactor defines the fraction of fluid having age between t and t + dt
a. Tank in series
b. Dispersion
c. Both (a) & (b)
d. Neither (a) nor (b).
6. The single parameter model proposed for describing non-ideal flow is the __________ model.
a. 0
b. 1
c. ∞
d. 2π
7. The mean conversion in the exit stream, for a second order, liquid phase reaction in a non-ideal
flow reactor is given by
a.
b.
c.
d.
.
8. The exit age distribution curve E(t) for an ideal CSTR with the average residence time, τ, is
given by
a.
b.
c.
d.
.
9. The exit age distribution curve E(t) for an ideal CSTR with the average residence time, τ, is
given by
a. e-t/τ
b.
c. 1 - e-t/τ
d.
.
Session 4: Residence Time Distribution

Outline of SLO8
• RTD Measurement – Pulse Input Experiment
1.The Pulse Input Experiment
Non-Ideal Reactors – Pulse Input
Non-ideal reactors (real reactors) - The reactors always deviate some degree from these ideal behaviors called real reactors.
The known quantity of tracer (M kg or moles) is suddenly injected in one shot
into the fluid entering the vessel in a very short time period
The tracer concentration in the exit stream is measured as a function of time.
In RTD analysis, the effluent concentration-time curve is referred to as the C
curve (Cpulse curve).
The concentration of effluent stream increases with time, reaches a maximum
value and then falls, eventually approaching zero.
The amount of tracer material, ∆M, leaving the vessel between t and t+∆t is obtained by the material balance of the
tracer
E curve from C curve
Questions
1. Which of the following graphs would you expect to see if a pulse tracer test were performed on
an ideal CSTR?
A B C D
Tracer Conc
Tracer Conc
Tracer Conc
Tracer Conc
τ
t t t t
2. Which of the following graphs would you expect to see if a pulse tracer test were performed on a
PBR that had dead zones?
A B C D
Tracer Conc
Tracer Conc
Tracer Conc
Tracer Conc
τ
t t t t
4. __________ is the response curve for a step input signal from a reactor.
a. A - Curve
b. E - Curve
c. C - Curve
d. D - Curve
5. Stimulus-response techniques are commonly used to characterize the extent of non-ideal flow
in vessels. Tracer input signal is used as stimulus. Any material can be used
a. As tracer if it can disturb the flow pattern in the vessel
b. As tracer if it does not disturb the flow pattern in the vessel and it can be detected.
c. As tracer if it follows ideal flow patterns
d. As tracer.
6. Which of the following types of tracer input signal can be used to study the extent of
non-ideal flow?
a. Periodical signal
b. Step signal
c. Pulse signal
d. All of the above
a. 0
b. ∞
c. 1
d. 2

9. For an ideal mixed flow reactor (CSTR), the exit age distribution E(t) is given by
a. A dirac delta function

b. A step function.
c. A ramp function.
d. None of the above
Session 5: E Curve Problems
Session Learning Objective (SLOs) - 9 & 10

Outline of SLO 9 & 10
• RTD Measurement – Pulse Input Experiment
A pulse of tracer was injected into a reactor, and the effluent concentration as a function of time is in the graph below.
Construct a figure of C(t) & E(t) and calculate the fraction of material that spent between 3 & 6 min in the reactor
t min 0 1 2 3 4 5 6 7 8 9 10 12 14
C g/m3 0 1 5 8 10 8 6 4 3 2.2 1.5 0.6 0
Tabulate E(t): divide C(t) by the total area under the C(t) curve, which
Plot C vs time:
must be numerically evaluated
Construct a figure of C(t) & E(t) and calculate the fraction of material that spent between 3 & 6 min in the reactor.
t min 0 1 2 3 4 5 6 7 8 9 10 12 14
C g/m3 0 1 5 8 10 8 6 4 3 2.2 1.5 0.6 0
Tabulate E(t): divide C(t) by the total area under the C(t) curve, which
Plot C vs time: must be numerically evaluated
t min 0 1 2 3 4 5 6 7 8 9 10 12 14
C g/m3 0 1 5 8 10 8 6 4 3 2.2 1.5 0.6 0
E(t) 0 0.02 0.1 0.16 0.2 0.16 0.12 0.08 0.06 0.044 0.03 0.012 0
Plot E vs time:
Tabulate E(t): divide C(t) by

the total area under the C(t)
curve:
t min 0 1 2 3 4 5 6 7 8 9 10 12 14
C g/m3 0 1 5 8 10 8 6 4 3 2.2 1.5 0.6 0
E(t) 0 0.02 0.1 0.16 0.2 0.16 0.12 0.08 0.06 0.044 0.03 0.012 0
E vs time: Fraction of material that spent between 3 & 6 min in reactor = area
under E(t) curve between 3 & 6 min
Evaluate numerically:
2. Step-Input to Determine E(t)
Disadvantages of pulse input:
•Injection must be done in a very short time
• Can be inaccurate when the c-curve has a long tail
• Amount of tracer used must be known
Alternatively, E(t) can be determined using a step input:
•Conc. of tracer is kept constant until outlet conc. = inlet conc.
injection detection
Cin C0 C0
Cout
The C curve
t t t t
Non Ideal reactors - Step-Input
Session 6: Non-Ideal Reactors

Outline of SLO 11
• Introduction
• Models for non-ideal flow
• Application and Advantages
Conversion in non-ideal flow reactors
To evaluate the reactor behavior in general we have to know four factors
1.Kinetics of the reaction
2.The RTD of fluid in the reactor
3.The earliness or lateness of fluid mixing in the reactor
4.Whether the fluid is micro or macro fluid
Models for Non ideal flow
Models are useful to represent flow in the real reactor, scale up and diagnosing the poor flow. When a single parameter is
used to account for the non ideal flow in the reactor is called one parameter model. This parameter is evaluated by
analyzing the RTD determined from the tracer used.
Types of models for non ideal (real) reactors,
1.Dispersion model
2.Tanks-in-series model
3.Segregation model and
4.Compartment model These models are used to predict the conversion from RTD data
The dispersion model - This model is used to account for deviation from ideal plug flow and involves a modification of
the ideal reactor by imposing axial dispersion on plug flow.
Tanks-in-series model - This model is used to model non ideal tubular reactor as a series of equal sized stirred tanks.
Dispersion and tanks-in-series model
Applications Disadvantages
Turbulent flow in pipes These models are not applicable to
Laminar flow in very long tubes Laminar flow in short tubes or

Laminar flow of viscous materials
Flow in packed beds
Shaft kilns
Long channels
Screw conveyors etc.

Axial Dispersion
1. The vessel dispersion number (D/μL) for plug flow is
a. Zero
b. 500
c. 750
d. Infinity
2. For perfect mixed flow the dispersion number must be
a. Zero
b. Less than 2100
c. Less than 2
d. Infinity
1. The vessel dispersion number (D/μL) for plug flow is
a. Zero
b. 500
c. 750
d. Infinity
2. For perfect mixed flow the dispersion number must be
a. Zero
b. Less than 2100
c. Less than 2
d. Infinity
Session 5: Non-Ideal Reactors

Outline of SLO 12
• Axial Dispersion
• Dispersion Model
• Significance of D
Axial Dispersion
Suppose an ideal pulse of tracer is introduced into the fluid entering vessel.
The pulse spreads as it passes through the vessel and to characterize the spreading according to this model (as shown in
the figure).
We assume a diffusion like process superimposed on plug flow.
We call this dispersion or longitudinal dispersion to distinguish it from molecular dispersion.
The dispersion coefficient D (m2/s) represents the spreading process
Significance of D
Large D means – rapid spreading of the tracer curve
Small D means – slow spreading
D=0 – No spreading hence plug flow
(D/uL) is the dimensionless group characterizing the spread in the whole vessel.
These measures are directly linked by theory of D or D/uL.
Dispersion Model
Consider a plug flow of fluid, on top of which is superimposed some degree of back mixing, the magnitude of which
is independent of position within the vessel.
This condition implies that there exist no stagnant pockets and no gross bypassing or short-circuiting of fluid in the
vessel. This is called the dispersed plug flow model or dispersion model.
With varying intensities of turbulence or intermixing the predictions of this model should range from plug flow at one
extreme and mixed flow at the other.
The reactor volume for this model will lie between those calculated for plug flow and mixed flow.
Intermixing of fluid flowing in the x-direction to be described by
Where D is the longitudinal or axial dispersion coefficient uniquely characterize

the degree of back mixing during flow.
Streamline flow of fluids through pipes, axial mixing is mainly due to fluid
velocity gradients, whereas radial mixing is due to molecular diffusion alone.
The basic differential equation representing this dispersion model becomes
The dimensionless group (D/uL) called the vessel dispersion number, is the
parameter that measures the extent of axial dispersion.
Significance of D/uL
Application
Real packed beds and
Long tubes (streamline flow)
Large Deviation from Plug Flow D/uL>0.01 (Pulse Tracer)
1. Open boundary conditions

Either the flow is undisturbed as it passes the entrance and exit boundaries
2. Closed boundary conditions
Will have plug flow outside the vessel up to the boundaries
Correlations for Axial Dispersion
Experiments show that the dispersion model well represents flow in packed beds and in pipes
Session 6: Non ideal reactors – Dispersion Model

• Chemical reaction and dispersion model
Chemical Reaction and Dispersion
Steady state flow chemical reactor (closed vessel)
Reactor length = L
Constant velocity of fluid = u
Axial mixing with a dispersion coefficient, D
Cross sectional area S
Session 6: Non ideal reactors –Tanks in Series Model

• Tanks in Series Model
Tanks-in-Series Model
One parameter model used to represent non ideal flow in tubular reactors.
The parameter of this model is the number of tanks, N, in series
In modelling non ideal tubular reactor is to be considered as a series of
equal-sized stirred tanks
First develop the RTD equation for three tanks in series and then generalize it to
N tanks in series to arrive at equation that gives the number of tanks in series
that best fits the data
Steady flow of fluid in and out (v m3/s) of the first three ideal stirred tanks
Volume (V1 m3)
At time t=0, inject a pulse of tracer into the first tank.
Tracer balance over the first tank at any time t
The fraction of tracer material leaving the system of three tanks
that has been in the system b/w time t and t+∆t
If we connect M tanks to already existing chain of N tanks (same size) then the
individual means and variance are additive.
Conversion from Tanks-in-Series Model
For first order reaction in one tank
Session 9: Models Summary & Surprise Test

Summary
1. The non-ideal (real) reactors and its design – many problems performed in
this area.
2. The factors that make up the contacting or flow pattern in the non-ideal
reactors (RTD, state of aggregation of fluid and earliness and lateness of fluid
mixing in the vessel) - many problems performed in this area.
3. Basic models used for non-ideal reactors (SFM,Dispersion model and
Tanks-in-series model) - many problems performed in this area.
4. The conversions obtained from the non-ideal flow reactors.
Check your understanding
1. The reasons for non-ideality in the real reactors.
2. RTD means____________
3. Give the experimental methods for finding out exit age distribution function, E
4. Pulse input will give _________ curve
5. Step input will give __________ curve
6. Example for zero parameter modelling _________
7. Examples for one parameter modelling _________
8. What is Dispersion number
9. Significance of Dispersion number
10. If the number of tanks are connected in series then the reactor will be acting as like
________ Reactor
Answers:
1.Channeling, Recycling of fluid, Stagnant region
2.Residence Time Distribution
3.Pulse, Step, Periodic and Random input
4.C curve
5.F curve
6.Segregated Flow Model (SFM)
7.Dispersion Model and Tanks-in-series model
8.D/uL
9.D/uL=0 , plug flow: D/uL=∞ - mixed flow
10.Plug flow reactors
Online Resources
• Best Resources
• http://umich.edu/~elements/5e/18chap/Fogler_Web_Ch18.pdf
• https://authors.library.caltech.edu/25070/9/FundChemReaxEngCh8.pdf
Learning Resources
TEXT BOOKS
1.Octave Levenspiel, Chemical Reaction Engineering,
2. H.Scott Fogler, Elements of Chemical Reaction Engineering, 2ndEdition. Pearson, 2008.
3.Shuler. M.L., Kargi. F., “Bioprocess Engineering: Basic Concepts”, 2ndEdition. Pearson, 2002.
4. Blanch. H.W., Clark. D.S., “Biochemical Engineering”, Marcal & Dekker, Inc., 1997.
REFERENCE BOOKS/OTHER READING MATERIAL

1. Najaf pour. G.D, “Biochemical Engineering and Biotechnology”, Elsevier, 2007.
2. Lee. J.M, “Biochemical Engineering”, Prentice-Hall, 1992.
3. Bailey. J. E.,Ollis.D.F, “Biochemical Engineering Fundamentals”, 2nd Edition, McGraw-Hill, 1986.
4. Doran. P. M., “Bioprocess Engineering Principles”, Academic press, 1995.
5. Scragg A. H., “Bioreactors in Biotechnology- A Practical approach”, Ellis Harwood, 1991.

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18BT202J – BIOPROCESS ENGINEERING

UNIT – I – DESIGN AND ANALYSIS OF BIOREACTORS I

Session 1: Introduction to ideal and non-ideal reactors

Session Learning Objective (SLOs) - 1

No radial variation in concentration Affect the reactor design, the yield or

100% Back mixing (CSTR)

No radial gradients – only axial

1. A reactor is generally termed as an autoclave, when it is a

2. The batch reactor has the disadvantage(s) of

3. A batch reactor is suitable for

UNIT – I – DESIGN AND ANALYSIS OF BIOREACTORS I

Session 1: Introduction to ideal reactors: performance equations

Session Learning Objective (SLOs) - 2

1) Time variant conditions 1. Continuous production

2) Discontinuous production 2. Steady state after start-up period (usually)

Then A is disappearing at the same rate: -rA = 0.2 mole/dm3/s

The rate of formation (generation of A) is rA = - 0.2 mole/dm3/s

NOTE: dCA/dt is not the rate of reaction

4. In an exothermic chemical reaction, the reactants compared to the products have

5. __________ explains the mechanism of catalysis.

7. With decrease in temperature, the equilibrium conversion of a reversible endothermic

8. The rate constant of a chemical reaction decreases by decreasing the

UNIT – I – DESIGN AND ANALYSIS OF BIOREACTORS I

Session 2: Ideal reactors - Equations

Session Learning Objective (SLOs) - 3

CAo - Initial concentration of A

(rA) V = - NAo dXA/dt

(rA) t ∫ dt= - (NAo /V)X∫AdXA

rA.t = - CAo .XA

t= - (NAo) X∫A dXA / (rA V) (2)

t= - (CAo) X∫AdXA / rA (3)

1. A reactor is generally termed as an autoclave, when it is a

2. The batch reactor has the disadvantage(s) of

3. A batch reactor is suitable for

UNIT – I – DESIGN AND ANALYSIS OF BIOREACTORS I

Session 2: Ideal reactors - Equations

Session Learning Objective (SLOs) - 4

By differentiating: dXA = 0- dCA /CAo

∫dXA= ∫dCXAaf Caf

Input = output + disappearance + accumulation

FAo (1- XAo) = FA + (-rA V)

For zero conversion of feed : XAo = 0

Now, FAo (1- XAo) = FAo (1- XA) + (-rA V)

FAo = FAo (1- XA) - rA V

XA /-rA = V/FAo Basic performance equation of

Mixed Flow Reactor (MFR)

Ʈ = 1/ s = CAo V/FAo = (XA CAo )/(- rA )

= (CAo - CA) CAo /(- rA CAo ) [since, XA = (CAo - CA) / CAo ]

Ʈ= (CAo - CA) /(- rA)

For space velocity:

V/FAo= ∆XA/(- rA)f = (XA final – XA initial)/(- rA ) f

Ʈ = CAo V/FAo = CAo(XA final – XA initial)/(- rA ) f

1. In an ideal mixed reactor at steady-state

UNIT – I – DESIGN AND ANALYSIS OF BIOREACTORS I

Session 3: Ideal reactors - Equations

Session Learning Objective (SLOs) - 5

No radial gradients – only axial

The integral form is:

XAo, FAo, CAo XAf, FAf, CAf