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P. L. T. BRIAN,B. A. L~~E.-wJ,
and 1. P. EYMERY
of Chemical Engineering,
Massachusetts
Institute of Technology
281
SHELL COOLING
GASES
F
.c
CATALYST
CATALYST
BED
SECTlON
-G
-D
HEAT
-B
Es%FR
GASES
ENTRANCE
BY PASS
INLET
R. F. BAJXXXJR,
P. L. T. BRIAN,B. A. LOGEAIS and J. P. EYMERY
an increase in the average feed temperature is
necessary to avoid instability and keep the ammonia production up.
To investigate the steady state behavior of such
a reactor, VAN HEERDEN[l], ANNABLE[5], BEUTLER
and ROBERTS [6], and KJAER [7] have derived
mathematical models of Haber-Bosch type reactors.
VAN HEERDEN,ANNABLE,BEUTLERand ROBERTS
derived one-dimensional
models allowing for
temperature and composition variations in the
longitudinal direction only. Even though their
results approximated experimental results, none
investigated the effect of operating and design
variables on the production, stability and temperature profiles in the reactor. KJAERSmodel took
into account the variations in temperature in both
the longitudinal and radial directions. His mathematical model consisted of three partial differential
equations which were solved by hand computation
using a double step integration technique, The
temperature and composition profiles in the reactor
were computed for only one set of operating conditions. The agreement of the computed production
rate and average bed temperatures with plant data
was very good. However, the KJAERmodel could
not explain the radial temperature gradient reported by SLACK,ALLGOODand MAUNE. KJAER gave
a qualitative explanation of this discrepancy based
on the location of the various thermocouple wells
with respect to the cooling tubes in the catalyst
bed. The work already published on the T.V.A.
reactor still leaves the following important areas
to be investigated. The effect of operating and
design variables on:
(1) the optimum feed temperature,
(2) the stability of the reactor,
(3) the temperature profiles in the reactor.
This information is necessary to determine the
conditions of maximum production. The objective
of this paper is to present the results of calculations
using a computer simulation of a T.V.A. reactor.
The operating variables investigated were : space
velocity, ammonia and inert content of the feed,
and catalyst activity. The design variable was the
heat conductance per unit volume of reactor
between the reacting gas and the gas in the cooling
tube. The pressure was kept constant, and the
hydrogen to nitrogen ratio was equal to 3.0.
9000
13,800 18,000
0.01
0.05
0.10
0.08
0.0
0.4
.
30,000 :&IO
0.15
investigated
appears
&IOO
MATHEMATICAL
MODEL
282
CATALYST
SECTON
EMPTY
TUBE
sEcnm
Tc
TT
l--L
1 I
TINLET
Atg=O,
To=l,
Tr=l,
y=y*
(4)
for
for
0<ct<0.5
0.5<~<1
m =
d~
exp
-20,300
~
X {[ (K~P)2'~(~ -- y)1.5(c~ _ y)
Y
:.l (1 + Y) t
(a~ - y ) 1 5 ]
(1)
1 + y* J
/ US \ / A C \ T.
The model was checked with plant data provided byALLGOOD [10]. These results were obtained
in a converter 17ft long containing 144 ft a of
catalyst. The operating variables used in the
model and in the plant are reported in Table 3.
In comparing the model with the actual converter,
an attempt was made to reproduce the south
thermocouple profile and to obtain the same rate
of ammonia production. By trial and error, a
value of heat transfer conductance, US, equal to
55,000 Btu/(hr) (F) was found to give the best fit
between the temperature profiles. This is in agreement with calculations of the overall heat transfer
-- [ C p o ] \ 1 + y / J
+
I US \ / A C \ T
r(-AHo)
-L
Component
Ha
Ns
NHa
Inerts
AC
7"19
7"20
11.12
6.67
3"26
-- T~AC
y*,,dy,
283
top
REACTOR
FIG.
Operating Conditioh
Actual
Parameter
HB
bottom
LENGTH, (ft )
Converter
Model
0.65
0.219
O-052
0.079
13,800
286
144
O-6375
O-2125
0.050
O-08
13,800
300
144
COOLING
0
OUTER
FIG. 4.
TUBES
THERMOCOUPLE
WELL
THERMCCOlJP,_E
Thermocouple arrangement.
-----
0
top
MODEL
PLANT DATA
IO
REACTOR L~~oTH,
(ft 1
I5
bottom
225
2001
300
I
400
TOP
FIG. 6.
TEMPERATURE,
I
500
(C)
The effect of top temperature on ammonia production rate is shown in Fig. 7. The middle curve
corresponds to the standard conditions of operation with a space velocity of 13,800. Figure 7 reveals
the existence of an optimum top temperature equal
to 425C for the standard conditions of operation.
As space velocity is varied, the optimum top
temperature changes as shown in Fig. 7. When
the space velocity increases from 9,000 to 18,000,
production rate increases as expected, but the
production rate near the maximum becomes more
and more sensitive to a change in the top temperature. A deviation from the optimum top temperature affects the production rate more strongly at
higher space velocity.
An analogous result is found when the ammonia
content of the feed gas decreases. The production
rate of the T.V.A. reactor is quite sensitive to
changes in ammonia mole fraction in the feed gas
but much less sensitive to changes in the inert
content of the feed gas. A decrease in catalyst
286
FIG.
350
400
450
TOP
TEhtPEFfATLRE,
(=C)
11
11
11
l0,000
,
15,000
I,
81
0.05
I$,,
Y;
,,,II,llllllll
0.05
0.5
I
I
3QOoO
I,
0.10
t
1.0 1
50,000
0.15
f
I
I,
l30,ooo
287
Y'
0.10
US
I
v.
= SWCE
Table 5.
+lOC
VELOCITY
Operating variable
Space velocity, VO
Ammonia mole fraction, y*
Inert mole fraction, yc*
Catalyst activity, f
50[
300
TOP
FIG. 9.
500
450
350
TEMPERATURE
550
(C)
Reference
value
13,800
0.05
0.08
1.0
Change
+600
+oGN3
$0.024
-0.05
Operating variable
Reference
value
13,800
0.05
0.08
1.0
Change
-700
+0.01x
+0.02x
-10%
288
I_
100 -
01
YK
Y;
III!
US
I
05
I,
30.000
0.05
I
54000
,!!I
IIII
0.05
0.10
III)
"0
Y'
Y;
0.15
0.10
{
1.0
I
15,000
0
f
10,000
f
I
I
00,000
us
0
Y-
I-
0.05
0
Y;
0.15
0.10
I
30,000
II
11
00,000
50,000
us
I
l0,000
0
YS
Yi*
CO
f.
II
I
II
15,000
I
I
I
I
1
I
I
I
0.10
0.05
, I I I I I IS
I I I I f I I1
11
0.15
0.05
0.10
0.5
us 30,000
50,000
"0
Y
y;
f
I
I.o
I
11
us
80,000
I,
I
0.05
IO
I,
I I I I ,,,I
0.05
0
I
0.5
I
I
30,000
FIG. 13.
II,,,
10,000
15,000
I
I
I I I I I I
I
0.10
I
0.15
0.10
1.0
I
*
50,000
Yi*
f
80,OO
290
Y'
Us
Steady-state
simulation
291
NOMENCLATURE
(359) (1.75 x 1016) (P-0.5)
(1.5 (Y$,
Yl*,2)1.5(03 +
Y;,)/(i
+ y*)2,5
1*5y*)l(1*5 - Y * a)
(YNa) + @5Y*)/(@5 - YN2)
molal heat capacity of the feed gas, Btu/(lb mole)
(F)
(1 + Y*)l(1*5 - Y&P5
molal feed rate
lb mole/hr
catalyst activity factor
equilibrium constant
(atm)-1
length of reactor
ft
total pressure
atm.
total heat transfer area
fP
top temperature
R
catalyst temperature
R
empty tube section temperature,
R
base temperature for enthalpy datum = 537R
normalized catalyst temperature
TCP&p
normalized empty tube section temperature T$/T&,,
normalized base temperature
T,*I%,
heat transfer coefficient
Btu/(hr)(ftz)(F)
space velocity = (359)(F)/v
W-1
reactor volume
fts
ammonia mole fraction
NHa mole fraction in the feed gas
Ha mole fraction in the feed gas
N2 mole fraction in the feed gas
inerts mole fraction in the feed
distance from the top of the reactor, ft
normalized distance = z/L
decrease in heat capacity resulting from the formation
of one mole of ammonia
Btu/(lb mole)(oF)
heat of formation of ammonia
Btu/lb mole
R. F. BADDOUR,
P. L. T. BRIAN,B. A. LOGEAISand J. P. EYMERY
&iFERENCES
VAN HEERDENC., Zndustr. Engng. Chem.,
EYMERYJ. P., Clrem. Engng. Sc.D. thesis,
RtiLEn
se basant sur un modele uni-dimensionnel du r&acteur T.V.A. pour la synth&se de
lammoniaque on a calcule leffet de la v&cite spatiale, de la composition de lalimentation, de la conductibilit6 thermique du lit et de lactivite du catalyseur sur la stabilitt du reacteur, la production et
les profils de temperature.
292