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OUTLINE
1. First impressions
2. Chemical reactions from a Chemical Engineering perspective
3. From reactions to reactors
4. Isothermal reactor sizing
5. Non-isothermal reactor sizing
6. Quick look into catalysis and heterogeneous reactors
2
PART 1
First impressions
3
4
– QUESTION –
5
– REMEMBER –
6
– CHEMICAL REACTIONS IN FEW WORDS –
7
– CHEMICAL REACTIONS IN FEW WORDS –
8
– CHEMICAL REACTIONS IN FEW WORDS –
9
– CHEMICAL REACTIONS IN FEW WORDS –
→ Isomerization →
cis-2-pentene trans-2-pentene
10
– QUESTION –
11
– MICROREACTORS –
https://news.illi
nois.edu/blog/v
iew/6367/2068
61
12
– BENCH-SCALE REACTORS –
13
– PILOT-SCALE REACTORS –
14
– INDUSTRIAL-SCALE REACTORS –
Hydrocracking reactor
for the Achinsk refinery
(Krasnoyarsk, Russia)
15
– QUESTION –
16
– POSSIBLE ANSWERS –
Production capacity
Importance of
Operating conditions chemical kinetics!
Costs
… 17
– BASIC CLASSIFICATION OF CHEMICAL REACTORS –
CHARACTERISTICS semicontinuous/
batch continuous
OF THE OPERATION semibatch
18
– TYPES OF CHEMICAL REACTORS –
– BATCH REACTOR –
19
– TYPES OF CHEMICAL REACTORS –
– BATCH REACTOR –
https://www.youtube.com/watch?v=TIMXE5FeAy0
20
– TYPES OF CHEMICAL REACTORS –
– BATCH REACTOR –
✓ Always operate in unsteady state
✓ Operate in cycles:
1. Filling
2. Heating ✓ High labor costs
3. Reacting ✓ Variability of product quality
4. Unloading ✓ Complicated large-scale operation
5. Cleaning, preparing
✓ Uses:
1. Small/moderate productions (volumes)
2. High conversions per unit volume (long reaction times if necessary)
3. Productions needing flexibility
4. Easy to clean (maintenance)
21
– TYPES OF CHEMICAL REACTORS –
– BATCH REACTOR –
✓ Classic uses:
▪ Testing new products (laboratory productions)
▪ Production of expensive products and small volumes
▪ Pharmaceuticals
▪ Resins for the dye industry
▪ Fermentation of beverages
▪ Wastewater treatment
▪ …
22
– TYPES OF CHEMICAL REACTORS –
– CONTINUOUS STIRRED-TANK REACTOR (CSTR) –
23
– TYPES OF CHEMICAL REACTORS –
– CONTINUOUS STIRRED-TANK REACTOR (CSTR) –
✓ Usually operated in steady state
✓ Reactants are added and products are removed continuously (no (un)loading cycles)
→ Internal agitation and/or external (or internal) recycling
✓ Uses:
1. Large productions
2. Primarily for liquid-phase reactions
3. Moderate reaction-rate reactions
4. Low and moderate temperatures
5. Low conversions per unit volume
6. Productions that do not require versatility/flexibility 24
– TYPES OF CHEMICAL REACTORS –
– CONTINUOUS STIRRED-TANK REACTOR (CSTR) –
✓ Classic uses:
▪ Polymer production
▪ Synthetic rubber polymerization
▪ Fermentors in biological processes (brewing, antibiotics…)
▪ Waste treatment (activated sludge)
▪ Cell culture
▪ …
25
– TYPES OF CHEMICAL REACTORS –
– TANK REACTORS –
https://www.youtube.com/watch?v=HGil3aApf7E
26
– TYPES OF CHEMICAL REACTORS –
– TUBULAR REACTOR / PLUG-FLOW REACTOR (PFR) –
27
– TYPES OF CHEMICAL REACTORS –
– TUBULAR REACTOR / PLUG-FLOW REACTOR (PFR) –
https://www.youtube.com/watch?v=Sm4bYdqyW2w
28
– TYPES OF CHEMICAL REACTORS –
– TUBULAR REACTOR / PLUG-FLOW REACTOR (PFR) –
✓ Usually operated in steady state
✓ Reactants are added and products are removed continuously (no (un)loading cycles)
✓ Assumes constant parameters radially and angularly, and variable parameters axially
(it’s a model)
→ The reaction rate varies axially
✓ Uses:
1. Large productions
2. Normally for gas-phase reactions, but also for liquid phases
3. High reaction-rate reactions
4. High conversions per unit volume
5. Low variations in the operating conditions or products
29
– TYPES OF CHEMICAL REACTORS –
– TUBULAR REACTOR / PLUG-FLOW REACTOR (PFR) –
✓ Classic uses:
▪ Transesterification of oils for biodiesel fuel production
▪ Production of low-density polyethylene
▪ Production of industrial metals (blast furnaces)
▪ Anaerobic digesters
▪ Nitric oxide oxidation
▪ …
30
– TYPES OF CHEMICAL REACTORS –
31
– TYPES OF CHEMICAL REACTORS –
PACKED-BED REACTOR (PBR) FLUIDIZED-BED REACTOR (FBR)
32
PART 2
33
– REMEMBER –
Chemical Kinetics is
the study of the rates of reaction.
34
– REACTION RATE –
35
– REACTION RATE –
𝑎𝐴 + 𝑏𝐵 → 𝑐𝐶 + 𝑑𝐷
𝐴 −𝑟𝐴 >0
𝐵 −𝑟𝐵 >0
𝐶 𝑟𝐶 >0
𝐷 𝑟𝐷 >0
36
– REACTION STOICHIOMETRY –
– COMPARING REACTION RATES –
𝒃 𝒄 𝒅
𝑎𝐴 + 𝑏𝐵 → 𝑐𝐶 + 𝑑𝐷 𝐴 = limiting reactant 𝑨+ 𝑩→ 𝑪+ 𝑫
𝒂 𝒂 𝒂
37
– REACTION STOICHIOMETRY –
– COMPARING REACTION RATES –
𝒃 𝒄 𝒅
𝑎𝐴 + 𝑏𝐵 → 𝑐𝐶 + 𝑑𝐷 𝐴 = limiting reactant 𝑨+ 𝑩→ 𝑪+ 𝑫
𝒂 𝒂 𝒂
−𝑟𝐴 −𝑟𝐵 𝑟𝐶 𝑟𝐷 𝑟𝐴 𝑟𝐵 𝑟𝐶 𝑟𝐷
= = = = = =
𝑎 𝑏 𝑐 𝑑 −𝑎 −𝑏 𝑐 𝑑
38
– RATE LAW (KINETIC EXPRESSION) –
Rate law Algebraic relation between reaction rate (−𝑟𝐴 ) and the reactants concentrations
−𝒓𝑨 = 𝒌𝑨 × 𝒇(𝑪𝑨 , 𝑪𝑩 , … )
39
– RATE LAW (KINETIC EXPRESSION) –
−𝒓𝑨 = 𝒌𝑨 × 𝒇(𝑪𝑨 , 𝑪𝑩 , … )
transition state /
activated state
41
– ACTIVATION ENERGY –
42
– ACTIVATION ENERGY –
43
– REACTION ORDER –
𝑎𝐴 + 𝑏𝐵 → 𝑐𝐶 + 𝑑𝐷
−𝑟𝐴 = 𝑘𝐴 𝐶𝐴𝛼𝐶𝐵𝛽
44
– REACTION ORDER –
𝑎𝐴 + 𝑏𝐵 → 𝑐𝐶 + 𝑑𝐷
−𝑟𝐴 = 𝑘𝐴 𝐶𝐴𝛼𝐶𝐵𝛽
45
– REACTION ORDER –
𝑎𝐴 + 𝑏𝐵 → 𝑐𝐶 + 𝑑𝐷
−𝑟𝐴 = 𝑘𝐴 𝐶𝐴𝛼𝐶𝐵𝛽
46
– REACTION ORDER –
𝑎𝐴 → 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 −𝑟𝐴 = 𝑘𝐴 𝐶𝐴𝛼
𝒄𝒐𝒏𝒄𝒆𝒏𝒕𝒓𝒂𝒕𝒊𝒐𝒏 𝟏−𝒏
Reaction 𝒏 Law SI-unit of 𝒌 𝒕𝒊𝒎𝒆
𝑚𝑜𝑙
Zero-order reaction 0 −𝑟𝐴 = 𝑘𝐴
𝑚3 𝑠
First-order reaction 1 −𝑟𝐴 = 𝑘𝐴 𝐶𝐴 𝑠 −1
𝑚3
Second-order reaction 2 −𝑟𝐴 = 𝑘𝐴 𝐶𝐴2
𝑚𝑜𝑙 𝑠
2
𝑚3
Third-order reaction 3 −𝑟𝐴 = 𝑘𝐴 𝐶𝐴3 𝑠 −1
𝑚𝑜𝑙
47
– REACTION ORDER –
𝑎𝐴 → 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 −𝑟𝐴 = 𝑘𝐴 𝐶𝐴𝛼
𝒄𝒐𝒏𝒄𝒆𝒏𝒕𝒓𝒂𝒕𝒊𝒐𝒏 𝟏−𝒏
Reaction 𝒏 Law SI-unit of 𝒌 𝒕𝒊𝒎𝒆
𝑚𝑜𝑙
Zero-order reaction 0 −𝑟𝐴 = 𝑘𝐴
𝑚3 𝑠
First-order reaction 1 −𝑟𝐴 = 𝑘𝐴 𝐶𝐴 𝑠 −1
𝑚3
Second-order reaction 2 −𝑟𝐴 = 𝑘𝐴 𝐶𝐴2
𝑚𝑜𝑙 𝑠
2
𝑚3
Third-order reaction 3 −𝑟𝐴 = 𝑘𝐴 𝐶𝐴3 𝑠 −1
𝑚𝑜𝑙
If a reaction is said elementary, then the reaction orders are equal to the
stoichiometric coefficients. However, not all reactions whose coefficients are equal
to the stoichiometric coefficients are elementary reactions, even though it is said
that such reactions follow an elementary rate.
49
– REACTION REVERSIBILITY –
𝑎𝐴 + 𝑏𝐵 ⇌ 𝑐𝐶 + 𝑑𝐷
Many reactions seem to cease before the limiting reactant is used up.
50
– REACTION REVERSIBILITY –
𝑎𝐴 + 𝑏𝐵 ⇌ 𝑐𝐶 + 𝑑𝐷
Many reactions seem to cease before the limiting reactant is used up.
The forward reaction has not completely ceased but the reverse reaction is occurring.
51
– REACTION REVERSIBILITY –
𝑎𝐴 + 𝑏𝐵 ⇌ 𝑐𝐶 + 𝑑𝐷
Many reactions seem to cease before the limiting reactant is used up.
The forward reaction has not completely ceased but the reverse reaction is occurring.
When no further changes occur in the amounts of products and reactants (forward and
reverse reactions equally fast), equilibrium is reached (macroscopically static, but
dynamic at molecular level).
−𝑟𝐴 = 𝑟𝐴 = 0 52
– CONVERSION –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎
Moles of 𝑨 consumed
Moles of 𝐴 consumed = Moles of 𝐴 fed x ______________________
Moles of 𝑨 fed
53
– CONVERSION –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎
Moles of 𝑨 consumed
Moles of 𝐴 consumed = Moles of 𝐴 fed x ______________________
Moles of 𝑨 fed
𝑁𝐴 = 𝑁𝐴0 - 𝑁𝐴0 𝑋𝐴
54
– CONVERSION –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎
Moles of 𝑨 consumed
Moles of 𝐴 consumed = Moles of 𝐴 fed x ______________________
Moles of 𝑨 fed
𝑁𝐴 = 𝑁𝐴0 - 𝑁𝐴0 𝑋𝐴
56
– QUESTION –
57
– STOICHIOMETRIC TABLE –
– BATCH SYSTEMS –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎
58
– STOICHIOMETRIC TABLE –
– BATCH SYSTEMS –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎
59
– STOICHIOMETRIC TABLE –
– BATCH SYSTEMS –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎
60
– STOICHIOMETRIC TABLE –
– BATCH SYSTEMS –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎
61
– STOICHIOMETRIC TABLE –
– BATCH SYSTEMS –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎
63
– WRITING CONCENTRATIONS FOR CONSTANT-VOLUME
BATCH SYSTEMS –
𝑁𝐴 𝑁𝐴0 − 𝑁𝐴0 𝑋𝐴 𝑁𝐴0 (1 − 𝑋𝐴 ) 𝑁𝐴0 (1 − 𝑋𝐴 )
𝐶𝐴 = = = = = 𝐶𝐴0 (1 − 𝑋𝐴 )
𝑉 𝑉 𝑉 𝑉0
𝑏 𝑏 𝑏
𝑁𝐵 𝑁𝐵0 − 𝑎 𝑁𝐴0 𝑋𝐴 𝑁𝐵0 − 𝑎 𝑁𝐴0 𝑋𝐴 𝑁𝐴 𝑁𝐴0 Θ𝐵 − 𝑋𝐴 𝑏
0 𝑎
𝐶𝐵 = = = = = 𝐶𝐴0 Θ𝐵 − 𝑋𝐴
𝑉 𝑉 𝑉 𝑁𝐴0 𝑉 𝑎
𝑁𝑖0 𝐹𝑖 𝐶𝑖
Θ𝑖 = = 0 = 0
𝑁𝐴0 𝐹𝐴0 𝐶𝐴0
64
– WRITING CONCENTRATIONS FOR CONSTANT-VOLUME
BATCH SYSTEMS –
𝑁𝐴 𝑁𝐴0 − 𝑁𝐴0 𝑋𝐴 𝑁𝐴0 (1 − 𝑋𝐴 ) 𝑁𝐴0 (1 − 𝑋𝐴 )
𝐶𝐴 = = = = = 𝐶𝐴0 (1 − 𝑋𝐴 )
𝑉 𝑉 𝑉 𝑉0
𝑏 𝑏 𝑏
𝑁𝐵 𝑁𝐵0 − 𝑎 𝑁𝐴0 𝑋𝐴 𝑁𝐵0 − 𝑎 𝑁𝐴0 𝑋𝐴 𝑁𝐴 𝑁𝐴0 Θ𝐵 − 𝑋𝐴 𝑏
0 𝑎
𝐶𝐵 = = = = = 𝐶𝐴0 Θ𝐵 − 𝑋𝐴
𝑉 𝑉 𝑉 𝑁𝐴0 𝑉 𝑎
Species
𝐶𝐴 = 𝐶𝐴0 (1 − 𝑋𝐴 )
𝑏
𝐶𝐵 = 𝐶𝐴0 Θ𝐵 − 𝑋𝐴
𝑎 𝑁𝑖0 𝐶𝑖0
Θ𝑖 = =
𝑐 𝑁𝐴0 𝐶𝐴0
𝐶𝐶 = 𝐶𝐴0 Θ𝐶 + 𝑋𝐴
𝑎
𝑑
𝐶𝐷 = 𝐶𝐴0 Θ𝐷 + 𝑋𝐴
𝑎
𝑁𝑇 = 𝑁𝑇0 + 𝛿𝑁𝐴0 𝑋𝐴
65
– WRITING CONCENTRATIONS FOR CONSTANT-VOLUME
FLOW SYSTEMS –
Definition of concentration for a flow system.
variables
readily 𝐹 molar flow rate (𝑚𝑜𝑙 𝑠 −1 ) 𝐹 instead of
available in 𝐶= (𝑚𝑜𝑙 𝑚−3 ) 𝐶=
𝑁
𝑣 volumetric flow rate (𝑚3 𝑠 −1 ) 𝑣 𝑉
the industry
The stoichiometric table for flow systems is the same, but changing 𝑁 for 𝐹.
66
– WRITING CONCENTRATIONS FOR VARIABLE-VOLUME
BATCH SYSTEMS –
𝑃0 𝑉0 = 𝑁𝑇0 𝑅𝑇0 𝑃0 𝑇 𝑁𝑇 Reactions in gas phase with
𝑉 = 𝑉0 variation of the number of
𝑃𝑉 = 𝑁𝑇 𝑅𝑇 𝑃 𝑇0 𝑁𝑇0 moles; ideal gas
67
– WRITING CONCENTRATIONS FOR VARIABLE-VOLUME
BATCH SYSTEMS –
𝑃0 𝑉0 = 𝑁𝑇0 𝑅𝑇0 𝑃0 𝑇 𝑁𝑇 Reactions in gas phase with
𝑉 = 𝑉0 variation of the number of
𝑃𝑉 = 𝑁𝑇 𝑅𝑇 𝑃 𝑇0 𝑁𝑇0 moles; ideal gas
𝑁𝑇 𝑁𝐴0
𝑁𝑇 = 𝑁𝑇0 + 𝛿𝑁𝐴0 𝑋𝐴 =1+𝛿 𝑋 = 1 + 𝛿𝑦𝐴0 𝑋𝐴
𝑁𝑇0 𝑁𝑇0 𝐴
68
– WRITING CONCENTRATIONS FOR VARIABLE-VOLUME
BATCH SYSTEMS –
𝑃0 𝑉0 = 𝑁𝑇0 𝑅𝑇0 𝑃0 𝑇 𝑁𝑇 Reactions in gas phase with
𝑉 = 𝑉0 variation of the number of
𝑃𝑉 = 𝑁𝑇 𝑅𝑇 𝑃 𝑇0 𝑁𝑇0 moles; ideal gas
𝑁𝑇 𝑁𝐴0 𝑃0 𝑇
𝑁𝑇 = 𝑁𝑇0 + 𝛿𝑁𝐴0 𝑋𝐴 =1+𝛿 𝑋 = 1 + 𝛿𝑦𝐴0 𝑋𝐴 𝑉 = 𝑉0 (1 + 𝜀𝐴 𝑋𝐴 )
𝑁𝑇0 𝑁𝑇0 𝐴 𝑃 𝑇0
69
– WRITING CONCENTRATIONS FOR VARIABLE-VOLUME
BATCH SYSTEMS –
𝑃0 𝑉0 = 𝑁𝑇0 𝑅𝑇0 𝑃0 𝑇 𝑁𝑇 Reactions in gas phase with
𝑉 = 𝑉0 variation of the number of
𝑃𝑉 = 𝑁𝑇 𝑅𝑇 𝑃 𝑇0 𝑁𝑇0 moles; ideal gas
𝑁𝑇 𝑁𝐴0 𝑃0 𝑇
𝑁𝑇 = 𝑁𝑇0 + 𝛿𝑁𝐴0 𝑋𝐴 =1+𝛿 𝑋 = 1 + 𝛿𝑦𝐴0 𝑋𝐴 𝑉 = 𝑉0 (1 + 𝜀𝐴 𝑋𝐴 )
𝑁𝑇0 𝑁𝑇0 𝐴 𝑃 𝑇0
70
– WRITING CONCENTRATIONS FOR VARIABLE-VOLUME
BATCH SYSTEMS –
𝑃0 𝑉0 = 𝑁𝑇0 𝑅𝑇0 𝑃0 𝑇 𝑁𝑇 Reactions in gas phase with
𝑉 = 𝑉0 variation of the number of
𝑃𝑉 = 𝑁𝑇 𝑅𝑇 𝑃 𝑇0 𝑁𝑇0 moles; ideal gas
𝑁𝑇 𝑁𝐴0 𝑃0 𝑇
𝑁𝑇 = 𝑁𝑇0 + 𝛿𝑁𝐴0 𝑋𝐴 =1+𝛿 𝑋 = 1 + 𝛿𝑦𝐴0 𝑋𝐴 𝑉 = 𝑉0 (1 + 𝜀𝐴 𝑋𝐴 )
𝑁𝑇0 𝑁𝑇0 𝐴 𝑃 𝑇0
instead of
𝐶𝐴0 (1 − 𝑋𝐴 ) 𝐶𝐴0 Θ𝐵 − 𝑏ൗ𝑎 𝑋𝐴
𝐶𝐴 = 𝐶𝐵 =
𝐶𝐴 = 𝐶𝐴0 (1 − 𝑋𝐴 ) 𝑃 𝑇 𝑃 𝑇
(1 + 𝜀𝐴 𝑋𝐴 ) 𝑃0 𝑇 (1 + 𝜀𝐴 𝑋𝐴 ) 𝑃0 𝑇
0 0 71
– WRITING CONCENTRATIONS FOR VARIABLE-VOLUME
FLOW SYSTEMS –
𝐹𝑇 𝑃0 𝑇 Reactions in gas phase with
𝑣 = 𝑣0 variation of the number of
𝐹𝑇0 𝑃 𝑇0 moles; ideal gas
instead of
𝐶𝐴0 (1 − 𝑋𝐴 ) 𝐶𝐴0 Θ𝐵 − 𝑏ൗ𝑎 𝑋𝐴
𝐶𝐴 = 𝐶𝐵 =
𝐶𝐴 = 𝐶𝐴0 (1 − 𝑋𝐴 ) 𝑃 𝑇 𝑃 𝑇
(1 + 𝜀𝐴 𝑋𝐴 ) 𝑃0 𝑇 (1 + 𝜀𝐴 𝑋𝐴 ) 𝑃0 𝑇
0 0
73
– REMEMBER –
We want to calculate
reaction times for batch reactors
and reactor volumes for continuous reactors.
74
– MOLE BALANCES –
control volume
do not cross the system’s boundaries
GEN
A
IN C OUT
C
crosses the system’s crosses the system’s
boundaries boundaries
𝐈𝐍 − 𝐎𝐔𝐓 + 𝐆𝐄𝐍 = 𝐀𝐂𝐂
75
– MOLE BALANCES –
control volume
do not cross the system’s boundaries
GEN
A
IN C OUT
C
crosses the system’s crosses the system’s
boundaries boundaries
𝐈𝐍 − 𝐎𝐔𝐓 + 𝐆𝐄𝐍 = 𝐀𝐂𝐂
𝐈𝐍 = 𝐎𝐔𝐓 + 𝐀𝐂𝐂 − 𝐆𝐄𝐍
76
– MOLE BALANCES –
control volume
do not cross the system’s boundaries
GEN
A
IN C OUT
C
crosses the system’s crosses the system’s
boundaries boundaries
𝐈𝐍 − 𝐎𝐔𝐓 + 𝐆𝐄𝐍 = 𝐀𝐂𝐂
𝐈𝐍 = 𝐎𝐔𝐓 + 𝐀𝐂𝐂 − 𝐆𝐄𝐍
77
– MOLE BALANCES –
Mole balance for the species 𝑖 in time 𝑡 in the control volume.
78
– MOLE BALANCES –
Mole balance for the species 𝑖 in time 𝑡 in the control volume.
1𝐿
0.5 𝐿
𝑵𝒊
𝑪𝒊 =
𝟎. 𝟓 𝑳
79
– MOLE BALANCES –
Mole balance for the species 𝑖 in time 𝑡 in the control volume.
80
– MOLE BALANCES –
Mole balance for the species 𝑖 in time 𝑡 in the control volume.
81
– MOLE BALANCES –
– BATCH REACTOR –
𝒕 =?
𝒅𝑵𝒊
= 𝒓𝒊 𝑽
𝒅𝒕
82
– MOLE BALANCES –
– BATCH REACTOR –
𝒕 =?
𝒅𝑵𝒊
= 𝒓𝒊 𝑽
𝒅𝒕
𝒅𝑪𝒊
= 𝒓𝒊
𝒅𝒕
83
– MOLE BALANCES –
– BATCH REACTOR –
𝒕 =?
𝒅𝑵𝒊
= 𝒓𝒊 𝑽
𝒅𝒕
𝒅𝑪𝒊 𝟏 𝒅𝑽 𝒅𝑪𝒊
= 𝒓𝒊 𝑪𝒊 +𝑽 = 𝒓𝒊
𝒅𝒕 𝑽 𝒅𝒕 𝒅𝒕
𝒅 𝒍𝒏 𝑽 𝒅𝑪𝒊
𝑪𝒊 + = 𝒓𝒊
𝒅𝒕 𝒅𝒕
84
– MOLE BALANCES –
– CSTR –
𝑽 =?
𝑭𝒊𝟎 = 𝑭𝒊 − 𝒓𝒊 𝑽
85
– MOLE BALANCES –
– CSTR –
𝑽 =?
𝑭𝒊𝟎 = 𝑭𝒊 − 𝒓𝒊 𝑽
𝑭𝒊𝟎 − 𝑭𝒊
𝑽𝑪𝑺𝑻𝑹 =
−𝒓𝒊
86
– MOLE BALANCES –
– PFR –
𝑽 =?
a 1-D balance is enough
𝑭𝒊 = 𝑭𝒊 + 𝒅𝑭𝒊 − 𝒓𝒊 𝒅𝑽 because PFR assumes radial
and angular homogeneity
87
– MOLE BALANCES –
– PFR –
𝑽 =?
a 1-D balance is enough
𝑭𝒊 = 𝑭𝒊 + 𝒅𝑭𝒊 − 𝒓𝒊 𝒅𝑽 because PFR assumes radial
and angular homogeneity
𝒅𝑭𝒊 𝒅𝑭𝒊
− = −𝒓𝒊 − = −𝒓𝒊 𝑨𝒄
𝒅𝑽 𝒅𝒚
88
– REMEMBER –
89
PART 4
90
– ISOTHERMAL REACTOR SIZING –
– BATCH REACTOR –
𝒕 =?
91
– ISOTHERMAL REACTOR SIZING –
– BATCH REACTOR –
𝒕 =?
𝑑𝑁𝑖 𝑑𝑁𝐴
= 𝑟𝑖 𝑉 ⟹ − = −𝑟𝐴 𝑉 𝒅𝑿𝑨
𝑑𝑡 𝑑𝑡 𝑵𝑨𝟎 = −𝒓𝑨 𝑽
𝒅𝒕
𝑁𝐴 = 𝑁𝐴0 1 − 𝑋𝐴
92
– ISOTHERMAL REACTOR SIZING –
– BATCH REACTOR –
𝒕 =?
𝑑𝑁𝑖 𝑑𝑁𝐴
= 𝑟𝑖 𝑉 ⟹ − = −𝑟𝐴 𝑉 𝒅𝑿𝑨
𝑑𝑡 𝑑𝑡 𝑵𝑨𝟎 = −𝒓𝑨 𝑽
𝒅𝒕
𝑁𝐴 = 𝑁𝐴0 1 − 𝑋𝐴
𝒕𝑹 𝑿𝑨
𝒅𝑿𝑨
න 𝒅𝒕 = න 𝑪𝑨𝟎
𝟎 𝑿𝑨𝟎 −𝒓𝑨
93
– ISOTHERMAL REACTOR SIZING –
– BATCH REACTOR –
𝒕 =?
𝑑𝑁𝑖 𝑑𝑁𝐴
= 𝑟𝑖 𝑉 ⟹ − = −𝑟𝐴 𝑉 𝒅𝑿𝑨
𝑑𝑡 𝑑𝑡 𝑵𝑨𝟎 = −𝒓𝑨 𝑽
𝒅𝒕
𝑁𝐴 = 𝑁𝐴0 1 − 𝑋𝐴
𝒕𝑹 𝑿𝑨
𝒅𝑿𝑨 𝑵𝑨𝟎 𝒅𝑿𝑨
න 𝒅𝒕 = න 𝑪𝑨𝟎 𝒅𝒕 =
𝟎 𝑿𝑨𝟎 −𝒓𝑨 −𝒓𝑨 𝑽
94
– ISOTHERMAL REACTOR SIZING –
– BATCH REACTOR –
𝒕 =?
𝑑𝑁𝑖 𝑑𝑁𝐴
= 𝑟𝑖 𝑉 ⟹ − = −𝑟𝐴 𝑉 𝒅𝑿𝑨
𝑑𝑡 𝑑𝑡 𝑵𝑨𝟎 = −𝒓𝑨 𝑽
𝒅𝒕
𝑁𝐴 = 𝑁𝐴0 1 − 𝑋𝐴
𝒕𝑹 𝑿𝑨
𝒅𝑿𝑨 𝑵𝑨𝟎 𝒅𝑿𝑨
න 𝒅𝒕 = න 𝑪𝑨𝟎 𝒅𝒕 =
𝟎 𝑿𝑨𝟎 −𝒓𝑨 −𝒓𝑨 𝑽
𝒕𝑹 𝑿𝑨
𝒅𝑿𝑨 𝑵𝑨𝟎 𝒅𝑿𝑨
න 𝒅𝒕 = 𝑪𝑨𝟎 න 𝑽(𝒕)𝒅𝒕 =
𝑷 𝑻
𝟎 𝑿𝑨 𝟎 −𝒓𝑨 𝟏 + 𝜺𝑨 𝑿𝑨 𝑷𝟎 𝑻 −𝒓𝑨
𝟎
95
– USEFUL CONCEPTS FOR FLOW REACTORS –
97
– ISOTHERMAL REACTOR SIZING –
– CSTR –
𝑽 =?
𝐹𝐴0 − 𝐹𝐴
𝐹𝐴0 = 𝐹𝐴 + −𝑟𝐴 𝑉 ⟹ 𝑉𝐶𝑆𝑇𝑅 = 𝑭𝑨𝟎 𝑿 𝑨
−𝑟𝐴 𝑽𝑪𝑺𝑻𝑹 =
−𝒓𝑨
𝐹𝐴 = 𝐹𝐴0 − 𝐹𝐴0 𝑋𝐴
98
– ISOTHERMAL REACTOR SIZING –
– PFR –
𝑽 =?
99
– ISOTHERMAL REACTOR SIZING –
– PFR –
𝑽 =?
100
– COMPARISON OF CONTINUOUS REACTORS –
– CSTR vs. PFR –
1 𝐹𝐴0
Levenspiel plot A plot of −𝑟𝐴
× 𝑋𝐴 or of −𝑟𝐴
× 𝑋𝐴
101
– COMPARISON OF CONTINUOUS REACTORS –
– CSTR vs. PFR –
1 𝐹𝐴0
Levenspiel plot A plot of −𝑟𝐴
× 𝑋𝐴 or of −𝑟𝐴
× 𝑋𝐴
𝑋𝐴 𝑋𝐴
𝐹𝐴 𝑋𝐴 𝑉𝐶𝑆𝑇𝑅 1 𝑑𝑋𝐴 𝑉𝑃𝐹𝑅 𝑑𝑋𝐴
𝑉𝐶𝑆𝑇𝑅 = 0 ⟹ = 𝑋 𝑉𝑃𝐹𝑅 = 𝐹𝐴0 න ⟹ =න
−𝑟𝐴 𝐹𝐴0 −𝑟𝐴 𝐴 𝑋𝐴0 −𝑟𝐴 𝐹𝐴0 𝑋𝐴 −𝑟𝐴
0
102
– COMPARISON OF CONTINUOUS REACTORS –
– CSTR vs. PFR –
1 𝐹𝐴0
Levenspiel plot A plot of −𝑟𝐴
× 𝑋𝐴 or of −𝑟𝐴
× 𝑋𝐴
𝑋𝐴 𝑋𝐴
𝐹𝐴 𝑋𝐴 𝑉𝐶𝑆𝑇𝑅 1 𝑑𝑋𝐴 𝑉𝑃𝐹𝑅 𝑑𝑋𝐴
𝑉𝐶𝑆𝑇𝑅 = 0 ⟹ = 𝑋 𝑉𝑃𝐹𝑅 = 𝐹𝐴0 න ⟹ =න
−𝑟𝐴 𝐹𝐴0 −𝑟𝐴 𝐴 𝑋𝐴0 −𝑟𝐴 𝐹𝐴0 𝑋𝐴 −𝑟𝐴
0
103
– QUESTION –
104
– COMPARISON OF CONTINUOUS REACTORS –
– CSTR vs. PFR –
1 𝐹𝐴0
Levenspiel plot A plot of −𝑟𝐴
× 𝑋𝐴 or of −𝑟𝐴
× 𝑋𝐴
𝑋𝐴 𝑋𝐴
𝐹𝐴 𝑋𝐴 𝑉𝐶𝑆𝑇𝑅 1 𝑑𝑋𝐴 𝑉𝑃𝐹𝑅 𝑑𝑋𝐴
𝑉𝐶𝑆𝑇𝑅 = 0 ⟹ = 𝑋 𝑉𝑃𝐹𝑅 = 𝐹𝐴0 න ⟹ =න
−𝑟𝐴 𝐹𝐴0 −𝑟𝐴 𝐴 𝑋𝐴0 −𝑟𝐴 𝐹𝐴0 𝑋𝐴 −𝑟𝐴
0
𝐶𝐴0
≈ 𝐶𝐴
𝐶𝐴
𝑑𝑋𝐴
𝐶𝐴0
−𝑟𝐴
𝑋𝐴
106
– SYSTEMS OF REACTORS –
107
– SYSTEMS OF REACTORS –
– PFRs –
Conversion for
reactors in series 𝑿𝑨 =
𝒕𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒎𝒐𝒍𝒆𝒔 𝒓𝒆𝒂𝒄𝒕𝒆𝒅 𝒖𝒑 𝒕𝒐 𝒕𝒉𝒆 𝒑𝒐𝒊𝒏𝒕 𝒖𝒏𝒅𝒆𝒓 𝒂𝒏𝒂𝒍𝒚𝒔𝒊𝒔
when there are no lateral 𝒕𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒎𝒐𝒍𝒆𝒔 𝒇𝒆𝒅 𝒕𝒐 𝒕𝒉𝒆 𝒇𝒊𝒓𝒔𝒕 𝒓𝒆𝒂𝒄𝒕𝒐𝒓
streams and the feed mixture
is fed to the first reactor of the
series
𝑋𝐴𝑖 𝑑
𝑉𝑠𝑖𝑠𝑡 𝑋𝐴
𝜏𝑠𝑖𝑠𝑡 = = 𝐶𝐴0 න
𝑣0 𝑋𝐴 −𝑟𝐴
0
108
– SYSTEMS OF REACTORS –
– PFRs –
Conversion for
reactors in series 𝑿𝑨 =
𝒕𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒎𝒐𝒍𝒆𝒔 𝒓𝒆𝒂𝒄𝒕𝒆𝒅 𝒖𝒑 𝒕𝒐 𝒕𝒉𝒆 𝒑𝒐𝒊𝒏𝒕 𝒖𝒏𝒅𝒆𝒓 𝒂𝒏𝒂𝒍𝒚𝒔𝒊𝒔
when there are no lateral 𝒕𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒎𝒐𝒍𝒆𝒔 𝒇𝒆𝒅 𝒕𝒐 𝒕𝒉𝒆 𝒇𝒊𝒓𝒔𝒕 𝒓𝒆𝒂𝒄𝒕𝒐𝒓
streams and the feed mixture
is fed to the first reactor of the
series
𝑋𝐴𝑖 𝑑
𝑉𝑠𝑖𝑠𝑡 𝑋𝐴
𝜏𝑠𝑖𝑠𝑡 = = 𝐶𝐴0 න
𝑣0 𝑋𝐴 −𝑟𝐴
0
109
– SYSTEMS OF REACTORS –
– CSTRs of same capacity and 𝜌 = 𝑐𝑡𝑒 –
Conversion for
reactors in series 𝑿𝑨 =
𝒕𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒎𝒐𝒍𝒆𝒔 𝒓𝒆𝒂𝒄𝒕𝒆𝒅 𝒖𝒑 𝒕𝒐 𝒕𝒉𝒆 𝒑𝒐𝒊𝒏𝒕 𝒖𝒏𝒅𝒆𝒓 𝒂𝒏𝒂𝒍𝒚𝒔𝒊𝒔
when there are no side streams 𝒕𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒎𝒐𝒍𝒆𝒔 𝒇𝒆𝒅 𝒕𝒐 𝒕𝒉𝒆 𝒇𝒊𝒓𝒔𝒕 𝒓𝒆𝒂𝒄𝒕𝒐𝒓
and the feed mixture is fed to
the first reactor of the series
111
– SELECTIVITY AND YIELD –
Recommended readings!
112
PART 5
113
– QUESTION –
114
– NON-ISOTHERMAL REACTORS –
115
– ENERGY BALANCE –
Control volume: the reactor (an open system)
Elements of Chemical
Reaction Engineering
H. Scott Fogler
4th Edition
Chap. 8
pp. 471-486 116
– ENERGY BALANCE –
– BATCH REACTOR –
Elements of Chemical
Reaction Engineering
H. Scott Fogler
4th Edition
Chap. 9
pp. 591-595
Mole balance
Constant volume
for a batch Constant pressure
reactor No phase change
No inflows
Constant volume
Constant pressure
−𝑋𝐴 ∆𝐻𝑅 𝑇0 No phase change
𝑇 − 𝑇0 =
σ Θ𝑖 𝐶𝑃𝑖 + 𝑋𝐴 Δ𝐶𝑃 No inflows
Adiabatic
No shaft work
117
– ENERGY BALANCE –
– CSTR AND PFR AT STEADY-STATE OPERATION –
119
– EQUILIBRIUM CONVERSION
IN NON-ISOTHERMAL REACTORS –
It is the intersection point between the expressions of
1) the equilibrium conversion vs. temperature plot from the rate law and
van’t Hoff’s equation
120
PART 6
121
– QUESTION –
122
– CATALYSTS –
123
– CATALYSTS –
124
– CATALYSTS –
126
– CATALYTIC REACTIONS –
http://www.essentialchemicalindustry.org/processes/catalysis-in-industry.html 127
– CATALYTIC REACTIONS –
http://www.essentialchemicalindustry.org/processes/catalysis-in-industry.html 128
– CATALYSTS –
HETEROGENEOUS catalysts
Porous catalysts
Monolithic catalysts
(porous and nonporous)
Supported catalysts
Need to be separated
from the mixture once
the reaction took place
130
– CATALYSIS –
https://www.youtube.com/watch?v=PbiNmhD6vzk
131
– CATALYSIS –
https://www.youtube.com/watch?v=9K0uPq9l0mQ
132
– CATALYSIS –
https://www.youtube.com/watch?v=KYD5LNVWne8
133
– CATALYSIS –
https://www.youtube.com/watch?v=XTUm-75-PL4
134
– HETEROGENEOUS CATALYST DEACTIVATION –
The activity of the catalyst is not constant throughout its life.
Sintering (aging)
Coking or fouling Poisoning
135
– QUESTION –
136
– HETEROGENEOUS CATALYTIC REACTION:
A MULTISTEP PHENOMENON –
http://slideplayer.com/slide/8482317/
137
– STEPS OF A HETEROGENEOUS CATALYTIC REACTION –
chemical reaction
138
– DIMENSIONLESS NUMBERS –
Da = Damköhler number
reaction rate
Da =
rate of diffusive mass transfer
0 < Da < ∞
Mass-transfer controlled “reaction” approx. Da > 3
Kinetically controlled “reaction” approx. Da < 3
139
– DIMENSIONLESS NUMBERS –
ϕ = Thiele modulus
reaction rate
ϕ=
rate of internal diffusive mass transfer
η , Ω = effectiveness factors
141