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Kinetics and Reactor Design

by

Prof. Gustavo Henndel Lopes

No part of this material may be transmitted in any form or by ane means, electronic or mechanical, including
photocopying, recording, or any information storage and retrieval system, without permission in writing from the author. 1
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 –

When you dissolve salt in water,


do you do it in a chemical reactor?

5
– REMEMBER –

The velocity of a chemical reaction


is the determining phenomenon
for something to be studied and designed
as a chemical reactor.

6
– CHEMICAL REACTIONS IN FEW WORDS –

Chemical species Chemical component or element with an identity

7
– CHEMICAL REACTIONS IN FEW WORDS –

Chemical species Chemical component or element with an identity

Identity Kind, number and configuration of the chemical species

8
– CHEMICAL REACTIONS IN FEW WORDS –

Chemical species Chemical component or element with an identity

Identity Kind, number and configuration of the chemical species

Chemical reaction When chemical species lose their identity

9
– CHEMICAL REACTIONS IN FEW WORDS –

Chemical species Chemical component or element with an identity

Identity Kind, number and configuration of the chemical species

Chemical reaction When chemical species lose their identity

→ Decomposition 2 𝐾𝐶𝑙𝑂3 → 2 𝐾𝐶𝑙 + 3 𝑂2

→ Combination (synthesis) 𝐻2 + 𝐶𝑙2 → 2 𝐻𝐶𝑙

→ Substitution (single replacement) 2 𝑁𝑎 + 2 𝐻2 𝑂 → 2 𝑁𝑎𝑂𝐻 + 𝐻2

→ Metathesis (double displacement) 𝐵𝑎𝐶𝑙2 + 2 𝐴𝑔𝑁𝑂3 → 2 𝐴𝑔𝐶𝑙 + 𝐵𝑎 𝑁𝑂3 2

→ Isomerization →
cis-2-pentene trans-2-pentene

10
– QUESTION –

How big are chemical reactors?

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 –

What to consider when designing a reactor?

16
– POSSIBLE ANSWERS –
Production capacity

Size of the recipient

Time necessary for the reaction to occur

Importance of
Operating conditions chemical kinetics!

Heat transfer conditions

Costs

… 17
– BASIC CLASSIFICATION OF CHEMICAL REACTORS –
CHARACTERISTICS semicontinuous/
batch continuous
OF THE OPERATION semibatch

FORM OF THE tank tubular


REACTOR (batch, continuous) (continuous)

PHASES INVOLVED homogeneous heterogeneous

CONDITIONS OF isothermal non-isothermal adiabatic


TEMPERATURE
THE USE OF catalytic non-catalytic
CATALYSERS

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

✓ Assumes no spatial variation

✓ 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

✓ Assumes vigorous, perfect mixing within the reactor (it’s a model)


→ Conditions inside the reactor = in the exit stream (no spatial variation)

✓ 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

Chemical reactions from


a Chemical Engineering perspective

33
– REMEMBER –

Chemical Kinetics is
the study of the rates of reaction.

34
– REACTION RATE –

Chemical reaction The total collective mass is conserved,


but not the mass of the individual species

Reaction rate Rate of disappearance or formation of a chemical species


(rate of reaction)
Number of moles that lose or gain a new chemical identity
𝒎𝒐𝒍
per unit volume (for homogeneous reactions)
𝒎𝟑 𝒔 per unit time
𝑟
Function of the reacting materials and reaction conditions

Independent of the type of reactor

35
– REACTION RATE –

Reaction rate Products (formation) 𝑟 > 0

Reactants (disappearance) 𝑟 < 0

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

Always refer to a single species in the reaction, usually 𝐴

−𝒓𝑨 = 𝒌𝑨 × 𝒇(𝑪𝑨 , 𝑪𝑩 , … )

reaction rate rate constant rate law

39
– RATE LAW (KINETIC EXPRESSION) –

Collision model For molecules to react, they need to collide effectively

−𝒓𝑨 = 𝒌𝑨 × 𝒇(𝑪𝑨 , 𝑪𝑩 , … )

includes the fraction chances of collision


of effective collisions
40
– ARRHENIUS EQUATION –

Arrhenius equation Gives the temperature behavior of most reaction rates

𝑬𝒂 activation energy (𝑱/𝒎𝒐𝒍)


𝒌 𝑻 = 𝑨𝒆−𝑹𝑻
preexponential factor /
𝐸𝑎 1 frequency factor
𝑙𝑛 𝑘𝐴 = 𝑙𝑛 𝐴 −
𝑅 𝑇

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

Overall order of reaction (𝒏) 𝛼+𝛽

Order of reaction with respect to 𝑨 𝛼

Order of reaction with respect to 𝑩 𝛽

45
– REACTION ORDER –
𝑎𝐴 + 𝑏𝐵 → 𝑐𝐶 + 𝑑𝐷

−𝑟𝐴 = 𝑘𝐴 𝐶𝐴𝛼𝐶𝐵𝛽

Overall order of reaction (𝒏) 𝛼+𝛽

Order of reaction with respect to 𝑨 𝛼

Order of reaction with respect to 𝑩 𝛽

𝛼 and 𝛽 are the reactant orders determined from experiments


𝛼 and 𝛽 are not the stoichiometric coefficients

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.

Much more complex reaction orders exist. 48


– RATE LAWS AND REACTION ORDERS –
– EXAMPLES –

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).

𝐶𝐶𝑒𝑞 𝑐 𝐶𝐷𝑒𝑞 𝑑 𝑘𝑖𝑛𝑒𝑡𝑖𝑐 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡


𝐾𝐶 = 𝑜𝑓 𝑐ℎ𝑒𝑚𝑖𝑐𝑎𝑙 𝑒𝑞𝑢𝑖𝑙𝑖𝑏𝑟𝑖𝑢𝑚
𝐶𝐴𝑒𝑞 𝑎 𝐶𝐵𝑒𝑞 𝑏

−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

Moles of 𝐴 consumed = 𝑁𝐴0 x 𝑿𝑨

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

Moles of 𝐴 consumed = 𝑁𝐴0 x 𝑿𝑨

Moles of 𝐴 in the reactor = Moles of 𝐴 fed - Moles of 𝐴 consumed

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

Moles of 𝐴 consumed = 𝑁𝐴0 x 𝑿𝑨

Moles of 𝐴 in the reactor = Moles of 𝐴 fed - Moles of 𝐴 consumed

𝑁𝐴 = 𝑁𝐴0 - 𝑁𝐴0 𝑋𝐴

𝑁𝐴 = 𝑁𝐴0 − 𝑁𝐴0 𝑋𝐴 = 𝑁𝐴0 (1 − 𝑋𝐴 )


55
– QUESTION –

What is the maximum value of conversion?

56
– QUESTION –

Why and how to express rate laws


as functions of conversion?

57
– STOICHIOMETRIC TABLE –
– BATCH SYSTEMS –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎

Species Initial number of moles Final number of moles


𝐴 𝑁𝐴0 𝑁𝐴 = 𝑁𝐴0 − 𝑁𝐴0 𝑋𝐴
𝑏
𝐵 𝑁𝐵0 𝑁𝐵 = 𝑁𝐵0 − 𝑁𝐴0 𝑋𝐴
𝑎
𝑐
𝐶 𝑁𝐶0 𝑁𝐶 = 𝑁𝐶0 + 𝑁𝐴0 𝑋𝐴
𝑎
𝑑
𝐷 𝑁𝐷0 𝑁𝐷 = 𝑁𝐷0 + 𝑁𝐴0 𝑋𝐴
𝑎
𝐼 (inerts) 𝐼 𝐼
TOTAL 𝑁𝑇0 𝑁𝑇 = 𝑁𝑇0 + 𝛿𝑁𝐴0 𝑋𝐴

58
– STOICHIOMETRIC TABLE –
– BATCH SYSTEMS –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎

Species Initial number of moles Final number of moles


𝐴 𝑁𝐴0 𝑁𝐴 = 𝑁𝐴0 − 𝑁𝐴0 𝑋𝐴
𝑏
𝐵 𝑁𝐵0 𝑁𝐵 = 𝑁𝐵0 − 𝑁𝐴0 𝑋𝐴
𝑎
𝑐
𝐶 𝑁𝐶0 𝑁𝐶 = 𝑁𝐶0 + 𝑁𝐴0 𝑋𝐴
𝑎
𝑑
𝐷 𝑁𝐷0 𝑁𝐷 = 𝑁𝐷0 + 𝑁𝐴0 𝑋𝐴
𝑎
𝐼 (inerts) 𝐼 𝐼
TOTAL 𝑁𝑇0 𝑁𝑇 = 𝑁𝑇0 + 𝛿𝑁𝐴0 𝑋𝐴

59
– STOICHIOMETRIC TABLE –
– BATCH SYSTEMS –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎

Species Initial number of moles Final number of moles


𝐴 𝑁𝐴0 𝑁𝐴 = 𝑁𝐴0 − 𝑁𝐴0 𝑋𝐴
𝑏
𝐵 𝑁𝐵0 𝑁𝐵 = 𝑁𝐵0 − 𝑁𝐴0 𝑋𝐴
𝑎
𝑐
𝐶 𝑁𝐶0 𝑁𝐶 = 𝑁𝐶0 + 𝑁𝐴0 𝑋𝐴
𝑎
𝑑
𝐷 𝑁𝐷0 𝑁𝐷 = 𝑁𝐷0 + 𝑁𝐴0 𝑋𝐴
𝑎
𝐼 (inerts) 𝐼 𝐼
TOTAL 𝑁𝑇0 𝑁𝑇 = 𝑁𝑇0 + 𝛿𝑁𝐴0 𝑋𝐴

60
– STOICHIOMETRIC TABLE –
– BATCH SYSTEMS –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎

Species Initial number of moles Final number of moles


𝐴 𝑁𝐴0 𝑁𝐴 = 𝑁𝐴0 − 𝑁𝐴0 𝑋𝐴
𝑏
𝐵 𝑁𝐵0 𝑁𝐵 = 𝑁𝐵0 − 𝑁𝐴0 𝑋𝐴
𝑎
𝑐
𝐶 𝑁𝐶0 𝑁𝐶 = 𝑁𝐶0 + 𝑁𝐴0 𝑋𝐴
𝑎
𝑑
𝐷 𝑁𝐷0 𝑁𝐷 = 𝑁𝐷0 + 𝑁𝐴0 𝑋𝐴
𝑎
𝐼 (inerts) 𝐼 𝐼
TOTAL 𝑁𝑇0 𝑁𝑇 = 𝑁𝑇0 + 𝛿𝑁𝐴0 𝑋𝐴

61
– STOICHIOMETRIC TABLE –
– BATCH SYSTEMS –
𝑏 𝑐 𝑑
𝐴+ 𝐵 → 𝐶+ 𝐷
𝑎 𝑎 𝑎

Species Initial number of moles Final number of moles


𝐴 𝑁𝐴0 𝑁𝐴 = 𝑁𝐴0 − 𝑁𝐴0 𝑋𝐴
𝑏
𝐵 𝑁𝐵0 𝑁𝐵 = 𝑁𝐵0 − 𝑁𝐴0 𝑋𝐴
𝑎
𝑐
𝐶 𝑁𝐶0 𝑁𝐶 = 𝑁𝐶0 + 𝑁𝐴0 𝑋𝐴
𝑎
𝑑
𝐷 𝑁𝐷0 𝑁𝐷 = 𝑁𝐷0 + 𝑁𝐴0 𝑋𝐴
𝑎
𝐼 (inerts) 𝐼 𝐼
TOTAL 𝑁𝑇0 𝑁𝑇 = 𝑁𝑇0 + 𝛿𝑁𝐴0 𝑋𝐴

increase in the total 𝑑 𝑐 𝑏


number of moles per mole 𝛿 = + − −1
of A reacted 𝑎 𝑎 𝑎 62
– 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

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.

𝑁𝑖0 𝐹𝑖0 𝐶𝑖0


Θ𝑖 = = =
𝑁𝐴0 𝐹𝐴0 𝐶𝐴0

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

> 0 expansion factor


𝜀𝐴 = 𝛿𝑦𝐴0
< 0 contraction factor

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

> 0 expansion factor


𝜀𝐴 = 𝛿𝑦𝐴0
< 0 contraction factor

𝑁𝐴 𝑁𝐴0 − 𝑁𝐴0 𝑋𝐴 𝑁𝐴0 (1 − 𝑋𝐴 ) 𝑁𝐴0 (1 − 𝑋𝐴 )


𝐶𝐴 = = = =
𝑉 𝑉 𝑉 𝑃 𝑇
𝑉0 (1 + 𝜀𝐴 𝑋𝐴 ) 0
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

> 0 expansion factor


𝜀𝐴 = 𝛿𝑦𝐴0
< 0 contraction factor

𝑁𝐴 𝑁𝐴0 − 𝑁𝐴0 𝑋𝐴 𝑁𝐴0 (1 − 𝑋𝐴 ) 𝑁𝐴0 (1 − 𝑋𝐴 )


𝐶𝐴 = = = =
𝑉 𝑉 𝑉 𝑃 𝑇
𝑉0 (1 + 𝜀𝐴 𝑋𝐴 ) 0
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

𝑃0 𝑇 volumetric flow rate of


𝑣 = 𝑣0 (1 + 𝜀𝐴 𝑋𝐴 ) the gaseous stream
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

Batch/flow reactors: the volume/density/velocity/volumetric flow rate


may vary between the feed and the exit, not the mass rate!
72
PART 3

From reactions to reactors

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.

volume occupied by the


moles (taking off the
equipments)

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.

𝐈𝐍 = 𝐎𝐔𝐓 + 𝐀𝐂𝐂 − 𝐆𝐄𝐍

𝒅𝑵𝒊 uniform conditions in


𝑭𝒊𝟎 = 𝑭𝒊 + − 𝒓𝒊 𝑽 the control volume
𝒅𝒕

80
– MOLE BALANCES –
Mole balance for the species 𝑖 in time 𝑡 in the control volume.

𝐈𝐍 = 𝐎𝐔𝐓 + 𝐀𝐂𝐂 − 𝐆𝐄𝐍

𝒅𝑵𝒊 uniform conditions in


𝑭𝒊𝟎 = 𝑭𝒊 + − 𝒓𝒊 𝑽 the control volume
𝒅𝒕
𝒅𝑵𝒊 non-uniform conditions
𝑭𝒊𝟎 = 𝑭𝒊 + − න 𝒓𝒊 𝒅𝑽 in the control volume
𝒅𝒕 𝑽

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

The extent of reaction in a PFR depends on


the reactor volume, not on its form!

88
– REMEMBER –

Reasoning. Not memorizing.

89
PART 4

Isothermal reactor sizing

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 –

– SPACE TIME – SPACE VELOCITY –


(MEAN) RESIDENCE TIME (velocidad espacial)

HOLDING TIME – Reactor volumes processed per unit


(tiempo espacial) time at specific conditions
(not necessarily the feed conditions)
Time necessary to process one reactor
volume of fluid on real feed conditions 𝟏 𝒗∗𝟎
𝑺𝑽 = ∗ = s-1
𝝉 𝑽
𝑽 reactor volume (m3)
𝝉=
𝒗𝟎 volumetric flow rate (m3 s-1)

Mean time reactants will be inside the


reactor in steady-state conditions
96
– ISOTHERMAL REACTOR SIZING –
– CSTR –
𝑽 =?

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 =?

𝑑𝐹𝐴 𝑑𝐹𝐴 𝑑𝑋𝐴


− = −𝑟𝐴 ⟹ = −𝐹𝐴0 𝑿𝑨
𝑑𝑉 𝑑𝑉 𝑑𝑉 𝒅𝑿𝑨
𝑽𝑷𝑭𝑹 = 𝑭𝑨𝟎 න
𝑿𝑨 𝟎 −𝒓𝑨
𝐹𝐴 = 𝐹𝐴0 (1 − 𝑋𝐴 )

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 –

Which will be smaller: a CSTR or a PFR?

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

CSTR operates at lowest


reaction rate. PFR starts at
a high rate, then gradually
decreases to the exit rate.
1
𝑉∝
−𝑟𝐴 105
– BATCH PLOT –
– Isothermal constant-volume batch reactor –
𝑡𝑅 𝑋𝐴 𝑋𝐴
𝑑𝑋𝐴 𝑑𝑋𝐴
Batch plot න 𝑑𝑡 = 𝑡𝑅 = 𝐶𝐴0 න
−𝑟𝐴
= 𝑁𝐴0 න
0 𝑋𝐴0 𝑋𝐴 −𝑟𝐴 𝑉
0

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

𝑋𝐴1 𝑑𝑋𝐴 𝑋𝐴2 𝑑 𝑋𝐴𝑖 𝑑𝑋𝐴


𝑋𝐴
𝜏𝑠𝑖𝑠𝑡 = ෍ 𝜏𝑖 = 𝐶𝐴0 න + 𝐶𝐴0 න + ⋯ + 𝐶𝐴0 න
𝑋𝐴0 −𝑟𝐴 𝑋𝐴 −𝑟𝐴 𝑋𝐴 −𝑟𝐴
𝑖 1 𝑖−1

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

𝑋𝐴1 𝑑𝑋𝐴 𝑋𝐴2 𝑑 𝑋𝐴𝑖 𝑑𝑋𝐴


𝑋𝐴
𝜏𝑠𝑖𝑠𝑡 = ෍ 𝜏𝑖 = 𝐶𝐴0 න + 𝐶𝐴0 න + ⋯ + 𝐶𝐴0 න
𝑋𝐴0 −𝑟𝐴 𝑋𝐴 −𝑟𝐴 𝑋𝐴 −𝑟𝐴
𝑖 1 𝑖−1

𝑋𝐴𝑖 𝑑
𝑉𝑠𝑖𝑠𝑡 𝑋𝐴
𝜏𝑠𝑖𝑠𝑡 = = 𝐶𝐴0 න
𝑣0 𝑋𝐴 −𝑟𝐴
0

Attention: tubular reactors of different diameter: not in series because 𝑣0 changes

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

Molar balance for the reactor 𝑖:

𝐹𝐴𝑖−1 = 𝐹𝐴𝑖 + −𝑟𝐴 𝑖 𝑉𝑖

𝐹𝐴𝑖−1 = 𝐹𝐴0 1 − 𝑋𝐴𝑖−1 𝐹𝐴𝑖−1 − 𝐹𝐴𝑖 = 𝐹𝐴0 𝑋𝐴𝑖 − 𝑋𝐴𝑖−1

𝐹𝐴𝑖 = 𝐹𝐴0 1 − 𝑋𝐴𝑖

𝐹𝐴0 𝑋𝐴𝑖 − 𝑋𝐴𝑖−1 𝐶𝐴0 𝑣0 𝑋𝐴𝑖 − 𝑋𝐴𝑖−1 𝑉𝑖 𝐶𝐴0 ∆𝑋𝐴 𝑖


𝑉𝑖 = = ⟹ 𝜏𝑖 = =
−𝑟𝐴 𝑖 −𝑟𝐴 𝑖 𝑣0 −𝑟𝐴 𝑖
110
– SELECTIVITY AND YIELD –
Basically:

𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟𝑚𝑒𝑑 𝑑𝑢𝑟𝑖𝑛𝑔 𝑎 𝑔𝑖𝑣𝑒𝑛 𝑝𝑟𝑜𝑐𝑒𝑠𝑠


𝑌𝑖𝑒𝑙𝑑 =
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑

𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟𝑚𝑒𝑑 𝑑𝑢𝑟𝑖𝑛𝑔 𝑎 𝑔𝑖𝑣𝑒𝑛 𝑝𝑟𝑜𝑐𝑒𝑠𝑠


𝑆𝑒𝑙𝑒𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑢𝑛𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟𝑚𝑒𝑑 𝑑𝑢𝑟𝑖𝑛𝑔 𝑎 𝑔𝑖𝑣𝑒𝑛 𝑝𝑟𝑜𝑐𝑒𝑠𝑠

111
– SELECTIVITY AND YIELD –

Recommended readings!

112
PART 5

Non-isothermal reactor sizing

113
– QUESTION –

Why wouldn’t a reactor be


isothermal?

114
– NON-ISOTHERMAL REACTORS –

When a reactor is operated at non-isothermal conditions,


the temperature is a variable in the molar balance.

Temperature becomes an independent variable.

NON-ISOTHERMAL REACTOR DESIGN:

MOLE BALANCE coupled to the ENERGY BALANCE

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 –

𝑄ሶ − 𝑊ሶ 𝑠 − 𝐹𝐴0 ෍ Θ𝑖 𝐶𝑃𝑖 𝑇 − 𝑇𝑖0 − 𝐹𝐴0 𝑋𝐴 ∆𝐻𝑅 𝑇𝑅 + Δ𝐶𝑃 𝑇 − 𝑇𝑅 =0

Elements of Chemical Reaction Engineering H. Scott Fogler 4th Edition

Eq. (8-27) (general)


Chapter 8.6 (CSTR)
Chapter 8.3 (PFR)
118
– EQUILIBRIUM CONVERSION
IN NON-ISOTHERMAL REACTORS –
For any reversible reaction, the highest conversion posible is the equilibrium conversion.

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

2) the equilibrium conversion vs. temperature plot relationship from the


energy balance

120
PART 6

Quick look at catalysis and heterogeneous reactors

121
– QUESTION –

Why “speed up” chemical


reactions?

122
– CATALYSTS –

𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟𝑚𝑒𝑑 𝑑𝑢𝑟𝑖𝑛𝑔 𝑎 𝑔𝑖𝑣𝑒𝑛 𝑝𝑟𝑜𝑐𝑒𝑠𝑠


𝑌𝑖𝑒𝑙𝑑 =
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑

𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟𝑚𝑒𝑑 𝑑𝑢𝑟𝑖𝑛𝑔 𝑎 𝑔𝑖𝑣𝑒𝑛 𝑝𝑟𝑜𝑐𝑒𝑠𝑠


𝑆𝑒𝑙𝑒𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑢𝑛𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟𝑚𝑒𝑑 𝑑𝑢𝑟𝑖𝑛𝑔 𝑎 𝑔𝑖𝑣𝑒𝑛 𝑝𝑟𝑜𝑐𝑒𝑠𝑠

123
– CATALYSTS –

Substances which are able to speed up reactions without being consumed.

Catalysts alter reaction rates.

Catalysts do not alter equilibrium.

Catalysts are used in small amounts.

124
– CATALYSTS –

Substances which are able to speed up reactions without being consumed.

Catalysts alter reaction rates.

Catalysts do not alter equilibrium. “Catalysis” is the


increase in the
reaction rate due to
Catalysts are used in small amounts. the presence of a
“catalyst”

Forward and inverse


reactions are affected
125
– CATALYSTS –

HETEROGENEOUS catalysis HOMOGENEOUS catalysis


𝑃𝑡(𝑠) /𝑉2 𝑂5(𝑠) 𝑁𝑂(𝑔)
2 SO2(g) + O2(g) ⟶ 2SO3(g) 2 SO2(g) + O2(g) ⟶ 2SO3(g)

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

Big interfacial area


Porous structure (e.g., 300 m2/g)
May be used as a molecular sieve
E.g.: zeolites

Monolithic catalysts
(porous and nonporous)

Reactions occur on the surface


Often focus more on selectivity
than on accelerating reations

Supported catalysts

Small particles of an active


material which are dispersed in a
less active matrix
129
– CATALYSTS –
HOMOGENEOUS 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.

−rA (t) −𝑟𝐴′ = 𝑎 × −𝑟𝐴′ 0


a t =
−rA (t = 0)
past history fresh catalyst

Reduction in the number of active sites due to:

Sintering (aging)
Coking or fouling Poisoning

135
– QUESTION –

How does a heterogeneous


reaction fluid-solid takes place?

136
– HETEROGENEOUS CATALYTIC REACTION:
A MULTISTEP PHENOMENON –

http://slideplayer.com/slide/8482317/

137
– STEPS OF A HETEROGENEOUS CATALYTIC REACTION –

interphase mass transfer

chemical reaction

138
– DIMENSIONLESS NUMBERS –

Da = Damköhler number

reaction rate
Da =
rate of diffusive mass transfer

Chemical Kinetics Transport Phenomena / 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

For a spherical catalyst particle


140
– DIMENSIONLESS NUMBERS –

η , Ω = effectiveness factors

η = internal effectiveness factor

real reaction rate


η=
reaction rate assuming no internal diffusion resistance

Ω = overall effectiveness factor

real reaction rate


Ω=
reaction rate assuming no diffusion resistance

141

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