Balagtas, Noverlyn B.

1. Batch Reactor

Batch reactors are perhaps the simplest reactors used in chemical processes. When
using batch reactors, reactants are first placed inside the reactor and then allowed to react
over time. Batch reactors are closed systems that operate under unsteady-state conditions.

1.1 Applications
a. Batch Reactors are typically used for liquid phase reactions that require a fairly long
reaction time such as in Beverage Processes
b. Batch reactors are also used when only a small amount of product is desired. For this
reason batch reactors are favored when a process is still in the testing phase, or when
the desired product is expensive. This reactor is used in Pharmaceutical industry,
wherein consistent and high quality results are required.
1.2 Advantages
a. High conversions can be obtained by leaving reactants in reactor for extended periods of
time.
b. High conversions can be obtained by leaving reactants in reactor for extended periods of
time.
c. Versatile, can be used to make many products consecutively.
d. Versatile, can be used to make many products consecutively.
e. Versatile, can be used to make many products consecutively.
1.3 Disadvantages
a. High cost of labor per unit of production.
b. High cost of labor per unit of production.
c. High cost of labor per unit of production.

II. Continuous Stirred reactor

Continuous stirred tank reactors (CSTR) are the most basic of the continuous reactors
used in chemical processes. These reactors are open systems, where material is free to
enter or exit the system that operates on a steady-state basis, where the conditions in the
reactor don't change with time.

Operation: Reactants are continuously introduced into the reactor, while products are
continuously removed. CSTRs are very well mixed, so the contents have relatively uniform
properties such as temperature, density, etc. throughout. Stirring blades, also called
agitators, are used to mix the reactants. Also, conditions in the reactor's exit stream are the
same as those inside the tank. Systems connecting several CSTRs are used when the
reaction is too slow. Multiple CSTRs can also be used when two immiscible liquids or viscous
liquids are present and require a high agitation rate.

2.1 Applications
Balagtas, Noverlyn B.

a. Continuous stirred-tank reactors are most commonly used in industrial processing,

primarily in homogeneous liquid-phase flow reactions, where constant agitation is
required.
b. CSTRs are also used in the pharmaceutical industry as a loop reactor.
c. CSTRs are often used in biological processes such as for high-density animal cell culture
in research or production.
d. Fermenters are another application of CSTR s that involves the use of a biological
catalyst to generate products. In a fermenter, microbes catalyze a reaction that breaks
down much larger molecules into smaller molecules such as ethanol, methanol, or other
hydrocarbons. Vapor product can be removed from the top of a unit without separation,
or liquid product can be removed from the bottom, filtering out and recycling the
microbial media. Industries that use fermenters are in brewing, pharmaceuticals,
wastewater treatment, and hydrocarbon processing.
e. A CSTR can also function as a loop reactor when a heated, pressurized fluid is injected
into the system to facilitate the stirring. This allows for higher heat and mass transfer
rates while simplifying maintenance because there is no agitator.
2.2 Advantages
a. Good temperature control is easily maintained
b. Reactor has large heat capacity
c. Cheap to construct
d. Interior of reactor is easily accessed.
2.3 Disadvantages
a. Conversion of reactant to product per volume of reactor is small compared to other flow
reactors
b. Deadzones, where no mixing occurs, can develop
c. Reactants can bypass if outlet placed improperly

III. Plug Flow reactor

Plug flow, or tubular, reactors consist of a hollow pipe or tube through which reactants
flow. Plug flow reactors, also known as tubular reactors, consist of a cylindrical pipe with
openings on each end for reactants and products to flow through. Plug flow reactors are
usually operated at steady-state. Reactants are continually consumed as they flow down the
length of the reactor.

Operation: Plugs of reactants are continuously fed into the reactor from the left. As
the plug flows down the reactor the reaction takes place, resulting in an axial concentration
gradient. Products and unreacted reactants flow out of the reactor continuously. Plug flow
reactors may be configured as one long tube or a number of shorter tubes. They range in
diameter from a few centimeters to several meters. The choice of diameter is based on
construction cost, pumping cost, the desired residence time, and heat transfer needs.
Typically, long small diameter tubes are used with high reaction rates and larger diameter
tubes are used with slow reaction rates.
Balagtas, Noverlyn B.

3.1 Applications
a. Plug flow reactors have a wide variety of applications in either gas or liquid phase
systems. Common industrial uses of tubular reactors are in gasoline production,
b. oil cracking,
c. synthesis of ammonia from its elements,
d. oxidation of sulfur dioxide to sulfur trioxide.
e. Tubular reactors can also be used as bioreactors or for small scale production like for
the production of algae. The algae are then compressed and dried and can be used as
feed for a biodiesel reactor.
3.2 Advantages
a. Easily maintained since there are no moving parts.
b. High conversion rate per reactor volume.
c. Mechanically simple.
d. Unvarying product quality.
e. Efficient use of reactor volume.
f. Good for studying rapid reactions.
g. Low pressure drops.
h. Tubes are easy to clean.
3.3 Disadvantages
a. Difficult to control due to temperature and composition variations.
b. Hot spots may occur within reactor when used for exothermic reactions.
c. Reactor temperature difficult to control.