BATANGAS STATE UNIVERSITY

College of Engineering, Architecture & Fine Arts

Gov. Pablo Borbon Campus II, Alangilan, Batangas City, Philippines 4200
www.batstate-u.edu.ph Telefax: (043) 300-4404 locs. 106-118

CHEMICAL AND FOOD ENGINEERING DEPARTMENT

Steady State Mixed

Flow Reactors

ESPIRITU, John Paul C.

MAULEON, Aila Mae M.
TORRANO, Gilbert C.
ChE – 4202

Engr. Rodolfo Sotto Jr.

Instructor
STEADY-STATE MIXED FLOW REACTOR
The performance equation for the mixed flow reactor is obtained from:

(1)

As shown in Fig. 5.3, if 𝐹𝐴𝑜 = 𝑣𝑜 𝐶𝐴𝑜 is the molar feed rate of component A to the
reactor, then considering the reactor as a whole we have

Introducing these three terms into Eq. 1, we obtain

𝐹𝐴𝑜 = (1 − 𝑋𝐴𝑂 ) = 𝐹𝐴𝑜

which on rearrangement becomes

(2)

Where 𝑋𝐴 and 𝑟𝐴 are measured at exit stream conditions, which are the same as
the conditions within the reactor. More generally, if the feed on which conversion is
based, subscript 0, enters the reactor partially converted, subscript i, and leaves at
conditions given by subscript f, we have

(3)

For the special case of constant-density systems 𝑋𝐴 = 1 − 𝐶𝐴 /𝐶𝐴0 , in which case

the performance equation for mixed reactors can also be written in terms of
concentrations or
 (4)

These expressions relate in a simple way the four terms 𝑋𝐴 , −𝑟𝐴 , V, 𝐹𝐴𝑜 ; thus,
knowing any three allows the fourth to be found directly. In design, then, the size of
reactor needed for a given duty or the extent of conversion in a reactor of given size is
found directly. In kinetic studies each steady-state run gives, without integration, the
reaction rate for the conditions within the reactor. The ease of interpretation of data from
a mixed flow reactor makes its use very attractive in kinetic studies, in particular with
messy reactions (e.g., multiple reactions and solid catalyzed reactions).
Figure 5.4 is a graphical representation of these mixed flow performance
equations. For any specific kinetic form the equations can be written out directly.

𝐶𝐴
As an example, for constant density systems = 1 − 𝑋𝐴 thus the performance
𝐶𝐴0
expression for first-order reaction becomes

(5a)
On the other hand, for linear expansion

thus for first-order reaction the performance expression of Eq. 2 becomes

(5b)

For second-order reaction, A →product, −𝑟𝐴 = kCA2 , Ɛ𝐴 = 0, the performance

equation of Eq. 2 becomes

(6)
Similar expressions can be written for any other form of rate equation. These
expressions can be written either in terms of concentrations or conversions. Using
conversions is simpler for systems of changing density, while either form can be used
for systems of constant density.
Continuous Flow Stirred Tank Reactor (CFSTR)
A Continuous Flow Stirred Tank Reactor (CFSTR) is one in which the contents
are stirred so uniformly that it is assumed that no variation or concentration gradients exist
within the vessel. In theory, any sample taken from the overflow of the reactor will be
identical with any sample taken from within the vessel. In this reactor, there is an in-flow
of nutrient and an equal out-flow of nutrient, plus microbial waste products and microbial
cells.

Three Parameters Affecting Reactor Dynamics

1. Flow rate (Q=V/RT)
That is Flow rate (Q) in ml/min is equal to the reactor volume (V) in ml,
divided by the Residence Time (RT) in minutes. It can be measured empirically in
a reactor in steady state, as the volume of effluent from the reactor per unit of time.
In steady state the inflow and outflow of the reactor are equal and the culture
volume of the reactor does not change.
The flow rate (Q) (in ml/min) then is expressed as shown above, where V is
the reactor volume and RT is the residence time. If for example the volume of the
reactor is 400 ml and the flow rate is 40ml/min. then the Residence time R is 10
minutes.
2. Retention time (RT = V/Q)
The residence time (RT) in minutes is the time it takes to entirely exchange
the volume of the reactor and is expressed as shown above, where V = the volume
of the reactor and Q is the flow rate of the effluent leaving the system.
3. Dilution Rate (D = Q/V)
The dilution rate equals the flow rate divided by the reactor volume.
In the example above, the dilution rate is:
40 𝑚𝑙/𝑚𝑖𝑛
D= = 0.1/𝑚𝑖𝑛
400 𝑚𝑙
That is 0.1 or 10% of the volume of the vessel is changed every minute.

In microbiology classes, a CFSTR is called a chemostat. Adjusting the flow rate

can alter the rate of growth of the culture therein. Reducing the flow rate permits the
exhaustion of some nutrients and the accumulation of wastes slowing growth as the
culture approaches stationary phase. Increasing the flow rate increases the nutrient
concentration and reduces wastes bringing the culture closer to exponential phase. In a
chemostat at steady state u (the instantaneous growth rate of the culture is equal to D
(the dilution rate).

If one increases the flow rate such that D > u, then the planktonic culture is flushed
from the system leaving only attached cells within the reactor. At this point the reactor is
operating as a biofilm reactor. Of course planktonic cells are constantly being released
from the biofilm by erosion or scheduled release (see chapter 2) but these cells are rapidly
washed from the reactor.

Typically in setting up a reactor, the vessel is filled to capacity with nutrient

medium, coupons are inserted and the reactor is seeded (inoculated) with the organism
or combination of organisms desired. A time interval with the nutrient inflow closed is
permitted in order for cells to attach to the coupons and then the influent is adjusted to a
level which will rapidly clear the planktonic population (i.e. growth rate > residence time).

The CFSTR is an easily constructed, versatile and cheap reactor, which allows
simple catalyst charging and replacement. Its well -mixed nature permits straightforward
control over the temperature and pH of the reaction and the supply or removal of gases.
CFSTRs tend to be rather large as the: need to be efficiently mixed. Their volumes are
usually about five to ten time the volume of the contained immobilised enzyme. This,
however, has the advantage that there is very little resistance to the flow of the substrate
stream, which may contain colloidal or insoluble substrates, so long as the insoluble
particles are not able to sweep the immobilised enzyme from the reactor. The mechanical
nature of the stirring limits the supports for the immobilised enzymes to materials which
do not easily disintegrate to give 'fines' which may enter the product stream.

An ideal CFSTR has complete back -mixing resulting in a minimisation of the

substrate concentration, and a maximisation of the product concentration, relative to the
final conversion, at every point within the reactor the effectiveness factor being uniform
throughout. Thus, CFSTRs are the preferred reactors, everything else being equal, for
processes involving substrate inhibition or product activation. They are also useful where
the substrate stream contains an enzyme inhibitor, as it is diluted within the reactor. This
effect is most noticeable if the inhibitor concentration is greater than the inhibition constant
and [S]0/Km is low for competitive inhibition or high for uncompetitive inhibition, when the
inhibitor dilution has more effect than the substrate dilution. Deviations from ideal CFSTR
behaviour occur when there is a less effective mixing regime and may generally be
overcome by increasing the stirrer speed, decreasing the solution viscosity or biocatalyst
concentration or by more effective reactor baffling.

The rate of reaction within a CFSTR can be derived from a simple mass
balance to be the flow rate (F) times the difference in substrate concentration
between the reactor inlet and outlet.

Figure.1. The residence time distribution of a CFSTR.

 The relative number of molecules resident within the reactor for a particular time
N, is plotted against the normalised residence time (i.e., tF/V, where V is the reactor
volume, and F is the flow rate; it is the time relative to that required for one reactor volume
to pass through the reactor). The residence time distribution of non -reacting media

molecules (-----------) which obeys the relationship , where [M] is the

concentration of media molecules, giving a half-life for remaining in the reactor of, product
and substrate are shown.

Continuous Stirred Tank Reactor (CSTR)

A continuous stirred tank reactor (CSTR) also known as backmix flow reactor
is a batch reactor equipped with an impeller or other mixing device to provide efficient
mixing.

Assumptions
 Open System

 Steady State – conditions such as temperature, reaction

rate, and neutron flux do not change appreciably with
time.

 Well-mixed – all volume elements are equally likely to

be withdrawn from the reactor.

General Mole Balance:

𝑑𝑁𝐴
𝐹𝐴0 − 𝐹𝐴 + ∫ 𝑟𝐴 𝑑𝑉 =
𝑑𝑡

CSTRs are operated at steady state (accumulation = 0) and are assumed to be

perfectly mixed.
𝐹𝐴0 − 𝐹𝐴 = −𝑟𝐴 𝑉
𝐹𝐴 = 𝐶𝐴 𝑣 ; 𝑣 = volumetric flow rate

Then,
𝐶𝐴0 𝑣 − 𝐶𝐴 𝑣 = −𝑟𝐴 𝑉

The conversion X of species A in a reaction is equal to the number of moles

of A reacted per mole of A fed.

𝐶𝐴0 − 𝐶𝐴
𝑋=
𝐶𝐴0

In terms of conversion, X,
 𝐹𝐴 = 𝐹𝐴0 (1 − 𝑋) or 𝐶𝐴 = 𝐶𝐴0 (1 − 𝑋)

𝐹𝐴0 − 𝐹𝐴 = −𝑟𝐴 𝑉
𝐹𝐴0 − (𝐹𝐴0 − 𝐹𝐴0 𝑋) = −𝑟𝐴 𝑉

𝐹𝐴0 𝑋
𝑉=
−𝑟𝐴

Space Time:
𝑉
𝜏=
𝑣

Space Velocity:
1
𝑠=
𝜏

Example:

One liter per minute of liquid containing A and B (𝐶𝐴0 = 0.10 mol/liter, 𝐶𝐵0 =0.01
mol/liter) flow into a mixed reactor of volume V = 1 liter. The materials react in a complex
manner for which the stoichiometry is unknown. The outlet stream from the reactor
contains A, B, and C (𝐶𝐴𝑓 = 0.02 mol/liter, 𝐶𝐵𝑓 = 0.03 mol/liter, 𝐶𝐶𝑓 = 0.04 mol/liter), as
shown in the figure. Find the rate of reaction of A, B, and C for the conditions within the
reactor.

Conclusions
1. None of ideal reactor model performances will predict the reality due to extremely
simplified assumptions.
2. Backmixing in a tubular reactor will have a definite adverse effect on performance
of the reactor.
3. The higher the reaction order, the higher the adverse effect of backmixing.