Recycle reactor. Example.

Question: Let us consider a first order reaction A → 2 B . It is a liquid phase reaction (no change
in volume) and other standard assumptions (such as isothermal conditions , steady state etc)
apply. The incoming fresh feed is pure A, at a concentration of 1 mol/lit, volumetric flow rate Q
= 10 lit/min, the volume of the reactor = 300 lit and the rate constant k = 0.1 min-1. What is the
output conversion when R = 1 and when R = 3?. In addition, (i) determine concentration of A
and B in the net output stream and recycled stream, and (ii) confirm that for the PFR section, the
calculations based on FA,1 and Xs yield the correct concentrations in stream 2.
Solution:

We will find the overall conversion X0 first. For a recycle reactor,

X0
V dX
( R + 1) FA0
=
R
∫ −rA
X0
R +1

Here rA = kC A0 (1 − X A ) where CA0 = 1 mol/lit, Q = 10 lit/min, FA,0 = 10 mol/min, k = 0.1 min-1

Since there is no volume change, ϵ = 0

0 1 2
3

When R = 1,

0X
300 dX
= ∫
2 × 10 1 0.1× 1× (1 − X )
X0
2

Integrating and evaluating at the upper and lower limits, we have

  1 
1 − 2 X 0 
ln   = 1.5
 1 − X 0 
 

Solving this, we get X0 = 0.874

Next, let us calculate the concentration of the species in stream 3 and R

If X0 = 0.874, C Aout = C A3 = C A0 (1 − X 0 ) = 0.126 mol/ lit

FA,3 = 1.26 mol/min

FA,R = 1.26 mol/min

Molar flow rate, volumetric flow rate and concentrations in the ‘combined input stream to PFR’
are

FA,1 = FA0 + FA, R = 10 + 1.26 = 11.26 mol/min

Q1 = 20 lit/min

CA1 = 0.563 mol/lit (This is between 0.126 and 1 mol/lit, as expected)

Also, FB,1 = 0 +1.748 = 1.748mol/min

CB,1 = 0.0874 mol/lit

To use the design equation, we don’t actually need FB,1 and CB,1 , we have just calculated them to
get an idea of their values. Now, we use the design equation of the PFR to calculate the single
pass conversion Xs.

Xs
V dX
FA,1
= ∫ kC
0 A1 (1 − X )

Note that we have to use CA1 (and not CA0) here in the definition of X. i.e. Within the PFR, the
concentration at any location is given by CA = CA1(1-X)
 300 1
= [ − ln(1 − X s )]
11.26 0.1× 0.563

∴[ − ln(1 − X s ) ] = −1.5

X s = 0.7769 . Using this, we can calculate the concentration and molar flow rate of A at the
outlet stream.

∴ FA,2 = FA,1 (1 − X s ) = 11.26(1 − 0.7769) = 2.5124mol / min

FA,3 = FA,R = 1.256 mol/min (confirmed within a few %)

We can repeat the calculations for R =3.

If R = 3,

R 3
=
( R + 1) 4

0 X
V 300 dX
= = ∫
( R + 1) FA0 4 ×10 3 0.1×1× (1 − X )
X0
4

1 − 3 X 0 
0.75 = ln  4 
 1− X0 
 
1 − 3 X 0 
 4  = 2.117
 1− X0 
 
X 0 = 0.8171

This is lower than that for R = 1, which is expected. For a first order reaction, simple PFR gives
more conversion, R =1 will reduce the conversion a bit, R = 3 will reduce it more, and R =
infinity will bring it to the CSTR conversion.

When R = 3, if Xo = 0.817

FA,3 = 10 (1 − 0.817 ) = 1.83 mol/min

Molar flow rate, volumetric flow rate and concentrations in the recycle streams are

FA,R = 5.49 mol/min

Q,R = 30 lit/min ; CA,R = 0.183 mol/min
Molar flow rate, volumetric flow rate and concentrations in the ‘combined input stream to PFR’
are

FA,1 = 15.49 mol/min

Q,1 = 40 lit/min, CA1 = 0.38725 mol/lit
Instead of saying we have, FA,1 = 15.49 mol/min, we can say we have FA0(R+1) = 40 mol/min,
but converted by 0.612825.

For the first order kinetics, we can show the equality of the design equations in the PFR form and
in the recycle reactor form.

Recycle reactor design equation is

X0
V dX
FA0
= ( R + 1)
R
∫ kC A0 (1 − X )
(1)
X0
R +1

 
V 1  1− X0 
= ( R + 1) ln  
FA0 kC A0 1 − R X 
 R +1 
0

PFR design equation is

Xs
V dX
FA1
= ∫ −r
0 A

FA1 = FA0 + RFA,3 = FA0 + RFA0 (1 − X 0 )

 FA1 FA0 + RFA0 (1 − X 0 ) 1 + R(1 − X 0 ) 
C A1 = = = C A0  
Q1 Q0 + RQ0  R +1 

XS
V dX
FA0 [1 + R(1 − X 0 ]
= ∫ kC
0 A1 (1 − X A )

1 + R (1 − X 0 )
Since C A1 = C A0 , this gives
R +1

XS
V ( R + 1) dX
=
FA0 [1 + R(1 − X 0 ] [1 + R(1 − X 0 ) ] ∫ kC
0 A0 (1 − X )
(2)

Equating (1) and (2),

 
 1− X0 
ln 
R  = ln [1 − X S ]
1 − X0 
 R +1 

∴
(1 − X 0 ) ( R + 1) = 1 − X = 1−
X0
=
1 + R − RX 0 − X 0
S
1 + R(1 − X 0 ) 1 + R (1 − X 0 ) 1 + R(1 − X 0 )

=
(1 − X 0 ) ( R + 1)
1 + R(1 − X 0 )

LHS = RHS, hence confirmed