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The expression for the rate of formation of ammonia at pressures from 150 to 300 atm. derived here is the
simplest available for a modern catalyst, is suitable for design, optimization, and control studies, and i s
believed to be as accurate as the most complex expressions in the composition, temperature, and pressure
regions of commercial importance. The rate expression i s based on the Temkin and Pyzhev expression
corrected for high pressures and fitted to recently reported kinetic measurements of Nielsen, Kjaer, and
Hansen for an industrially used catalyst. In addition, simple expressions permit rapid calculation of effec-
tiveness factors for 6- to 1 0-mm. particles for the process conditions found in modern synthesis units.
ASY \vorkers have sought a reaction rate expression which for commercially available ammonia synthesis catalyst and the
M not only correlates experimental data but is also satis- experimental conditions are representative of process condi-
factory from the mechanistic standpoint. Since a prohibitive tions. These data can be correlated fairly well by a slightly
amount of evidence is required to determine the mechanism modified form of the simple Temkin (1950) expression
uniquely (Nielsen et a/., 1964; Petersen, 1965) and the ex-
pressions involved are inherently complex, it is expedient to
find a simpler expressicmn, which adequately represents experi-
mental equilibrium studies and packed-bed kinetic studies. Subscripts designate components ; nitrogen is considered as
T h e need for a simple rate expression becomes apparent when component 1, hydrogen as component 2, ammonia as compo-
one considers that the computation time required even for nent 3, and all inert components in the system, taken collec-
steady-state design calculations is highly dependent on the tively, as component 4. Parameter a: has been used by in-
complexity of the rate expression. For recycle studies which vestigators of ammonia synthesis kinetics to correlate kinetic
involve the solution of nonlinear equations, or for optimization data (Bokhoven e t ai., 1955). Both cy = 0.5 and a: = 0.75 are
studies in ivhich pararneters are varied and calculations are used in this paper to determine if one of these yields a better fit
repeated many times, the use of a simple rate expression is of the data. T h e more complicated expression used by Nielsen
essential. et al. (1964) fits their d a t a only slightly better (see Figure 4).
T h e literature conta.ins innumerable rate expressions and Some thermodynamic data are required to relate activities
several of these could be used after slight modification for c d - al, a2, and a3 to the composition, pressure, and temperature.
culating industrial converters. T h e range of applicability To this end we use :
of these expressions must alivays be carefully recognized and 1. The equation of Gillespie and Beattie (1930) :
one must note as well (if stated) the type and size of the cata-
lyst. Adams and Comings (1953), Annable (1952), Haysetal.
loglo K, = -2.691122 loglo T - 5.519265 x T f
(1964), Kubota and Shindo (1959), and Kielsen (1956) give
information and rate expressions useful for converter calcula-
1.848863 X lo-’ T 2 + ___
2001.6
T
+ 2.6899 (2)
tions. For this equation the temperature, T , is in degrees Kelvin and
A pseudo-homogeneous expression is developed for a bed K , replaces Gillespie and Beattie’s K,*.
packed with fine (laboratory size) catalyst, and an effectiveness 2. The Lewis and Randall rule (1961): This is known to
factor is developed for industrial size catalyst pellets by inte- be valid in the T , P range \ve are considering (Denbigh, 1964;
Kazarnovskii, 1945).
grating the transport equations for spherical particles. T h e activity of a component is given by definition as
Pseudo-Homogeneous Expression for a fi
ai = - (3)
Bed Packed with Fine Catalyst
fi*
T h e only experimental kinetic data we consider are those of wheref,* is the fugacity of component i at a particular arbitrarily
Nielsen et al. (1964). This is the most recent set of kinetic data chosen standard state. Choosing fi* as equal to the fugacity
fio = (5)
and then use literature expressions for the activity coefficients
as follows:
For hydrogen, from Cooper (1967) and Shaw and Wones
2 .I
(1964) we obtain 2t
0
?, , , = exp{e(-3.840ZT + 0.54l)P - e(-0.1?63T Os5 +
- l5.980)P? 0
0
-
-I
300 [e(-0.011901T - 5.941)](e-P/300 - 1) ] (6)
For nitrogen and ammonia, the correlations of Cooper I.
(1967) and Newton (1935) have been fitted accurately by the
following expressions:
71 = 0.93431737 + 0.3101804 >i T +
0.295896 x P - 0.2707279 x T z -t
0.4775207 x P2 (7) 0.1
L=o[
F I O ?=?,
molar flow of NP at inlet - molar flow of N? across section k= -
d17
molar flow of Nz at inlet
(10)
AL
Ka2Xifio ___
)'f:zy:'( ( )]
- f,03/?X23/z
fa0X3
:3.3
0.
L
W
m
0
5 0.
z
0
0
W
(0 0.
m
z
P
0)
CT 0.
>
z
U
0 ;
0 -.PLAUSIBLE
COLD SHOT TRAJECTORY
/ 0 /-
0 ' II I I I
10 700 800 900 1000 1100 1200 I
TEMPERATURE ,OF
al. (1964)
Figure 3. Contours of constant reaction rate V3 (pound
moles of ammonia per cubic foot of catalyst bed per hour)
in plane of conversion and temperature for a stoichiometric,
of fit of the assumed form. Either form fits the data well
inert-free reaction mixture at a total pressure of 300 atm.
enough, as calculations given below show, to be useful for the
calculation of industrial converters. The form of the rate Reported exit conversions from experimental converter of Nielsen ef
0 Equilibrium d a t a of Lorson (1924)
al. ( 1 964).
expression with cy = 0.5 is to be preferred, as it is the simpler of
the t n o and fits the data in as consistent a manner as the more
complicated expression. The rate constant, k , does not appear
to be a function of presure, which is as expected, considering tory calculated for a plausible set of industrial conditions is dis-
the introduction of the component fugacities into the rate ex- played, so that one may observe the approximate region of the
q , T plane which is of industrial importance. I n both figures
pression.
Regression has been used to fit straight lines through the the isothermal kinetic experimental measurements are shown
points shown in Figure 1. The slope of the upper line which is by small squares. The equilibrium line ( V3 = 0) lies very close
the activation energy has been found to be -40,765 and the to the equilibrium data of Larson (1924).
antilog of the intercept, which is the frequency factor, equal to Figure 4 demonstrates the ability of the proposed rate ex-
8.843 X lo1*. Hence, k as a n explicit function of temperature pression to fit the kinetic data. I t is a plot of the calculated
is minus the measured per cent of ammonia at the outlet of the
experimental reactor us. the measured outlet per cent of
k = 8.849 X 1014 e-40,765/RT (18) ammonia. The calculated outlet per cent of ammonia is deter-
mined by numerical integration of the differential equation
I n Equation 18 the units of the temperature are degrees Kelvin which results from a mole balance taken on a differential ele-
and the appropriate value of R, the universal gas constant, is
ment of the reactor. The mole balance differential equation is
1.987. T h e rate of formation of ammonia in kilogram-moles
solved for both the rate expression given by Nielsen et al. and
of ammonia formed per cubic meter of catalyst bed per hour is
that presented in this paper. T h e Kutta-Merson algorithm
therefore (Fox, 1962; Lance, 1960) was employed a t each set of ex-
perimental conditions.
Effectiveness Factor
The rate expression presented in Equation 19 adequately
describes the experimental situation under which the reaction
data were taken. The particle size was sufficiently small to
Discussion of Rate Exp,ression
exclude the possibility of interaction of kinetic and transport
Figures 2 and 3 display some reaction rate contours in the effects. Particles of 6- to 10-mm. size [used in some current
7, T plane. I n both figures the inlet mixture to the reactor is converter designs (Chemical Week, 1966)] are, however, subject
considered to be an inert-free, stoichiometric mixture of hy- to diffusion restriction in their pore structure.
drogen and nitrogen. The numbers used to label the contours The classical approach to this problem is to calculate the
are the corresponding reaction rates (pound moles of ammonia effectiveness factor, E, which is defined as the rate a t which the
per cubic foot of catalyst bed per hour). I n Figure 2 a trajec- reaction occurs in a pellet divided by the rate at which the reac-
+ ' O 4cI
+.03
t.02
-
0
0
-
I
-.OI/ -l e I I -0 c
0 0
-.02
-03t
t 1 00
--
-
-.04 I I I I I I I I I I I I I I
.02 .04 06 .08 .IO .I2 14 .I6 .I8 .20 .'22 .24 26 .28 I
GMFilONlA M O L E FRGCTION MEASURED
Figure 4. Comparison of three reaction rate expressions for fine catalyst with experi-
mental points of Nielsen et a / . (1964)
~
Our expression [with 01 = 0.5). -Expression which can b e developed from Equation 1 with 01 = 0.75.
0 Expression of Nielsen ef al. ( 1 964)
tion would occur if the concentration and temperature through- In the ensuing discussion the symbol p i represents the stoichio-
out the pellet were the same as those at the surface-Le., metric coeficient of the ith component in the reaction scheme
given in Equation 21. Following the ordinary convention, vi
(
molar flux of component
i across surface 1 surface area
(
of pellet ) (20)
is positive if the component is a product, negative if the compo-
nent is a reactant, and zero if the component is an inert sub-
' = (y~i::) x
rate of formation of component
( i at surface comp., T , P ) stance.
A mole balance for component i gives
This factor has been calculated for different kinetic expressions I d
by several authors (Akehata et al., 1961; Bokhoven and - -
r2 dr
(r2,\'*) = vi
van Raayen, 1954; Kubota and Shindo, 1956; Kubota et al.,
where N iis the molar flux of the ith component in the r-direc-
1959; Xielsen, 1956), but in all calculations which have
tion and V iis the rate of formation of component i. The rate
appeared either pseudo-first-order kinetics were used, or the
of formation, V,, is the rate of formation of component i per
bulk flow terms in the equations for the transport within the
unit volume of catalyst pellet. ( I t is found from the rate ex-
catalyst pellets were omitted.
pression developed above by dividing by 1 - E , where E is the
The following assumptions are made :
void fraction for the laboratory packed bed.)
1. The catalyst particles may be considered to be spheres. The molar flux, I\,' may be related to the concentration
2. The diffusion coefficients of each component are in- gradient by
dependent of position within a particle.
3. The particles are isothermal.
4. Knudsen diffusion is not experienced.
Assumption 1 is discussed by Nielsen (1956). Assumption 2 The following relation exists between the molar fluxes at
is believed to be reasonable in view of the accuracy to which the steady state of any two components i and]
diffusion coefficients in a porous medium can be estimated. As
Vi?\.; = YjNi (24)
a result of this assumption a small error is introduced into the
calculated gas compositions in a particle (Delbridge, 1968 ; Equation 24 implies that the molar flux of any inert component
M'ei, 1963). (The mole fractions do not sum to 1 inside the is equal to zero.
particle; ho\vever, at the center this sum varied over the The boundary conditions for Equation 22 are
narrow range 0.97 to 1.03.) The third assumption may be ,Vi= 0 at r = 0
easily validated by application of the relation derived by
Xi= Xi, at r = R' (25)
Prater (1958) for the temperature difference between the bulk
phase and a region interior to the pellet surface. The maxi- where Xi,is the mole fraction at the surface and this will be
mum temperature difference calculated from this relation is assumed to be the same as in the gas phase. (Such an assump-
approximately 2.5" C. Assumption 4 is based on the paper by tion is valid at the high gas velocities found in present-day
Bokhoven and van Raayen (1954). plant converters.)
We may now develop the equations for the molar flux of a Substitution of Equation 24 into Equation 23 and utilization
reference substance across the surface. The reaction under of the relationship
consideration is 3
CY,= -2
Nz + 3Hz 2"3 (21) j=1
--
- I R’ = h/2 $ (35)
1 + 2 Yi
5 .‘[I +2:j +
where A and are the equivalent diameter and shape factor,
respectively (Nielsen, 1956). For industrial particles of 6- to
Integrating this equation twice leads to 10-mm. range the particle radius is 2.85 mm. Considering
the effective diffusion coefficients one should note that the
range of industrial operation is outside the region where Knud-
sen diffusion is important (Bokhoven and van Raayen, 1954)
As a consequence of this relation, the solution of only one mole and therefore we use the relation given by LVheeler (1955):
balance (Equation 22) need be considered.
Combination of Equation 22 with Equation 27 and per- Die = ‘/z 0 Dt (36)
formance of some differentiation and manipulation lead to where 0 is the intraparticle porosity and D , is the bulk diffusion
d2Xi 2 dXi dX coefficient of component i. The porosity is approximately
+ - - i2=
- (ut + 2 X ) (2;) r dr
-
( ____
f
(30)
0.52 according to Hoogschagen (1955). The value of D,used
in Equation 36 is found in the following manner (Fairbanks and
iYilke, 1950). The bulk diffusion coeficient of component i
I n writing this equation the symbol f has been introduced to at 0’ C. and 1 atm. is given by
represent the rate of reaction, a quantity related to the rate of
formation of a component i by (37)
vi = .if (31)
Introducing 2’= 4R we obtain The values used in the calculations are (Sielsen, 1956)
2 &lo = D13’ = 0.161 sq. cm./sec.
condition at the center with tolerable accuracy (Simon, 1968). T h e conversion, q , refers to the conversion of nitrogen as mea-
This surface flux may then be substituted into the following sured from the reference mixture (7 = 0 ) which has the follow-
equation, yielding the effectiveness factor : ing composition: a 3 to 1 HZ/N? ratio and 12.77, inerts. T h e
- /-dX3\ temperature, T , is in degrees Kelvin, and the constants in
Equation 39 are given for various pressures in Table I. T h e
(7) effect of pressure on the effectiveness factor is such that a higher
5 = D’2 / i \ (33)
pressure will cause a lower effectiveness factor. This is con-
-- ”” \ - -I
trary to the results calculated by Bokhoven and van Raayen
(1954) by representing the rate as pseudo-first-order, but in Xi,= mole fraction of component i in gas (bulk) phase
t = coordinate measuring distance along reactor
agreement with the results obtained by Kubota and Shindo
2‘ = dimensionless radial coordinate of a spherical particle
(1956). Similar calculations have been made for other H P / N ~
ratios. There were variations of the resulting effectiveness GREEKSYMBOLS
factors from those given here, but the over-all effect on the a = kinetic parameter
design of converters for industrial use was negligible. yz = activity coefficient
7 = conversion based on nitrogen
7. = conversion of outlet mixture
Conclusions
f: = effectiveness factor
For fine catalyst with no diffusion restriction, the relation e = void fraction of laboratory reactor
pt = stoichiometric coefficient of component i
between the rate of formation of ammonia, V3, and the tem- 6 = compressibility factor
perature, pressure, and composition in the bulk gas phase may d = equivalent diameter
be obtained from Equations 2, 5, 6, 7, 8, and 19. $ = shape factor
For catalyst of 6- to 10-mm. particle size, the corresponding e = intraparticle porosity
relation is
literature Cited
Rate = Va * E (40)
Adams, R. M., Comings, E. \V., Chem. Eng. Progr. 49 (7), 359
where E is as given in Equation 39. Several minor additional (1953).
Akehata, T., et d., Can. J . Chem. Eng. 39, 127 (1961).
correction factors are necessary to correct this equation for the Annable, D., Chem. Eng. Sci.1, 145 (1952).
effects of particle size on reduction, poisoning, and catalyst Bokhoven, C., et d . , in “Catalysis,” Vol. 111, Chap. 7 , P. H.
aging (Nielsen, 1956). Emmett, Ed., Reinhold, New York, 1955.
Bokhoven, C., van Raayen, I\’., J . Phys. Chem. 58, 471 (1954).
Chem. Week 98 (9),97 (1966).
Acknowledgment Conte, S. D., “Elementary Numerical ..\nalysis,” McGraw-Hill,
New York, 1965.
Some programs were run on the Common Research Com- Cooper, H. LY., Hydrocarbon Process Petrol. Refiner 46 (2), 159
(1967).
puter Facility at the Texas Medical Center, supported by Delbridge, H. T., Rice University, personal communication, 1968.
U.S.P.H.S.GrantSo. FR00254. Denbigh, K. G., “Principles of Chemical Equilibrium,” pp.
We are particularly indebted to Anders Nielsen, who made 150-1, Cambridge University Press, London, 1964.
Fairbanks, D. F., IVilke, C. R., Ind. Eng. Chem. 42, 471 (1950).
several important comments which led to an improved manu- Fox, L., “Numerical Solution of Ordinary and Partial Differential
script. Equations,” p. 24, Pergamon, Oxford, 1962.
Gillespie, L. J., Beattie, J. A., Phys. Rev. 36, 743 (1930).
Hays, G. E., et d . , Chem. Eng. Progr. 60 (l), 61 (1964).
Nomenclature Henrici, P., “Elements of Numerical Analysis,” p. 260, Wiley,
New York, 1964.
A = cross-sectional area of experimental reactor Hoogschagen, J., Ind. Eng. Chem. 47, 906 (1955).
ai = activity of component i Kazarnovskii, Y. S., Z h . Fzz. Khim. 19, 392 (1945).
bi = constants in Equation 39 Kubota, H., Shindo, 41.,Chem. Eng. (Japan) 20, 11 (1956).
C = total concentration Kubota, H., Shindo, M., Chem. Eng. (Japan) 23, 242 (1959).
Di = diffusion coefficient of component i Kubota, H., et al., Chem. Eng. (Japan) 23, 284 (1959).
Lance, G. N., “Numerical Methods for High Speed Computers,”
Dio = diffusion coefficient of component i a t O o C. and 1 atm. p. 56, Iliffe and Sons, London, 1960.
Dji = diffusion coefficient of componentj in component i Larson, A . T., J . Am. Chem. SOC. 46, 367 (1924).
D,,= effective diffusion coefficient of component i Lewis, G. N., Randall, M., “Thermodynamics,” 2nd ed., p. 225,
E = activation energy for reverse reaction McGraw-Hill, New York, 1961.
f = rate of reaction Newton, R. H., Znd. Eng. Chem. 27, 302 (1935).
fi = fugacity of component i in mixture Nielsen, A , , “Investigation on Promoted Iron Catalyst for the
f%* = fugacity of component i a t standard state Synthesis of Ammonia,” 2nd ed., Jul Gjellerups, Copenhagen,
1956.
f,” = fugacity of pure component i at temperature and pres- Nielsen, A., et al., J . Catalysis 3, 68 (1964).
sure of system Petersen, E. E., “Chemical Reaction Analysis,” p. 27, Prentice-
Fo = total molar flow a t reactor inlet Hall, Englewood Cliffs, N. J., 1965.
Fio = molar flow rate of component i at reactor inlet Porcelli, K. V., A.I.CI2.E. ( A m . Inst. Chem. Engrs.) Student Bull. 8
H
. . = frequency factor for reverse reaction (l), 21 (1967).
t , ~= as suffixes: 1 refers to NP, 2 refers to Hs, 3 refers to Prater, C. D., Chem. Eng. Sci. 8, 284 (1958).
”3, 4 refers to inerts Shaw, H. R., \Yones, D. R., A m . J.Sci. 262,918 (1964).
k = rate constant for decomposition of ammonia Simon, J. M., Ph.D. thesis, Rice University, Houston, Tex., 1968.
K, = equilibrium constant in terms of activities Temkin, M., J . Phys. Chem. ( U S S R )24, 1312 (1950).
Wei, J., J . Catalysis 1, 526 (1963).
L = length of experimental reactor Weisz, P. B., Hicks, J. S., Chem. Eng. Sci. 17, 265 (1962).
Ni = molar flux of component in 7 direction Wheeler, A, in “Catalysis,” Vol. 11, P. H. Emmett, Ed., Chap. 2,
P = pressure Reinhold, New York, 1955.
R = universal gas constant
R’ = radius of spherical particle RECEIVED
for review November 29, 1967
Y = radial coordinate of spherical particle ACCEPTEDJuly 23, 1968
T = temperature
Vi = rate of formation of component i Work supported by Systems Grant from the National Science
Xi = mole fraction of component i in catalyst pellet Foundation (No. GU-1153).