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Numerical and graphical methods are presented for estimating the temperatures and partial
pressures at the surfaces of catalyst particles for gaseous reactions in flow systems. The errors cube of packed bed is considered with
resulting in the interpretation of catalytic reaction-rate data, where surface conditions are the fluid flowing through the bed
assumed to be those of the ambient gas stream, are presented. A numerical method of evaluating normal to two opposite faces of the
the reaction model with nonisothermal surface conditions is indicated.
cube. The wetted area of the fluid
In kinetic studies dealing with fluid this paper where a reaction model is channel available for mass transfer per
reactions catalyzed by solid particles sought. unit volume of bed is equal to +av and
the interpretation of experimental data the cross section of the channel is
is greatly facilitated by operating at MASS TRANSFER DATA AT equal to the void fraction E . The hy-
SufFiciently high velocities and small LOW REYNOLDS NUMBERS draulic radius is equal to duwI$, and
particle sizes so as to maintain the the actual mass velocity is equal to
composition and temperature of the Flow reactions in catalyst beds fre- G / e . Hence
fluid in contact with the catalyst sur- quently take place at low Reynolds
face nearly the same as in the ambient number where insufficient mass and . .
main stream. Under these favorable heat transfer data have been available P 4au
conditions resistances to mass and heat until recently. The data of Wakao, The term q5uv should then also be used
transfers from particle to ambient Oshima, and Yagi ( I ) now give the in equations for mass and heat transfer.
stream become negligible, and point required reliability to mass transfer Thus for the rate of transfer of com-
reaction rates become independent of coefficients at low Reynolds numbers. ponent A per unit volume of bed
fluid velocity. Such high velocities are These data were obtained from the
rate of dissolution of betanaphthol by rvA=kGAau+ (4)
(PA-PAi)
encountered in industrial reactors but
water flowing over spheres and cylin- or on the basis of unit mass of parti-
are often not realized in laboratory
ders of betanaphthol where the water cles
scale reactors. Many examples appear
in the literature where large drops of
stream completely filled the external
void space of the bed. The beta-
+
= k a a m (1). - p.6) (5)
temperature and partial pressure from The term 4 is retained to permit
catalyst to ambient gas stream have naphthol particles were mixed with
glass beads to reduce the attainment data obtained on spheres (I$ = 1) to
been neglected with consequent er- be extended to other shapes.
roneous interpretation of the reaction of saturation in the exit stream of thin
model. beds. The data of Wilke and Hougen
(2) were obtained from rates of evapo- RECORRELATION OF j D AT LOW
This paper deals with the calcula- ration of water from celite pellets to REYNOLDS NUMBERS
tion of the temperatures and partial
pressures of gases at the surface of an air stream flowing through the bed. By recorrelation of the data of
catalyst particles for flow reactions Both sets of data were recorrelated in Wilke and Hougen (2); Gamson,
terms of the i. factor, as defined by Thodos, and Hougen ( 5 ) ; and Wakao,
taking place in b e d beds; the errors
Chilton and Colburn ( 3 ) . Oshima, and Yagi ( I ) a smooth con-
involved in the correlation of rate data
For gases tinuous curve of iD values against
in terms of the ambient gas stream
when high resistances to mass and values of Re was obtained on a loga-
heat transfer are ignored; and the in- rithmic plot. For convenience without
terpretation of experimental data appreciable loss in accuracy the cor-
where large drops of temperature and The exponent 2/3 on the Schmidt relations were divided into two parts
partial pressure from catalyst to the number was used in the correlation of as follows:
ambient stream prevail.
Another serious error arising in the
experimental data and is acceptable at For 0.01 < Re < 50
low Reynolds numbers encountered in
interpretation of rate data is the neg- experimental reactors. i,, = 0.84 Re-' (6)
lect of gradients of temperature and The Reynolds number adopted in
partial preisures inside catalyst pellets. the present correlation is defined as
For 50 < Re < 1,000
The methods employed in this paper iD= 0.57 Re"." (7)
still apply to the calculation of surface G
conditions despite these internal gra- Re=- (2) No significance is attached to the inter-
a.4P section of these two equations at
dients, but for the correlation of reac-
tion rate constants the internal gradi- For spheres I$ = 1.0; for cylinders Re = 50.
ents of temperature and composition 4 = 0.91; for flakes +
= 0.81; for ir-
should also be known. The mathemati- regular granules 4 = 0.90 (assumed). PRESSURE FACTOR pr
cal procedures for calculating the
internal gradients are reported in For diffusion through a stagnant
DERIVATION OF REYNOLDS NUMBER film in binary gas mixtures the pres-
literature (8, 9 ) and are considered in
In the derivation of an appropriate sure factor p, is the logarithmic mean
Fumitake Yoshida is at Kyoto University, Kyoto, value of the partial pressure of the non-
Japan. form for the Reynolds number a unit
Fig. 1. Evaluation of partial pressure gradients between a flowing fluid and the exterior surface of catalyst particles in a packed bed.
diffusing gas between the interface For a fluid film of thickness &x an
and the main ambient stream. In case integrated form of Equation (15),
of equimoIa1 diffusion the fluid has with DmA assumed constant across the
zero molar velocity with respect to film, gives
fixed coordinates normal to the stream.
The diffusion of a component normal D m n ~ APA
From Equation (10) N, = - -=
to the stream is the same relative to ( p f A ) m R T AX
the bulk of the fluid or to fixed coor-
.lr D ~ PA
A
N A =-
dinates. In general however the rate a+b-r-s RTax - D ~ APAA --
- Tm* (16)
of transfer across the stream is affected
by bulk flux as well as by diffusion
“ - P A ( a )- (yr.) zm RT AX a,
(11) The necessity of using the pressure
through the fluid. Where a bulk flux
of fluid occurs in the direction of dif- Application of Equation (11) to the factor term p , arises because the re-
fusion, an additional transfer of A transfer of A through a binary stag- ported correlations of iD were obtained
occurs in this direction. nant film gives from experiments in stagnant films
The effective diffusion coefficient where p f was used to allow for bulk
DmA of component A in a multicom- N A = - - - = DAB ?PA.
flow in the direction of dBusion.
ponent gaseous mixture is defined thus: (i--yn)RT ax
DABT
--- EFFECTIVE DlFFUSlVlTY OF
(12) MULTICOMPONENT MIXTURES
prRT ax
For diffusion in a multicomponent In the molecular diffusion of A
For a general gaseous reaction aA + mixture through a gaseous of B, R, S , . . the .
partial pressure gradient of A is given
bB + rR -f- sS catalyzed by a solid
surface the bulk flux F of the gaseous
p t A = ‘7I -P A ( a + byT-S) (13) by the Stefan-Maxwell equation as
mixture relative to fixed coordinates is or dividing by gives
(a+ber-s)
TI
the algebraic sum of the bulk fluxes
N,, N B , . . . of the separate compo- y f A = 1 -Y A (14)
nents; thus
F = NA + NB- Ng - Na = where yn = ~ J T I .The rate of diffu-
sion of A through a multicomponent
(a + b- T- s)- mixture then becomes From Equations (15) and (17)
NA (9) Stewart (6) developed the following
a
NA z= - _--- DmA a p A
DmA TI apA - for the effective diffusion coefficient of
The total transfer N n of A with respect p , RT ax VraRT ax component A in a multicomponent
to fixed coordinates becomes (15) mixture:
c0.12
+0.08
a
4
to.04
0.00
-0.04
-0.08
-0.12
R e = G/(q,f!h
Fig. 3. Evaluation of temperature drop between a flowing fluid and the -0.16
exterior surface of catalyst particles.
G, = gmoies)/ (cm%wr)
magnitude of R is by far the most im- Fig. 5. Pressure drops from catalyst surface to ambient gas
portant variable controlling the partial stream in the hydrogenation of propylene a t 1- a h . pressure.
pressure drop from catalyst particle to Ambient gas stream pcaas = 0.33; PH* = 0.67 atm.
ambient stream.
from representative experimental data 8.0. The calculated values of [Ap~/p,]
RANGE OF AyA VALUES IN reported in the literature for fourteen are plotted vs. [Rj/YJ] in Figure 2.
EXPERIMENTAL REACTORS easeous reactions catalvzed bv solids Both coordinates are dimensionless.
Values of [ApJ/pJ] were calculated fixed beds as give; in ?able 1. For reactants the ratio [Ap,/pl] can
for the separate reactants and products These values range from 0.0005 to never exceed unity; the maximum
value encountered was 0.5. However
for products this ratio may exceed
1000 unity manifold. The maximum value
encountered was 8.0. Hence neglect
of partial pressure drop for the prod-
ucts in correlation of rate data may
result in serious error in establishing
100 the kinetic adsorption constants. Par-
tial pressure drops should approach
zero for correlation of rate data in
terms of ambient conditions. It may be
observed from Figure 2 that the points
10 for all systems fall in a fairly narrow
band. The ratio [Ap,/p~]/[R,/y,] in
0
0 the fourteen investigations varies only
t from 1 to 6.5, whereas values of [ A p J
0 p , ] vary 10,000 fold. The width of the
1.0 band is due to variations of y,, i., and
Schmidt numbers which were pur-
posely neglected in this plot to em-
phasize that R j is the most significant
factor in controlling partial pressure
0.I drops. Figure 2 serves as a rough
guide in estimating the relative magni-
tudes of partial pressure drops without
requiring the data on viscosities and
diffusivities. A precise correlation of
0.0 I pressure drop data is shown in Figure
0.001 0.01 0.I I .o 10 100
1. It will be observed from Figure 2
that for eight of the fourteen investi-
r A H gations the values of [Apj/p,] were
Q= Iess than 0.1; for two investigations
am f l c p 6, the values of this ratio for products
Fig. 4. Experimental range 4 f between goses and catalytic particles in packed beds. were greater than 1.0
K
200 0 2
Gy :(g-molerl/ (cm*l(hour
8
I
10 12
The temperature drop from a cata- For the same system and runs pre- cylindrical pellets. The partial pres-
lyst surface to ambient fluid stream viously used in calculating values of sure of propane at the catalyst surface
may be estimated from the relation [ A p j / p , ] values of At were calculated is significant even though negligible
in = 1.076 i.. This relation is still and plotted vs. Q on logarithmic co- quantity appears in bulk stream. In
subject to some uncertainty. The iH ordinates in Figure 4. This chart serves this case the adsorption term for pro-
factor for heat transfer is defined by as a rough guide and indicates that pane is negligible, and hence no ad-
Chilton and Colburn ( 3 ) as temperature drop At is determined sorption term for propane need appear
largely by Q and to a minor extent even though propane is present at the
by the Prandtl and ja numbers. Thus interface.
the dimensionless ratio A t / Q varies The corresponding temperature drops
The temperature drop At from cata- from 1.3 to 6.4 within the variations of across the gas film are shown in Figure
lyst surface to the ambient stream may viscosity and thermal conductivity of 6 for the catalytic hydrogenation of
then be obtained from the following gases. The actual values of At obtained propylene. It will be observed that for
relation: in all the experimental runs cover a the high rates of these reactions tem-
wide range from 0.07" to 246"C., the perature drops of several hundred
latter value occurred in the hydrogena- degrees across the gas film may occur
tion of butylene. Even if the main gas at low mass velocities and that it may
Combining Equations (23) and (24) stream in a catalyzed reaction is kept become experimentally difficult to
one gets isothermal, the reaction taking place at render this drop negligible.
the surface will not be isothermal.
For all calculations of A p , and At CORRELATION OF REACTION RATE
, r -
an IBM-650 computer and data pro- DATA WHERE RESISTANCES TO
Q jR-' (Pv): (25) cessing machine were used. MASS AND HEAT TRANSFER ARE
where Q = (T,A AH,)/(a, 4 C, G M ) SIGNIFICANT
SPECIFIC ILLUSTRATION OF
The terms Q and At have the dimen- PARTIAL PRESSURE DROPS AND
Where experimental data on reaction
sions of temperature; the other terms TEMPERATURE DROP rates are obtained under conditions of
are dimensionless. The variations of significant resistances to mass and heat
in and the Prandtl number are small A specific case will be illustrated transfer, reaction rate equations ex-
compared with values of Q. For gase- for an extremely rapid reaction, pressed in terms of ambient conditions
ous systems the range of Prandtl num- namely the catalytic hydrogenation of become dependent on mass velocity
bers is from 0.6 to 1.0 and for liquid propylene. This illustration is based as well as on temperature and partial
systems from 2 to 400. Thus Q is the upon the excellent thesis of Fair, and pressures. Neglecting the effect of
most significant factor in controlling with the permission from Rase, his velocity may lead to the postulation of
temperature drop just as R is the most major professor. The partial pressure a false reaction model and to constants
significant factor in controlling the drops of the component gases from inconsistent with the correct model.
pressure drop ratio. the ambient stream to the catalyst par- These errors can be avoided by cal-
Values of At may be calculated from ticle as a function of mass velocity are culating the surface conditions and
Equation (25) or obtained more shown in Figure 5 for a feed mole establishing the kinetic model and re-
readily from Figure 3. Values of AH at fraction of hydrogen = 0.67 and pro- action rate constants from surface
reaction temperatures were obtained pylene = 0.33 at atmospheric pres- conditions. This method is extremely
from standard heats of reaction at sure, and ambient temperatures of tedious and should be avoided if pos-
298' K. combined with heat capacity 47" and 103°C. with a nickel catalyst sible by eliminating experimentally
data for the separate components. supported on keiselguhr, 1/8 x l/s in. these transfer resistances. The method
previously in Figures 6 and 5. The As a first approximation Equation relative change in each parameter;
number of runs at any level of surface ( 2 6 ) is expanded into a linear first- that is
temperatures now become so few that order Taylor series; thus
correlation at isothermal levels was no
= f ( T , rJ?H, PlJ, p E , 83, 8%$8, 64,
longer possibIe without eliminating
60% of the experimental data, To use 05, 66, 67, 8 s ) (27) In general this iteration may or may
all the data required the acceptance
where B,, , . . ., O8 are substituted for not converge, depending on the guess
of temperature as a simultaneous vari-
able along with partial pressures.
the ( A d 1( R ) , (-4) 1( R ) , (41( R )f values. In the present case the func-
(-Bz) 1 ( R ) , (As) 1( R ) , /(R) 9
tional relationship is highly nonlinear.
The maximum possible temperature (A,) / ( R ), ( -BP)/ ( R ) in Equation An optional feature of this program,
drops inside the catalyst pellets were (26). A first approximation in accord- the Lagrangian interpolation, gave the
estimated by the method of Schilson nnce with Taylor's theorem gives best choice of parameters in each
(8) for all the 141 runs. In the ex- iteration with rapid convergence.
treme case the maximum value en- =f ( T , prr, ps, Oi", . . ., O n " ) + In these calculations nonlinear esti-
countered was 12°C. compared with mation program written by Booth and
325°C. for the corresponding external Peterson (13) for the IBM-704 was
drop, giving a ratio of 0.037. The used. The details of the computer
average internal temperature drop for . . . + he;---af programs for the various calculations
mentioned earlier are reported by
all the runs was 4.5"C., giving a ratio 888
Ramaswami (26).
of only 0.015 compared with the aver- The final correlations are given in
age external drop. It may be concluded Table 2 and the constants are com-
pared with those based upon ambient
rather than surface conditions.
'I.ABLE 2 In the use of ambient conditions the
correlations do not support the reac-
Hydrogenation of propylene Hydrogenation of isobutylene tion model in three defaults high
Model 2 Model 2 Model 2 Model 2
using surface using ambient using surface using ambient chemisorption is shown for both pro-
conditions conditions conditions conditions pane and isobutane, whereas the ad-
sorption of these products is neglig-
A1 +2,324.0 +8,607 +1,430.8 -1,547 (should be + ) ible; a negative value is obtained for
BI 8.8705 36.5 6.2245 -1.32 the energy of activation of isobutylene
A* -2,562.0 -11,610 -6,555.1 -3,112 AH+ (ambient) = -1,547; and the
B2 0.8419 -38.1 -7.5504 -2.66 heat of adsorption of isobutylene is
A8 -5,193.2 -1,217 -4,295.3 + 1,364 ( should be - ) endothermic (ambient) = 1,364. With
B8 -4.2497 -3.42 -5.4129 7.17
A, no adsorption -425.0 no adsorption -1,062 (should show the use of surface conditions the re-
no adsorption sults are consistent throughout; AH*
B, no adsorption 4.61 no adsorption 0.525 of isobu- (surface) = 1,431 and AH, (surface)
tane) = -4,295.