CHAPTER 4 REACTOR DESIGN

Topics covered;

4.1 Introduction

4.2 Types of fixed bed reactor

4.3 Selection of reactor type

4.4 Construction and operation of multi-tube

fixed bed reactor

4.5 Effect of variables on multi-tube fixed

bed reactor

4.6 Design Calculations

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CHAPTER 4 REACTOR DESIGN

FIXED BED CATALYTIC REACTORS

4.1 INTRODUCTION

Fixed-bed catalytic reactors have been aptly characterized as the workhorses

of me process industries. For economical production of large amounts of
product, they are usually the first choice, particularly for gas-phase reactions.
Many catalyzed gaseous reactions are amenable to long catalyst life (1-10
years); and as the time between catalyst change outs increases, annualized
replacement costs decline dramatically, largely due to savings in shutdown
costs. It is not surprising, therefore, that fixed-bed reactors now dominate the
scene in large-scale chemical-product manufacture.

4.2 TYPES OF FIXED BED REACTOR

Fixed-bed reactors fall into one of two major categories:

 Adiabatic or
 Non-adiabatic.

A number of reactor configurations have evolved to fit the unique requirements

of specific types of reactions and conditions. Some of the more common ones
used for gas-phase reactions are summarized in Table (4.1) and the
accompanying illustrations. The table can be used for initial selection of a
given reaction system, particularly by comparing it with the known systems
indicated.

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CHAPTER 4 REACTOR DESIGN

Table 4.1: Fixed-Bed Reactor Configurations for Gas-Phase Reactions

Classification Use Typical Applications

Moderately exothermic
Mild hydrogenation
Single adiabatic bed Or endothermic non-
equilibrium limited
Where low ∆P is
Styrene from
Radial flow essential & useful where
ethylbenzene
change in moles is large
SO2 oxidation
High conversion,
Adiabatic beds in series Catalytic reforming
equilibrium
with intermediate Ammonia synthesis
limited reactions
cooling or heating Hydrocracking Styrene
from ethylbenzene
Many hydrogenations
Highly endothermic or
Ethylene oxidation to
exothermic reactions
ethylene oxide,
Multi-tabular requiring
formaldehyde
non-adiabatic close temperature
by methanol oxidation,
control to
phthalic anhydride
ensure high selectivity
production
Highly endothermic,
Direct-fired Steam reforming
high temperature
non-adiabatic
reactions

4.3 SELECTION OF REACTOR TYPE

After analyzing different configuration of fixed bed reactors we have concluded

that for our system the most suitable reactor is multi tube fixed bed reactor.
Because this is exothermic reaction, so cooling will be required otherwise the
temperature of reactor will rise and due to rise in temperature the catalyst
activity and selectivity will be affected and in turn, the formation of by-
products will increase which is direct loss of productions.

As reaction temperatures are already high so if we keep the process adiabatic

temperature of reactor will rise and the structure of the catalyst will be
changed and catalyst will be damaged. For such a situation the best reactor is
multi-tube fixed bed reactor

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 Feed Stream

CHAPTER 4 REACTOR DESIGN

4.4 CONSTRUCTION AND OPERATION OF MULTI-TUBE

FIXED BED REACTOR

Because of the necessity of removing or adding heat, it may not be possible to

use a single large-diameter tube packed with catalyst. In this event the reactor
may be built up of a number of tubes encased in a single body, as illustrated in
figure given below. The energy exchange with the surroundings is obtained by
circulating, or perhaps boiling, a fluid in the space between the tubes. If the
heat effect is large, each catalyst tube must be small (tubes as small as one
inch diameter have been used) in order to prevent excessive temperatures
within the reaction mixture. The problem of deciding how large the tube
diameter should be, and thus how many tubes is necessary, to achieve a given
production forms an important problem in the design of such reactors.
Feed Stream

Cooling
(or Heating)
fluid out

Cooling
(or Heating)
fluid in

Product Stream

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CHAPTER 4 REACTOR DESIGN

A disadvantage of this method of cooling is that the rate of heat transfer to

the fluid surrounding the tubes is about the same all along the tube length, but
the major share of the reaction usually takes place near the entrance.

For example, in an exothermic reaction the rate will be relatively large at the
entrance to the reactor tube owing to the high concentrations of reactants
existing there. It will become even higher as the reaction mixture moves a
short distance into the tube, because the heat liberated by the high rate of
reaction is greater than that which can be transferred to the cooling fluid.
Hence the temperature of the reaction mixture will rise, causing an increase in
the rate of reaction. This continues as the mixture moves up the tube, until the
disappearance of reactants has a larger effect on the rate than the increase in
temperature. Farther along the tube the rate will decrease. The smaller
amount of heat can now be removed through the wall with the result that the
temperature decreases. This situation leads to a maximum in the curve of
temperature versus reactor-tube length.

4.5 EFFECT OF VARIABLES ON MULTI-TUBE FIXED BED

REACTOR

Particle Diameter

The overall heat transfer coefficient declines with decrease in particle size in
the usual practical range. Redial gradients increase markedly with decrease in
particle size. Small size, however, may improve rate or selectivity in some case
by making catalyst inner surface more accessible.

Tube Diameter

Reducing tube diameter reduces the radial profile. Heat transfer area per unit
volume is inversely proportion al to the tube diameter and reaction
temperature is affected by a change in this area.

Outside Wall Coefficient

Improvement up to the point where this resistance becomes negligible is

worthwhile. Boiling liquids are advantageous because of the high heat
transfer coefficient.

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CHAPTER 4 REACTOR DESIGN

Heat of Reaction and Activation Energy

Accurate values should be used since calculated temperature is sensitive to

both of these, particularly to the value of energy of activation. This roust
be determined carefully over the range of interests, but calculated results
should be obtained based on different activation energies over the probable
range of accuracy for the data so that final equipment sizing can be done
with a feel for uncertainties.

Particle Thermal Conductivity

One of the mechanisms of radial heat transfer in a bed, conduction through the
solid packing which must quite logically depend on the thermal conductivity of
the bed, can be reasoned to have some dependence on the thermal
conductivity of the solid. But since it only affects one of the several
mechanisms, the proportionally cannot be direct.
Differences in effective conductivity and the wall heat transfer coefficient h
between beds of packing having high and low solid conductivity may be in the
range of a factor of 2-3. The largest difference will occur at lower Reynolds
numbers. Most catalyst carriers have low conductivities, but some such as
carbides have high conductivities.

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CHAPTER 4 REACTOR DESIGN

4.6 DESIGN CALCULATIONS

Volume of Reactor

Volume of Reacting fluid

Reaction Temperature = 195 oC

Reaction Pressure = 15 atm

XA
dXA
V / FAO  
0
 rA

rA  kCA n
CA  CA 0 (1  XA )

 rA  kCA 0 ^ n (1  XA)^ n

Volumetric flow rate of feed to reactor = Vo = 15.648 m3/hr

Conversion = 95%

CA0 = 2.277922992 Kgmol/m3

FA0 = 35.64554074 kgmol/s

k = 1.246077

n = 1.59699

Volume of reacting fluid

XA
dXA
V / FAO  0
 rA
V = 27 m 3

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CHAPTER 4 REACTOR DESIGN

Volume of Catalyst

(Diphonix Resin Polymer Matrix Support of size 2 mm of granules shape is used)

Wt of catalyst in kg = Fao*3.515 / (k * Cao^n -1)

Wt of catalyst = 27 kg

Density = 1110 kg/m3

Volume of catalyst = 0.024m3

Porosity m3/m3 = 0.55

Actual vol. of catalyst = (1-0.55)*0.024 = 0.01094 m3

Volume of reactor = 27 m3

τ = 1.72 hr

Number of Tubes

Length of Pipe:

Volume of reactor = V = /4 (D2L)

L/D = 200 (P.F.R)

L = 200 * D

V = 50  D3

D = (V/50)1/3

D = (27/50 * )1/3

D = 0.5565 m

L = 200 * 0.5565 = 111.3 m

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CHAPTER 4 REACTOR DESIGN

Selection of Pipe:

Nominal Pipe Size = 2”

Schedule No. 80

Required Flow Area for Plug Flow = /4 (0.5565)2

= 0.243 m2

Flow Area of 2”, Schedule No.80

I.D = 1.939” = 1.939/12*3.281

I.D = 0.05 m

Flow Area of one tube = 3.14*D2/4

= 1.9048 * 10-3 m2

No. of pipes required/pass = required flow area/flow area available

= 0.243/1.9048 * 10-3

= 128 pipes

Assume # of sections: - 17

Length of each pipe = 111.3/17

= 6.5 m

Length of pipe = 6.5 m

Total no. of pipes = 128 * 6.5

= 839 pipes

Thus Total pipe sections = 17

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CHAPTER 4 REACTOR DESIGN

Minimum Wall Thickness of the Pipe:

Min. wall thickness = {P (inside radius) / SEj – 0.6P} + Cc

Where
P = Max. Allowable internal pressure, kPa = 1694.5 kPa
S = Max. Allowable working stress, kPa = 94500kPa

Ej = Efficiency of joints expressed as a fraction =0.85

Cc = Allowance for corrosion, m = 0.0032

Check for 2”, Schedule No. 80

Putting the values of P, inside radius and other values;

Min. wall thickness = t

t = {1694.5(1.939/2*12*3.281)}/ {94,500(0.85)-0.6(1694.5)} + 0.0032

By solving the above Equation, we get

Min. wall thickness = 0.0037 m = 0.1445”

Actual Wall Thickness = 2.38 - 1.939/2

= 0.2205

Safety Factor = (0.2205 - 0.1445)/ 0.1445

= 50%

Nominal Pipe Size 2” and Schedule No. 80 is selected.

Diameter of Shell

To calculate shell diameter equation (from Ludwig)

 2π 
 D s - K1  4  K 2  - Pt  D s - K1  nK 3  K 4 
NT 
1.223 Pt  2

Where
NT = number of tubes = 2171

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CHAPTER 4 REACTOR DESIGN

Ds = shell dia =?
PT = pitch = 1.34 of tube dia
= 2.6 in
For this pitch
K1 = 1.08 K2 = - 0.9
K3 = 0.69 K4 = - 0.8
n = 1 (1 tube pass)
By solving above equation.

Ds = 152.11 inch = 3.86 meter

Shell Height

Length of tube = 6.5 m

Leaving 10 % spacing above and below

So height of shell = 6.5 x 1.2 = 8 m

Pressure Drop
1/ 2
P  2L 
 1  
P0  Po 

G 1    150(1   )  
 3 
 1.75G 
g c D P   DP 

φ = porosity = 0.55

DP = particle dia = 2 mm = 0.002 m

ℓ = feed density = 318 Kg/m3

G = mass velocity = 1201.4 kg/hr. m2

 = viscosity of feed = 0.67028 kg/hr. m

gc = 1.3*10^8 m/hr

P0 =Initial pressure = 15 atm

So

β = 0.4 atm/m

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CHAPTER 4 REACTOR DESIGN

P = 12.6 atm

And ∆P = 2.4 atm

Calculations of Heat Transfer Co-efficients

Shell Side

For shell side film coefficient

h0 D 0
 a Re m Pr 0.34 F1 F2
k

a = constant = 0.273 (From Timmerhaurse)

m = constant = 0.635
F1 = 1

Number of tube rows = greater than 10

F2 = 0.99 (from table 14-2 Timmerhaurse)
K = Thermal conductivity = 0.606 J/s.m.K

Pr = Cµ/k

Pr = 5.96

Vmax = mt/ℓNt(Pt-D0)L

mt = mass flow rate = 41.44 Kg/s

D0 = outside tube dia = 0.0604 m

Nt = number of tubes = 2171

L = length of tube = 7.5 m

Vmax= 4.652*10-4 m/s

Re = Do Vmaxℓ/µ

Re = 308.4

So

ho= 19 W/m2 K

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CHAPTER 4 REACTOR DESIGN

Tube Side

An equation proposed by LEVA to find heat transfer co-efficient inside the

tubes filled with catalyst particles.
0.7
hpD  DpG  Dp
 3.5
 μ   e  4.6
k   D

G = 1201.4 kg/hr. m2

 = 0.67028 kg/hr. M

k = 96.4 j/hr. m k

Dp = dia of particle = 0.0020117 m

D = dia of tube = 0.005251 m

Putting values in above eq

h p  0.005251  0.00201176 1201.44 

0.7

 3.5  e 4.6*0.0020117 / 0.00525

96.445  0.067028 

hp = 10527 W/ m2 K

ID 10527  2.204

hio = hp  = = W/ m2 K
OD 2.5

= 9.1472*103 W/ m2 K

Dirt Factor

Assume dirt factor = 0.003

Over all H.T. Coefficient

1 1 1
   RD
U D h io h o

1 1 1
   0.003
U D 9.1472 *10^3 19

UD = 35 W/m2.K

Area required for Heat Transfer

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CHAPTER 4 REACTOR DESIGN

Q = 2436590.2 J/hr

LMTD = 149.5K

UD = 35 W/m2.K

θ 2436590.2
A=  = 465.6 m2
U D LMTD 35  149.5

Area Available for Heat Transfer

Length of tube = Lt = 6.5 m

Outer Dia of tube = Dot = 0.0304 m

Surface area of one tube =  Dot Lt

= 3.14  0.0304  6.5

= 6.2336*10-1m2

Total surface area available = 839  2.4*10-1

= 523 m2

So sufficient area is available for heat transfer.

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CHAPTER 4 REACTOR DESIGN

SPECIFICATION SHEET
Identification

Item Reactor
No. required 1

Function: Production of isopropyl acetate from propylene and acetic acid

Operation: Continuous
Type: Catalytic
Multi tube, fixed bed

Chemical Reaction:
C2H4O2 + C3H6 C5H10O2
 H298 = 16.4 Kcal/mol

Catalyst: Diphonix resin polymer matrix

Shape: Spherical
Size: 2 mm

Tube side: Tubes:

Material handled Feed Product No. 2177
(kg/hr) (kg/hr) Length 7.5m
C2H4O2 3000 902.73 O. D 60.5 mm
C3H6 1500 36 Pitch 66.04 mm  pattern
C5H10O2 ----- 3497.14 Material of construction = carbon steel
Temp (oC) 120 315
Shell side Shell
Fluid handled = Cooling water Dia = 2.15 m
Temperature 25oC to 35oC Material of construction = Carbon steel

Heat transfer area required = 465.6 m2

Overall heat transfer coefficient = 35W/m2 K

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