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Chemical Reaction Engineering

Lecture No. 15
REACTORS IN SERIES

Reactors in Series
reactors are connected together so that the exit stream of one reactor is the feed stream for another reactor. Consider, FA1 , x A1 FA0 V1 xA = 0

V2 V3 where: FA2 , x A2 FA3 , x A3

FA0 xA = 0

V1

FA1 , x A1 FA0 xA = 0 V2 V3 FA3 , x A3 V1

FA1 , x A1 V2

Considering the figure above,

FA2 , x A2

Considering the individual reactors above, Reactor 1: Reactor 2: Reactor 3: FA1 = FA0 - FA0 xA1 FA2 = FA0 - FA0 xA2 FA3 = FA0 - FA0 xA3

V3 FA2 , x A2 FA3 , x A3 Consider the CSTR: Entering Molar Exit Molar Rate of - rate of A + generation of = 0 rate of A A FA1 FA2 rA2V2 Rearranging, or

Illustrative Problems:
Consider the isothermal, gaseous decomposition reaction: A 3B At T = 149 C, PT = 10 atm. Initial Charge: equimolar mixture of A and inerts Data: xA
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.85 0.0053 0.0052 0.0050 0.0045 0.0040 0.0033 0.0025 0.0018 0.00125 0.00100 189 192 200 222 250 303 400 556 800 1000

Plotting

vs. xA :
1000 900 800 700 600 500 400 300 200 100 0

0. 3

0. 5

0. 6

xA

0. 8 0. 85

0. 4

0. 1

0. 2

0. 7

Prob.1]

For substance A, calculate the entering concentration, CA0 , and the entering molar flow rate, FA0. The gas mixture, which consists of 50% A and 50% inerts at 10 atm, enters the reactor with a flow rate of 6 lit/s at 149 C. The ideal gas constant is 0.08205 lit-atm/mol-K.

Prob.2]

Using the data for the given reaction, for the two CSTRs in series, 40% conversion is achieved in the first reactor. What is the total volume of the two reactors necessary for 80% overall conversion of the species A entering reactor 1? Solution: F
A0

Solution: Assuming ideal gas case:

V1

FA1 xA1 = 0.40

V2

FA2 xA2 = 0.80

And, FA0 = CA0 q0

From Prob. 1, FA0 = 0.866 From the data: xA1 = 0.40 ,

Mole Balance in CSTR1: Rearranging,

FA0 - FA1 + rA1V1 = 0

Mole Balance in CSTR2: Rearranging,

FA1 - FA2 + rA2V2 = 0

but

FA0 - FA1 = FA0 xA1 then or

but

FA1 - FA2 = FA0 (xA2 - xA1) or

then

Therefore, = 86. 6 lit

Therefore, = 277. 1 lit VT = V1 + V2 = 86. 6 lit + 277. 1 lit VT = 363. 7 lit

Or, using the curve drawn earlier:


1000 900 800 700 600 500 400 300 200 100 0

Prob. 3] Using either data in the previous problem, calculate the reactor volumes V1 and V2 for the plug-flow sequence shown below when the intermediate conversion is 40% and the final conversion is 80%. The entering molar flow rate is the same as in the previous examples, 0.867 mol/s. VCSTR2 Solution: FA0 xA = 0
V1

VCSTR1
0. 3 0. 5 0. 6

xA

xA = 0.4 FA1

0. 8 0. 85

0. 4

0. 1

0. 2

0. 7

V3

FA2 xA2 = 0.80

Using Simpsons Rule with x = 0.20:

For the second PFR:

For the first PFR:

0.4

0.60

0.80 = 153 lit

See DATA

0.20

0.40 VT = V1 + V2 = 71. 5 + 153 = 224. 5 lit

= 71. 5 lit

For a single PFR:

N = 4, x A = 0.20

NOTE that: For PFRs in series:

0.20

0.40

0.60
See DATA

0.80 This could be shown graphically, NOTE that V = V1 + V2

V1 VT = 224. 5 lit

V2 xA1 xA2 xA

V xA xA

For PFRs in series: For a single PFR: Prob. 4] Calculate the individual reactor volume as well as the total reactor volume for each scheme below for the data given earlier when the intermediate conversion is 50% and a final conversion of 0.8 and FA0 = 0. 866 mol/s Scheme A: V1 FA0 xA = 0.5 xA = 0
V3

V1 V V2 xA1 x xA A2 Therefore,

xA

Scheme B: Volume of a single PFR = Total volume of PFRs in series FA0 xA = 0


V1

FA2 xA2 = 0.80

xA = 0.5

V3

FA2 xA2 = 0.80

Solution: Scheme A:
1000 900 800 700 600 500 400 300 200 100 0

Design Equation for the PFR: Applying Simpsons Rule with x A = 0.25:

VCSTR VPFR
0. 3 0. 5 0. 6

0
xA
0. 8 0. 85 0. 4 0. 7

0.25

0.50

0. 1

0. 2

VPFR= 96.4 Liters

Using values obtained from the graph:

VCSTR= 207.84 lit VT = VPFR + VCSTR= 96.4 +207.84 = 304.24 liters Scheme B: Try this! V1= 96.4 lit V2= 130.03 lit VT = V1 + V2= 96.4 + 130.03 = 226.43 liters

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