Che 416 L4 PDF

Department of Chemical Engineering, LMU
DESIGNS FOR SINGLE

REACTIONS AND SIZE
COMPARISON FOR SINGLE
REACTORS.
CHE 416 – CHEMICAL REACTION ENGINEERING II
 At the end of this week’s lecture, students

should be able to:
 Differentiate between holding time and space
time.
 Design and compare MFR and PFRs for single
reactions
 Design multiple reactors for single reaction
 Multiple reactors in series
 Multiple reactors in parallel

 The distinction between these two measures of time, τ and 𝑡ҧ is as

shown from their definitions. They are defined as follows:
 Space-time:
 Holding time:
 For constant density systems (all liquids and constant density

gases)
 For changing density systems τ ≠ 𝑡ҧ and 𝑡ҧ ≠ V/υ0, in which case it

becomes difficult to find how these terms are related.

 The value of τ depends on what happens in the reactor, while the

value of 𝑡ҧ is independent of what happens in the reactor.
 Holding time 𝑡ҧ does not appear in the performance equations
developed for flow systems, while it is seen that space-time τ or
V/FA0 does naturally appear.
 Hence, τ or V/FA0is the proper performance measure for flow
systems.

 In chemical reaction, there are many ways of processing a fluid:

 in a single batch or flow reactor,
 in a chain of reactors possibly with inter-stage feed injection or heating,
 in a reactor with recycle of the product stream using various feed ratios
and conditions, and so on.
 Which scheme should we use?
 Factors to be considered in answering this question; for example,
 the reaction type,
 planned scale of production,
 cost of equipment and operations,
 safety,
 stability and flexibility of operation,
 equipment life expectancy,
 length of time that the product is expected to be manufactured,
 ease of convertibility of the equipment to modified operating conditions
or to new and different processes.
5

 For good design, all these factors are subjected to experience,

engineering judgment, and a sound knowledge of the
characteristics of the various reactor systems, the choice will also
be dictated by the economics of the overall process.
 The reactor system selected will influence the economics of the
process by dictating the size of the units needed and fixing the
ratio of products formed.
 The first factor, reactor size, may well vary a hundredfold among
competing designs while the second factor, product distribution, is
usually of prime consideration where it can be varied and
controlled.
 In single reactions; the reaction progress is described and followed
adequately by using one and only one rate expression coupled
with the necessary stoichiometric and equilibrium expressions
(synonymous to elementary reactions).
 For such reactions product distribution is fixed; hence, the
important factor in comparing designs is the reactor size.
6

 MFR Versus PFR

 For a given duty the ratio of sizes of MFRs and PFRs will depend on
the extent of reaction, the stoichiometry, and the form of the rate
equation.
 For nth order rate law
 where n varies anywhere from zero to three.
 For MFR the performance Eq. for nth order rate law is given
 4-1
 whereas for PFR, the performance equation for nth order rate law is
given as
 4-2
 Dividing 4-1 by 4-2, it yields

 4-3
 With constant density, or 𝜀 = 0, this expression integrates to
 4-4a
 or
 4-4b
 Equations 4-2 and 4-4a and b can be displayed in graphical form to

provide a quick comparison of the performance of plug flow with
mixed flow reactors.
8

• The ordinate
becomes the
volume ratio
Vm/Vp or space-
time ratio τm/τp
if the same
quantities of
identical feed
are used.
Fig.4-1Comparison of performance of single MFRs and PFRs for the nth order rxns 9

 For identical CA0 and FA0, the ordinate of the graph gives directly the
volume ratio required for any specified conversion.
 Figure 4-1 shows the following.
 For any particular duty and for all positive reaction orders the MFR is
always larger than the PFR. The ratio of volumes increases with reaction
order.
 When conversion is small, the reactor performance is only slightly
affected by flow type. The performance ratio increases very rapidly at
high conversion; consequently, a proper representation of the flow
becomes very important in this range of conversion.
 Density variation during reaction affects design; however, it is normally
of secondary importance compared to the difference in flow type.
10

 For variation of reactant ratio for Second-order reactions of two

components and of the type
 behave as second-order reactions of one component when the

reactant ratio is unity. Thus
 On the other hand, when a large excess of reactant B is used then

its concentration does not change appreciably (CB= CB0) and the
reaction approaches first-order behavior with respect to the
limiting component A, or
 Thus in Fig. 4-1, and in terms of the limiting component A, the size
ratio of MFR to PFR is represented by the region between the first-
order and the second-order curves.
11

 For reactions with arbitrary

but known rate, the
performance capabilities of
MFR and PFRs are best
illustrated in Fig. 4-2.
 The ratio of shaded and of
hatched areas gives the ratio
of space-times needed in
these two reactors.
 The rate curve in Fig. 4-2 is
typical of the large class of
reactions whose rate
decreases continually on
approach to equilibrium (for
all nth-order reactions, n > 0).
Figure 4-2 Comparison of performance of MFR
 For such reactions it can be and PFRs for any reaction kinetics.
seen that MFR always needs a
larger volume than does PFRs
for any given duty.
12

 Plug Flow Reactors in Series and/or in Parallel

 Consider N plug flow reactors connected in series, and let X1, X2, . .
. , XN be the fractional conversion of component A leaving reactor 1,
2, . . . , N.
 Basing the material balance on the feed rate of A to the first reactor,
we find for the ith reactor that
 4-5
 Or for the N reactors in series
 4-6
 Hence, N plug flow reactors in series with a total volume V gives the
same conversion as a single plug flow reactor of volume V.
13

 For the optimum hook up of PFRs connected in parallel or in any

parallel-series combination, the whole system is treated as a single
PFR of volume equal to the total volume of the individual units if the
feed is distributed in such a manner that fluid streams that meet
have the same composition.
 Thus, for reactors in parallel V/F or τ must be the same for each
parallel line. Any other way of feeding is less efficient.
 EXAMPLE 1
 The reactor setup shown in the Figure below consists of three plug
flow reactors in two parallel branches. Branch D has a reactor of
volume 50 liters followed by a reactor of volume 30 liters. Branch E
has a reactor of volume 40 liters. What fraction of the feed should
go to branch D?
14

 Branch D consists of two reactors in series; hence, it may be

considered to be a single reactor of volume
 VD = 50 + 30 = 80 liters
 Now for reactors in parallel V/F must be identical if the conversion
is to be the same in each branch. Therefore,
 or
 Therefore, two-thirds of the feed must be fed to branch D.
15

16

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Department of Chemical Engineering, LMU

DESIGNS FOR SINGLE

 At the end of this week’s lecture, students

CHE 416 – CHEMICAL REACTION ENGINEERING II

 The distinction between these two measures of time, τ and 𝑡ҧ is as

 For constant density systems (all liquids and constant density

 For changing density systems τ ≠ 𝑡ҧ and 𝑡ҧ ≠ V/υ0, in which case it

CHE 416 – CHEMICAL REACTION ENGINEERING II

 The value of τ depends on what happens in the reactor, while the

CHE 416 – CHEMICAL REACTION ENGINEERING II

 In chemical reaction, there are many ways of processing a fluid:

CHE 416 – CHEMICAL REACTION ENGINEERING II

 For good design, all these factors are subjected to experience,

CHE 416 – CHEMICAL REACTION ENGINEERING II

 MFR Versus PFR

 where n varies anywhere from zero to three.

CHE 416 – CHEMICAL REACTION ENGINEERING II

 With constant density, or 𝜀 = 0, this expression integrates to

 Equations 4-2 and 4-4a and b can be displayed in graphical form to

CHE 416 – CHEMICAL REACTION ENGINEERING II

CHE 416 – CHEMICAL REACTION ENGINEERING II

CHE 416 – CHEMICAL REACTION ENGINEERING II

 For variation of reactant ratio for Second-order reactions of two

 behave as second-order reactions of one component when the

 On the other hand, when a large excess of reactant B is used then

CHE 416 – CHEMICAL REACTION ENGINEERING II

 For reactions with arbitrary

CHE 416 – CHEMICAL REACTION ENGINEERING II

 Plug Flow Reactors in Series and/or in Parallel

 Or for the N reactors in series

CHE 416 – CHEMICAL REACTION ENGINEERING II

 For the optimum hook up of PFRs connected in parallel or in any

CHE 416 – CHEMICAL REACTION ENGINEERING II

 Branch D consists of two reactors in series; hence, it may be

 Therefore, two-thirds of the feed must be fed to branch D.

CHE 416 – CHEMICAL REACTION ENGINEERING II

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