Lecture 10.2 Batch Reactor Scenarios

Chemical Reactor Design
CHEN20141
Lecture 10.2
Heat Effects
Batch reactors with heat exchange

Example scenarios
Philip Martin
Lecture Plan
- Derivation of design equations

- Controlled isothermal operation
Exothermic
Endothermic
- Variation of the temperature profile to reduce reactor volume
- Minimum batch time
TC
Tin
Coolant flow
w
TR
Tout
Controlled Isothermal Operation of a Batch Reactor
Exothermic Reactions isothermal
TC
Qg
Tin
Coolant flow
w
TR time
Tout
Qg = V (−rA )H R Heat generated

 
  LMTD = log mean
 (TR − TIN ) − (TR − TOUT ) 
Qr = UA ( LMTD ) = UA temperature difference
  TR − TIN  
 ln 
T −T   
  R OUT  
For isothermal operation Qg = Qr g – heat generated

a – heat absorbed
As Qg falls, control valves reduce coolant flow (w) s – heat supplied
r – heat removed
This increases Tout, and reduces LMTD and Qr
To calculate coolant flow and Tout verses time
1. Determine UA
2. Integrate –rA = f(C, T) to get C (or X) verses t at TR (desired operating temp)
3. Calculate Qg verses t from Qg = (- rA)VHR
4. Calculate Tout verses t from:

  LMTD = log mean
 
 (TR − TIN ) − (TR − TOUT )  temperature difference
Qr = UA ( LMTD ) = UA
  T −T  
 ln  R IN  
  TR − TOUT  
5. Calculate w verses t from:

Qr = ωCP (Tout − Tin )
Limitations:
Cooling water velocity not below 1 m/s e.g. at end of reaction Qg is low
Cooling water temperature not above 65 °C
Use 2 coils ?
Controlled Isothermal Operation of a Batch Reactor
Endothermic reactions
TC
Heat
absorbed
Qa
Tin
steam
TR trap
condensate time
Qa = V (−r )H R For isothermal:

QS = UA(TS − TR ) Qa(rate of heat absorption) = Qs (rate of heat supply)
As Qa falls, control valve reduces steam flow and pressure
As steam pressure reduces, so does condensing temperature Ts
As Ts falls, so does Qs
Limitations:
Steam pressure falls below atmospheric pressure Use 2 coils?
Will a reactor temperature profile reduce the reactor volume?
⎯⎯⎯
A⎯→
k1
R exothermic
k2
 X 
− rA = k1C A0 1 −  Eqn 1
 X e 
1
As T increases:
Xe decreases
k1 increases X -rA
-rA = 0
Equilibrium
line
For each XA there is a value of T which gives the maximum value of (-rA)
Will a reactor temperature profile reduce the reactor volume?
The minimum reactor volume (or the minimum batch time) will be achieved if the
temperature profile can be chosen to give the maximum reaction rate at each value of
conversion
Optimum relationship between X and T can be found by differentiating (-r) = f(C, T)
− rA = k1C A − k 2C R = A1e − E1 RT
C A0 (1 − X A ) − A2 e − E2 RT
C A0 X A
d (−rA ) E E2 − E 2
= A1 (1 − X A ) 1 2 e − E1 RT
− A2 X A e RT
=0
dT RT RT 2
XA AE  E − E1 
or = 1 1 exp  2  (2)
(1 − X A ) A2 E2  RT 
1
Locus of
maximum rates,
best path Optimum T falls as X increases
X
T Tmax allowable
What is the minimum batch time for a reversible exothermic reaction? Contd.
E.g. ⎯⎯⎯
For A⎯→
k
R 1
CRO = 0, const density system
k 2
 X 
− r A = k1 C Ao 1 − A  Eqn 1
 X Ae 
XA AE  E − E1 
= 1 1 exp  2 
(1 − X A ) A2 E 2   Eqn 2
 RTopt 
k1 A1e −E1 RT X Ae
K= = Eqn 3
k 2 A2 e −E2 RT 1 − X Ae
1. Select values of XA
2. Calculate Topt at each value of XA from eqn (2)
3. Calculate XAe at each value of Topt from (3)
4. Calculate at (-rA)max each (Topt, XA, XAe) a dataset from (1)

XA
dX A
5. Evaluate (t batch )min = C Ao 
0
(−r A )max
graphically
What is the minimum batch time for a reversible exothermic reaction? Contd.
C Ao
( −r A )max
t1
t2
t3 t
4 t5
0 X1 X2 X3 X4 X5
X
The graph supplies (t batch )minfrom  t and also X versus time.
The values found in step 2 of the procedure then will give Topt versus time.
This is the information required to design the temperature control system for the
reactor.
Summary
Derived the energy balance for batch reactors with heat effects
Example scenarios for exothermic, endothermic reactions,

isothermal operation, temperature progressions

Lecture 10.2 Batch Reactor Scenarios

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Lecture 10.2 Batch Reactor Scenarios

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Chemical Reactor Design

Batch reactors with heat exchange

- Derivation of design equations

Qg = V (−rA )H R Heat generated

For isothermal operation Qg = Qr g – heat generated

2. Integrate –rA = f(C, T) to get C (or X) verses t at TR (desired operating temp)

3. Calculate Qg verses t from Qg = (- rA)VHR

4. Calculate Tout verses t from:

5. Calculate w verses t from:

Qa = V (−r )H R For isothermal:

As Qa falls, control valve reduces steam flow and pressure

As steam pressure reduces, so does condensing temperature Ts

4. Calculate at (-rA)max each (Topt, XA, XAe) a dataset from (1)

The graph supplies (t batch )minfrom  t and also X versus time.

Example scenarios for exothermic, endothermic reactions,

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