SOLTEQ CSTR DYNAMICS (Model: BP 107)

CONTINUOUS
STIRRED TANK
REACTOR (CSTR)
DYNAMIC

SOLTEQ CSTR DYNAMICS (Model: BP 107)

1.0

INTRODUCTION
In the majority of industrial chemical processes, a reactor is the key item of equipment in
which raw materials undergo a chemical change to form desired products. The design and
operation of chemical reactors is thus crucial to the whole success of the industrial
operation. Reactors can take a widely varying form, depending on the nature of the feed
materials and the products. Understanding non-steady behaviour of process equipment is
necessary for the design and operation of automatic control systems. One particular type of
process equipment is the continuous stirred tank reactor. In this reactor, it is important to
determine the system response to a change in concentration. This response of
concentration versus time is an indication of the ideality of the system.
The SOLTLEQ CSTR Dynamics (Model BP 107) has been designed to follow the
dynamics of the simplest classic case of a well-mixed, multi-staged process operation. The
unit comes with three stirred tank reactors connected in series complete with sump tanks
and circulation pumps. Instruments are provided for the measurement of conductivity in
each reactor. Students may select either step change input or impulse input to the reactor
and will continuously monitor the responses in each reactor at a suitable interval.

SOLTEQ CSTR DYNAMICS (Model: BP 107)

2.0

GENERAL DESCRIPTION
Before operating the unit, students must familiarize themselves with the unit. Please refer
to Figure 1 to understand the process. The unit consists of the followings:
a)

Reactors
Three reactors made of borosilicate glass, each having approximately 2 liters
capacity. Each reactor is fitted with variable speed stirrer mounted on the top plate.
Temperature and conductivity sensors are provided for each reactor. Flows
between vessels are by gravity. Overflow tubes are provided for the 2 nd and 3rd
reactor.

b)

Stirrer System
Variable speed stirrer system with digital display consisting of a motor and a shaft
with impellers made of stainless steel. Speed adjustments by means of a speed
controller knob on each stirrer.

c)

Feed Tanks
Two 15-L cylindrical tanks made of stainless steels are provided with the unit. Each
tank has a feed pump to transfer the liquid from feed tank to the reactors. Each
tank is fitted with a level switch to protect the pumps from dry run.

d)

Waste Tank
A rectangular 50-L waste tank made of stainless steel is provided at the bottom of
the equipment.

e)

Dead Time Coil

Material
:
Volume
:

f)

3/8 stainless steel tubing

approx. 200 ml

Instrumentations
Flowmeter:
Range
Output
Display

:
:
:

Conductivity Meter:
Sensor Range :
No. of Sensors :
Output
:
Display
:

0 to 500 ml/min
0 to 5 VDC
LCD digital display
0 to 200 mS/cm
4 (CT1, CT2, CT3, CT4)
4 to 20 mA
conductivity controller with digital display for each sensor
mounted on the control panel

Temperature Sensor:
No. of Sensors : 3 (TT1, TT2, TT3)
Sensor type
: RTD

SOLTEQ CSTR DYNAMICS (Model: BP 107)

g)

Data Acquisition System

The Data Acquisition System consists of a personal computer, ADC modules and
instrumentations for measuring the process parameters. A flowmeter with 0 to 5
VDC output signal is supplied for feed flowrate measurement. Conductivity sensors
with controller are provided for monitoring the tracer concentration in each reactor.
All analog signals from the sensors will be converted by the ADC modules into
digital signals before being sent to the personal computer for display and
manipulation.

SOLTEQ CSTR DYNAMICS (Model: BP 107)

Figure 1. Process Diagram for CSTR Dynamics (BP 107).

SOLTEQ CSTR DYNAMICS (Model: BP 107)

3.0

SUMMARY OF THEORY
Consider a stirred tank as of Figure 1. The fundamental quantities whose values provide
the information about the dynamics of the system are:
a.
b.
c.

The total mass of the liquid in the tank

The total energy of the material in the tank
Its momentum

Figure 2. Stirred Tank.

Type of Reactor

Characteristics

Continuously Stirred Tank Run at steady state with continuous flow of reactants and products;
Reactor (CSTR)
the feed assumes a uniform composition throughout the reactor, exit
stream has the same composition as in the tank

Kinds of Phases
Present
1. Liquid phase
2. Gas-liquid
rxns
3. Solid-liquid
rxns

Usage
1. When
agitation
required

Advantages
1. Continuous operation
is

2. Series
configurations
for different
concentration
streams

2. Good temperature control

3. Easily adapts to two phase
runs
4. Good control
5. Simplicity of construction
6. Low operating (labor) cost
7. Easy to clean

Disadvantages
1. Lowest
conversion per
unit volume
2. By-passing and
channeling
possible with
poor agitation

SOLTEQ CSTR DYNAMICS (Model: BP 107)

General Mole Balance Equation

V

FA0 FA rAdV
0

dN A
dt

Figure 3.

Assumptions:
1. For steady state dN A dt 0 .
2. Well mixed, therefore rA is the same throughout the reactor.
V

rAdV
0

rA dV

rAV

Rearranging the generation,

FA0 FA
rA

In terms of conversion,
X

FA 0 FA
FA 0

FA 0 X
rA

Reactors in Series
Given rA as a function of conversion, rA = f(X), one can also design any sequence of
reactors in series provided there are no side streams by defining the overall conversion at
any point.

SOLTEQ CSTR DYNAMICS (Model: BP 107)

Xi

moles of A reacted up to point i

moles of A fed to first reactor

Figure 4. Reactors in Series

Mole Balance on Reactor 1:

In Out Generation 0
FA0

FA1 rA1V1 0

X1

FA 0 FA1
FA 0

FA1 FA 0 FA 0 X 1
V1

FA 0 X 1
r A1

Mole Balance on Reactor 2:

In Out Generation 0
FA1 FA2

rA2V2

FA 0 FA 2
FA 0

X2

FA 2

FA 0 FA 0 X 2

V2

FA 0 ( X 2 X 1 )
rA2

SOLTEQ CSTR DYNAMICS (Model: BP 107)

Given rA = f(X), the Levenspiel Plot can be used to find the reactor volume.

Figure 5. Reactor Volume Plot.

Example of Design Equation for Reactor in Series:

Acetic acid is hydrolysed in three stirred tank reactors operated in series. The feed
flows to the first reactor (V = 1 lit) at a rate of 400 cm3/min. The second and third
reactors have volumes of 2 and 1.5 litres respectively. The first order irreversible
rate constant is 0.158 min-1. Calculate the fraction hydrolysed in the effluent from the
third reactor.
Calculations:
The design equation for series, steady flow mixed reactor is
Vi =FAo (XA,i - XA,i-1) / (-rA)i
Where Vi = volume of reactor i
FAo = molal flow rate of A into the first reactor
XA,i = fractional conversion of A in the reactor i
XA,i-1 = fractional conversion of A in the reactor i-1
For first order reaction, -rA,i = kCA,i = kCAo(1 - XA,i)
v = volumetric flow rate of A = 400 cm3/min = 0.4 lit/min
For the first reactor: (V = 1 lit)
(-rA)1 = (kCA)1 = k CA,1 = k CAo ( 1- XA,1)
CAo= FAo / v
i.e., FAo = v CAo
XA,i-1 = XA,0 = 0
Therefore,
Vi =FAo (XA,i - XA,i-1) / (-rA)i
1 = 0.4 (XA,1 - 0) / (0.158 x ( 1 - XA,1 ) )
XA,1 = 0.283

SOLTEQ CSTR DYNAMICS (Model: BP 107)

For the second reactor: (V = 2 lit)

(-rA)2 = (kCA)2 = k CA,2 = k CAo ( 1- XA,2)
Therefore,
(-rA)2 = k CAo ( 1- XA,2)
XA,1 = 0.283
FAo = v CAo
Vi =FAo (XA,i - XA,i-1) / (-rA)i
2 = 0.4 (XA,2 - 0.283) / ( k ( 1- XA,2) )
5 k = (XA,2 - 0.283) / ( 1- XA,2)
0.79 - 0.79 XA,2 = XA,2 - 0.283
1.073 = 1.79 XA,2
XA,2 = 0.60
For the third reactor: (V = 1.5 lit)
(-rA)3= (kCA)3 = k CA,3 = k CAo ( 1- XA,3)
XA,2 = 0.6
FAo = v CAo
Vi =FAo (XA,i - XA,i-1) / (-rA)i
1.5 = 0.4 (XA,3 - 0.60) / ( k ( 1- XA,3) )
0.5925 = (XA,3 - 0.60) / ( 1- XA,3)
0.5925 - 0.5925 XA,3 = XA,3 - 0.60
1.1925 = 1.5925 XA,3
XA,3 = 0.749
The fraction hydrolyzed in the effluent from the third reactor = 0.749

10

SOLTEQ CSTR DYNAMICS (Model: BP 107)

Tracer Analysis on the Transient Behaviour of Continuous Stirred-Tank in Series

Unlike the above, the tracer analysis will help us understand the transient behaviour of the
continuous stirred tank reactor in series by having a step input or pulse of tracer
component such as salts. The conductivity measurement will indicate the progression of
the tracer throughout the stirred tank in series.

Figure 6.

dC i dt (C11 C i ) where V v and V=Tank Volume, v = volume flow rate, and Ci

= concentration in ith Tank. The differential equations must be solved simultaneously.
A real reactor will be modeled as a number of equally sized tanks-in-series. Each tank
behaves as an ideal CSTR. The number of tanks necessary, n (our one parameter), is
determined from the E(t) curve.

Figure 7.

11

SOLTEQ CSTR DYNAMICS (Model: BP 107)

For n tanks in series, E(t) is,

t n 1e t i
E (t )
(n 1) / in

where, i n
It can be shown that

n i

tm

In dimensionless form

t t n i
n t i
n(n ) n 1 e n
E ( ) E (t )
(n 1)

2
2 0 (t ) E (t )d
2

2
2 2 ( 1) 2 E ( )d
0

Carrying out the integration for the n tanks-in-series E(t),

2
n

2
2

1
n

2
2

For a first order reaction,

X 1

1
(1 i k )

, i

For reactions other than first order and for multiple reactions, the sequential
equations must be solved.

12

SOLTEQ CSTR DYNAMICS (Model: BP 107)

Vi
Vi
Vi

n
(C C A1 )
v 0 A0
r A1
v0

(C A1 C A 2 )
rA2

Vi

v0

(C A( n 1) C An )
r An

Example:
For a second order reaction with n = 3,
(V1 = V2 = V3 = V/3)

V3

(C A0 C A )
v0
kC A2

( 1 2 3 )

3 kC A2 C A C A
C A1

1 1 4 3 kC A 0
2 3 k

Similarly,
C A2
C A3

1 1 4 3 kC A1
2 3 k
1 1 4 3 kC A 2

X 1

2 3 k
C A3
,
C A0

13

SOLTEQ CSTR DYNAMICS (Model: BP 107)

Effect of Step Change in Input Concentration to the Concentration of Solute in

Stirred Tank Reactors in Series.
When a step change of solute concentration is introduced at the feed of tank 1, the tank in
series will experience a transient behaviour as of Figure 8 below. The response will be
dependent on the residence time of each reactor in series.

Figure 8a. Step change input.

Figure 8b. Transient response of tank in series

to the step input.

Effect of Pulse in Input Concentration to the Concentration of solute in Stirred Tank

in Series.
When a pulse input of solute concentration is introduced at the feed of tank 1, the transient
behaviour will be different than the step change input due to the diminishing concentration
from the input after pulsing as described in Figure 9.

Figure 9a. Pulse input.

Figure 9b. Transient response of tank in series

to the pulse input.

14

SOLTEQ CSTR DYNAMICS (Model: BP 107)

References
Levenspiel, O., Chemical Reaction Engineering, John Wiley, 1972.
Fogler, H.S., Elements of Chemical Reaction Engineering, 3rd Edition, Prentice Hall PTR, 1999.
Smith, J.M., Chemical Engineering Kinetics, McGraw Hill, 1981.
Astarita, G., Mass Transfer with Chemical Reaction, Elsevier, 1967.

15

SOLTEQ CSTR DYNAMICS (Model: BP 107)

4.

EXPERIMENTAL PROCEDURES
4.1

Experiment A: The Effect of Step Change Input

In this experiment a step-change input would be introduced and the progression of
the tracer will be monitored via the conductivity measurements in all the three
reactors and after the dead time coil.
1.

Fill up the feed tank T1 with deionised water.

2.

Prepare about 10-L of 0.025M sodium chloride solution in feed tank T2.

3.

Set the 3-way valve V3 position towards pump P1. Close valve V6.

4.

Open valve V5. Switch on Pump P1 to initially fill up all three reactors with
deionised water. Record each reactor volume.

5.

Adjust needle valve V4 to obtain a flowrate of approximately 150 ml/min

on flowmeter FT1. Make sure that no air bubbles are trapped in the piping.
Note: It is important to maintain the liquid level in each reactor. Adjust
the flowrate if necessary.

6.

Switch on stirrers 1, 2 and 3. Set the stirrer speed to approximately 200

rpm.

7.

Continue pumping the de-ionized water until all conductivity readings

(CT1, CT2, CT3) are stable at low values.

8.

Record these conductivity values at time t0.

9.

Switch off pump P1. Quickly set the 3-way valve V3 position towards
pump P2. Switch on pump P2 and start the timer simultaneously.

10.

Record all conductivity values (CT1, CT2, CT3) at a suitable interval in an

appropriate table.

11.

Continue recording the conductivity values until all readings are almost
constant.

12.

Switch off pump P2. Close valve V4.

13.

Drain all liquids in each reactor by opening valves V11, V12, and V13.

Note:
For operations with SOLDAS Data Acquisition System, refer to the DAS operating
procedure. In step 9, click the START button. Conductivity values will be recorded
automatically and a table will be generated.

16

SOLTEQ CSTR DYNAMICS (Model: BP 107)

4.2

Experiment B: The Effect of Pulse Input

In this experiment a pulse input would be introduced and the progression of the
tracer will be monitored via the conductivity measurements in all the three reactors
and after the dead time coil.
1.

Fill up feed tank T1 with deionised water.

2.

Prepare about 10-L of 0.025M sodium chloride solution in feed tank T2.

3.

Set the three-way valve V3 position towards pump P1. Close valve V6.

4.

Open valve V5. Switch on Pump P1 to fill up all three reactors with
deionised water. Record each reactor volume.

5.

Adjust needle valve V4 to obtain a flowrate of approximately 150 ml/min

on flowmeter FT1. Make sure that no air bubbles are trapped in the piping.
Note: It is important to maintain the liquid level in each reactor. Adjust
the flowrate if necessary.

6.

Switch on stirrers 1, 2 and 3. Set the stirrer speed to approximately 200

rpm.

7.

Continue pumping the deionised water until all conductivity readings (CT1,
CT2, CT3) are stable at low values.

8.

Record these conductivity values at time t0.

9.

Switch off pump P1. Quickly set the 3-way valve V3 position towards
pump P2. Switch on pump P2 and start the timer simultaneously.

10.

Let pump P2 to operate for 2 minutes, and then switch off pump P2.
Quickly switch the 3-way valve V3 position back towards pump P1. Switch
on pump P1 and let it run till the end of experiment.

11.

Record all conductivity values (CT1, CT2, CT3) at a suitable interval in an

appropriate table.

12.

Continue recording the conductivity values until all readings are almost
constant.

13.

Switch off pump P1. Close valve V4.

14.

Drain all liquids in reactors by opening valves V11, V12 and V13.

Note:
For operations with SOLDAS Data Acquisition System, refer to the DAS operating
procedure. In step 9, click the START button. Conductivity values will be recorded
automatically and a table will be generated.

17

SOLTEQ CSTR DYNAMICS (Model: BP 107)

4.3

Experiment C: The Investigation on Dead Time Coil

In this experiment the modeling of real (non-ideal) reactor can be accomplished by
assembling the CSTR and dead time coil in parallel. A pulse input would be
introduced in such a way that a fraction of it passes through the coil. This is
analogous to the existing of a stagnation zone in a real reactor. Then, the
progression of the tracer will be monitored via the conductivity measurements at
the exit.
1.

Fill up feed tank T1 with de-ionized water.

2.

Prepare about 10-L of 0.025M sodium chloride solution in feed tank T2.

3.

Set the three-way valve V3 position towards pump P1.

4.

Open valves V6 and V10. Close valves V5 and V15. Switch on Pump P1
and allow the liquid to flow slowly through the coil for few minutes to bleed
off any air trapped.

5.

Close valve V10. Open valve V15.

6.

Adjust needle valve V4 to obtain a flowrate of approximately 150 ml/min

on flowmeter FT1. Make sure that no air bubbles are trapped in the piping.
Note: It is important to maintain the liquid level in reactor R3. Adjust the
flowrate if necessary.

7.

Switch on stirrer 3. Set the stirrer speed to approximately 200 rpm.

8.

Continue pumping the de-ionized water until conductivity reading (CT3) is

stable at low values.

9.

Record this conductivity value at time t0.

10.

Switch off pump P1. Quickly set the 3-way valve V3 position towards
pump P2. Switch on pump P2 and start the timer simultaneously.

11.

Let pump P2 to operate for 2 minutes, and then switch off pump P2.
Quickly switch the 3-way valve V3 position back towards pump P1. Switch
on pump P1 and let it run till the end of experiment.

12.

Record conductivity value (CT3) at a suitable interval (e.g. 30 sec) in an

appropriate table.

13.

Continue recording the conductivity value until readings are almost

constant.

14.

Repeat the experiment (steps 5 to 13) but this time allow the liquid to
partially flow through the dead time coil. This is done by adjusting valve
V15 to get the right flow while valve V10 remains open.

15.

Stop the experiment and drain all liquids in reactors by opening valves
V11, V12 and V13.

Note:
For operations with SOLDAS Data Acquisition System, refer to the DAS operating
procedure. In step 10, click the START button. Conductivity values will be recorded
automatically and a table will be generated.

18

SOLTEQ CSTR DYNAMICS (Model: BP 107)

5.

6.

MAINTENANCE
1.

After each experiment, drain off any liquids from the reactor and make sure that
the reactor and tubings are cleaned properly. Flush the system with de-ionized
water until no traces of salt are detected.

2.

Dispose all liquids immediately after each experiment. Do not leave any solution or
waste in the tanks over a long period of time.

3.

Wipe off any spillage from the unit immediately.

SAFETY PRECAUTIONS
1.

Always observe all safety precautions in laboratory.

2.

Always wear protective clothing, shoes, helmet and goggles throughout the
laboratory session.

3.

Always run the experiment after fully understand the equipment and procedures.

4.

Always plug in all cables into appropriate sockets before switching on the main
power on the control panel. Inspect all cables for any damage to avoid electrical
shock. Replace if necessary.

5.

Make sure that the stirrer assembly is secured properly. Avoid excessive load to
the electrical motor to prevent damage.

6.

Inspect the unit, including tubings and fittings, periodically for leakage and worn
out. Leakage might cause damage to equipments by corrosive chemical in the long
run.

19

SOLTEQ CSTR DYNAMICS (Model: BP 107)

APPENDIX

20