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Conversion and Reactor Sizing

1) The document discusses sizing continuous stirred-tank reactors (CSTRs) and plug flow reactors (PFRs) given a rate of reaction equation dependent on conversion. 2) It derives the design equations for these reactor types by writing mole balance equations in terms of conversion and relating the change in conversion to reactor volume. 3) The key design equations are: for a CSTR, the volume needed for a given conversion is determined by the feed rate and rate of reaction equation; for a PFR, the volume is found by integrating the rate equation with respect to conversion from 0 to the desired conversion.

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Jiana Nasir
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55 views19 pages

Conversion and Reactor Sizing

1) The document discusses sizing continuous stirred-tank reactors (CSTRs) and plug flow reactors (PFRs) given a rate of reaction equation dependent on conversion. 2) It derives the design equations for these reactor types by writing mole balance equations in terms of conversion and relating the change in conversion to reactor volume. 3) The key design equations are: for a CSTR, the volume needed for a given conversion is determined by the feed rate and rate of reaction equation; for a PFR, the volume is found by integrating the rate equation with respect to conversion from 0 to the desired conversion.

Uploaded by

Jiana Nasir
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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CHAPTER 2:

Conversion and Reactor


Sizing
Objective: To size CSTRs and PFRs given the rate of reaction as a function
of conversion and to calculate the overall conversion and reactor
volumes for reactors in series

KC32203 Chemical
Reaction Engineering
Previously, we learn about…..
• Definition:
– Rate of rxn
– Rate equation
– Rate of generation
• Mole balance eqn of reactors:
– Batch
Refer Reactor
– Continuous Flow Mole Balance
• CSTR Table!
• PFR(Tubular)
• PBR

KC32203 Chemical
Reaction Engineering
Summary of Reactor Mole Balances

Note: Steady state – cond. Do not change with time


No spatial variations – perfect mixing
KC32203 Chemical
Reaction Engineering
Today’s Lecture:

1) Evaluate mole balance eqn to


size CSTRS & PFRs
2) How???: Design
Equation
• Define conversion
• Rewrite balance eqn in terms of
conversion
3) Size the reactor
• Find vol to achieve specified
conversion (Given –rA = f(X)
• Compare CSTRs and PFRs
• Overall conversions for reactor to be
arranged in series

KC32203 Chemical
Reaction Engineering
PART 1:
Derive Design Equation

KC32203 Chemical
Reaction Engineering
2.1 Conversion
Stoichiometric
Coefficients (lowercase) Chemical species
Consider general rxn: (uppercase)

Take A as basis, divide by a; per


mole of
A basis

How many moles of C formed, when every moles of A is consumed????


Therefore, conversion;

Irreversible rxn: max X = 1 (complete conversion)


Reversible rxn: max X = equilib X (Xmax = Xe)
KC32203 Chemical
Reaction Engineering
2.2 Design Equations for Batch Reactor
NA0 = initial no of moles of A
Consider this equation: NA0X = total no of moles of A that has reacted

No of moles of A remained after time, t

KC32203 Chemical
Reaction Engineering
Rearrange:

For batch, when there


no spatial variation
(perfect mixing)

Mole balance from Eqn 1-5:

A is disappearing, hence multiply Eqn 2-5 with -1

* Note also rate of disappearance


can be given like this!

KC32203 Chemical
Reaction Engineering
How long the reactant should be in a reactor to achieve desired X???

No of moles of A after conversion X;

Differentiate with respect to time, t:

𝑑𝑋 Differential form
Note: There are 𝑁𝐴𝑂 =−𝑟𝐴 𝑉 (2-6)
missing variables 𝑑𝑡 of design equation
in text book!

KC32203 Chemical
Reaction Engineering
For a constant vol batch reactor, V = Vo

Rearrange Eqn 2-5

To yield

To find the time for a desired X, rearrange Eqn 2-6

Integrate with limit


starting with t= 0 and
X=0

Integral form of
design equation
2.3 Design Equations for Flow Reactors
• For batch, X increase
with t
• For cont – flow, X
increases with V

Consider this equation:


FA0 = Molar flow rate of A fed
FA0X = Molar flow rate of A
reacting in syst

Molar flow rate of A leaving the syst:

Rearrange, to yield:
Important note!
Entering molar flow rate (mol/s) Entering conc (mol/dm3) Entering vol flow (dm3/s)

Liquid phase (usually in


terms of molarity for eg:
2 mol/dm3)

For a gas system (on ideal


gas)

The entering molar flow rate is:

KC32203 Chemical
Reaction Engineering
Lets go through one example! Use ideal gas law to
calculate CA0 and FA0
Example 2-1

Solution:

KC32203 Chemical
Reaction Engineering
Since pure A enters, total P and partial P are same!

Entering molar flow rate, FA0 can be calculated by:

Will be used in Examples


2-2 until 2-5

Note that:

KC32203 Chemical
Reaction Engineering
2.3.1 CSTR (Backmix Reactor or Vat)
For a perfect mixing (no spatial variations in reactor).
Recall CSTR mole balance (Eqn 1-7)

Apply to;

And rearrange;

KC32203 Chemical
Reaction Engineering
Simplify;

Hence, the vol. necessary to achieve desired X;

For a perfectly mixed reactor:


• Exit composition = Inside
composition
• - rA is evaluated at exits!

KC32203 Chemical
Reaction Engineering
2.3.2 Tubular Flow Reactor (PFR)
Consider mole balance Eqn of PFR
Multiply both sides with -1

We know;

Differentiate

Substitute into Eqn 2-14, to yield;

Differential form of
design equation
KC32203 Chemical
Reaction Engineering
To find the vol. necessary to achieve desired X,

Integrate Eqn. 2-15 with


limit starting with V = 0
and X = 0

(2-16)

To do integration for design eqn of:


• Batch (Eqn 2-9)
Need to know
• Plug flow reactor (Eqn 2-16)
how –rA varies
To evaluate CSTR design eqn (2-13): with CA (also X)

KC32203 Chemical
Reaction Engineering
2.3.3 Packed-Bed Reactor
Design eqn. derivation is similar to PFR (Refer Eqn 2-15 and 2-16)

Substitute Eqn 2-12 into 1-15

To yield;
PBR
design equation
If the pressure
drop, P = 0; Eqn
2-17 can be
integrated with
X = 0 at W = 0

KC32203 Chemical
Can calc W necessary for desired X, when P = 0 With pressure drop???
Reaction Engineering

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