Solid Fluid Reactor Design

Solid Fluid Reactors

Three factors control design: Reaction kinetics for single particles The size distribution of solids being treated The Flow patterns of solids an fluids

Frequently these parameters are difficult to measure therefore idealized systems are used Solids and gas both in plug flow Counter-current Cross-current Co-current

Solid Fluid Reactors

Solid Fluid Reactors

Solids in Mixed Flow: The Fluidized bed.

Gas flow difficult to characterize, often worse than mixed.

Solids have high Cp assume isothermal

Semibatch Operations: Ion exchange column

Solid bed
Fluid plug flow

Batch operations Reaction and dissolution of solids, e.g. acid attack of a solid.

Solid Fluid Reactors

Various assumptions are taken to simplify the design of solid fluid systems. Composition of fluid can be considered to be uniform throughout the reactor Reasonable approximation where Fractional conversion of fluid-phase reactants are not too great Fluid backmixing is considerable Solids wander about the reactor

Number of frequently met contacting patterns will be discussed:

1. Particle of Single Size, Plug flow of solids, Uniform gas composition Contact time or reaction time needed for any specific conversion of solid is found directly from the Conversion-Time Expressions for Various Shapes of Particles, Shrinking-Core Model.

Solid Fluid Reactors

2. Mixture of Particles of Different but Unchanging Sizes, Plug Flow of Solids, Uniform Gas Composition Solid feed consisting of a mixture of different-size particles

Discrete distribution used to measure size distribution

Let F = volumetric/mass feed rate (where density change is neg.) Therefore, let F(Ri) = quantity of mat of size Ri fed to reactor If Rm is the largest particle size in the feed:

=
=0

3 () ,

Solid Fluid Reactors

2. Mixture of Particles of Different but Unchanging Sizes, Plug Flow of Solids, Uniform Gas Composition Solids stay in reactor for same length of time, tp

From this and resistance controls, the conversion XB(Ri) can be found which leads to the mean conversion :
=

1 =

(=)

() [1 ]

, = . = .

Solid Fluid Reactors

EXAMPLE 1: Conversion of a size mixture in Plug Flow A feed consisting of 30 % of 50 um radius particles 40 % of 100 um radius particles 30 % of 200 um radius particles

is to be fed continuously in a thin layer onto a moving grate crosscurrent to a flow of reactant gas. For the planned operating conditions, the time required for complete conversion is 5, 10 and 20 minutes for the three sizes of particles. Find the conversion of solids on the grate for a residence time of 8 mins in the reactor.

Solid Fluid Reactors

EXAMPLE 1: Conversion of a size mixture in Plug Flow From:

1 =
(=)

() [1 ]

1 = 1 50

50 100 + 1 100 +

(50 ) 200 100 & = 0.30; = 0.40

50 = 5 ; 100 = 10 ; 200 = 20 1: 2: 3 = 1: 2: 3
1 = 1 ()
3

Solid Fluid Reactors

EXAMPLE 1: Conversion of a size mixture in Plug Flow 1 1 = 1 (50 ) 8 = 1 5
3 3

(50 ) + 1 (100 )
3

(100 ) +

8 0.30 + 1 10

8 0.40 + 1 20

0.30

1 = 0 + 0.0032 + 0.0648 = 0.068

, 93.2 %
.

Solid Fluid Reactors

3. Mix Flow of Particles of Single Unchanging Sizes, Uniform Gas Composition Consider the fluidized bed reactor, constant flow of solids and gas into and out of reactor.

Since length of stay of particles not the same, mean conversion of material is calculated:
+

: 1 =
0

, ( )

Solid Fluid Reactors

3. Mix Flow of Particles of Single Unchanging Sizes, Uniform Gas Composition , :

1 =
0

1 =
0

Solid Fluid Reactors

3. Mix Flow of Particles of Single Unchanging Sizes, Uniform Gas Composition

1 =
0

1 =
0

; = 1

= 1

, /, : 1 1 1 = 2! 3!
2

1 + 4!

2 3 4 = 1 + + + + + 2! 3! 4!

Solid Fluid Reactors

3. Mix Flow of Particles of Single Unchanging Sizes, Uniform Gas Composition :

1 =
0

1 =
0

; = 1
2

= 3 6

+6

, /, : 1 1 1 = 4 20
2

1 + 120

2 3 4 = 1 + + + + + 2! 3! 4!

Solid Fluid Reactors

3. Mix Flow of Particles of Single Unchanging Sizes, Uniform Gas Composition :

1 =
0

= 1 3 1

2 3

+ 2(1 )

: 1 19 1 = 5 450
2

41 + 4620

0.00149

Solid Fluid Reactors

Solid Fluid Reactors

EXAMPLE 2: Conversion of a Single-sized feed in a Mixed Flow Reactor

Iron sulfide (pyrrhotite) particles were roasted and dispersed in asbestos fibers. It was found that the time for complete conversion was related to particle size as follows: 1 5 Particles remained as hard solids of unchanging size during reaction.
.

A fluidized-bed reactor is planned to convert pyrrhotite ore to the corresponding oxide. The feed is to be uniform in size, = 20 mins, with mean residence time = 60 mins in the reactor.
What fraction of original sulfide ore remains unconverted?

Solid Fluid Reactors

EXAMPLE 2: Conversion of a Single-sized feed in a Mixed Flow Reactor Since hard product material formed film diffusion can be ruled out as controlling resistance.

Can expect chemical reaction and ash layer diffusion as controlling:

For chemical reaction controlling: For ash layer diffusion controlling: 2 As experimentally diameter dependency lies between these two values, reasonable to expect both mechanisms offer resistance. The solids in fluidized bed approximate mixed flow; hence: For chemical reaction controlling: 1 1 1 = 4 20
2

1 + 120
2

1 20 1 20 1 = 4 60 20 60

1 20 + 120 60

= 0.078

Solid Fluid Reactors

EXAMPLE 2: Conversion of a Single-sized feed in a Mixed Flow Reactor For ash layer diffusion controlling: 1 19 1 = 5 450
2

41 + 4620
2

0.00149
3

1 20 19 20 1 = 5 60 450 60

41 20 + 4620 60

20 0.00149 60

+ = 0.062

Therefore, the fraction of sulfide remaining is between 6.2 % and 7.8 % or on averaging: 1 0.07 7.0 %

Solid Fluid Reactors

4. Mix Flow of a Size Mixture of Particles of Unchanging Size, Uniform Gas Composition Often the range of particle sizes is used as feed to a mixed flow reactor.

This method leads to the combination of:

1 =
(=)

1 =

Solid Fluid Reactors

4. Mix Flow of a Size Mixture of Particles of Unchanging Size, Uniform Gas Composition

() () = = , = .

Solid Fluid Reactors

4. Mix Flow of a Size Mixture of Particles of Unchanging Size, Uniform Gas Composition In addition, the mean residence time, of material of any size Ri is equal to the mean residence time of solid in the bed: ( ) = = = ( ) Let be the mean conversion of particles of size Ri in the bed, we have:
()

1 () =
0

[1 ()]

However the feed consists of particles of different sizes; hence the overall mean of B unconverted in all these sizes is:

Solid Fluid Reactors

4. Mix Flow of a Size Mixture of Particles of Unchanging Size, Uniform Gas Composition In symbols: 1 = 1
=0

Combining for film diffusion controlling:

1 1 1 = 2! 3!
2

1 + 4!

We obtain:

1 =

1 () 1 () 2! 3!

1 () + 4!

Similarly we obtain for chemical reaction controlling:

1 =

1 () 1 () 4 20

1 () + 120

And for ash diffusion controlling:

1 =

1 () 19 () 5 420

41 () + 4620

Solid Fluid Reactors

EXAMPLE 3: Conversion of a Feed Mixture in a Mixed Flow Reactor A feed consisting of: 30 % of 50 um radius particles 40 % of 100 um radius particles

30 % of 200 um radius particles

Is to be reacted in a fluidized-bed steady state flow reactor constructed from a vertical 2-m long 20-cm ID pipe. The time required for complete conversion is 5, 10 and 20 minutes for the three sizes of feed.

Find the conversion of solids in the reactor for a feed rate of 1 kg solids/min if the bed contains 10 kg solids.
Additional information: The solids are hard an unchanged in size and weight during reaction A cyclone separator is used to separate and return to the bed any solids that may be entrained by the gas The change in gas-phase composition in the bed is small.

Solid Fluid Reactors

EXAMPLE 3: Conversion of a Feed Mixture in a Mixed Flow Reactor Solids in mixed flow As with Example 1, R1:R2:R3 =1:2:3, chemical reaction controls Therefore for a mixed flow reactor with a feed of mixture of sizes:

1 =

1 () 1 () 4 20

1 () + 120

, = 1

, = 10 10 = = 10 1 50 = 5

, = : 50 = 0.3 /

100 = 0.4 / 100 = 10

200 = 0.3 / 200 = 20

Solid Fluid Reactors

EXAMPLE 3: Conversion of a Feed Mixture in a Mixed Flow Reactor

1 =

1 () 1 () 4 20
2

1 () + 120

1 5 1 5 1 = 4 10 20 10

0.3 / + 1 /
2

1 10 1 10 + 4 10 20 10 1 20 1 20 + 4 10 20 10

0.4 / + 1 / 0.3 / + 1 /

1 1 1 1 1 1 1 1 2 = + 0.3 + + 0.4 + + + 0.3 8 80 4 20 120 2 5 15 10 = 0.034 + 0.083 + 0.105 = 0.222 = 77.8%

Solid Fluid Reactors

EXAMPLE 4: Finding the Size of a Fluidized Bed In a gas-phase environment, particles of B are converted to solid product as follows: + + () Reaction proceeds according to shrinking core model with reaction control and time for complete conversion of particles is 1 hr. A fluidized bed is to designed to treat 1 ton/hr of solids at 90 % conversion using a stoichiometric feed rate of A, fed at CAO. Find the weight of solids in the reactor is gas is assumed to be in mixed flow.

Solid Fluid Reactors

EXAMPLE 4: Finding the Size of a Fluidized Bed In a CAO environment with reaction controlling: = = 1

And in any other environment,

For equal stoichiometric feed XA=. Thus the gas leaving is at 0.1 CAO (at 90 % conversion). Since the gas is mixed flow, CA = 0.1CAO, the solids see this exit gas, or =10 hrs. 1 1 2 1 3 From 1 = + = 0.9 4 20 120 = 0.435 = = 23 By trial and error, we find Thus, the needed weight of bed is = = 23 1 = 23

Solid Fluid Reactors

5. Instantaneous reaction When reaction between gas and solid is fast enough that at any volume element contains only one or other of the two reactants, but not both, then the reaction is considered instantaneous, e.g. high temperature combustion with finely divided solids.

Batch solids
Batch of solids contacted with gas, e.g. packed or fluidized bed. In both cases, gas leaving is fully converted.

When all solids are consumed, conversion of gas drops to zero.

Solid Fluid Reactors

Countercurrent Plug Flow of Gas and Solids

Sharp reactant plane where reactants meet. Occur either end of reactor depending on which feed stream is in excess of stoichiometry. (a) A little less gas entering reactor

(b) A little more gas entering reactor

(c) Slight excess of gas enters but removed a bit more than excess at reaction zone.

Solid Fluid Reactors

Cocurrent and Crosscurrent Plug Flow of Gas and Solids

(a) Co-current, reaction occurs at the feed end. Poor method of contacting with regards to heat utilization and pre-heating of entering materials. (b) Cross-current, Definite reaction plane in the solids whose angle depends on stoichiometry and the relative feed rate of reactants. Mixed Flow of Solids and Gas Either gas or solids will be completed converted depending on which stream is in excess.