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CDB2043 REACTION ENGINEERING
CHAPTER 2: CONVERSION AND
REACTOR SIZING
(part 1)
Basic
knowledge
Application
CHAPTER 2
Relating mole
balance to
conversion
Re-write
reactor sizing
in terms of
conversion
APPLYING
DESIGN
EQUATION TO
SOLVE
PROBLEMS
RELATED TO
FLOW REACTOR
AND REACTOR
IN SERIES
CSTR
PFR
PBR
dN A
rAV
dt
What is conversion?
Consider the general equation (irreversible eqn)
aA + bB cC + dD
We will choose A as our basis of calculation
b
c
d
A B C D
a
a
a
How do we define
conversion?
Conversion
Conversion is define as:
moles of A reacted
XA
moles of A feed
MAXIMUM CONVERSION?
Irreversible Reaction
Reversible Reaction
X=1
X = Xe
NA
N A0 - N A0 X
FA
FA0 - FA0 X
Relating V to X
Now, recap back our design equation:
dN A
rAV
dt
WHAT WE HAVE JUST
DISCOVERED:
NA
N A0 - N A0 X
FA
FA0 - FA0 X
HOW TO REWRITE
V = f(X)
PFR
Design Equation
(Summary)
Reactor
Batch
CSTR
PFR
PBR
Differential
Algebraic
Integral
13
FA0/-rA
FA0/-rA
X
14
FA0 X
V
rA
FA0
dX
rA
dV
XA
-rA (mol/m3.s)
1.
0.0
0.45
0.1
0.37
0.2
0.30
0.4
0.195
0.6
0.113
0.7
0.079
0.8
0.05
2.
3.
17
1
FA0 X
V
rA
XA
-rA (mol/m3.s)
1/-rA
3.
(m .s/mol)
FA0/-rA
(m3..s/mol)
0.0
0.45
2.22
0.89
0.1
0.37
2.70
1.08
0.2
0.30
3.33
1.33
0.4
0.195
5.13
2.05
0.6
0.113
8.85
3.54
0.7
0.079
12.70
5.06
0.8
0.05
20.00
8.00
0.8
FA0
dX
rA
XA
-rA
(mol/m3.s)
FA0/-rA
(m3..s/mol)
0.0
0.45
0.89
0.2
0.30
1.33
0.4
0.195
2.05
0.6
0.113
3.54
0.8
0.05
8.00
X4
X0
f X dX
h
f0 4 f1 2 f 2 4 f3 f 4
3
X4 X0
h
4
Volume
CSTR
Volume PFR
Reactors in Series
Knowing rA = f(XA), we can design any sequence of
reactors
Provided theres no side reactors, conversion at any
reactor outlet is define as:
Xi
Reactors in series
2 CSTR in series
FA1
X1=0.4
FA0
10
FA0/-rA
6
4
FA2
X2=0.8
2
0
0
0.1
0.2
0.3
0.4
0.5
Conversion, X
0.6
0.7
0.8
0.9
2 PFR in series
10
8
FA0/-rA
FA1
X1=0.4
FA0
1
6
4
2
0
FA2
X2=0.8
0.1
0.2
0.3
0.4
0.5
Conversion, X
0.6
0.7
0.8
0.9
Equals to
1
As no. of CSTR in series increases, the total volume required for a given
conversion is similar to the volume of one PFR
10
CSTR 5
8
FA0/-rA
CSTR 4
6
CSTR 3
4
CSTR 2
CSTR 1
PFR
0
0
0.2
0.4
0.6
Conversion, X
0.8
Reactors in series
Example 2-5: Comparing volumes for CSTR in
series
From data below, calculate the volume of CSTR if 2 CSTR in series
is use for the reaction. Given that the intermediate conversion is
40% and the final conversion is 80%. Then, use the Levenspiel
plot to help you explain on the difference of the reactor volume for
single CSTR and CSTR in series.
Will there be any difference in volume if the reaction is carried out
in 2 PFR in series? Use the Levenspiel plot to explain your answer.
X
0.0
FA0/-rA 0.89
0.1
0.2
0.4
0.6
0.7
0.8
1.09
1.33
2.05
3.54
5.06
8.0
2.0m 3
rA X 0.4
V1 2.0m 3 0.4
10
V1 0.8m 3
FA0/-rA
FA0
8.0m 3
rA X 0.8
FA0
X 2 X 1
V2
rA2
V2 8.0m 3 0.8 0.4 3.2m 3
6
4
2
0
0
0.1
0.2
0.3
0.4
0.5
Conversion, X
0.6
0.7
0.8
0.9
Reactors in series
Example 2-6: Sizing plug flow reactors in series
Redo Example 2-5 but using 2 PFR in series. The
intermediate and final conversion remains the same. The
f ( x)dX
X0
0.4
V1 FA0
0
dX
rA
X
f X 0 4 f X 1 f X 2
3
0.8
dX
rA
0.4
V2 FA0
FA0
FA0
FA0
FA0
FA0
X FA0
r
(
0
)
r
(
0
.
2
)
r
(
0
.
4
)
A
A
A
V2
3 rA (0.4)
rA (0.6) rA (0.8)
0.2
0.89 41.33 2.05m3 0.551m3
V1
0.2
3
2.05 43.54 8.0m3 1.614m3
V1
3
V1
X
3
Reactors in series
Example 2.7 An adiabatic liquid phase isomerisation
The isomerisation of butane was carried out adiabatically in
the liquid phase and the data in Table 2-7 was obtained. The
entering molar flow rate of n-butane of 50 kmol/hr.
Table 2-7
X
-rA (kmol/m3.hr) 39
0.2
0.4
0.6
0.65
53
59
38
25
Reactors in series
V1
X2=0.6
X1=0.2
X3=0.65
Figure E2-7.1
FA0/-rA
2.00
1.50
1.00
0.50
CSTR
0.00
0.00
0.10
0.20
PFR
0.30
0.40
0.50
0.60
0.70
Conversion, X
1st CSTR
33
PFR
2nd CSTR
rA rB rC rD
a
b
c
d
Space time
Also know as Mean Residence Time or Holding Time
Defined as the time necessary to process one reactor volume of fluid based on
entrance condition (volumetric flow rate)
Volume of reactor
Fluid
Volumetric flowrate
Reactor
Space time = time it for the fluid to enter the reactor completely
END OF LECTURE
37