Series 5400 Continuous Flow Tubular Reactors

Series Number:

5400
Type:

Bench Top, Cart, or Floor Stand

Vessel Sizes, mL:

ubular reactors are always used in a continuous flow mode with reagents flowing in and products being removed. They can be the simplest of all reactor designs. Tubular reactors are often referred to by other names: Pipe reactors Packed-bed reactors Trickle-bed reactors Bubble-column reactors Ebulating-bed reactors Single-phase flow in a tubular reactor can be upward or downward. Two-phase flow can be co-current up-flow, counter-current (liquid down, gas up) or, most commonly, co-current down-flow. Tubular reactors can have a single wall and be heated with an external furnace or they can be jacketed for heating or cooling with a circulating heat transfer fluid. External furnaces can be rigid, split-tube heaters or be flexible mantle heaters. Tubular reactors are used in a variety of industries: Petroleum Petrochemical Polymer Pharmaceutical Waste Treatment Specialty Chemical Alternative Energy Tubular reactors are used in a variety of applications: Carbonylation Dehydrogenation Hydrogenation Hydrocracking Hydroformulation Oxidative decomposition Partial oxidation Polymerization Reforming Tubular reactors may be empty for homogenous reactions or packed with catalyst particles for heterogeneous reactions. Packed reactors require upper and lower supports to hold particles in place. Uppermost packing is often of inert material to serve as a pre-heat section. Preheating can also be done with an internal spiral channel to keep incoming reagents close to the heated wall during entry, as shown above.

15 mL - 300 mL
Standard Pressure Rating MAWP, psi (bar):

1500 (103), 3000 (207), or 5000 (345)

Maximum Operating Temperature, C:

350 or 550

5402 Tubular Reactor System

It is often desirable to size a tubular reactor to be large enough to fit 8 to 10 catalyst particles across the diameter and be at least 40-50 particle diameters long. The length to diameter ratio can be varied to study the effect of catalyst loading by equipping the reactor with spools to change this ratio. Temperature is typically controlled by thermocouples located on the outer wall of an externally heated tubular reactor. A moveable internal thermocouple is often employed to observe the temperature changes occurring as the reaction proceeds through the reactor. Tubular reactor systems are highly customizable and can be made to various lengths and diameters and engineered for various pressures and temperatures. We provide a split-tube furnace for heating these vessels. Insulation is provided at each end so that the end caps are not heated to the same

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Series 4590 Micro Reactors

Series 5400 Tubular Reactor System Specifications Shaded bar indicates specifications that change within series. Model Number Sizes O.D. / I.D. (in.) O.D. / I.D. (mm) Heated Length (in.) Max. Pressure (psi) Max. Temperature Support Spools Spiral Pre-Heat No. Ports in Top Head No. Ports in Bottom Head Internal Thermocouple

5401
3/8 in. 0.38/0.28 9.5/7.0

5402
1/2 in. 0.50/0.37 13/9.4 3000 550 No No 1 1 Yes

5403
1.0 in. 1.9/1.0 48/25 5000 550 Yes Yes 4 4

5404
1.5 in. 2.0/1.5 51/38 3000 350

6, 12, 24

12, 24, 36

When ordering mass flow controllers, you will need to specify: 1. Type of gas to be metered (e.g. N2, H2, CH4) 2.  Maximum operating pressure of the gas (100 or 300 bar) 3.  Maximum flow rate range in standard ccs per minute (sccm) 4. Pressure for calibration of the instrument
3-Zone Split Tube Furnace with 1" I.D. Tubular Reactor.

temperature as the core of the reactor. The heater length is normally divided into one, two, or three separate heating zones, although it can be split into as many zones as required. We can furnish either a fixed internal thermocouple in each zone or a single movable thermocouple that can be used to measure the temperature at points along the catalyst bed. External thermocouples are typically provided for control of each zone of the heater. Gas Feed Systems Various gas feeds can be set up and operated from a Gas Distribution Panel. In order to deliver a constant flow of gas to a reactor, it is necessary to provide gas at a constant pressure to an electronic Mass Flow Controller. This instrument will compare the actual flow rate delivered to the set point chosen by the user, and automatically adjust an integral control valve to assure a constant flow. Care must be taken to size these controllers for the specific gas, the flow rate, and the pressure of operation. A mass flow controller needs a power supply and read-out device, as well as a means of introducing the desired set point.
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Mass flow controllers are available for use to 1500 psi and to 4500 psi. Considerable savings can be obtained if the mass flow controller is to be used only to 1500 psi. The schematic at right depicts the installation of a mass flow controller for the introduction of Gas gas to a continuous-flow reaction system. Such installations are enhanced with the addition of a by-pass valve for rapid filling. A purge line can also be added. It is typically used for feeding nitrogen or helium to Gas remove air before reaction or to remove reactive gases before opening the reactor at the end of a run. The purge line includes a shut-off valve, metering valve, and a reverse-flow check valve. Shut-off valves can be automated when using a 4871 Control system. Liquid Metering Pumps High pressure piston pumps are most often used to inject liquids into a pressurized reactor operating in a continuous-flow mode. For low flow rates, HPLC pumps, many of which are rated for 5000 psig, are excellent choices.

FIC F MFC

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Series 5400 Continuous Flow Tubular Reactors

Tubular Reactor System on Floor Stand with 3-zone Flexible Mantle Heater, one Mass Flow Controller, one Liquid Pump, and a High Pressure Gas/Liquid Separator.

Tubular Reactor System on Cart with Flexible Mantle Heater, two Mass Flow Controllers, one Liquid Pump, and Manual Back Pressure Regulator.

Typical flow rates for pumps of this type range up to 10 or 40 mL per minute. Pumps are available to accommodate manual control from their digital faceplate or computer-control from a 4871 Process Controller. Chemical feed pumps are our recommendation for continuous feeding of liquids when the desired flow rate is greater than 2 liter per hour. Parr can assist with the feed pump selection. We will need to know the type of liquid; the minimum, typical, and maximum desired feed rate; the maximum operating pressure; and any special operating considerations such as explosion proof operation or corrosion possibilities. Back Pressure Regulators In addition to supplying gases to a reaction through electronic mass flow controllers, the reactor is kept at a constant pressure by installing a Back Pressure Regulator (BPR) downstream of the reactor. This style of regulator will release products only when the reactor pressure exceeds a preset value.
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When a BPR is used in conjunction with mass flow controllers, the user is assured that a constant flow of gas is passing through a reactor, which is being held at a constant pressure. This provides for the highest degree of control and reproducibility in a continuous-flow reactor system. Cooling Condensers It is often desired to cool the products of the reaction prior to handling them. For this purpose, tube-and-shell heat exchangers are available to act as the cooling condensers. An adaptation of our standard condensers provides an excellent design. Descriptions and available sizes are found on our web site at www.parrinst.com. Gas/Liquid Separators Tubular reactors operating in continuous-flow mode with both gas and liquid products will also require a Gas/Liquid Separator for smooth operation. The separator is placed downstream
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of the reactor, often separated from the reactor by a cooling condenser. In the separator vessel, liquids are condensed and collected in the bottom of the vessel. Gases and non-condensed vapors are allowed to leave the top of the vessel and pass to the back pressure regulator. It is important to operate the BPR with a single fluid phase to prevent oscillation of the reactor pressure. The gas/liquid separator can be sized large enough to act as a liquid product receiver that can be manually drained periodically. Many of the non-stirred pressure vessels made by Parr are ideally suited for use as gas/liquid separators. Vessels of 300, 600, 1000, or 2000 mL are commonly chosen. Control and Data Acquisition Systems A variety of solutions exist to meet the needs of system operators. System accessories such as heaters, mass flow controllers, and pumps can be obtained with individual control packages to create a manual, Distributed Control System (DCS). As the number of channels to be controlled increases, economics and convenience will often dictate that the distributed system of individual controllers should be replaced with the computer-based Model 4871 Process Controller (PCC). This controller is described in detail on our web site at www.parrinst.com.

This Continuous Flow Stirred Reactor System is on a Cart with our new Modular Frame System. This modular frame allows for easy access and flexibility for components in the feed and product handling systems.

< This 3-zone tubular reactor system is specially equipped for hydrogenating materials resulting in the following products: Longer chain alpha and internal olefins (>C6). These materials are used for the production of alcohols used largely in detergents and plastics for making polyalphaolefins used in synthetic lubricants and oil field drilling applications. Long chain (>C9) dicarboxylic acids (diacids) and olefin / carboxylic monomers & derivatives. These materials are used in producing nylon, coatings, adhesives, greases, polyesters, dyestuffs, detergents, flame retardants, and fragrances. Esters for lubricants, surfactants, personal care and other applications. Fatty esters have diverse applications. They are employed as emulsifiers, emollients or lubricants in many and diverse industrial applications such as food, personal care, plastics, synthetic lubricants, metal treatment, pharmaceuticals, agrochemicals, paints and textiles. Precursors for these products are generally difficult to pump or otherwise introduce into a reactor. As a result, this system incorporates both a heated and pressurized liquid feed reservoir fitted with an oblong high-pressure sight glass. Additionally, the system comes equipped with a high pressure metering pump retrofitted with a heated pump head. Provision is also made to heat trace the transfer lines both to and from the pump. The system is equipped with a mass flow controller for hydrogen, automated shut-off valves and on the lower shelf, a gas liquid product separator. The head space above the product receiver is connected to an automated back pressure regulator that maintains the entire system at a user established working pressure.

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Series 5400 Continuous Flow Tubular Reactors

< Synthesis gas (H2/CO) related chemistry is studied with this 30 cm long tubular reactor. This system features the following main system components: Three gas mass flow controllers for hydrogen, carbon monoxide and carbon dioxide. Each MFC is equipped with an automated air piloted valve to ensure a positive shutoff of the reactant gas flow. The 2.5 cm ID reactor and its associated single zone heater. The reactor is rated for use up to 100 bar @ 550 C and is equipped with an internal pre-heater and catalyst spools for easily changing the catalyst loading. A jacketed gas/liquid product separator coupled with an automated back pressure regulating system. The jacket is used for cooling the reaction products. The process controller and valve interface are conveniently located on the lower shelf of the moveable reactor stand. The system was provided with a high pressure liquid metering pump (not shown) to optionally introduce liquid reactants into the reactor. This system is used primarily to facilitate the study and development of industrial scale catalysts from biomass ash and char, focusing on engineered manipulation of the char structure and surface to enhance catalytic activity and selectivity. The emphasis is on catalysts for the synthesis of liquid fuels and chemicals such as the conversion of synthesis gas to mixed alcohols.

Reactor Schematic Examples and their Respective Order Numbers Below and right are schematic representations of typical tubular reactor systems, along with a symbols chart to facilitate understanding. We have provided the ordering number for each of these examples.
Order No.: 5402C-SS-115-FM1500-DCS-GF(1)-PL-LF(1)-ITW-CHXGLS(300)
Single-zone Tubular Reactor System with one Liquid Feed, one Gas Feed, and a Purge Line.
Gas F FIC TIC Gas F MFC PT T/C T/C

Order No.: 5403F-SS-230-ST3(24)-3000PCC-GF(2)-PL-LF(1)-ISP-CSS-ITW-GLS(600)TR(3)-AP-ASV

Tubular Reactor System with Three-Zone Heater, 600 mL Separator Vessel and 4871 Controller
S Gas1 F S Purge GAS 1 S Gas 2 F MFC MFC

Key to Symbols
Inlet Relief Valve

Ball Valve

F
Filter

Metering

MFM
Mass Flow Meter

3-way

SIC
Speed Indicating Controller

Rupture Disc Pump Tank Pressure Regulator

PT Liquid T/C

PG

PT
Pressure Transducer

Back Pressure Regulator

FIC
Flow Indicating Controller

4871 Process Controller

T/C T/C T/C

S
Electric-Actuated Air-Operated Solenoid Valve

Check Valve

PIC
Liquid F

PG
Pressure Gage

MFC
Mass Flow Controller

Vent BPR

PI
Pressure Indicator

T/C
Thermocouple

PIC
Pressure Indicating Controller

TIC
Temperature Indicating Controller

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Series 5400 Ordering Guide

A composite identification number to be used when ordering a 5400 Series Reactor can be developed by combining individual symbols from the separate sections below. The Order No. for a typical system is:

5402C-SS-115-ST3(24)-3000-DCS-GF2-LF1-ITW-GLS1000

A Base Model Model No. Size 5401 3/8 in. 5402 1/2 in. 5403 1.0 in. 5404 1.5 in. Add suffix F for Floor Stand mounting Add suffix B for Bench Top mounting Add suffix C for Cart mounting B Materials of Construction -SS T316 Stainless Steel -HC Alloy C-276 -TI Titanium -IN Alloy 600 -MO Alloy 400 C Electrical Supply -115 115 Volt, 50/60Hz -230 230 Volt, 50/60Hz D Heater Options -ST1(#) Split Tube, 1-Zone -ST3(#) Split Tube, 3-Zone -FM(#) Flexible Mantle -WJ(#) Welded Jacket Add suffix (6), (12), (24), (36) for heated length in inches.

E Maximum Operating Pressure -1500 1500 psi / 100 bar -3000 3000 psi / 200 bar -4500 4500 psi / 300 bar F Controller -PCC PC-based Process Control (4871-style) -DCS Distributed Control System G Custom -GF(#) -PL -LF(#) -ISP -CSS -ITW -CHX -GLS(#) Options Number of gas feeds Purge gas feed line Number of liquid feeds Internal pre-heat spiral (5403/5404 only) Catalyst support spools (5403/5404 only) Internal thermowell, with T/C Cooling heat exchanger Gas/Liquid Separator, Volume (300), (600), (1000), (2000) in mL.

-SPH Separator heater -TR(#) Number of gas tank regulators -AP* Automated pressure control -ASV* Automated shut-off valves *Available only with 4871 Process Control H Certifications -No Symbol No Certification -ASME ASME Certification -CE European CE/PED Certification -P Parr Certification

In addition

to the tubular reactors offered in our standard product line, be sure to contact Parr for all of your custom needs.
Fluidized Bed Reactor Systems This Tubular Reactor System was designed for upward gas flow to fluidize coal particles enroute to syngas production.

Multiple Reactor Systems This Tubular Reactor System can be used with its three reactors configured for series or parallel operations.

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The Parr Warranty

arr Instrument Company (Parr) combustion bombs, calorimeters, reactors, pressure vessels, and associated products are designed and manufactured only for use by or under the direct supervision of trained professionals in accordance with specifications and instructions for use supplied with the products. For that reason, Parr sells only to professional users or through distributors to such users. Parr produces precision equipment and associated products which are not intended for general commercial use. Exclusive Warranty To the extent allowed by law, the express and limited warranties herein are the sole warranties. Any implied warranties are expressly excluded, including but not limited to implied warranties of merchantability or fitness for a particular purpose. Express Warranties Subject to the above Conditions, Parr expressly warrants that its products: Are as described in the applicable Parr sales literature, or as specified in Parr shipping documents. Will function as described in corresponding Parr sales bulletins, or for specifically engineered assemblies, as stated in the sales proposal and purchase agreement. Will remain free from defects in materials and workmanship for one year from date of delivery of the product to the original purchaser/user. Note that there is no guarantee of a service life of one year after delivery. Limitations on the Parr Warranty As to the original purchaser/user and to the distributors to such users, Parr limits its liability for claims other than personal injury as follows: Replacement or repair. With respect to express warranties herein, Parrs only obligation is to replace or repair any parts, assemblies or products not conforming to the warranties provided herein. Disclaimer of consequential commercial damages, including but not limited to: damages for loss of use, damages for lost profits, and damages for resulting harm to property other than the Parr product and its component parts.

Bulletin 5400 0810

211 53rd Street Moline, Illinois 61265 USA Phone: 1-309-762-7716 or 1-800-872-7720 Fax: 1-309-762-9453 E-mail: parr@parrinst.com http://www.parrinst.com

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