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4. Non-Isothermal CSTR
Reactor Design Non-Isothermal Reactions
Ta V
FH FH
FA0 FA,exit
T0 i i V T i i V V
TA,exit
V V+V
FH i i Fi H i UaV(Ta T) 0
V V V
Differentiating with dH i dT
respect to V C Pi
dV dV
Reactor Design Non-Isothermal Reactions
dT
Ua(Ta T) vi H i (rA ) Fi CPi 0
dV
H Rx (T )
d c b
Heat of reaction H Rx (T ) H D (T ) H C (T ) H B (T ) H A (T )
at temperature T a a a
dT rA H Rx Ua(T Ta )
dV Fi C Pi
Reactor Design Non-Isothermal Reactions
The energy balance equation must be coupled with mole balance equation and
solved simultaneously.
Reactor Design Non-Isothermal Reactions
Equilibrium Conversion
T T
Reactor Design Non-Isothermal Reactions
Adiabatic Temperature and Equilibrium Conversion
(Exothermic Reactions)
kA
A B First order, reversible, liquid-
k-A phase, exothermic reaction
KC
1. Net rate rA k AC A k ACB
CB k A
2. At equilibrium rA 0 KC
C A k A
3. Stoichiometry v v0 C A C A0 (1 X )
T
C B C A0 X
4. Combining KC
C C A0 X e Xe X Xe
KC B 1 1 KC
C A C A0 (1 X e ) (1 X e )
KC
Xe
1 KC
T
Reactor Design Non-Isothermal Reactions
5. Energy balance
Steady-State No
phase change, n
constant CP , no A 0 i Pi
F C ( T Ti0 ) H Rx ( T ) FA0 Q 0
X
shaft work i 1
Energy Balance
X EB
Ci Pi (T T0 )
X H Rx (T )
X EB
Ci Pi (T T01)
1 H Rx (T )
XEB,0
KC
Xe
XEB,1 1 K C T0 increase
XEB decrease
Adiabatic temperature
T0 T01 T
Graphical solution of equilibrium and energy balance equations to obtain the
adiabatic temperature and the adiabatic equilibrium conversion X
Reactor Design Non-Isothermal Reactions
Example 8.6 Calculating the adiabatic equilibrium temperature
kA
First order, reversible, liquid-phase,
A B exothermic reaction
k-A
H A (298 K) 40,000 cal/mol CPA 50 cal / (mol K) Ke 100,000 at 298 K
H B (298 K) 60,000 cal/mol CPB 50 cal / (mol K)
- Determine the adiabatic equilibrium temperature and conversion when pure A is fed
to the reactor at a temperature of 300 K
Solution
Ke
1. Equilibrium constant Xe
1 Ke
CP CPB CPA 50 50 0
H Rx
1 1 20,000 1 1
K e (T ) K e (T1 ) exp K e (T ) 100,000 exp
R T1 T 1.987 298 T
Reactor Design Non-Isothermal Reactions
T 298
K e 100,000 exp 33.78
T
2. Equilibrium conversion from thermodynamics
T 298
100,000 exp 33.78
T
Xe
T 298
1 100,000 exp 33.78
T Xe
Ke
X 1 Ke
3. Energy balance 1
X EB
Ci Pi (T T0 )
CPA (T T0 )
XEB
H Rx (T ) H Rx (T )
50(T 300) 0.42 C PA (T T0 )
X EB 2.5 103 (T 300) X EB
H Rx (T)
20,000
300 K 465 K T
Reactor Design Non-Isothermal Reactions
Reactor Staging with Interstage Cooling/Heating
(Adiabatic, Exothermic/Endothermic Reactions)
Higher conversion than those allowed by thermodynamics can be obtained by
connecting reactors in series with interstage cooling for adiabatic, exothermic reactions
T0 T1 T0 T2 T0 T3
570 C
T0 T1 T0 T1 T0 Texit
X
1 X EB
C i Pi (T T0 )
H Rx (T )
Interstage
heating for
KC
endothermic Xe
reversible 1 KC
reactions
T1 T0 T
Reactor Design Non-Isothermal Reactions
Example 8.7 Interstage cooling for exothermic reactions
kA
First order, reversible, liquid-phase,
A B exothermic reaction
k-A
H A (298 K) 40,000 cal/mol CPA 50 cal / (mol K) Ke 100,000 at 298 K
H B (298 K) 60,000 cal/mol CPB 50 cal / (mol K) T feed 300 K
- What conversion could be achieved in Example 8.6 if two intestage coolers cool the
exit streams from two subsequent reactors to 350 K? Determine the heat duty of
each heat exchanger for a molar flow rate of 40 mol/s. Assume that 95% of
equilibrium is achieved in each reactor.
Solution
350 K 350 K
300 K T1 T2 Texit
X1 X2 X3
X 1, adiabatic 0.42
T1, adiabatic 465 K
X 1 0.95 X1, adiabatic 0.95 0.42 0.4
Reactor Design Non-Isothermal Reactions
X 1, adiabatic 0.42
T1, adiabatic 465 K
X 1 0.95 X1, adiabatic 0.95 0.42 0.4
X EB 2.5 103 (T 300) T 300 400 X
(energy flow in) - (energy flow out) (heat in) - (shaft work) (heat of reaction) 0
n n
F
i 1
i0 H i 0 Fi H i Q 0
i 1
Reactor Design Non-Isothermal Reactions
n n
F
i 1
i0 H i 0 Fi H i Q 0
i 1
Fi in Fi out
n n n n
i i i0 i0 i i i0 i Pi 1,out 1
F H F H F ( H H ) F C (T T )
Q
i 1 i 1 i 1 i 1
(F C F C )(T T )
Q A PA B PB 1,out 1
(F F )(C )(T T )
Q A B PA 1,out 1
FA 0C PA (T1,out T1 )
220 kcal/s must be removed to cool the reacting mixture from 460 K to 350 K for a
feed rate of 40 mol/s.
Reactor Design Non-Isothermal Reactions
3. Second reactor
F C (T T )
Q A 0 PA 2,out 2
Entering condition: T1,out=350 K, X=0.4
40 mol 50 cal (350 430) K
Q
Corresponding adiabatic equilibrium conversion = 0.63 s mol.K
Conversion = 0.95 x 0.63 = 0.6 kcal
-160
Corresponding exit temperature = 430 K s
X 2.5 103 (T2 Tout,1 ) T2 350 400X 350 (0.6 0.4)400 430 K
X 4. Third reactor
1 Entering condition: T2,out=350 K, X=0.6
Adiabatic equilibrium conversion = 0.80
0.76 Conversion = 0.95 x 0.80 = 0.76
Corresponding exit temperature = 414 K
0.60
T3 350 400X
0.40 350 (0.76 0.6)400
414 K
Final conversion achieved with three reactors
300 414 430 460
and two interstage coolers is 0.76!
350 T
Reactor Design Non-Isothermal Reactions
Optimum Feed Temperature
Consider an adiabatic reactor of fixed size or catalyst weight and investigate what
happens as the feed temperature is varied.
The reaction is reversible and exothermic
Sharp increase is
X KC X
Xe referred to as the point
1 1 KC 1 or the temperature of
ignition
0.75 0.75
T0 =600
0.25 0.25
T0 =350
350 450 600 T 0 W
T0 =600
0.25 0.25
T0 =350
350 450 600 T 0 W
At low T, T=350 K, Xe=0.75 Low rate X= 0.05, virtually all reactants will
pass through without reacting
Reactor Design Non-Isothermal Reactions
The conversion is low for high feed temperature and for low feed temperature.
0.75
0.50
0.25
Curve A: Reaction rate slow, conversion dictated by rate of reaction and reactor
volume. As temperature increases rate increases and therefore conversion increases.
Curve B: Reaction rate very rapid. Virtual equilibrium reached in reaction conversion
dictated by equilibrium conversion.
Reactor Design Non-Isothermal Reactions
Non-Isothermal CSTR
Consider a steady-state operation of a CSTR with first order exothermic reaction
Heat is removed from the reactor by a cooling jacket or a cooling coil.
FA0 T0
Heat removal rate Q UA(Ta T )
(valid only for large coolant flow rates!!)
Ta Ta
T
Steady-State No phase change, constant CP , no shaft
work Energy Balance
n
A0 i Pi
Q 0
F C (T Ti0 ) H Rx C P (T TR ) FA0 X
i 1
A0 i Pi
UA(Ta T ) 0
F C (T Ti0 ) H Rx C P (T TR ) FA0 X
i 1
Reactor Design Non-Isothermal Reactions
A0 i Pi
UA(Ta T ) 0
F C (T Ti0 ) H Rx C P (T TR ) FA0 X
i 1
Neglecting C P
A0 i Pi
UA(Ta T ) 0
F C (T Ti0 ) H Rx FA0 X
i 1
Solving for X
UA(Ta T ) n
i CPi (T Ti 0 ) Fi 0
FA0 i 1 i
Energy balance X EB FA0
[H Rx
]
Size the CSTR
X MB X EB
FA0 X MB
CSTR mole balance V
rA ( X MB , T )
Reactor Design Non-Isothermal Reactions
n
A0 i Pi
UA(Ta T ) 0
Energy balance
F C (T Ti0 ) H Rx FA0 X
i 1
n
Let C
i 1
i Pi CP0 after rearrangement it follows:
UA
Non
XH
Rx CP0 (1 )(T Tc ) with FA0C P0
adiabatic
Ta T0 parameters
Tc
C P0 (1 )(T Tc ) 1
X EB
H Rx
(H Rx
) X EB
T Tc
CP0 (1 )
Sizing of a CSTR
a) X specified: Calculate V and T
b) T specified: Calculate X and V
c) V specified: Calculate X and T
Reactor Design Non-Isothermal Reactions
Solving mole and energy balances for a CSTR
CP0 (1 )(T T ) c
Consider a first-order reaction X EB
H Rx
(H Rx
) X EB Ways to specify the sizing of a CSTR
T Tc
CP0 (1 ) C P0 (1 )(T Tc )
X EB
H Rx
C P0 (1 )(T Tc )
X EB
H Rx
FA0 X MB
V
rA ( X MB , T )
Reactor Design Non-Isothermal Reactions
Outline
0.25 XH Rx
CP0 (1 )(T Tc )
350 450 Ta T0
TCSTR 600 with
UA
FA 0 C P0
Tc
T 1
n
C P0 i C Pi
Mole balance for a CSTR i 1
FA0 X rAV
V X Heat generated Heat removed
rA FA0
Replacing in the energy balance (rAV / FA0 )(H Rx
) CP0 (1 )(T Tc )
G (T ) R(T )
Reactor Design Non-Isothermal Reactions
Heat Removed Term R(T) Heat generated Heat removed
UA Ta T0
R(T ) CP0 (1 )(T Tc ) with Tc
FA0C P0 1
slope
Vary the entering temperature T0 Vary parameter k
Increasing T0
Increasing k
Tc1 Tc2 T Ta T0 T
Reactor Design Non-Isothermal Reactions
Heat Generated Term G(T) Heat generated Heat removed
G (T ) (H ) X
(rAV / FA0 )(H Rx
) CP0 (1 )(T Tc )
Rx
G (T ) R(T )
To plot G(T) as a function of T we must replace X = f(T)
G(T) G(T)
High E
Increasing
Low E
T T
Reactor Design Non-Isothermal Reactions
Ignition-Extinction Curve R(T ) CP0 (1 )(T Tc )
(H Rx
)A exp( E / RT )
The point of intersection of R(T) and G(T) G (T )
represents a steady-state condition for the CSTR 1 A exp( E / RT )
UA T T
Tc a 0
G(T) FA0C P0 1
R(T)
9 Upper steady states
G(T) 6 8 9
Ts 8
3 6
R(T) 3 Unstable
5 5
7 7
4
2 Ts2 4 Lower steady states
2
1 Ts1
1 Ignition temperature
. . T05
T01 Ts1 T02 Ts2 Ts7 Ts3 T01 T02 T0
T
Extinction
temperature
Reactor Design Non-Isothermal Reactions
Ignition-Extinction Curve
R(T) G(T)
9 Upper steady states
G(T) 6 8 9
Ts 8
3 6
R(T) 3 Unstable
5 5
7 7
4
2 Ts2 4 Lower steady states
2
1 Ts1
1 Ignition temperature
. . T05
T01 Ts1 T02 Ts2 Ts7 Ts3 T01 T02 T0
T
Extinction
temperature
Ignition temperature - Any fraction of a degree increase in temperature beyond T07
and the steady state reactor temperature will jump up to Ts8
. . Ts8
T01 T02 T07 T0 Ts4 Ts7 T
Reactor Design Non-Isothermal Reactions
Non-Isothermal Multiple Reactions with Heat Effects
To account for heat effects in multiple reactions, we simply replace the term (-HRx)
(-rA) in equations
dT rA H Rx Ua(T Ta )
PFR energy balance
dV Fi C Pi
m
CSTR energy balance FA 0 i C Pi (T T0 ) [H Rx ][rA V] UA(Ta T) 0
i 1
by: (r )(H
ij Rxij ) for q reactions and m species i = Reaction number
j = Species
The heat of reaction for reaction i must be referred to the same species in the rate, rij,
by which (-HRXij) is multiplied, that is,
(r )H
q
FC
dV m= Number of species
j Pj
j1
CSTR energy balance, q multiple reactions
m q
FA 0 i CPi (T T0 ) V rijH Rxij(T) UA(Ta T) 0
i 1 i 1
For example, for two parallel reactions
k1
Reaction 1: A B
k2
Reaction 2: A C
Solution
1. Combined mole balance and rate law for A
v0 (C A0 C A ) C A0
V CA
k1C A 1 k1
2. Combined mole balance and rate law for B
v0 (0 CB ) CB v0 CB v0 k1C A k1C A0
V CB
rB (r1B r2 B ) k1C A k 2CB 1 k 2 (1 k1 )(1 k 2 )
Reactor Design Non-Isothermal Reactions
3. Rate laws
k1C A0
r1 A k1C A
1 k1
k 2k1C A0
r2 B k 2CB
(1 k1 )(1 k 2 )
4. Non-isothermal energy balance
m q
FA0 i CPi (T T0 ) V ri , j H Rxij (T ) UA(Ta T ) 0
i 1 i 1
T0 Ta 283 (0.667)(330)
Tc 301.8 K ODE Solver
1 1 0.667
Use Matlab to plot R(T) and G(T) vs T. 16
x 10
4 Example8.11
Example 8.12
k1C A 0
CC C A 0 C A C B
14
CA
C A0 C
(1 k1 )(1 k 2 )
B
1 k1 12
10
SS T(K) CA CB CC
(mol/dm3) (mol/dm3) (mol/dm3) 8
G,R
6
1 310 0.285 0.015 0
4
2 363 0.189 0.111 0
2
3 449 0.033 0.265 0.002
0
4 558 0.004 0.163 0.132
-2
5 677 0.001 0.005 0.294 0 50 100
t
150 200