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Comparing Reactors
One of the most basic criteria of reactor selection is the reactor size
necessary to achieve a desired conversion in a reaction. We saw above that
these are:
XA
VPFR = − FA0 ∫
0
VCSTR = − FA0
easily visualize the reactor volume in what is called “1/r-plots” (or also
‘Levenspiel-plots’)…
1
1/r-Plots
XA
ChE 400 - Reactive Process Engineering
dX A
Let’s look at the PFR first: VPFR = − FA0 ∫0 ν A r ( X )
r
1st order kinetics: r ∝ (1-X)
2nd order kinetics: r ∝ (1-X)2
zero order kinetics: r ≠ f(X)
negative 1st order: r ∝ (1-X)-1
1 or Xeq X
r-1
2 1 or Xeq X
ChE 400 - Reactive Process Engineering
1/r - Plots
n > 0 n < 0
r-1 operating point r-1
for CSTR
Xeq
XA X XA X
operating line
for PFR
•• Volume
VolumePFR
PFR ??
•• Volume
VolumePFR
PFR??
ChE
•• CSTR
CSTRoperates
operatesat
atlowest
lowest
3
•• PFR
PFRoperates
operatesat
athighest
highest
ChE 400 - Reactive Process Engineering
Example
Compare the volumes of CSTR and PFR that are necessary to consume 90%
of A. The entering molar and volumetric flow rates are 5 mol/h and 10 L/h
of pure A, respectively. The reaction rate coefficient is k = 0.0001 s-1.
(What is hence the rate law?)
4
ChE 400 - Reactive Process Engineering
Solution
20
18
16
14
12
FA0/(-rA)
10
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
ChE
Conversion (X)
5
ChE 400 - Reactive Process Engineering
Reactor Combinations
How about combinations of PFRs and CSTRs?
1/r
What kind of combinations of
reactors would be optimal for
a (somewhat bizarre…) kinetics
as shown at right?
Xtarget X
Even for ordinary kinetics, a sequence
rV-1
of a CSTR and a PFR might be used
(typically for cost reasons), where
the CSTR is then operated at low
conversion (i.e. first), followed by the
ChE
CSTR 1
CSTR 2 X3
CSTR 3
X1 X2 X3 X
Optimization problem: for n > 1, the volume of subsequent CSTRs must decrease
for minimal overall reactor volume... (how can we see that in the graph above?!)
7
CSTR cascade: Example
Let’s assume an irreversible 1st order reaction A -> B is conducted in a cascade of
ChE 400 - Reactive Process Engineering
equal-volume CSTRs. If k= 0.5 min-1, how long does it take to reach 90% conversion in
a cascade with 1, 2, 5 and 20 CSTRs? Compare these values to a PFR!
The total residence time for a cascade of n-CSTR is (read this in LDS, 109-111!):
111!)
⎧
n ⎪⎛ C A0 ⎞
1/ n
⎫⎪
τ n = n ⋅ τ = ⎨⎜ ⎟ − 1⎬
k ⎪⎝ C A ⎠ ⎪⎭
⎩
-> the residence time in the CSTR cascade decreases with increasing number of
reactors towards the “PFR-limit”.
ChE
PFR-”cascades”…
(However,
ChE
9
ChE 400 - Reactive Process Engineering
“Repairing” low X: Recycle Reactors
The simplest way of improving a low conversion is through a recycle loop: a part of
the product stream is fed back to the reactor inlet (without prior separation!).
This is called a recycle reactor.
reactor
10
ChE 400 - Reactive Process Engineering
“Repairing” low X: Recycle Reactors
The simplest way of improving a low conversion is through a recycle loop: a part of
the product stream is fed back to the reactor inlet (without prior separation!).
This is called a recycle reactor.
reactor
−
overall conversion: XA = = 1−
FA0 FA0
− + − −
“per-pass” conversion: xA = = =
FA,in FA0 + R FAe FA0 + R FAe
1 −? XA
xA = =
ChE
1+ ? 1 +?
Solve for XA.
test: R → 0:
Discuss the result!
11 R→ ∞:
ChE 400 - Reactive Process Engineering
Recycle Reactor: Design
Fout
From PFR design: dFA FA,in FA,out
∫
FA0
V = − FAe
Fin
rA
FA,rec= R FAe
Assume 1st order rctn: rA = k cA = k FA / V
rA = k FA
rA in ‘design equation’:
( R +1) Fe
( R + 1) V0 dFA V0 ( R + 1) Fe V0 ⎧ F0 − Fe ⎫
V= − ∫ = −( R + 1) ln = ( R + 1) ln ⎨1 + ⎬
F0 + R Fe
k FA k F0 + R F e k ⎩ ( R + 1) Fe ⎭
R → 0: V=
ChE
R→ ∞ : V=
12