PLUG FLOW REACTOR (PFR)

EXPERIMENT 3

2.0 DATA & RESULTS

Concentration of NaOH (M) Conductivity (mS/cm)

0.0500 10.7
0.0375 9.7
0.0250 7.5
0.0125 5.6
0.0000 4.0

Table 1: Table of calibration curve

Calibration Curve

12

10
Conductivity, mS/cm

y = 140x + 4
8 R² = 0.9898

0
0 0.01 0.02 0.03 0.04 0.05 0.06

Concentration of NaOH, M

Graph 1: Calibration curve of concentration of NaOH, M vs conductivity, mS/cm

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 PLUG FLOW REACTOR (PFR)
EXPERIMENT 3
RESULTS FOR EXPERIMENTS

Reactor volume = 1.5 L Flowrate = 200 mL/min

Temperature = 30 °C

Total flow
Inlet Outlet
rate of
Flow rate Residence concentration concentratio Conversio
Flow rate solutions, Outlet
of time, τ Inlet of NaOH, n of NaOH, n,
Temperature of NaOH, F0 (mL/min) Conductivit
Time Et(Ac), (min) conductivity CNaOH (M) CNaOH (M) X (%)
(°C) FNAOH = FNAOH + y
(min) FET (Self- (mS/cm) (from (from (Self-
(mL/min) FET (mS/cm)
(mL/min) calculate) calibration calibration calculate)
(Self-
curve) curve)
calculate)
Inlet Outlet
0 32.2 32.5 202 204 406 3.695 10.52 0.0466 7.51 0.0251 46.14
5 32.2 32.4 202 200 402 3.731 11.78 0.0556 7.39 0.0242 56.47
10 32.2 32.4 202 202 404 3.713 10.67 0.0476 7.36 0.0240 49.58
15 32.2 32.4 201 203 404 3.713 11.40 0.0529 7.40 0.0243 54.06
20 32.3 32.4 200 200 400 3.750 11.77 0.0555 7.43 0.0245 55.86
25 32.3 32.4 200 201 401 3.741 11.47 0.0534 7.48 0.0249 53.37
30 32.4 32.4 197 202 399 3.759 10.89 0.0492 7.47 0.0248 49.59
35 32.4 32.4 201 201 402 3.731 10.53 0.0466 7.47 0.0248 46.78
F0,avg = 402.3 τavg = 3.729

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 PLUG FLOW REACTOR (PFR)
EXPERIMENT 3

Conversion vs Time

80

60
Conversion, X

40 y = -0.0399x + 52.179
R² = 0.0149

20

0
0 5 10 15 20 25 30 35 40

Time, min

Graph 2: Conversion, X vs. reaction time, t for the flowrate 200 mL/min

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 PLUG FLOW REACTOR (PFR)
EXPERIMENT 3
RESULTS FOR EXPERIMENTS

Reactor volume = 1.5 L Flowrate = 300 mL/min

Temperature = 30 °C

Total flow
Inlet Outlet
rate of
Residence concentration concentration Conversio
Flow rate Flow rate solutions, Outlet
time, τ Inlet of NaOH, of NaOH, n,
Temperature of NaOH, of Et(Ac), F0 (mL/min) Conductivit
Time (min) conductivity CNaOH (M) CNaOH (M) X (%)
(°C) FNAOH FET = FNAOH + y
(min) (Self- (mS/cm) (from (from (Self-
(mL/min) (mL/min) FET (mS/cm)
calculate) calibration calibration calculate)
(Self-
curve) curve)
calculate)
Inlet Outlet
0 32.4 32.4 301 299 600 2.500 12.56 0.0611 8.20 0.0300 50.90
5 32.5 32.4 306 301 607 2.471 11.20 0.0514 8.04 0.0289 43.77
10 32.5 32.5 301 300 601 2.496 10.82 0.0487 7.97 0.0284 41.68
15 32.5 32.5 300 299 599 2.504 9.57 0.0398 8.02 0.0287 27.89
20 32.5 32.5 299 300 599 2.504 9.79 0.0414 8.00 0.0286 30.92
25 32.4 32.4 299 301 600 2.500 9.16 0.0369 8.01 0.0286 22.49
30 32.4 32.4 300 297 597 2.513 9.10 0.0364 8.06 0.0290 20.32
35 32.4 32.4 292 296 588 2.551 9.38 0.0384 8.04 0.0289 24.74
F0,avg = 598.9 τavg = 2.505

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 PLUG FLOW REACTOR (PFR)
EXPERIMENT 3

Conversion vs Time

80
Conversion, X

60

y = -0.845x + 47.627
R² = 0.8506
40

20

0
0 5 10 15 20 25 30 35 40

Time, min

Graph 3: Conversion, X vs. reaction time, t for the flowrate 300 mL/min

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 PLUG FLOW REACTOR (PFR)
EXPERIMENT 3

3.0 ANALYSIS & DISCUSSION

This experiment all about discussing the plug flow reactor (PFR) which used to carry out
saponification reaction between sodium hydroxide, NaOH and ethyl acetate, Et(Ac). The objective
of the experiment is to determine the effect of residence time on the conversion in a PFR and to
determine the reaction rate constant as well.

Based on the results obtained, we can figure out that the conversion, X partially decreases
as the residence time increases. First of all, for the flow rate of 200 mL/min, the conversions ranges
from 46.14% to 56.47%. For the flow rate of 300 mL/min, the conversions are ranges around
20.32% to 50.90%. The residence time is the time needed to process particular reactor volume of
fluid based on its entrance condition. It is broadly useful concept where expresses how fast
something moves through a system in equilibrium. Based on result we can refer from the results
section we can deduce that the highest conversions are from the flow rate of 200 mL/min and also
at the flow rate 200 mL/min, the residence time is longer compared to 300 mL/min. So, the reactant
spend more in the reactor so the conversion yield is more compared to the other one.

From the simplest version of PFR, all reactants are introduced into the front end of a pipe
of sufficient length to ensure the reaction is complete. PFR is relatively easiest reactor to maintain
because mostly it is used in gas phase and do not have any moving parts unlike other fluids. PFR
also can be used in heterogeneous and homogenous reaction and production terms can be used in
large scale production. In additionally, PFR also produces a high conversion per reactor volume
of any flow reactor and can run for long period of time in other word can be used for continuous
process. PFR also can be used for high temperature reaction. However, it is very difficult to control
temperature within the reactor and hot spot can occur when the reaction is exothermic.

The highest conversion for the flow rate of 200 mL\min is 56.47% and the residence time
is 3.695 min. The average residence time calculated is 3.729 min. The highest conversion for the
flow rate of 300 mL\min is 50.90 and the residence time is 2.5 min. The average residence time is
2.505 min. From the graph 2 we can observe that the conversion and residence time drops and
increase back as the time increases while from graph 3 we can deduce that the conversion decreases
drastically.
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 PLUG FLOW REACTOR (PFR)
EXPERIMENT 3

When the size of the system is changed, the residence time of the system will be changed
as well. Based on theory, the larger the systems, the larger the residence time, thus the inflow and
outflow rates are held constant more or less similar. The smaller the system, the shorter the
residence time will be and assume as steady state conditions. Inflow and outflow will also have an
effect on the residence time of a system. If the inflow and outflow are increased, the residence time
of the system will be shorter. However, if the inflow and the outflow of a system are decreased,
the residence time will be longer. This is assuming that the concentration of the substance in the
system and the size of the system remain constant, and assuming steady-state conditions.

The Reaction Rate Constant; k was calculated using the formula given;

FO  X 
K  
VPFRCAO  1  X 
To obtain the rate of reaction, -rA of the second order reaction, the equation used is;

-rA = kCA2
Substituting the k value obtained;

Flow Rate, mL/min Reaction Rate Constant, k Rate of Formation, rA

200 -5.8590 0.14180
300 -6.6653 0.19996

One of the industrial application of PFR is ammonia synthesis. In ammonia synthesis, the
reactants are in gas phase while the reactor filled in with a catalyst which is iron catalyst. Besides,
this reactor is suitable for the reaction involving catalyst as ammonia is a catalytic reaction. The
ammonia reaction also involving a very high pressure which is in between 100 to 250 bar with the
temperature 350 to 500 oC. The ammonia synthesis is a continuous and large scale process. So PFR
is the most suitable for the synthesis of ammonia.

In this experiment, the major problem that usually we encounter is the reactor is
hard to maintain its steady state level. This would affect the accuracy of the result and fluctuating
readings. In order to maintain the steady state of reactor the flow rate of the reactant should be
monitored time to time.

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