RECYCLE REACTOR SYSTEM

Figure 6.13 shows a PFR where part of the reactor

output is recycled to the input. As the recycle ratio
increases the reactor behaves more like a MFR!
The reactor in the system is still governed by the
performance equation for a PFR but we need to
account for the fact that the feed to the PFR is not the
feed to the system.
We can obtain the properties of the feed to the PFR in
terms of the properties of the feed to the system by
writing mass balances around the mixing point.

Recycle reactor system

Recycle reactor Mass balances around mixing point

Total mass (volume) :

Mols of A :

v 0 v 3 v1

FA 0 FA3 FA1
C A 0v 0 C A3v 3 C A1v1

if there is no change in density with composition then :

v0 vf

and v 3 Rv f Rv 0

The total mass balance becomes :

v 0 Rv 0 v1 or , v1 v 0 (R 1)
The A balance can then be written :
C A 0v 0 C Af Rv 0 C A1v 0 (R 1)

The A balance :
C A 0v 0 C Af Rv 0 C A1v 0 (R 1)
Divide through by C A 0v 0
1

C Af
C
R A1 (R 1)
CA0
CA0

Using the definition of X A1 and X Af :

1 (1 X Af )R (1 X A1 )(R 1)

Rearranging :
1 R X Af R R 1 X A1R X A1
X A1 (R 1) X Af R

R
X A1
X Af
R 1

So we now have
expressions relating
the feed to the PFR
and the feed to the
system as a whole
The PFR itself had
been analyzed
previously

Performance equation for plug flow reactor derived earlier:

X Af

CA0

1
dX A
rA

XAf

or ,

V C A 0v 0

1
dX A
rA

In our system, we have v0(R+1) entering the reactor instead of v0

and an entering conversion XA1 instead of 0.
Thus we get, for the performance equation for the recycle reactor:
X Af

V C A 0v 0 (R 1)

R
X Af
R 1

1
dX A
rA
or ,

V
(R 1)
FA 0

XAf

R
X Af
R 1

1
dX A
rA

Performance equation for the recycle

reactor system
V
(R 1)
FA 0

XAf

R
X Af
R 1

1
dX A
rA

This is shown graphically in Fig. 6.14

The integral gives the area under the curve between
XA1 and XAf . It represents the V/FA0 for the PFR if
there was no recycle.
If we multiply the average 1/rA in this interval with
(R+1) we get the required volume of the reactor with
recycle

Fig6_14

Recycle reactor system performance

We can evaluate the performance of the recycle reactor
system at any recycle ratio relative to a straight PFR
(recycle ratio of zero) by looking at the space time
ratio.
This will need to be done for specific reaction rate
expressions, rA
Figure 6.16 looks at 1st order reaction, 6.17 looks at 2nd
order. (these are analogous to Fig. 6.5 and 6.6 which
looked at the effect of N for MFRs in series).

1st order
rxn
PFR with
recycle

2nd order
rxn
PFR with
recycle

RECYCLE REACTOR
We have seen that recycling makes a PFR behave
more like a MFR.
We have also seen that PFR is the more attractive
solution in most cases because it achieves the same
conversion with smaller volume.
Why then, would we be interested in degrading the
performance of a PFR by recycling some of its output
to the inlet?
An autocatalytic reaction proceeds faster with some
product in the feed, or in extreme cases may not
proceed at all if there is no product in the feed.

AUTOCATALYTIC REACTIONS
one of the products acts as a catalyst:
A+M=M+M
Important example:the treatment of biodegradable organic wastes by
microorganisms, biodegradation:
biodegradable material + microorganisms + O2 (dissolved oxygen)
------ CO2 + H20 + more microorganisms
The presence of microorganisms is required for the reaction to proceed. The
product of the reaction is more microorganisms.
The reaction rate shows some dependence on the initial presence of
microorganisms (Fig. 6.18).

Fig6_18

Autocatalytic
reactions
See Chp. 3 for test of
reaction rate expression
from batch reactor data
for the special case:

AR R R
dC A
rA
kC ACR
dt

Autocatalytic reactions
What type of reactor is best for these reactions?
PFR with pure A in the feed will not work! We need at least some product in
the feed. But how much? If we have too much, that might affect the
reaction rate as well. Where do we get the product? One possibility is to
use recycle.
MFR with pure A feed will work if we get it going initially by having some
product in the reactor.
We have also seen that a PFR in recycle mode behaves more and more like a
MFR as recycle rate increases.
So the question is not simply PFR vs MFR, but a PFR with the optimum
recycle ratio vs a MFR.

Fig6_19

Autocatalytic reactions MFR vs PFR

Figure 6.19 shows that for an autocatalytic reaction
MFR is more efficient than PFR at low conversions.
At higher conversions they become equivalent, and at
even higher conversions, PFR becomes better.
What about a combination of MFR and PFR in series?

Autocatalytic reactions
MFR- PFR in series
Since MFR is better than PFR at low XA it makes sense
to use MFR at low XA and then switch to PFR for high
XA , Fig. 6.21 (a)
If the product can be separated from the remaining
reactant we dont need the PFR, we can simply
operate a MFR with a separator, Fig. 6.21 (b)
Note: Fig. 6.21 has been drawn using CA instead of XA. You should
be able to go from one to the other with ease.

Fig6_21

Autocatalytic reactions MFR vs PFR

What is different about these reactions?
i.e. what happened to our analysis resulting in Fig. 6.2
which showed PFR better than MFR?
Compare Fig. 6.18 and 6.19 with Fig. 6.2. It is the
minimum in the 1/rA curve ( maximum in rA ) that
gives rise to the observation in Fig.6.19

Autocatalytic reactions
recycle reactor using a PFR
In Figure 6.20 we can distinguish two systems:
1) The actual PFR with feed at XAi and product at XAf
2) The recycle reactor with feed XA0 and product at XAf

The PFRs performance equation says the area under

the 1/rA curve from XAi to XAf is V/FAi
We can define an average rate for the PFR by
drawing a line that will give us the same area
underneath, between XAi to XAf

Autocatalytic reactions
recycle reactor using a PFR
Now looking at the recycle reactor, the only reaction taking place is in
the PFR. So the same reaction rate applies.
The feed to the recycle reactor is at XA0 and its flow is FA0 .
The rectangular area under (1/rA)average from XA0 to XAf is V/FA0
This is the actual measure of performance for our system.
If we had no recycle (just the PFR) V/FA0 would be the area under the
1/rA curve from XA0 to XAf
If we had a MFR, V/FA0 would be the rectangular area under the 1/rA
(evaluated at Xaf ) line from XA0 to XAf

Autocatalytic reactions
optimum recycle ratio in PFR
At high recycle rate (I.e. high XAi, see Fig. 6.14) the
recycle reactor resembles a MFR and is clearly
inferior to the PFR.
As we reduce the recycle rate, the recycle reactors
performance improves (V/FA0 is reduced).
At even lower recycle rates the performance
deteriorates again.

Autocatalytic reactions
optimum recycle ratio in PFR
Recall the performance equation:

XAf

V
(R 1)
FA 0

R
X Af
R 1

The optimal recycle rate is obtained

by taking the derivative of V/FA0
w.r.t. R in the performance equation
And setting it equal to zero, giving:

X Af

1
rA

X Ai

X Ai

1
dX A
rA

dX A
rA

X Af X Ai

The optimum recycle is one that introduces a feed which

corresponds to the average reaction rate in the reactor.

Recycle reactor - recap

- recycling of reactor output to the input may be done
for different reasons
- Performance equation for a PFR with recycle follows
from the equation for a PFR but incorporates a mass
balance around the mixing point to relate fresh feed,
recycle stream, and reactor feed
- Increasing the recycle rate makes PFR look more like
a MFR

Autocatalytic reactions - recap

- These require recycle if a PFR is to be used
- MFR superior to PFR at low XA (In contrast to
reactions of general order n>0)
- PFR superior at high XA
- There is an optimum recycle rate
- Good idea to use two reactors in series (MFR first,
PFR next)

Example 6.3 Best reactor setup for

an autocatalytic reaction
Degradation of A in the presence of an enzyme
Reaction rate data has been obtained in a MFR
(Table E6.3)
v0=0.1 m3/min with CA0=10 mmol/m3 to be treated to
XA=0.9
Alternatives considered:
(a) PFR with recycle
(b) 1 or 2 MFRs in series
(c) MFR-PFR in series

Example 6.3 (a) PFR with recycle

Trial and error graphical solution: find optimum
recycle by adjusting feed to correspond to the
average rate of reaction, Fig.E6.3a
CAi=6.6 mmol/m3
R=0.607
V=1.08 m3

Example 6.3 (b) 1 or 2 MFRs

For one MFR we can use the reaction rate data directly in the
general form of the performance equation.
Two MFRs in series. Possibilities:
Equal size
Unequal size
How do we determine the size(s)?
For two equal sized MFRs we could use Fig.6.5 if the reaction was
1st order (or Fig.6.6 if the reaction was second order as in
Example 6.2) But we do not even have a reaction rate
expression, just numerical data.
The graphical method of maximization of rectangles enables us to
find the optimum sizes of two unequal MFRs in series (which
turns out slightly better than two equal size MFRs) even when we
only have reaction rate data but no reaction rate expression.

Example 6.3 (b) 1 MFR

One MFR,
CA0=10 mmol/m3 ; CAf=1 mmol/m3 (90% conversion)
1/rA = 10 m3.min/mmol (from reaction rate data)

CA0 CA

90 min
rA
V (90 min)(0.1 m 3 / min) 9 m 3

Example 6.3 (b) 2 MFRs

Two MFRs in series Fig.E6.3b

CA0 CA
1
(10 2.6)(0.8) 5.92 min
rA
V1 1 (5.92 min)(0.1 m 3 / min) 0.592 m 3
CA0 CA
2
(2.6 1)(10) 16 min
rA
V2 2 (16 min)(0.1 m 3 / min) 1.6 m 3

Example 6.3 (c) MFR-PFR combo

Fig.E6.3c
CA0 CA
MFR:

rA

(10 4)(0.2) 1.2 min

V (1.2 min)(0.1 m 3 / min) 0.12 m 3

PFR:

CA 0

CA

dC A
dC A

5.8 min (determined graphically)

rA 1 rA

V (5.8)(0.1) 0.58 m 3

Example 6.3 Summary

Case

Vol.1, m3

Vol.2, m3

Total vol.,m3

Recycle
PFR

1.08

1.08

1 MFR

2 MFRs

0.59

1.6

2.19

0.12 (MFR)

0.58 (PFR)

0.7

MFR-PFR

MFRs in series equal or

unequal size? Reality check!
Example 6.3(b) arrived at V1=0.59 m3, V2=1.6 m3 as optimum for 2
MFRs of unequal size
What would be the volumes if we used 2 equal sized MFRs?
If this had been a 1st or 2nd order reaction we could have made
use of Fig.6.5 or 6.6 to answer the question.
We only have the rate data which we need to use graphically.
Find that 2 MFRs of 1.25 m3 will do the job (exercise, see Fig
6.8)
Vtotal=2.2 m3 vs Vtotal=2.5 m3
The operational advantages of 2 identical reactors may outweigh
the marginal total volume advantage of 2 unequal reactors.