Introduction & Fundamental

Introduction
Packed bed reactors are the one of the most important reactor types widely used in the chemical
industry such as chemical applications such as absorption, distillation, stripping, separation, and
catalytic reaction. Among others for large-scale manufacturing of basic chemicals and intermediates
as well as for the removal of harmful or toxic chemicals from gas or liquid streams.
The main advantage of packed bed reactors that makes them very attractive compared to other more
sophisticated and novel reactor types is their low cost. Pressure drop, residence time distribution,
mass and heat transfer characteristics are crucial for the optimal design and operation of packed bed
reactors, and, hence, their accurate estimation is very important. These characteristics have been
studied both experimentally and numerically by several groups. (Theodoros Atmakidis, Eugeny Y.
Kenig, 2014). The packed bed reactor can produce the high conversion of reactants per unit mass of
catalyst, relatively low operating costs, and continuous operation. (Fogler, H. Scott, 2006). The value
of the temperature at the hot spot is determined mainly by the reaction rate sensitivity to changes in
temperature, the heat of reaction potential of the process, and the heat transfer potential of the
heat exchanger units employed. A heat exchanger is characterized by the heat transfer coefficient
and heat transfer areas. The selection of an appropriate fixed bed reactor design for a given process
is performed assessing the main limitations of these reactors. The fixed packed bed reactors can be
malfunctioning due to in-proper temperature control, pressure drop for processes with low
tolerance, and deactivation of the catalyst. (HA Jakobsen · 2008)
However, even packed bed reactor has contained the key to the advantages on the process, but the
packed bed reactor also has its own disadvantages during performed the process in the industry, but
all the disadvantages have the solution to prevent any disturbance and problem toward the process
and system of plant. Based on the information from (Michigan Engineering, Visual Encyclopedia of
Chemical Engineering Equipment). Below are the advantages and disadvantages of packed bed
reactors.
Advantages Disadvantages
1. High conversion rate per weight of catalyst. 1. Difficult temperature control.
2. Easy to build. 2. Temperature gradients may occur.
3. More contact between reactant and catalyst 3. Catalyst difficult to replace.
than in other types of reactors. 4. Channeling of gas stream can occur, leading
4. More product is formed due to increased to ineffective regions in the reactor.
reactant/catalyst contact. 5. Side reactions possible.
5. Low cost of construction, operation, and 6. Heat transfer to or from reactor can be
maintenance. difficult.
6. Effective at high temperatures and pressures.
Based on the design project 1, our operating condition on the reactor R-101 which is at the stream 3
is 200ᵒC of the temperature and the pressure is 3039.75 kPa and at the stream 4 is the temperature
increase to the 300ᵒC and the pressure also increase to the 8612.63 kPa. The mass flow rate at
stream 3 is 326337.2 kg/hr which contains carbon dioxide is 54950.50 kg/hr, carbon monoxide is
227228 kg/hr and hydrogen is 44159.2 kg/hr. At the stream 4, the total mass flow rate is 335027.2
kg/hr which is contain carbon dioxide 192719.8 kg/hr, carbon monoxide 40883.4 kg/hr, hydrogen
36384.0 kg/hr, water 23420.2 kg/hr and methanol 41664.8 kg/hr.
Fundamental Knowledge
Packed Bed Reactor is a type of chemical reactor commonly used in the chemical industry for
continuous-flow reactions. It consists of a cylindrical vessel filled with a solid catalyst material, which
serves as the reaction site. The reactants are continuously fed into the reactor, allowing for a steady
flow of reactions to take place. As the reactants pass through the packed bed of catalyst, they
undergo the desired chemical transformation, and the product stream exits the reactor, types of
reactors in pharma industry.
However, there are multiple types of reactors in the world of chemical processes. The selection of
reactor may vary from multiple chemical reaction and process needs such as the reaction type,
removal/addition of heat, need for catalyst, phases involve, pressure, production capacity and flow,
residence time and as well as the contact/mixing between the reactants ( Hussain at al. 2012). The
most reactors that has been widely use in the chemical industries across the world consists of;
Type of Equipment
a) Shell and Tube

The reactor shell is usually surrounded by thermal insulation materials to avoid any significant amount
of heat loss. Tubes packed with catalyst are arranged in equilateral triangle tube bundles and installed
inside the shell. The baffle plates are used to support the tube bundles, increase the flow distribution in
the inter-tubular space and for an effective heat transfer between the tube side and shell side.
b) Catalyst
The catalyst in the PBR provides a large surface area for the reactants to come into contact,
increasing the reaction rate and efficiency. The reactor’s design allows for precise control
over the reaction conditions, such as temperature, pressure, and flow rates, enabling
optimization for specific reactions. PBRs are commonly used in various industries, including
petrochemicals, pharmaceuticals, and fine chemicals production. Their continuous
operation, high conversion rates, and efficient use of catalysts make them attractive for large-
scale and continuous chemical processes, enhancing productivity and reducing waste. Cr also
improves stability of the catalysts against ambient conditions and prolongs their shelf life.
The catalyst containing 6.4 mol % Cr has a methanol selectivity of 83.5% and a catalytic
activity of 14.2 g methanol production which is the highest among other synthesized
catalysts. (S Ay · 2021)
Working Principle
Packed bed reactors are very versatile and are used in many chemical processing applications such
as absorption, distillation, stripping, separation processes, and catalytic reactions. Across the
diverse applications in which they are used, the physical dimensions of the beds can vary greatly.
Typical reactors consist of a chamber, such as a tube or channel that contains catalyst particles or
pellets, and a liquid that flows through the catalyst. The liquid interacts with the catalyst across the
length of the tube, altering the chemical composition of the substance. In this reactor the force of
gravity causes the catalyst pellets to move with respect to the wall from top to bottom while
maintaining their relative positions to one another. The moving bed thus offers the ability to
withdraw catalyst for regeneration outside the reactor in a continuous mode.(HA Jakobsen · 2008)
The schematic below shows a simplified design of a typical packed bed reactor:

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a) Shell and Tube

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