 Sir Bhavsinhji Polytechnic Institute, Bhavnagar

 Subject – Internship Report

 Semester – 5th
 Department – Chemical Engineering
 Prepared by – Parmar kartik Tansukhbhai
 Enrollment number – 236490305046
 Guided by – Jigar Malaviya
 Certificate

Date :- 5.07.2025

To Whom So Ever It May Concern

This is to certify that. Mr. Kartik Tansukhbhai Parmar . Enrollment No.

236490305046. Student of Chemical Engineering at sir Bhavsinhji
Polytechnic Institute, Bhavnagar has successfully completed his summer
internship at Sir Bhavsinhji Polytechnic Institute On process design of reactor.
Has successfully completed a six-week internship. From 27.05.2025 to
05.07.2025. During His Internship tenure with us. He Were exposed to
following Different processes and study of a reactor and were found sincere
and hardworking.

With best regards

Sir Bhavsinhji polytechnic institute

INDEX

Sr no. Topic Page no.

1. Introduction of 1-4
reactor

2. Classification of 5 - 17
reactor
Process design of
3. reactor 17- 27
1. Introduction to Reactor :-

 What is a Reactor?
A reactor is a central component in chemical and biochemical processes.
It is a vessel or system in which chemical reactions are carried out under
controlled conditions. The purpose of using a reactor is to facilitate and
optimize chemical reactions, ensuring they happen efficiently, safely,
and economically. Reactors are used in various industries such as
petrochemicals, pharmaceuticals, fertilizers, food processing, polymers,
environmental engineering, and energy production.

 Basic Function of a Reactor

In any chemical or biochemical process, reactants are converted into
products. The reactor ensures:
1. Proper mixing of reactants.
2. Heat transfer to maintain temperature.
3. Control of pressure and other operating conditions.
4. Efficient conversion of raw materials to products.
5. Safety, as many reactions are exothermic or involve toxic/reactive
substances.

 Components of a Reactor
1. Reactor Vessel – Main body where the reaction occurs.
2. Agitator or Stirrer – Ensures proper mixing.
3. Jacket or Coil – For heating/cooling the reactor.

4. Inlets and Outlets – For feeding reactants and removing products.

5. Sensors – For temperature, pressure, pH, etc.
6. Catalyst Bed (if used) – To increase reaction rate.

 Types of Reactions Inside Reactors

1. Exothermic (releases heat) – e.g., combustion.
2. Endothermic(requires heat) – e.g., steam reforming.
3. Catalytic – e.g., cracking hydrocarbons.
4. Biochemical – e.g., fermentation.
5. Polymerization – making plastics like polyethylene.

 Reactor Control and Instrumentation

Reactors are usually equipped with instruments and controllers:
 Temperature controllers
 Pressure valves
 Level indicators
 Flow meters
 pH sensors (for biochemical processes)

Automation and computer control (DCS/SCADA systems) ensure

efficient and safe operation.
  Real-Life Examples of Reactor Use
1. Pharmaceutical Industry – Synthesizing drugs.
2. Petrochemical Industry – Cracking crude oil into fuels.

3. Food Industry – Fermentation tanks for beer, yogurt.

4. Nuclear Power – Nuclear reactors convert nuclear fission heat to
electricity.
5. Environmental Engineering – Wastewater treatment bioreactors.

 Importance of Reactors in Industry

 They are the central unit in process plants.
 Responsible for yield and purity of products.
 Help in cost control by efficient conversion.
 Influence safety and sustainability in chemical plants.

 Safety in Reactor Operation

 Reactors may involve high pressure, flammable gases, toxic
chemicals, or exothermic reactions.
 Modern reactors are built with pressure relief valves, emergency
shutdown systems, and real-time monitoring.
 Operator training and automated safety protocols are critical.

 Summary
A reactor is more than just a vessel; it is a highly engineered
environment where physical science meets real-world application. It
allows us to transform basic materials into the products that power our
lives - from fuel and fertilizers to medicines and materials. A well-
designed reactor not only ensures efficient chemical conversion, but also
maximizes safety, sustainability, and economic value.

1. Classification of reactor :-
Several types of reactors are in use in industry. Basically they fall in two
categories:-
1.Batch reactor
2.Continuous reactor ( stirred reactor).
In each category, different designs are available. In fact, development of
a reactor can be an innovative idea and a process engineer can
Use his skills for such a development.
different types of reactors are represented schematically. Designs
Date back to a simple batch reactor to modem continuous catalytic
reactors such
As ammonia converter. Designs also vary with the type of reactions;
such as Homogenous, heterogeneous, run-away reactions, etc.
In many cases, a number of reactors are used in series. Continuous
stirred tank Reactors can be cited as an example. In some cases, number
of Parallel reactors are used. For example, in reforming of hydrocarbons
(such as Naphtha or natural gas), several hundred tubular reactors are
used in parallel in Which catalyst is packed in different shapes and sizes.
Selection is made on the Basis of degree of conversion, ease of heat
removal/addition, safety and other Considerations

1. Batch reactor:-
• Description :-
In a batch reactor all the reactants are initially charged into the reactor.
In most Cases, then they are allowed to react for certain period of time.
The

resultant Mixture is then discharged. In any batch reactor, composition

of reaction mass Changes with lime, hence it is called unsteady state
reactor. In an ideal batch reactor at any instant, composition throughout
the reactor is Uniform while the same is not true for a non-ideal batch
reactor. Size of batch Reactor does not directly depend on the reaction
time but it depends on volume of Material charged to the reactor. For
small capacity plant having production capacity less than 5 tones per
day, batch process with a batch reactor is more Economical than
continuous process (continuous reactor). In a batch reactor, variety of
agitators are used. Each one has its specific ad-Vantages and limitations.
Fig. gives different types of mixing equipment, Used in chemical
industry. Selection of an agitator plays an important role in Achieving
desired conversion in the reactors. In majority of reactors, turbine type
Agitators are used. While for simple mixing, flat blade turbine agitator is
used, Pitched blade turbine agitator is preferred for a slurry. For viscous
liquids (such As manufacture of amino/alkyl resins), anchor/paddle type
agitators of different Designs are used. For homogenizing applications,
such as milk powder dissolution in water, degumming of edible oils
(with phosphoric acid), etc., shear mixers an ideal choice but is a costly
equipment. For gas-liquid reactions gas induction type agitator and jet
loop reactor are preferred. Design of agitation equipment is discussed at
length in literature.

 Industrial Examples of Batch Reactor :-

(a) Synthesis of dyes: Sulfonation of napthalene gives /3-sulfonale
(b) Benzene sulfonic acid from benzene
(c) Nitrobenzene from benzene with mixed acid
(d) Synthesis of polyurethan from toluene diisocyanate and polyglycol
(e) Synthesis of cypermethrin

(f) Batch fermenter: Fermentation of molasses to ethanol

(g) Manufacture of active pharmaceutical ingradients (API)
(h) Manufacture of amino and alkyd resins, et

• process in short :-
All reactants are loaded into the reactor at the start. The reaction occurs
over time without adding or removing anything during the process. After
the reaction is complete, the product is removed, and the reactor is
cleaned for the next batch.
• Operation :- Unsteady state (time-dependent).
 Advantages of Batch Reactors Over Continuous Flow Reactors :-
(a) For small scale production, batch process with a batch reactor is
more economical than continuous process with continuous reactor.
(b) Batch reactors provide more flexibility. For example, it is readily
possible to increase the reaction time in the batch reactor while the same
is difficult in continuous flow reactor without sacrificing the production
rate.
(c) Some process steps (upstream or downstream processing) of the
reaction can also be performed in the reactor.
(d) Batch reactors require less and relatively simple or cheaper
instruments. while continuous flow reactors require more sophisticated
and costlier instruments.

 Disadvantages of Batch Reactors Over Continuous Flow Reactors:-

(a) High manpower requirement
(b) Time is wasted in between two batches
(c) Temperature control is poor, especially for highly endothermic or
exothermic reaction. While starting reaction in a batch reactor, rate of
reaction is high and hence heat duty is substantially high.
(d) Quality of the product may vary from a batch to batch.
2. Continuous reactor ( stirred reactor) :-

All continuous flow reactors are steady state flow reactors. In a steady
state flow Reactor, composition at any point is unchanged with time.
For continuous flow reactors, in-line mixers are used. In-line shear
mixers Are developed for continuous degumming of edible oils. In-line
static mixers are Effective in achieving desired mixing in continuous
systems.
In continuous Nitration, mixing of a reactant with mixed acid is very
effective through a static Mixer. Similarly mixing of natural gas/naphtha
vapour with steam prior to re-Forming can be carried out in an in-line
static mixer. For removal of free fatty Acids from edible/non-edible oils
with caustic soda solution, a static mixer is Used in a continuous plant.
Continuous flow reactors are used for achieving high throughputs. Also
quality of product can be maintained at desired level once the operating
conditions Are stabilised.
There are two ideal steady state flow reactors.

(a) Ideal plug flow reactor

(b) Ideal mixed flow reactor

 Operation :-
Steady state (if well controlled).

1. Plug Flow Reactor:-

It is also known as ideal tubular, unmixed flow, slug flow
or piston flow reactor.
Ideal plug flow reactor has flat velocity profile. In this type
of reactor, lateral or radial mixing is permitted, but axial
mixing is not permitted. Hence in ideal PFR, the residence
time in the reactor is same for all elements or particles of
fluid.

Ideal PFR is defined by two criteria.

(a) Over any cross section of ideal PFR, the mass flow rate, velocity and
the fluid properties like pressure, temperature and composition are
uniform and the same do not change with time.
(b) There is negligible diffusion relative to bulk flow or no element of
fluid overtaking or mixing with any other element ahead or behind. In
ideal PFR, composition at any point is not changing with time but it
changes with length or axial distance in reactor. Industrial plug flow
reactors can be fixed bed catalytic reactor, packed tower type reactor,
tubular reactor with very high length to diameter ratio and zigzag path,
shell and lube heat exchanger, double pipe heat exchanger, sieve tray
tower,etc. Working volume of ideal PFR can be determined by using
following equation.

 Advantages and Disadvantages of Plug Flow Reactors over Mixed

Flow Reactors:-
(a) Advantages:
(I) For any positive order reaction, plug flow reactor require minimum
volume Among all types of continuous flow reactors. Volume required
by ideal PFR Is very much less than the same by ideal mixed flow
reactor, particularly for A higher order reaction with higher desired
conversion.
(ii) Plug flow reactor does not use moving mechanical parts and hence it
is Suitable for high pressure reaction system, corrosive reaction system
and For the reaction system which involves the use of a toxic gas.
(b)Disadvantages:
(I) Cost per unit volume of plug flow reactors is higher than the same of
mixed Flow reactor.
(ii) It requires high investment cost for lower conversion and lower order
Reaction.

 Few Industrial Examples of Plug Flow Reactors

(I) Conversion of ethylene to low density polyethylene (LDPE)
(ii) Hydrolysis of ethylene oxide to ethylene glycol.
(iii) Fixed bed catalytic reaction.

Some examples are as follows:

(A).Conversion of NH3 from the mixture of N2 and H2
(B).Methanol synthesis reaction
(C).Conversion of synthesis gas (H2 + CO) to methanol
(D) .Air oxidation of methanol to formaldehyde
(E). Olefin production by steam cracking, e.g. ethylene
(F). Conversion of ammonium carbonate to urea in an autoclave.
2. Ideal Mixed Flow Reactor
It is also known as the back mix reactor (BMR), ideal continuous stirred
tank Reactor or as constant flow stirred tank reactor. In ideal mixed flow
reactor (MFR), Composition within the reactor is uniform throughout
and does not change with Time. Hence, in ideal MFR (or in ideal BMR
or CSTR) exit stream from the Reactor has the same composition as the
fluid within the reactor.
Among all types of continuous flow reactors, ideal mixed flow reactor
requires Maximum volume for the given positive order reaction. So,
volume required by Ideal mixed flow reactor (Vm) is greater than
volume required by ideal plug flow Reactor (Vp. Ratio yjVp increases
with increase in order of reaction and also With increase in required
conversion.
In an ideal CSTR, once the reactants enter into the reaction mass, they
Immediately (practically within no time) achieve final required
composition. This Is not due to very fast reaction but this is merely due
to the dilution of reactants By the products. Actually, the rate of reaction
is minimum in ideal CSTR, compared To all types of continuous flow
reactors, as it provides minimum concentration of Reactants during
reaction.
In an ideal CSTR, not only composition but temperature is also uniform
through-Out. Temperature of product stream is same as that within the
reactor.
Industrial mixed flow reactors can be:
(A) Agitated vessel type reactor
(B)Spared vessel (including gas induced agitator type) or bubble column
type Reactor
(C) Loop reactor (with recirculation, recirculating pump and external
heat Exchanger)
(D) Jet reactor with recirculation through an ejector.

 Advantages of Ideal Mixed Flow Reactor

(I)Temperature is easier to control. Good mixing and lower rate of
reaction(lower rate of heat generation in case of exothermic reaction)
makes the Temperature control easier. In the entrance portion of plug
flow reactor and In starting period of batch reaction, rate of reaction is
very high and hence Temperature control is difficult. Agitated vessel
type ideal mixed flow reactor also provides higher heat transfer
coefficient compared to packed tower Type or sieve tray type plug flow
reactor which are normally operated in Adiabatic manner.
(ii) Ideal mixed flow reactor may require less fixed cost compared to
ideal plug Flow reactor for lower order reaction with lower equilibrium
conversion Because cost per unit volume of mixed flow reactor is less
than the same of Plug flow reactor.
(iii) Polymerization reactions can be nicely controlled in ideal CSTR
compared To the same in ideal PFR. (e.g. desired molar mass of polymer
can be easily Achieved.)
(iv) Fine catalyst particles can be effectively suspended throughout the
liquid Reaction system with agitated vessel type mixed flow reactor.
(v) For highly viscous fluid or slurry solution, agitated vessel type mixed
flow Reactor provides higher heat transfer coefficient and mass transfer
coefficient, compared to plug flow reactor.

 Disadvantages of Ideal Mixed Flow Reactor

(I) Ideal mixed flow reactor provides the minimum rate of reaction
among all Types of continuous flow reactors. Hence, it requires
maximum volume Among all types of continuous reactors for any given
positive order reaction Required conversion.
(ii) Change over to other product is difficult compared to stirred tank
batch Reactor.
 Industrial Examples of Mixed Flow Reactors
(I) Carboxylation of methanol gives acetic acid in presence of liquid
phase Catalyst
(ii) Oxidation of acetaldehyde to acetic acid in presence of lime KMn04
(potassium permanganate) particles as catalyst.
(iii) Styrene to polystyrene by solution polymerization.

(iv) Slurry polymerization of propylene to polypropylene

(v) Chlorination of benzene to chlorobenzene by continuous process
(vi) Oxidation of toluene to benzoic acid.
(vii) Vinyl chloride to polyvinyl chloride by emulsion and suspension
polymerization.

3. Process design of reactor :-

XA
Performance equation of ideal batch reactor is ϴ = N ∫ dX A
AO
(−rA )V
0
Where,
ϴ = Time required to achieve the conversion X, s
XA = Fractional conversion of limiting reactant
(−rA ) V = Rate of reactionkmol/(m3 * s)
V= Working volume of reactor, m3
For the constant volume reaction system,
XA XA
N AO
ϴ= ∫ dXa =CA 0 ∫ (−rA)V
V 0 (−rA ) V
dXA
0

Where, CA, = Initial concentration of limiting reactant A.

Example 10.1
Butyl acetate formation is carried out in a batch reactor at 90°C with
sulphuric acid as a homogeneous catalyst. The feed contained 4.97
moles of n-butanol per mole .of acetic acid and the catalyst
concentration is 0.032% by mass as H2SO4,
Rate equation for this reaction is - rA = kC •
where, CA = Concentration of acetic acid in mol/cm3
k = 17 .4 cm3/(mol . min) (Ref. 4)

Density of the reaction mixture at 90°C can be assumed constant and

equal to 0.75 g/cm3.
(a) Calculate the time required to obtain conversion of 50%.
(b)Determine the size of reactor and the mass of reactants that must be
charged to the reactor in order to produce ester at the average rate of
100kg/h, Conversion in 50%.
Reactor will be shut down for 30 min between batches for removal of
product, cleaning and start up. Assume that batch reactor is ideal. Also
decide height and diameter of the reactor.
(c)Determine the heat duty required and heat transfer are required for
starting condition of the reaction.

Solution:
(a) For ideal batch reactor, time required to obtain the conversion X,
XA
dX A
ϴ = N ∫ (−rA
AO
)V
0

Given reaction is a liquid phase reaction in homogenous phase hence

working volume can be assumed constant.
XA XA
N AO
ϴ= ∫ dXa =CA 0 ∫ (−rA)V
V 0 (−rA ) V
dXA
0

0.5
θ=
1
[
1
] =
1
( 1
)( − 1
kC Ao 1− X A 0 kC Ao (1−0.5) (1−0) )
1 1
θ= ( 2−1 )=
kC Ao kC Ao

Mole of acetic acid

C Ao=
Total Volume

Moles ofacetic acid

∗Total moles
Total MOles
¿
Total Volume
 a
x A∗ρmix
C Ao=
M av

(1/5.97)
C Ao= ∗0.75
= 0.0018 mol/cm3
( 1
)(
+ 4.97
5.97∗60 5.97∗74 )
1 mole of acetic acid
Moleratio in feed = 4.97 mole of butyl alcohol
o
x A=1/5.97

M av = ( 5.97∗60
1
)+(5.97∗74 )
4.97 =71.655

Where, molar mass of acetic acid = 60

And molar mass of butyl alcohol = 74
k = 17.4 cm3 /(mol * min)
1
θ= =32min∨0.53 h
17.4∗0.0018

Time required to obtain 50% conversion is 32 min.

mass of liquid (raw material)charged
(b) Working volume of reactor = Density of liquid mixture chargerd

Assume that volume liquid mass inside the reactor will remain same
during the reaction (or change in liquid volume during the reaction in
negligible). For 100 kg/h ester production with 50% conversion.

Mass of acetic acid required per hour

100 kg /h
∗molar mass of acetic acid
molar mass of ester
¿
0.5
 110
∗60
116
¿ =103.45 k
0.5

(Molar mass of butyl acetate (CH 3COOC4H9)=6x 12+2x 16+ 1x 12 =

116) Mass of acetic acid required per batch
103.45∗( 32+ 30)
mA= (TIme between batc h es=30 min)
60

= 106.9 kg/batch

Reaction:
CH3COOC4H9 + C4H9OH(l) ⇌ CH3COOC4H9(l) + H2O(l)
Reaction is carried out at 90°C and with 50% conversion.
Mass of butanol required per batch,
106 . 9
mB =
60
* 74 * 4.97 = 655.26 kg/batch

Mass of H2SO4 required per batch

106.9+655.26
ms =
(1−0.00032)
∗0.00032 = 0.244 kg/batch

Total mass of raw materials = 762.4 kg

762.4 3
V working = =1.0165m
0.75∗1000

h
Let Di
=l

Where, h =Depth of liquid in reactor shell, m

Di = Diameter of vessel (inside Diameter), m

Let types of bottom head = Torispherical
Inside volume of Torispherical head,
π
V= 0.084 673 D + 4 D
3 2
i s
i f

(a) To determine heat duty required at starting condition of reactor, heat

of reaction ∆HR is required.

Table 10.1 Standard Heat of Formation and Heat Capacity Data

Compou 611/. kJ/mol al 25°C C kJl(kmol • °C)

nd u at57.5°C
,
Acclic -484.2 129.67
acid
Butanol -327.3 215.4 I
Waler -285.83 75.36
Butyl -522.766 267.12
acetate

In reactor, when reaction starts both reactants and products are at the
reaction temperature
Heat of reaction at reaction temperature (90°C)

. Vi
= Stoichiometric coefficient = 1 for all reactants
Assuming heat capacities to be nearly constant up to 90°C,

Heat required at the starting of reaction

∅= ∆HR * 1000 * kmol/h of acetic acid consumed +

Heat required to remove the water continuously from the reaction mass
of ternary azeotrope

Water will leave the reaction mass cither as binary azeotrope with
butanol (normal boiling point = 92.2°C) or as ternary azeotrope with
butyl acetate and butanol (normal boiling point = 89.4°C), Boiling point
of ternary azeotrope is less than binary azeotrope.
Composition of ternary azeotrope:
68.86% butyl acetate, 10.47%% butanol, 28.92% water (by mass).

Hence it will be logical to assume that water will leave as ternary

azeotrope.
Rate of reaction at the starting of reaction

Moles of acetic acid consumed per unit volume of reactor

Water formation rate = 3.438 37 kmol/h = 61.89 kg/h
Total flow rate of ternary azeotrope in starting of reaction

It will contain 130.24 kg/h of butyl acetate, 22.4 kg/h of butanol and
61.89 kg/h of water ∅ , at starting or reaction

As a heating medium saturated steam is used.

Let saturated steam pressure = 0,2 MPa a
Saturation temperature = 120.23°C
Latent heat of vaporization of steam, = 2201.6 kJ/kg
Saturated steam side heat transfer coefficient,

It is difficult to find the suitable correlation for the reacting mass side
heat transfer coefficient as the reaction is taking place. H i, can be
governed by boiling coefficient or by convective film coefficient. If flat
blade discturbine agitator is used to improve the reaction rate and to
improve the convective film beat transfer coefficient, then

To calculate the convective film coefficient let the tip velocity of turbine
agitator

For flat blade disc turbine

ρmix =75 kg /¿m3

Viscosity of mixture

C p =∑ C pi wi =2.1855∗0.1495+2.8763∗0.8595=2.78 kJ /(kg∗° C )
mix

Thermal conductivity of liquid mixture can be calculated by Li method.

Nucleate boiling coefficient for the boiling of azeotropic mixture can be
determined by Mostinski’s equation.
I is valid for single component boiling. But it can be used for close
boiling range and azeotropic mixture.

For nucleate boiling ∆Tm, =30.83°C (as decided earlier)

Heat transfer area provided with full height covered jackal,

(Assuming shell thickness, tm = 6.35 mm)

p=operating pressure bar = 0.9869 bar
pe= critical pressure, bar

Critical pressure of mixture

Pcm = ∑ P ci yi (Kay’s Rule)

Convecive film coefficient, hi =4594.25 W/(m2 °C)> hnB

Since nucleate boiling coefficient is less than the convective coefficient,
it is taken for heat transfer area calculations.

hi = 2524,95W/(m2 °C)

Jacket side or saturated steam side heat transfer coefficient, h, = 6000

W/(m2 °C) .
Thermal conductivity of reactor shell material (SS-304) = 16 W/(m2 °C)

Let thickness of reactor shell = 6.35 mm (Assumed but it should be

decided based on mechanical design)
Overall heat transfer coefficient:

Heat duty, ∅ =60.5944∗¿103 W , ∆ Tm=30.23 ° C

Heat transfer area required

Outside heat transfer area provided with full height covered jacket
% Excess heat transfer area = 27.06%
Thus available heat transfer area is sufficient
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