REACTORS

By: Ts. Kishan Gunesegeran

INTI INTERNATIONAL UNIVERSITY NILAI
Types of reactors

1.Batch- uniform composition everywhere in

reactor but changes with time
2. Semi batch- in semi-batch one reactant will be
added when reaction will proceed
3. Continuous reactor
a. Mixed flow- this is uniformly mixed ,
same composition everywhere, within the reactor
and at exit
b. Plug flow- flow of fluid through reactor with order
so that only lateral mixing is possible
Reactor design parameter

Reactor design basically means which type and size of reactor

and method of operation we should employ for a given
conversation
Parameters
• Volume of reactor
• Flow rate
• Concentration of feed
• Reaction kinetic
• Temperature
• pressure
Plug flow and mixed flow reactor design

Mixed flow reactor design

Applying mass balance performance
equation for mixed flow reactor

Plug flow reactor design

Performance equation for plug flow reactor
Plug flow vs CSTR

• For any particular duty and for all positive reaction

order the volume of mixed flow reactor will
always be grater then plug flow
• Area under curve in figure is very small for plug
flow as compared to mixed flow so volume is
small for plug flow.
• When conversion is small, the reactor
performance is only slightly affected by flow type.
the perforation ratio very rapidly at high
conversion.
• Density variation during reaction affects design,
however it is normally of secondary importance
compared to the difference in flow type.
Multiple reactor system

• Number of plug flow reactor in series are theoretically same as

equivalent volume of a single plug flow reactor.
• Number of mixed flow reactor of equal size in series may be
used when we need high conversion and can’t perform in a
single reactor.
• From the given graph, for first order reaction, conversion for
series of equal size reactor can be find
Mixed flow reactor of different size in series

• From the fig it is clear that for plug flow reactor volume can be find by
dashed area and for mixed flow whole area.
• When we are have to use mixed flow reactor, then we can use different size
mixed flow reactor so, that over all volume would be small
• To optimized or to find how different size of mixed flow reactor should used
we have to maximized lower dashed rectangle.
• This optimization gives the slope of diagonal of the rectangle should be
equal to slope of curve at intersection of these two reactor.
• Levenspiel , has proved that after overall economic consideration equal
size reactors in series are economical.
Design for parallel reaction
• When a reactant gives two product (desired, and
undesired)simultaneously with different rate constant then this is
called a parallel reaction.
• To keep maximum amount of desired product we can take following
steps.
• Ifa1>a2 or the desired reaction is of higher order then keep reactant
concentration high for high product concentration.
• If a1<a2 than for desired reaction keep reactant concentration low.
• For a1=a2 change in reactant concentration will not affect the
product then, because rate constant k1 and k2 are different at
different temperature so, we can keep our temperature such that
desired product will be high or use of catalyst would be a option
which are selective in nature.
Reactor design for multiple
reaction
• In multiple reaction reactor design contacting pattern is most important factor to get a
particular product.
• In irreversible reaction in series like

the mixing of fluid of different composition is the key to formation of intermediate. The
maximum possible amount of intermediate is obtained if fluid of different composition and
different stage of conversation are not allowed to mixed.
• In series of reaction if intermediate reactant is our desired product than semi batch reactor
will be used.
Irreversible series-parallel reaction

• Multiple reaction that consist of steps in series and steps in parallel

reaction.
• In these reaction proper contacting pattern is very important.

Halogenations of alkane is a
• The general representation of these reaction are example of this kind of reaction
where reaction is parallel with
respect to halogen

• Here the reaction is parallel with respect

to reactant B and in series with A.
Reaction type

• Chemical kinetics of reaction can be known by knowing the type of

reaction
• For reactor selection reaction type will tell us about heat of reaction either
reaction is endothermic or exothermic.
• Selectivity is defined as reaction rate ratio for two parallel reaction.
• Catalyst are used to increase reaction rate and selectivity for a specific
reaction.
• We can determine what type of catalyst will be used.
• Reaction temperature range will be determined.
Reactor type

• Reactor may be a plug flow or mixed flow or batch flow reactor

or other.
• Contacting pattern of reaction will be known.
• In case of expensive catalyst and high heat transfer rate
required, mixed flow(fludized bed) reactor are used.
• For high mass transfer plug flow (packed bed) reactor will be
used.
Definition of Multiple Reaction
 Parallel rxns (competing rxns)
k1
B
A k2

C
k1
 Series rxns (consecutive k2
rxns)

A B
C
k1
 Complex rxns k(Parallel
2
+ Series rxns)

A+B C+D
A+C E
k1
 Independentk rxns
2
 Figure A
Different reactors and schemes for maximizing the desired product
A B A
B
A
B A
B A B

(a) CSTR (b) tubular reactor (c ) batch (d) semi-batch 1 (e) semi-batch 2

A A
B B

(f) Tubular reactor with side streams (g) Tubular reactor with side streams

B
A A
B

(i) Tubular reactor with recycle (h) Series of small CSTRs

 Figure B
Different reactors and schemes for maximizing the desired product
 Example 1 Minimizing unwanted products for two reactants

for the parallel reaction

k1 D (Desired Product)
A+B
k2 U (Undesired Product)

Case I : a1 > a2, b1 > b2, a = a1-a2 > 0, b = b1-b2 > 0

the rate selectivity parameter rD k1 a b

S DU   C AC B
rU k 2

To maximize the SDU, maintain the concentration of both A and B as high as possible
 a tubular reactor (Figure 6.3 (b))
 a batch reactor (Figure 6.3 (c))
 high pressures (if gas phase), reduce inert
 Example 2: Minimizing unwanted products for two reactants

for the parallel reaction

k1 D (Desired Product)
A+B
k2 U (Undesired Product)

Case II : a1 > a2, b1 < b2, a = a1-a2 > 0, b = b2-b1 > 0

the rate selectivity parameter rD k1C Aa

S DU  
rU k 2C Bb

To maximize the SDU, maintain CA high and CB low.

 a semibatch reactor in which B is fed slowly into A.
 a tubular reactor with side stream of B continually
 a series of small CSTRs with A fed only to the first reactor
 Example 3: Minimizing unwanted products for two reactants

for the parallel reaction

k1 D (Desired Product)
A+B
k2 U (Undesired Product)

Case III : a1 < a2, b1 < b2, a = a2-a1 > 0, b = b2-b1 > 0

rD k1
the rate selectivity parameter S DU  
rU k 2C Aa C Bb

To maximize the SDU, maintain the concentration of both A and B as low as possible
 a CSTR
 a tubular reactor in which there is a large recycle ratio
 a feed diluted with inert material
 low pressures (if gas phase)
 Example 4: Minimizing unwanted products for two reactants

for the parallel reaction

k1 D (Desired Product)
A+B
k2 U (Undesired Product)

Case IV : a1 < a2, b1 > b2, a = a2-a1 > 0, b = b1-b2 > 0

the rate selectivity parameter rD k1C Bb

S DU  
rU k 2C Aa

To maximize the SDU, maintain the concentration of both A and B as high as possible
Maximizing the desired product in series reaction

k1 k2
A B C

 In parallel rxns, maximize the desired product

 by adjusting the reaction conditions
 by choosing the proper reactor

 In series rxns, maximize the desired product

 by adjusting the space-time for a flow reactor
 by choosing real-time for a batch reactor
 Maximizing the desired product in series reaction
k1 k2
A B C
Desired Product

 If the first reaction is slow and second reaction is fast, it will be extremely difficult to
produce species B.

 If the first reaction (formation of B) is fast and the reaction to form C is slow, a large yield
of B can be achieved.

 However, if the reaction is allowed to proceed for a long time in a batch reactor or if the
tubular flow reactor is too long, the desired product B will be converted to C.

 In no other type reaction is exactness in the calculation of the time needed to carry out
the reaction more important than in series reactions.
Reaction paths for different ks in series reaction
k1 k2
A B C

For k1/k2>1, a
B k1
1
Large quantity of B
Can be obtained k2

k1
~1
k2
For k1/k2<1, a
Little quantity of B  2'
Can be obtained  3' k1
1 1st rxn is slow
 '
1 k2 2nd rxn is fast

A C
Long rxn time in batch or long tubular reactor
-> B will be converted to C
 Multiple reactions in a CSTR
For a CSTR, a coupled set of algebraic eqns analogous to PFR differential eqns must be solved.

Fj0  Fj
V 
 rj q

Rearranging yields where  r j   rij  f j (C1 , C 2 ,..., C N )

F j 0  F j   r jV i 1

After writing a mole balance on each species in the reaction set, we substitute for concentrations in the respective
rate laws.

If there is no volume change with reaction, we use concentrations, C j, as variables.

If the reactions are gas-phase and there is volume change, we use molar flow rates, F j as variables.
q reactions in gas-phase with N different species to be solved

q
 F1 FN 
F10  F1   r1V  V   ri1  V  f 1  F C T 0 ,  , CT 0 

i 1  T FT 
 F1 FN 
F j 0  F j   r jV  V  f j 
F C T0 ,  , C T0 

 T FT 
 F1 FN 
FN 0  FN   rN V  V  f N 
F C T0 ,  , CT 0 

 T FT 