Chemical Reactors
Classification of Reactions
Elementary Non-elementary
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Type of Reactors
Multi Phase Fixed Bed Moving Bed Fluidized Bed Trickle Bed Rotary,Bubble
Batch Reactors
Batch reactors : Reactants charged into a vessel at beginning of the operation, products are discharged at end of the operation operation. . are the and the
The chemical reactions take place over time time. . The vessel is usually agitated to provide good contacting between the reactants and to create uniform conditions conditions. .
Uzi Mann_Principles_of_Chemical_Reactor_Analysis_and_Design__New_Tools_for_Industrial_Chemical_Reactor_Operations
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Batch Reactors
The use of batch reactors in commercial processes is usually most suitable for small volume production, particularly for situations in which switching from one process or product to another is required, as in the manufacture of pharmaceuticals. pharmaceuticals. Typically, in such processes, the value of the products is relatively large compared with the cost of production production. . It may be used for large volume production (with multiple units in parallel) such as the production of vinyl (polyvinyl chloride or PVC) involving suspension polymerization, and of emulsion emulsion-polymerized latex latex. .
Missen- Introduction to Chemical Reaction Engineering & Kinetics
Batch Reactors
The advantages : Simple in construction, Small instrumentation and cost, Flexibility of operation. The disadvantages : Inherent downtime (filling,heating, discharging and cleaning) between batches High maintenance cost. Unsteady State operations Difficult to control heat transfer and product quality.
Kayode Coker- Modeling of Chemical Kinetics and Reactor Design
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Batch Reactors
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Continuous Reactors
Continuous reactor : A vessel into which reactants are fed continuously and products are withdrawn continuously from it. Chemical reactions take place over space (the reactor volume), and the residence time of the reacting fluid in the reactor provides the required reaction time.
(a) tubular, (b) Continuous stirred tank reactors (c) CSTR in series
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Multiphase Reactors
LiquidLiquid-Liquid and GasGas-Liquid: Spray column, bubble column,membrane reactor,emulsion reactor LiquidLiquid-Gas and Solid Liquid : Slurry,fixed bed,moving bed,fluidized bed,rotary kiln reactor Three phase : Trickle bed, Membrane reactor
Chemical Process Design and Integration - R. Smith 2nd. Ed
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Catalytic
Non-Catalytic
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Hot spots: undesired reactions and catalyst degradation. Catalyst dilution (inert solid). Multi-tubular. Not recommended when frequent catalyst regeneration is required
Chemical Process Design and Integration - R. Smith 2nd. Ed
Alternatives:
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The temperature profiles between two configurations are different : For tubular reactor, the profile is seen to be relatively smooth. By contrast with the tubular reactor, the coldshot reactor experiences significant temperature fluctuations. Such fluctuations can, under some circumstances, cause accidental catalyst overheating and shorten catalyst life.
Chemical Process Design and Integration - R. Smith 2nd. Ed
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HOCH2CH2NH3HCO3
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Fluidizing Phenomena
Fluidizing Phenomena
ut
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Petrochemical applications
Acetone Recovery ,Aniline, Aniline from Nitrobenzene ,Ethanol from Butadiene ,Polyethylene, Hydrogen from Steam Coal Gasification, Styrenes from Hydrocarbons, Cracking of Methylcyclohexane, Maleic Anhydride Maleic Anhydride from Benzene and Butylenes Vinyl Chloride , Vulcanization of Rubber
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The disadvantages are: Inefficient contacting due to solids movement and the bypassing
of solids by bubbles. Possible channeling, slugging, and attrition of catalyst. Possible agglomeration and sintering of fine particles in the dilute phase under certain conditions (e.g., high temperature).
Slugging
Slugging occurs when the bubble size equals the tube diameter. Slugging can be avoided by reducing the height/diameter ratio.
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Channeling
Channeling occurs when the fluid has preferential paths through the reactor and may be avoided by a better distributor and by increasing the height-to-diameter ratio. A rule of thumb says that the pressure drop over the distributor should be at least one tenth of the pressure drop over the bed.
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Slurry Reactor
It is a multiphase flow reactor where the the reactant gas is bubbled through a solution containing solid catalyst particles particles. . Temperature control is quite simple simple. . Catalyst activity can be maintained by small addition of catalyst
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Membrane Reactors
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Membrane Reactors
A membrane reactor is really just a plug-flow reactor that contains an additional cylinder of some porous/membrane material within it. Membrane reactors combine reaction with separation to increase conversion. Membrane reactors are commonly used in dehydrogenation ,hydrogenation or partial oxydation reactions.
Fogler , Elements of Chemical Reaction Engineering
Membrane Reactors
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Membrane Reactors
Membrane Reactors
(a)
CH4
(b)
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Reactive Distillation
Reactive Distillation
Reactive distillation is used with reversible, liquid phase reactions. For many revesible reactions the equilibrium point lies far to the left and little product is formed : However, if one or more of the products are removed more of the product will be formed because of Le Chatlier's Principle :
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Reactive Distillation
Benefits of reactive distillation include:
Increased speed and improved efficiency Lower costs reduced equipment use, energy use and handling Less waste and fewer byproducts Improved product quality chemicals are exposed to heat only once, reducing opportunity for degradation
Reactive Distillation
Reactive distillation can be used with a wide variety of chemistries,including the following following: :
Acetylation; Aldol condensation; Alkylation Amination;Dehydration;Esterification Etherification;Hydrolysis;Isomerization Oligomerization;Transesterification
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Fuel Cell
A fuel cell an electrochemical reactor that converts hydrogen and oxygen to produce electricity, with water and heat as its by byproduct. product.
Fuel Cell
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References
1. Chemical Process Equipments Stanley M Walas 2. Allbrights Chemical Engineering Hand Book 3. Perrys Chemical Engineering Hand Book 4. Chemical Reactor Design and Analysis Froment & Bischoff 5. Elements of Chemical Reaction Engineering - Scott Fogler H 6. Chemical Reaction Engineering - Octave Levenspiel 7. Introduction to Chemical Reaction Engineering & Kinetics, Ronald W. Missen Missen, , Charles A. Mims, Bradley A. Saville 8. The Engineering of Chemical Reactions Lanny D. Schmidt 9. Chemical Reactor Design, Optimization and Scaleup E. Bruce Nauman
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