VARIOUS ISSUES INVOLVED IN THE DESIGN OF A PROCESS VESSEL

1. Shape/Geometry: This is arrived at based on Mechanical Strength Considerations. Mixing Considerations. Provision for Housing Internals and Externals.

Cylindrical geometry is the most preferred one for making process vessels. 2. Size: To find the size of a cylinder, we need to estimate three linear dimensions. Diameter (based on hydrodynamic considerations). Length (based on rate considerations). Shell wall thickness (as per codes and standards).

3. Operating Conditions: like Pressure, Temperature, Concentration, Flow rate, etc. These are arrived at based on thermodynamic and rate considerations. 4. Mode of Operation: Batch Operation. Continuous Operation. Semi batch Operation.

This is dictated by scales of production, flexibility to make multiple products based on market demand and economics. 5. A complete design of a process vessel involves two parts: Process Design. Mechanical Design.

In most of the cases, these two steps are interrelated and cannot be done independently. 6. Energy and Environmental Related Issues. 7. Safety Related Issues. 8. Economics.

VARIOUS INPUTS NEEDED FOR DESIGN OF A PROCESS VESSEL

1. Mass Balance Equations. 2. Heat /Energy Balance Equations. 3. Thermodynamic Equilibrium. 4. Transfer Rate Equations. 5. Desired Physical and Chemical Properties of all the Materials Involved at the Required Operating Conditions. 6. Appropriate Codes/ Standards for Mechanical Design.

VARIOUS ISSUES INVOLVED IN THE PROCESS DESIGN OF CHEMICAL REACTORS

1. Nature/type of reaction: Whether the reaction is Exothermic or Endothermic. Reversible or Irreversible. Single or Multiple. Homogenous or Heterogeneous.

This is required to arrive at the maximum possible extent of conversion for a given reaction based on equilibrium/thermodynamic considerations. 2. Mode of Operation: This is to be arrived at from two different perspectives. a) From the economic perspective: Batch Operation. Continuous Operation. Semi batch Operation.

b) From the heat transfer perspective: Isothermal. Adiabatic. Non-Isothermal/Non-Adiabatic.

So, as a result the actual mode of operation can be a combination of these two. For example: isothermal batch operation. 3. Heat Transfer Considerations: a) Mode of heat transfer: Whether by Conduction, Convection, radiation, or a combination.

b) Nature of heat transfer arrangement: Whether to provide a jacket or cooling coil. Whether to construct the vessel like a double pipe heat exchanger or a shell and tube heat exchanger. Should the reactor be housed in a furnace.

c) Heat transfer medium to be chosen. Whether to use cooling water, chilled brine, hot water, hot oil, saturated steam, hot gases/flames, electrical heating, etc.

This choice depends on the heat transfer rate/flux needed to perform a given duty. 4. Thermal Stability/Runaway. 5. Safety and Economics.

INPUTS NEEDED FOR THE DESIGN OF A REACTOR

1. Material Balance Equation/Design Equation. 2. Heat Balance Equations both on Reaction Mixture side and Heat Transfer Medium side. 3. Rate Equation. 4. Appropriate relation between Rate Constant and Temperature. 5. Information related to Hydrodynamics of the Contactor/Vessel chosen for design.

NON IDEAL BEHAVIOUR OF FLOW REACTORS

In understanding and evaluating the performance of a vessel to be used as a reactor, three factors play an important role. 1. Mixing time, i.e. the time needed for the materials to get mixed in the vessel. 2. Reaction time, the time needed for the reaction to occur. 3. Residence time, the time spent by the material in the vessel. Now, for a given vessel and a given contacting pattern, when a reaction occurs, the residence time of the materials in the vessel must be sufficient enough for the mixing and reaction to occur. a) The mixing time depends on the materials flowing through the vessel. The flowing materials may be in some particular state of aggregation, depending upon its nature. In the extremes these states are called Microfluids and Macrofluids. b) The reaction time is intrinsic to a given chemical reaction and the designer may not have much control over it. c) The residence time depends on the flow patterns prevailing in the vessel. d) The designer will have a control over mixing time and residence time through a proper choice of the contactor/vessel and contacting pattern. Now, in the context of a contactor and a contacting pattern, as well as the flow patterns to be prevailing in the contactor, the vessel geometry plays an important role. Since, cylindrical geometry is the most preferred one to make process vessels in general and reactors in particular; we will have the following two possibilities for flow reactors. A cylindrical tank (whose length to diameter ratio is very low) fitted with a stirrer. A long cylindrical tube (whose length to diameter ratio is very high).

This brings or enables us to define the two ideals of Perfect Mixed Flow and Ideal Plug Flow. These ideals form the basis for developing the subject of Non Ideal Flow Behaviour in Real Vessels.