Conceptual Reactor Design
Multi-phase
Reactors
Lecture
6
Non-isothermal reactors
Lecture
6
Conceptual Reactor Design
Multi-phase Reactors
Non-isothermal
reactors
Conceptual
Reactor
Design
Reactor Phase
Operation in the liquid phase is usually preferred
e.g. single reaction system : FEED
PRODUCT
r = k CFEED
a
Two-film theory
Effect of mass transfer
Gas
Liquid
Gas
Film
rAG = k AG ( p A p AI )
Interface
Liquid
Film
PA
rAL = k AL (CAI CA )
p AI = H ACAI
PAI
CAI
CA
PAI = HACAI
where
rG, rL
kAG, kAL
pA, pAI
CA, CAI
HA
rA =
1
1
k AG
H
+ A
k AL
(p
1
K AGL
1
k AG
HA
k AL
< Low solubility gases (HA is large) - kAG >> kAL/ HA : the mass transfer is liquid-film controlled
< High solubility gases (HA is small) - kAG << kAL/ HA : the mass transfer is gas-film controlled
< The capacity of dissolution
- The capacity of a gas to dissolve in a liquid is determined by the solubility of the gas.
- The capacity of a liquid to dissolve a gas is increased if it reacts with a species in the liquid.
a1
r1 = k1CFEED
2
FEED 6 BYPRODUCT r2 = k 2CFEED
Effect of temperature
< As temperature increases:
-
< The relative magnitude of mass tranfer enhancement and its consecutive effects depend on the
reaction system.
G
L
L
L
L
G
G
L
L
G
L
G+L
G
G
Mixed-flow
behaviour
Plug-flow
behaviour
Mixed-flow
behaviour
G
G
Plug-flow
behaviour
G
G
L
L
L
G
L
L
G
Counter-current packed beds offer the largest mass transfer driving force and
agitated tanks the lowest
Liquid-liquid Reactors
Liquid-liquid reactions
< Much of the discussion for gas-liquid reactions also applies to liquid-liquid reactions.
< The reaction may occur in one phase or both phases simultaneously
Dispersion of liquid
< External power input is required through an agitator or from pumping
< The degree of dispersion depends on
- Power input
- Interfacial tension between the liquids and physical properties
Multi-stage agitated
contactor
< A large number of stages
< Low back mixing
LL
LL HL
LL
LL HL
LL HL
HL
LL
HL
LL
HL
HL
LL
LL
LL HL
LL HL
HL
LL HL
HL
LL
LL HL
LL
LL HL
HL
LL HL
HL
LL
HL
HL
LL
LL
LL
LL HL
LL HL
LL HL
HL
HL
CaCO3
CaO
CO2
heat
< Air and fuel fluidize the solid particles and produce the high temperature
necessary for the reaction.
Kilns
Reactions involving free-flowing solid, paste, and slurry
materials can be carried out in kilns.
< Rotary kiln : rotation of cylinder shell
Example :
CaF2
calcium flouride
H2SO4
sulfuric acid
2HF
CaSO4
Reactor Configuration
from Optimisation of a Superstructure
So far, we have reviewed at length the factors influencing
the choice of reactor configuration and conditions
based on the development of the CONCEPTUAL ISSUES.
Superstructure
< Includes all the structural features that might be candidates for the final design
< Contains redundunt features that need to be removed
Feed
Product
Product 1
Feed 1
PHASE 1
Mass Transfer
PHASE 2
Feed 2
Product 2
Gas feed
Gas product
Liquid
Liquid
Liquid
feed
Gas
Liquid
Complex arrangements
cannot be obtained.
FEED
PHASE 1
Mass
Transfer
FEED
PHASE 2
Simulation
simulate a specific structure
Pertubation Moves
New features of design
Evaluation
Objectve function / Constraints
Simulated annealing
Accept / Reject
r1 = y (k 1 + k 2 )CLMC A + k 1k 2 CLDC A + k 2 CL C A
1
2
1
2
1
2
] (1+ k C )
3
L Cl2
r2 = k 3r1CL Cl
k1 = e
( 5.22 3120 T )
y = 0.037
k2 = e
( 0.00176 1880 T )
k 3 = 0.00136
Problem Data
Feed and Reaction Conditions
P = 10 bar
! Liquid feed: 13.3 kmoles of C A
4
! Gas feed: 100 kmoles of Cl
2
! Temperature bounds: 100 OC # T # 500 OC
!
a = 254.6 m2/m3 ,
gg = 0.5,
*L = 10-4 m
Conventional Designs
Counter current
packed bed
Mechanically
agitated vessel
Bubble column
Yield = 69.5%
Yield = 74.4%
Yield = 72.8%
Results
Reactor designs
Network model
Gas product
Liquid product
Gas Feed
Gas Product
Liquid
Gas
Liquid Feed
Liquid Product
Liquid feed
Gas feed
Yield = 96.9%
Vol = 9.93m3
Liquid Gas Liquid Gas
product feed product product
New design
Volume (m3)
69.5 %
16.1
74.4 %
12.0
72.8. %
12.2
96.9 %
9.9
Non-isothermal Reactors
Non-isothermal operation brings additional complexity to the superstructure
approach.
< Temperature profiles used to identify the optimum temperature profile for reactors.
(a) Isothermal.
(e) Asymptotic/exponential.
(d) Asymptotic/exponential.
Cooling
Heating