CHEE 321: Chemical Reaction Engineering 2. Isothermal Reactor Design Single Reaction in Batch, CSTR, PFR 2a.
Levenspiel plots (reactor sizing)
(Fogler Ch 2)
Summary - Design Equations of Ideal Reactors
Differential Equation Algebraic Equation Integral Equation
Nj
Remarks
Conc. changes with time but is uniform within the reactor. Reaction rate varies with time. Conc. inside reactor is uniform. (rj) is constant. Exit conc = conc inside reactor.
Batch
(well-mixed)
dN j dt
= (rj )V
t=
N j0
dN j (rj )V
CSTR
(well-mixed at steady-state)
V=
Fj 0 Fj ( rj )
PFR
(steady-state flow; well-mixed radially)
dF j dV
= rj
Fj
V=
Fj 0
dFj ( rj )
Concentration and hence reaction rates vary spatially (with length).
Design Equation in Terms of Conversion (limiting reactant A)
IDEAL REACTOR DIFFERENTIAL FORM ALGEBRAIC FORM INTEGRAL FORM
BATCH
N A0
dX A = ( rA )V dt
t = N A0
XA
dX A rAV
CSTR
V=
FA0 ( X A ) ( rA )
PFR
dX A FA0 = ( rA ) dV
V = FA0
XA
dX A rA
Fogler 2.2-2.3
Time is of the Essence
The extent of conversion of reactants in a chemical reactor is related to the time the chemical species spend in the reactor. Remember the definition: Average residence or space time of fluid in vessel is = V/v0
Space time is often used as a scaling parameter in reactor design
Residence time is chosen to achieve desired conversion (different for PFR and CSTR!), and can vary from a few seconds to several hours, depending on the rate of reaction
See Fogler Table 2-5
Fogler 2.6
Reaction Rates of Some Known Systems
Slow reaction
(requires large residence time)
Fast Reaction
(short residence time)
Sizing Reactors: A graphical interpretation These equations can be used to size reactors required to achieve a desired conversion for a single-reaction system Levenspiel Plots (Fogler, Ch 2.4-2.5)
Octave Levenspiel
considered to be one of the founders of Chemical Reaction Engineering
Basic idea: use plot of
FA0 ( rA )
vs. X to calculate V
Plug Flow Reactor (PFR)
FA0 ( rA )
VPFR =
X PFR
FA0 dX rA
XPFR
Continuous Stirred Tank Reactor (CSTR)
FA0 ( rA )
VCSTR
FA0 =[ ] [ X CSTR ] (rA )
Evaluated at X=XCSTR
XCSTR
Class Problem
The following reaction is to be carried out isothermally in a continuous flow reactor operating at steady-state: AB Compare the volumes of CSTR and PFR that are necessary to consume 90% of A (i.e. CA=0.1 CA0). The entering molar and volumetric flow rates are 5 mol/h and 0.5 L/h, respectively. The reaction rate for the reaction follows a first-order rate law: (-rA) = kCA where, k=0.0001 s-1
For same conversion, is the CSTR volume always higher than PFR volume ?
For most cases yes, provided that rA decreases as X increases. FA0 -rA See Fogler Section 2.4 (Ex. 2-2 to 2-4) for using Levenspiel plots to size reactors (PFR vs. CSTR) X
The real power of Levenspiel plots is for reactor networks (reactor in series)
PFR in Series
FA0 X=0 X=X1 FA1 FA2 X=X2 FA3; X=X3
Let us compare two scenarios (i) Single reactor achieving X3 (ii) 3 reactors in series achieving X3 How is the total volume of 3 reactors in series related to single reactor ??
FA0 -rA
X
Fogler 2.5
CSTR in Series
See Fogler 2.5.1
FA0 X=0 FA1 X=X1 FA2 X=X2 FA3; X=X3
Compare volume for the following 2 cases (i) A single reactor achieving X3 (ii) 3 reactors in series achieving X3 How is the total volume of 3 reactors in series related to single reactor ??
If you could replace one of the CSTRs with a PFR, which one would you choose to minimize the total volume of the reactor system?
FA0 -rA
We can model a PFR as a series of n equal volume CSTRs
Closing Thoughts on Levenspiel Plots
Levenspiel Plots are useful means to illustrate the difference between PFR and CSTR behavior
If the rate law is given in terms of conversion (-rA) = f(X) or can be generated/derived by intermediate calculations, one can size PFR, CSTRs, and batch reactors. PFR can be modeled as many CSTR in series (strategy often used in design software such as HYSYS)
Levenspiel plots are seldom used to design real world reactors
Restrictive conditions: no secondary side streams, single reaction Can only be used for scale-up if reaction conditions are kept identical: i.e.; (-rA) varies with conversion identically in the full-size reactors as in the lab
