Catalytic continuous flow stirred tank reactor

Various experimental methods to evaluate the kinetics of flow processes existed even in the last centuty. They developed gradually with the expansion of the petrochemical industry. In the 1940s, conversion versus residence time measurement in tubular reactors was the basic tool for rate evaluations. In the 1950s, differential reactor experiments became popular. Only in the 1960s did the use of Continuous-flow Stirred Tank Reactors (CSTRs) start to spread for kinetic studies. A large variety of CSTRs was used to study heterogeneous (contact) catalytic reactions. These included spinning basket CSTRs as well as many kinds of fixed bed reactors with external or internal recycle pumps (Jankowski 1978, Berty 1984.)... 

An example of a system which most nearly meets these requirements is a quartz continuous-flow stirred-tank reactor (CFSTR) (99-101,140,1%, 197) with catalyst configurations in which all surface metal atoms are on the exterior surface of the support. It satisfies the relevant requirements listed above and allows investigation over a broad range of both product and reactant concentrations. Furthermore, true poisoning rates can be measured directly, without requiring assumption of a model for the poisoning. The amount of sulfur adsorbed can be directly determined as a function of time and gas-phase H2S concentration, and the catalytic activity of the metal can be measured as a function of sulfur on the surface. 

V. P. Gupta and W. J. M. Donglas [AIChE J 13,883 (1967)] studied the catalytic hydration of isobutylene to f-butanol in a continuous flow stirred-tank reactor when the reaction is mediated by a cation exchange resin catalyst ... 

The second type of non-catalytic reactor is the continuous-flow, stirred-tank reactor (Figure 18.7), which has the notable feature of encouraging complete mixing of aU of the ingredients, and if there is added catalyst (suspended in the fluid phase) the reactor may be referred to as a slurry reactor. 

Although the system we have considered here is a relatively simple one involving a first-order reaction, it has revealed the existence of some fascinating and exotic phenomena. Such phenomena are not limited to catalytic reactions but arise in other nonisothermal systems, for example, in continuous-flow stirred tank reactors, and even in isothermal systems. Their common feature is that the performance curve describing the system has to exhibit an inflection. Such inflections have also been observed in a biological context, where they play the role of a biological switch, which is activated in response to particular stimuli. 

Tajbl, Simons, and Carberry lnd. Eng. Chem. Fundamentals, 5 (171), 1966] have developed a stirred tank reactor for studies of catalytic reactions. Baskets containing catalyst pellets are mounted on a drive shaft that can be rotated at different speeds. The unit is designed for continuous flow operation. In order to determine if... 

Catalytic tests in sc CO2 were run continuously in an oil heated flow reactor (200°C, 20 MPa) with supported precious metal fixed bed catalysts on activated carbon and polysiloxane (DELOXAN ). We also investigated immobilized metal complex fixed bed catalysts supported on DELOXAN . DELOXAN is used because of its unique chemical and physical properties (e. g. high pore volume and specific surface area in combination with a meso- and macro-pore-size distribution, which is especially attractive for catalytic reactions). The effects of reaction conditions (temperature, pressure, H2 flow, CO2 flow, LHSV) and catalyst design on reaction rates and selectivites were determined. Comparative studies were performed either continuously with precious metal fixed bed catalysts in a trickle bed reactor, or discontinuously in stirred tank reactors with powdered nickel on kieselguhr or precious metal on activated carbon catalysts. Reaction products were analyzed off-line with capillary gas chromatography. 

Chapter 7, Reactor Design, discusses continuous and batch stirred-tank reactors and die packed-bed catalytic reactor, which are frequently used. Heat exchangers for stirred-tank reactors described are the simple jacket, simple jacket with a spiral baffle, simple jacket with agitation nozzles, partial pipe-coil jacket, dimple jacket, and the internal pipe coil. The amount of heat removed or added determines what jacket is selected. Other topics discussed are jacket pressure drop and mechanical considerations. Chapter 7 also describes methods for removing or adding heat in packed-bed catalytic reactors. Also considered are flow distribution methods to approach plug flow in packed beds. 

In Table I the high-vacuum (HV) range means a pressure of 10 to 10 Torr entries designated by Torr mean pressures between 0.1 and 10 Torr flow refers to an unspecified steady-state flow pattern. It is apparent from Table I that there is a great diversity in the different oscillation conditions and catalytic systems. The pressures under which oscillations have been observed vary from 10 Torr for the CO/NO reaction on Pt(lOO) 141, 142) to atmospheric pressure for a large number of systems. The reactors used in these studies include ultrahigh-vacuum (UHV) systems, continuous stirred tank reactors (CSTRs), flow reactors, and reactors designed as infrared (IR) cells, calorimeters, and ellipsometric systems. 

In fact, since the leaving group, methyl carbonate, decomposes (reaction 3), the base is restored and can be used in truly catalytic amounts. This feature allows utihzation of continuous-flow (c-f) procedures (i.e. gas-liquid phase-transfer catalysis, GL PTC, and continuously stirred tank reactor, CSTR ). 

Kinetic models can be used to link the reactor design with its performance. The reaction rate may be expressed by power law functions, by more complex expressions, as Langmuit-Hinselwood-Hougen-Watson (LHHW) correlations for catalytic processes, or by considering user kinetics. There are two ideal models, continuous stirred tank reactor (CSTR) or plug flow (PFR), available in rating mode (reaction volume fixed) or design mode (conversion specified). 

The rate expression for Fiseher-Tropseh (FT) synthesis has been obtained using a 25 wt.% C0/AI2O3 eatalyst in a 1 liter continuously stirred tank reactor (CSTR) operated at 493K, 1.99 MPa (19.7 atm), H2/CO feed ratios of 1.0-2.4 with varying space velocities to produce 14-63% CO eonversion. Adjusting the ratios of inert gas and added water permitted the impact of added water to be made at the same total flow rate and H2 and CO partial pressures. The addition of water at low levels during FT sjmthesis did not impact CO conversion but at higher levels it decreased CO conversion relative to the same conditions without water addition. The catalytic activity recovered after water addition was terminated. The temporary reversible decline in CO conversion when water was added may be due to the kinetic effect of water by inhibition of CO and/or H2 adsorption. The data of this study are fitted fairly well by a simple power law expression of the form ... 

The continuous stirred-tank reactor is also known as a continuous backmix, bachnaed, or mixed flow reactor. In addition to the catalytic reactors mentioned in the preceding paragraph, the reactors that are used for certain continuous polymerizations, e.g., the polymerization of styrene monomer to polystyrene, closely approximate CSTRs. 

Table 11.4 lists reactors used for systems with two fluid phases. The gas-liquid case is typical, but most of these reactors can be used for liquid-liquid systems as well. Stirred tanks and packed columns are also used for three-phase systems where the third phase is a catalytic solid. The equipment listed in Table 11.4 is also used for separation processes, but our interest is on reactions and on steady-state, continuous flow. 

There are numerous reactor types, but in this chapter the objective is to consider only a few common types. These are batch, continuous stirred tank, homogenous plug flow and fixed bed catalytic reactors. To size other reactor types and for a more thorough treatment of reactor design than presented here, the reader can consult books written on reactor design, such as Fogler [16], Smith [23], and Forment and Bischoff [31]. 

---