Continuous reactors description

In this chapter the simulation examples are presented. They are preceded by a short description of simulation tools and the MADONNA program in particular. As seen from the Table of Contents, the examples are organised according to thirteen application areas Batch Reactors, Continuous Tank Reactors, Tubular Reactors, Semi-Continuous Reactors, Mixing Models, Tank Flow Examples, Process Control, Mass Transfer Processes, Distillation Processes, Heat Transfer, Biological Process Examples and Environmental Process Examples. There are aspects of some examples that make them relevant to more than one application area, and this is usually apparent from their titles. Within each section, the examples are listed in order of their degree of difficulty. 

Consequently, while I jump into continuous reactors in Chapter 3, I have tried to cover essentially aU of conventional chemical kinetics in this book. I have tried to include aU the kinetics material in any of the chemical kinetics texts designed for undergraduates, but these are placed within and at the end of chapters throughout the book. The descriptions of reactions and kinetics in Chapter 2 do not assume any previous exposure to chemical kinetics. The simplification of complex reactions (pseudosteady-state and equilibrium step approximations) are covered in Chapter 4, as are theories of unimolecular and bimolecular reactions. I mention the need for statistical mechanics and quantum mechanics in interpreting reaction rates but do not go into state-to-state dynamics of reactions. The kinetics with catalysts (Chapter 7), solids (Chapter 9), combustion (Chapter 10), polymerization (Chapter 11), and reactions between phases (Chapter 12) are all given sufficient treatment that their rate expressions can be justified and used in the appropriate reactor mass balances. 

Mathematical models describing formation of novolacs both in batch and continuous reactors have been developed by Frontini et al. [230] and Kumar et al. [231]. They consider the existence of at most one methylol group per molecule, and lump together all isomers with the same unit counts. A Monte Carlo method [232] can also be used in order to obtain a more detailed description at molecular level. 

The concept of macroscopic kinetics avoids the difficulties of microscopic kinetics [46, 47] This method allows a very compact description of different non-thennal plasma chemical reactors working with continuous gas flows or closed reactor systems. The state of the plasma chemical reaction is investigated, not in the active plasma zone, but... 

Technology Description Hybrid reactors, as the name implies, are a combination of suspended growth and fixed-film reactor principles. In these systems, the fixed film is submerged and the reactor contents are continuously stirred. A large amount of biomass is maintained in the system. 

The name continuous flow-stirred tank reactor is nicely descriptive of a type of reactor that frequently for both production and fundamental kinetic studies. Unfortunately, this name, abbreviated as CSTR, misses the essence of the idealization completely. The ideality arises from the assumption in the analysis that the reactor is perfectly mixed, and that it is homogeneous. A better name for this model might be continuous perfectly mixed reactor (CPMR). 

Glaser and Litt (G4) have proposed, in an extension of the above study, a model for gas-liquid flow through a b d of porous particles. The bed is assumed to consist of two basic structures which influence the fluid flow patterns (1) Void channels external to the packing, with which are associated dead-ended pockets that can hold stagnant pools of liquid and (2) pore channels and pockets, i.e., continuous and dead-ended pockets in the interior of the particles. On this basis, a theoretical model of liquid-phase dispersion in mixed-phase flow is developed. The model uses three bed parameters for the description of axial dispersion (1) Dispersion due to the mixing of streams from various channels of different residence times (2) dispersion from axial diffusion in the void channels and (3) dispersion from diffusion into the pores. The model is not applicable to turbulent flow nor to such low flow rates that molecular diffusion is comparable to Taylor diffusion. The latter region is unlikely to be of practical interest. The model predicts that the reciprocal Peclet number should be directly proportional to nominal liquid velocity, a prediction that has been confirmed by a few determinations of residence-time distribution for a wax desulfurization pilot reactor of 1-in. diameter packed with 10-14 mesh particles. 

The kinetic models are the same until the final stage of the solution of the reactor balance equations, so the description of the mathematics is combined until that point of departure. The models provide for the continuous or intermittent addition of monomer to the reactor as a liquid at the reactor temperature. 

No rate enhancement was observed when the reaction was performed under microwave irradiation at the same temperature as in conventional heating [47]. Similar reaction kinetics were found in both experiments, presumably because mass and heat effects were eliminated by intense stirring [47]. The model developed enabled accurate description of microwave heating in the continuous-flow reactor equipped with specific regulation of microwave power [47, 48]. Calculated conversions and yields of sucrose based on predicted temperature profiles agreed with experimental data. 

Even though all three reactors share the same precursor delivery system, each tool offers specific advantages. For example, a cold-wall reactor (reactor B) helps prevent decomposition of the precursor before it reaches the substrate. A pulsed aerosol injection system at low pressure (reactor C) allows the film to grow under better-defined conditions than in a continuous process (reactor A) because of the minimization of undesirable transient effects caused by the high volatility of the solvents used.46 A more detailed description of each of the conditions for film growth, including reactor type, precursor type, delivery method, deposition temperature, growth time, and other parameters are summarized in Table 6.2. Depositions were done on bare and Mo-coated... 

Reactor type Mathematical description (continuous variables)... 

The example simulation THERMFF illustrates this method of using a dynamic process model to develop a feedforward control strategy. At the desired setpoint the process will be at steady-state. Therefore the steady-state form of the model is used to make the feedforward calculations. This example involves a continuous tank reactor with exothermic reaction and jacket cooling. It is assumed here that variations of inlet concentration and inlet temperature will disturb the reactor operation. As shown in the example description, the steady state material balance is used to calculate the required response of flowrate and the steady state energy balance is used to calculate the required variation in jacket temperature. This feedforward strategy results in perfect control of the simulated process, but limitations required on the jacket temperature lead to imperfections in the control. 

A chromatographic reactor can be realized with different configurations from a single fixed-bed reactor to multireactor arrangement enabling continuous operation. Here, a short description of the basic types together with some recent results are presented. 

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