Continuous stirred tank reactor with recycle

Single continuous stirred-tank reactor with recycle of A... 

Continuous Stirred Tank Reactor with Recycle... 

The catalyst components are generally dissolved in methyl acetate which acts as both reactant and solvent. Other solvents may be used and in fact, upon several batch recycles where lower boiling products are distilled off, the solvent is an ethylidene diacetate-acetic acid mixture. Any water introduced in the reaction mixture will be consumed via ester and anhydride hydrolysis, therefore anhydrous conditions are warranted. Typical batch reaction examples are presented in Table 1. There is generally sufficient reactivity when carbon monoxide and hydrogen are present at 200-500 psi. Similar results were obtained from the pilot plant using a continuous stirred tank reactor (CSTR). The reaction can also be run continuously over a supported catalyst with a feed of methyl acetate, methyl iodide, CO, and hydrogen. 

L. T. Fan, L. E. Erickson, R. W. Sucher, and G. S. Mathad. Optimal design of a sequence of continuous-flow stirred-tank reactors with product recycle. I EC, 4 431, 1965. 

As in any type of polymerization, a batch reaction is not as commercially attractive as a continuous polymerization process that can produce larger quantities of polymer in the same amount of time. The first continuous polymerizations in C02 were reported (Charpentier et al., 1999) with the monomers acrylic acid and vinylidene fluoride. The vinylidene fluoride polymerization was extensively studied at 75 °C, 275 bar. The polymerizations were run with residence times that varied between 15 and 40 min in a continuous-stirred-tank reactor before collection in a filter. The maximum rate of polymerization was determined to be 19 x 10 5 mol L-1s-1. Future research will move toward continuous removal of polymer, recycling of unreacted monomer and C02, and expansion to other monomers. 

The production of substances that preserve the food from contamination or from oxidation is another important field of membrane bioreactor. For example, the production of high amounts of propionic acid, commonly used as antifungal substance, was carried out by a continuous stirred-tank reactor associated with ultrafiltration cell recycle and a nanofiltration membrane [51] or the production of gluconic acid by the use of glucose oxidase in a bioreactor using P E S membranes [52]. Lactic acid is widely used as an acidulant, flavor additive, and preservative in the food, pharmaceutical, leather, and textile industries. As an intermediate product in mammalian metabolism, L( +) lactic acid is more important in the food industry than the D(—) isomer. The performance of an improved fermentation system, that is, a membrane cell-recycle bioreactors MCRB was studied [53, 54], the maximum productivity of 31.5 g/Lh was recorded, 10 times greater than the counterpart of the batch-fed fermentation [54]. 

It may also be economical to remove the inhibitory product directly from the ongoing fermentation by extraction, membranes, or sorption. The use of sorption with simultaneous fermentation and separation for succinic acid has not been investigated. Separation has been used to enhance other organic acid fermentations through in situ separation or separation from a recycled side stream. Solid sorbents have been added directly to batch fermentations (18,19). Seevarantnam et al. (20) tested a sorbent in the solvent phase to enhance recovery of lactic acid from free cell batch culture. A sorption column was also used to remove lactate from a recycled side stream in a free-cell continuously stirred tank reactor (21). Continuous sorption for in situ separation in a biparticle fermentor was successful in enhancing the production of lactic acid (16,22). Recovery in this system was tested with hot water (16). 

The experimental study of solid catalyzed gaseous reactions can be performed in batch, continuous flow stirred tank, or tubular flow reactors. This involves a stirred tank reactor with a recycle system flowing through a catalyzed bed (Figure 5-31). For integral analysis, a rate equation is selected for testing and the batch reactor performance equation is integrated. An example is the rate on a catalyst mass basis in Equation 5-322. 

An initial theoretical study (Gilliland et al. 1964) established that, for a simple plant model consisting of a continuous stirred-tank reactor (CSTR) and a distillation column, the material recycle stream increases the sensitivity to disturbances together with increasing the time constant of the overall plant over those of the individual units. Moreover, it was shown that in certain cases the plant can become unstable even if the reactor itself is stable. 

Let us consider one of the simplest recycle processes imaginable a continuous stirred tank reactor (CSTR) and a distillation column. As shown in Figure 2.5. a fresh reactant stream is fed into the reactor. Inside the reactor, a first-order isothermal irreversible reaction of component A to produce component B occurs A -> B. The specific reaction rate is k (h1) and the reactor holdup is VR (moles). The fresh feed flowrate is Fs (moles/h) and its composition is z0 (mole fraction component A). The system is binary with only two components reactant A and product B. The composition in the reactor is z (mole fraction A). Reactor effluent, with flowrate F (moles/h) is fed into a distillation column that separates unreacted A from product B. 

As a (very simple) example, we consider the flowsheet in Fig. 4.2. The flowsheet has been designed in the process-integrated flowsheet editor that forms part of the PRIME environment (cf. Subsect. 3.1.3). The simulation model for the reactor device (CSTR - continuous stirred tank reactor) is already given. The developer s task is to find a suitable model to represent the separation. The designer can choose between several separation models, including complex combinations with recycle streams (backflows). 

An endothermic continuous stirred tank reactor (CSTR) is shown schematically in Figure 15.2. The symbols used in the control schematics are listed in Table 15.1 The controlled variable is the temperature of the product leaving the reactor, and the manipulated variable is the flow rate of steam to the heat exchanger, which adds heat to the recycle line. The final control element is the control valve and associated equipment on the steam hue. The sensor is a temperature sensor/trans-mitter that measures the temperature of the product stream leaving the reactor. The controller compares the measured value of the product temperature with its desired temperature (setpoint) and makes changes to the control valve on the steam to the heat exchanger. The process is the... 

A simplified scheme of the RCH/RP unit is presented in Figure 2 [1, 10, 11], The reactor (1) is essentially a continuous stirred tank reactor equipped with a gas inlet, a stirrer, a heat exchanger and a catalyst recycle line. Catalyst and reactants are introduced at the bottom of the reactor. Vent gas is taken from the head of the reactor and from the phase separator. Control of the liquid volume inside the reactor is simple the liquid mixture composed of catalyst solution and aldehydes leaves via an overflow and is transferred to a phase separator (2), where it is partially degassed. The separation of the aqueous catalyst solution (density of the catalyst solution 1100 g/L) and the aldehydes occurs rapidly and completely, favored by the difference in densities (density of aldehyde layer 600 g/L due to dissolved gases). The catalyst solution passes a heat exchanger and produces process steam that is consumed in downstream operations. Some water is extracted from the catalyst solution by its physical solubility in the aldehydes (about 1.3% w/w) which may be replaced before the catalyst solution re-enters the reactor. 

Reactions orders and rate coefficients can be established with methods that use either rate or concentration data. Batch, tubular plug-flow, and differential recycle reactors yield concentrations as directly measured quantities, and calculation of rates requires finite-difference approximations. To avoid these, concentration methods should be used. In contrast, continuous stirred-tank reactors allow rates to be calculated from material balances without approximation. Here, evaluation based on rates is equally suited. 

As the main responsible for the changes in the material balance, the chemical reactor must be modelled accurately from this point of view. Basic flowsheeting reactors are the plug flow reactor (PFR) and continuous stirred tank reactor (CSTR), as shown in Fig. 3.17. The ideal models are not sufficient to describe the complexity of industrial reactors. A practical alternative is the combination of ideal flow models with stoichiometric reactors, or with some user programming. In this way the flow reactors can take into account the influence of recycles on conversion, while the stoichiometric types can serve to describe realistically selectivity effects, namely the formation of impurities, important for separations. Some standard models are described below. 

The nonlinearity of chemical processes received considerable attention in the chemical engineering literature. A large number of articles deal with stand-alone chemical reactors, as for example continuously stirred tank reactor (CSTR), tubular reactor with axial dispersion, and packed-bed reactor. The steady state and dynamic behaviour of these systems includes state multiplicity, isolated solutions, instability, sustained oscillations, and exotic phenomena as strange attractors and chaos. In all cases, the main source of nonlinearity is the positive feedback due to the recycle of heat, coupled with the dependence of the reaction rate versus temperature. 

To illustrate the procedure, we consider a fairly complex process sketched in Fig. 6.4, which shows the process flowsheet and the nomenclature used. In the continuous stirred-tank reactor, a multicomponent, reversible, second-order reaction occurs in the liquid phase A + B C + D. The component volatilities are such that reactant A is the most volatile, product C is the next most volatile, reactant B has intermediate volatility, and product D is the heaviest component a/ > ac > olb > OiQ. The process flowsheet consists of a reactor that is coupled with a stripping column to keep reactant. A in the system, and two distillation columns to achieve the removal of products C and D and the recovery and recycle of reactant B. 

Hatton and coworkers have also analyzed processes involving ELMs. Using their advancing-front model as a basis, they have studied staged operations (10 1), continuous stirred tank reactors (105), and mixer cascades (106). One interesting aspect of their analysis is the effect of emulsion recycle. They analyzed the effect on extraction rate of recycling used emulsion and combining this with new emulsion. 

The simplest flow-sheet for the reaction Aj o Aj is the RD column sequence with an external recycling loop shown in Fig. 5.1. The system as a whole is fed with pure Aj. According to the assumed relative volatility of the two components a > 1, the reaction product A2 is enriched in the column distillate product whereas the bottom product contains non-converted reactant Aj, which is recycled back to the reactor (continuous stirred tank reactor, CSTR, or plug flow tube reactor, PFTR). The process has two important operational variables the recycling ratio cp = B/F, that is the ratio of recycling flow B to feed flow rate F, and the reflux ratio of the distillation column R = L/D. At steady-state conditions, D = F since the total number of moles is assumed to be constant for the reaction Aj A2. As principal design variables, the Damkohler number. 

The 2,5-dihydrofurane (bp = 66 °C) and the crotonaldehyde (bp = 104 C) can then be separated from the reaction mixture by distillation due to their low boiling points, while the higher boiling oligomers remain in the IL-catalyst phase. This phase is fruther treated with an extractant solvent such as naphtha, to recover the oligomers and recycle the IL-catalyst. The plant is operated with three continuous, stirred-tank reactors, a wiped-film evaporator, a distillation train, and a continuous, counter-current, liquid-liquid extractor for recovery of the catalysts. The plant is now idle, because the market for the product has declined. 

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