CSTR, kinetics

Fig. 9.9. Mixed-metallocene polymerization of ethylene in a CSTR. Kinetic data are the same as in Figure 9.8. Residence time CSTR 300 s feed concentrations identical to initial concentrations in Figure 9.8. Bivariate chain length/number of branches distribution. Hydrogen present. Based on molecular weight distribution and branching distribution from...

Over 25 years ago the coking factor of the radiant coil was empirically correlated to operating conditions (48). It has been assumed that the mass transfer of coke precursors from the bulk of the gas to the walls was controlling the rate of deposition (39). Kinetic models (24,49,50) were developed based on the chemical reaction at the wall as a controlling step. Bench-scale data (51—53) appear to indicate that a chemical reaction controls. However, flow regimes of bench-scale reactors are so different from the commercial furnaces that scale-up of bench-scale results caimot be confidently appHed to commercial furnaces. For example. Figure 3 shows the coke deposited on a controlled cylindrical specimen in a continuous stirred tank reactor (CSTR) and the rate of coke deposition. The deposition rate decreases with time and attains a pseudo steady value. Though this is achieved in a matter of rninutes in bench-scale reactors, it takes a few days in a commercial furnace. 

Experimental data that are most easily obtained are of (C, t), (p, t), (/ t), or (C, T, t). Values of the rate are obtainable directly from measurements on a continuous stirred tank reactor (CSTR), or they may be obtained from (C, t) data by numerical means, usually by first curve fitting and then differentiating. When other properties are measured to follow the course of reaction—say, conductivity—those measurements are best converted to concentrations before kinetic analysis is started. 

Composition The law of mass aclion is expressed as a rate in terms of chemical compositions of the participants, so ultimately the variation of composition with time must be found. The composition is determined in terms of a property that is measured by some instrument and cahbrated in terms of composition. Among the measures that have been used are titration, pressure, refractive index, density, chromatography, spectrometry, polarimetry, conduclimetry, absorbance, and magnetic resonance. In some cases the composition may vary linearly with the observed property, but in every case a calibration is needed. Before kinetic analysis is undertaken, the data are converted to composition as a function of time (C, t), or to composition and temperature as functions of time (C, T, t). In a steady CSTR the rate is observed as a function of residence time. 

Exploration for an acceptable or optimum design of a new reaction process may need to consider reactor types, several catalysts, specifications of feed and product, operating conditions, and economic evaluations. Modifications to an existing process hkewise may need to consider many cases. These efforts can oe eased by commercial kinetics services. A typical one can handle up to 20 reactions in CSTRs or... 

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.)... 

The spread of CSTR use for kinetic studies only started in the 1960s. References can be found even earlier than that of Bodenstein (1908) although most of these references discuss only the use for homogeneous kinetic studies. In view of this background, the story of the development at Union Carbide Corporation may be interesting. 

The experimental unit, shown on the previous page, is the simplest assembly that can be used for high-pressure kinetic studies and catalyst testing. The experimental method is measurement of the rate of reaction in a CSTR (Continuous Stirred Tank Reactor) by a steady-state method. 

Figure 6.4.2 Table of error-free kinetic data from CSTR simulation.

Figure 6.4.3 Data for kinetic analysis. Simulated CSTR results with random error added to UCKRON-I.

Kelkar and McCarthy (1995) proposed another method to use the feedforward experiments to develop a kinetic model in a CSTR. An initial experimental design is augmented in a stepwise manner with additional experiments until a satisfactory model is developed. For augmenting data, experiments are selected in a way to increase the determinant of the correlation matrix. The method is demonstrated on kinetic model development for the aldol condensation of acetone over a mixed oxide catalyst. 

In previous studies, the main tool for process improvement was the tubular reactor. This small version of an industrial reactor tube had to be operated at less severe conditions than the industrial-size reactor. Even then, isothermal conditions could never be achieved and kinetic interpretation was ambiguous. Obviously, better tools and techniques were needed for every part of the project. In particular, a better experimental reactor had to be developed that could produce more precise results at well defined conditions. By that time many home-built recycle reactors (RRs), spinning basket reactors and other laboratory continuous stirred tank reactors (CSTRs) were in use and the subject of publications. Most of these served the original author and his reaction well but few could generate the mass velocities used in actual production units. 

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). 

Steady-State CSTR with Highei Order, Reversible Kinetics... 

Monod kinetics are considered in a CSTR with an organism growing with an initial substrate concentration of 50g-l 1 and kinetic parameters of Ks = 2g-l 1 and /Amax = 0.5lr. (a) What would be the maximum dilution rate for 100% yield of biomass with maximum rate (b) If the same dilution is used, what would be number of CSTRs in series ... 

The performance data for plug versus mix reactor were obtained. The data were collected as the inverse of qx vs inverse of substrate concentration. Table E.1.1 shows the data based on obtained kinetic data. From the data plotted in Figure E.1.1, we can minimise the volume of the chemostat. A CSTR works better than a plug flow reactor for the production of biomass. Maximum qx is obtained with a substrate concentration in the leaving stream of 12g m 3. 

In a batch fermentation of ethanol, kinetic data were collected as product formed. The data are shown in Table E.5.1. The data will be used to design a continuous bioreactor (CSTR) with a 1001 working volume. 

Since a CSTR operates at or close to uniform conditions of temperature and composition, its kinetic and product parameters can usually be predicted more accurately and controlled with greater ease. The CSTR can often be operated at a selected conversion level to optimize space-time yield, or where a particular product parameter is especially favored. 

The described experimental rig for the anionic polymerisation of dienes has been shown to behave as an ideal CSTR. The mathematical model developed allows the prediction of the MWD at future points in the reactor history, once suitable kinetic parameters have been estimated. 

Example 4.3 Suppose a pure monomer polymerizes in a CSTR with pseudo-first-order kinetics. The monomer and pol5Tner have different... 

Strictly gas-phase CSTRs are rare. Two-phase, gas-liquid CSTRs are common and are treated in Chapter 11. Two-phase, gas-solid CSTRs are fairly common. When the solid is a catalyst, the use of pseudohomogeneous kinetics allows these two-phase systems to be treated as though only the fluid phase were present. All concentration measurements are made in the gas phase, and the rate expression is fitted to the gas-phase concentrations. This section outlines the method for fitting pseudo-homogeneous kinetics using measurements made in a CSTR. A more general treatment is given in Chapter 10. 

Example 4.12 used N stirred tanks in series to achieve a 1000-fold reduction in the concentration of a reactant that decomposes by first-order kinetics. Show how much worse the CSTRs would be if the 1000-fold reduction had to be achieved by dimerization i.e., by a second order of the single reactant type. The reaction is irreversible and density is constant. 

The results of Example 5.2 apply to a reactor with a fixed reaction time, i or thatch- Equation (5.5) shows that the optimal temperature in a CSTR decreases as the mean residence time increases. This is also true for a PFR or a batch reactor. There is no interior optimum with respect to reaction time for a single, reversible reaction. When Ef < Ef, the best yield is obtained in a large reactor operating at low temperature. Obviously, the kinetic model ceases to apply when the reactants freeze. More realistically, capital and operating costs impose constraints on the design. 

CSTRs, shell-and-tube reactors, and single-tube reactors, particularly a single adiabatic tube. Realistically, these different reactors may all scale similarly e.g., as but the dollar premultipliers will be different, with CSTRs being more expensive than sheU-and-tube reactors, which are more expensive than adiabatic single tubes. However, in what follows, the same capital cost will be used for all reactor types in order to emphasize inherent kinetic differences. This will bias the results toward CSTRs and toward shell-and-tube reactors over most single-tube designs. 

The CSTRs are wonderful for kinetic experiments since they allow a direct determination of the reaction rate at known concentrations of the reactants. 

The reaction of Example 7.4 is not elementary and could involve shortlived intermediates, but it was treated as a single reaction. We turn now to the problem of fitting kinetic data to multiple reactions. The multiple reactions hsted in Section 2.1 are consecutive, competitive, independent, and reversible. Of these, the consecutive and competitive t5T>es, and combinations of them, pose special problems with respect to kinetic studies. These will be discussed in the context of integral reactors, although the concepts are directly applicable to the CSTRs of Section 7.1.2 and to the complex reactors of Section 7.1.4. 

When the mass transfer resistances are eliminated, the various gas-phase concentrations become equal a/(/, r, z) = j(r, z) = a(r, z). The very small particle size means that heat transfer resistances are minimized so that the catalyst particles are isothermal. The recycle reactor of Figure 4.2 is an excellent means for measuring the intrinsic kinetics of a finely ground catalyst. At high recycle rates, the system behaves as a CSTR. It is sometimes called a gradientless reactor since there are no composition and temperature gradients in the catalyst bed or in a catalyst particle. 

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