Derived Reactor Design

The U.S. Department of Energy has funded a research program to develop the Hquid-phase methanol process (LPMEOH) (33). This process utilizes a catalyst such as copper—zinc oxide suspended in a hydrocarbon oil. The Hquid phase is used as a heat-transfer medium and allows the reaction to be conducted at higher conversions than conventional reactor designs. In addition, the use of the LPMEOH process allows the use of a coal-derived, CO-rich synthesis gas. Typical reactor conditions for this process are 3.5—6.3 MPa (35—60 atm) and 473—563 K (see Methanol). 

The kinetics of a complex catalytic reaction can be derived from the results obtained by a separate study of single reactions. This is important in modeling the course of a catalytic process starting from laboratory data and in obtaining parameters for catalytic reactor design. The method of isolation of reactions renders it possible to discover also some other reaction paths which were not originally considered in the reaction network. 

Example 2.2 Derive the batch reactor design equations for the reaction set in Example 2.1. Assume a liquid-phase system with constant density. 

The derivation and development of a mathematical model which is as general as possible and incorporates detailed knowledge from phenomena operative in emulsion polymerization reactors, its testing phase and its application to latex reactor design, simulation, optimization and control are the objectives of this paper and will be described in what follows. 

The notes that form the basis for the bulk of this textbook have been used for several years in the undergraduate course in chemical kinetics and reactor design at the University of Wisconsin. In this course, emphasis is placed on Chapters 3 to 6 and 8 to 12, omitting detailed class discussions of many of the mathematical derivations. My colleagues and I stress the necessity for developing a seat of the pants feeling for the phenomena involved as well as an ability to analyze quantitative problems in terms of design framework developed in the text. 

Then, a survey of micro reactors for heterogeneous catalyst screening introduces the technological methods used for screening. The description of microstructured reactors will be supplemented by other, conventional small-scale equipment such as mini-batch and fixed-bed reactors and small monoliths. For each of these reactors, exemplary applications will be given in order to demonstrate the properties of small-scale operation. Among a number of examples, methane oxidation as a sample reaction will be considered in detail. In a detailed case study, some intrinsic theoretical aspects of micro devices are discussed with respect to reactor design and experimental evaluation under the transient mode of reactor operation. It will be shown that, as soon as fluid dynamic information is added to the pure experimental data, more complex aspects of catalysis are derivable from overall conversion data, such as the intrinsic reaction kinetics. 

There are five primary reactor designs based in theory batch, semibatch, continuous-stirred tank, plug flow, and fluidized bed. The operating expressions for these reactors are derived from material and energy balances, and each represents a specific mode of operation. Selected reactor configurations are presented in Fig. 1. 

In this chapter, first, the existing correlations for three-phase monolith reactors will be reviewed. It should be emphasized that most of these correlations were derived from a limited number of experiments, and care must be taken in applying them outside the ranges studied. Furthermore, most of the theoretical work concerns Taylor flow in cylindrical channels (see Chapter 9). However, for other geometries and flow patterns we have to rely on empirical or semiempirical correlations. Next, the modeling of the monolith reactors will be presented. On this basis, comparisons will be made between three basic types of continuous three-phase reactor monolith reactor (MR), trickle-bed reactor (TBR), and slurry reactor (SR). Finally, for MRs, factors important in the reactor design will be discussed. 

To express variations of the nsactor temperature, we apply the energy balance equation (first law of thermodynamics). Chapter 5 covers in detail the derivation and application of the energy balance equation in reactor design. The applications of the energy balance equation to ideal reactor configurations are covered in Chapters 5-9. 

This chapter covers the second fundamental concept used in chemical reaction engineering—chemical kinetics. The kinetic relationships used in the analysis and design of chemical reactors are derived and discussed. In Section 3.1, we discuss the various definitions of the species formation rates. In Section 3.2, we define the rates of chemical reactions and discuss how they relate to the formation (or depletion) rates of individual species. In Section 3.3, we discuss the rate expression that provides the relationship between the reaction rate, the temperature, and species concentrations. Without going into the theory of chemical kinetics, we review the common forms of the rate expressions for homogeneous and heterogeneous reactions. In the last section, we introduce and define a measure of die reaction rate—the characteristic reaction time. In Chapter 4 we use the characteristic reaction time to reduce the reactor design equations to dimensionless forms. 

In Section 4.2, we derive the design equations for the first three ideal reactor models. Other reactor configurations are discussed in Chapter 9. 

In this chapter, the analysis of chemical reactors is expanded to additional reactor configurations that are commonly used to improve the yield and selectivity of the desirable products. In Section 9.1, we analyze semibatch reactors. Section 9.2 covers the operation of plug-flow reactors with continuous injection along their length. In Section 9.3, we examine the operation of one-stage distillation reactors, and Section 9.4 covers the operation of recycle reactors. In each section, we first derive the design equations, convert them to dimensionless forms, and then derive the auxiliary relations to express the species concentrations and the energy balance equation. 

To derive the design equation of a semibatch reactor, we write a species balanee for any speeies, say species j, that is not fed continuously into the reactor. Its molar balance equation is... 

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