First effectiveness factor

Let us compare computations of the effectiveness factor, using each of the three approximations we have described, with exact values from the complete dusty gas model. The calculations are performed for a first order reaction of the form A lOB in a spherical pellet. The stoichiometric coefficient 10 for the product is unrealistically large, but is chosen to emphasize any differences between the different approaches. 

Catalyst Effectiveness. Even at steady-state, isothermal conditions, consideration must be given to the possible loss in catalyst activity resulting from gradients. The loss is usually calculated based on the effectiveness factor, which is the diffusion-limited reaction rate within catalyst pores divided by the reaction rate at catalyst surface conditions (50). The effectiveness factor E, in turn, is related to the Thiele modulus,

first-order rate constant, a the internal surface area, and the effective diffusivity. It is desirable for E to be as close as possible to its maximum value of unity. Various formulas have been developed for E, which are particularly usehil for analyzing reactors that are potentially subject to thermal instabilities, such as hot spots and temperature mnaways (1,48,51). 

The performance of adsorption processes results in general from the combined effects of thermodynamic and rate factors. It is convenient to consider first thermodynamic factors. These determine the process performance in a limit where the system behaves ideally i.e. without mass transfer and Idnetic limitations and with the fluid phase in perfect... 

There are two fundamental chromatography theories that deal with solute retention and solute dispersion and these are the Plate Theory and the Rate Theory, respectively. It is essential to be familiar with both these theories in order to understand the chromatographic process, the function of the column, and column design. The first effective theory to be developed was the plate theory, which revealed those factors that controlled chromatographic retention and allowed the... 

The first three factors are present in compressors, but they are small and on the whole can be neglected. The clearance volume problem, however, is unique to reciprocating piston compressors. The volumetric efficiency e estimates the effect of clearance. The volumetric efficiency can be approximated as... 

Diffusion effects can be expected in reactions that are very rapid. A great deal of effort has been made to shorten the diffusion path, which increases the efficiency of the catalysts. Pellets are made with all the active ingredients concentrated on a thin peripheral shell and monoliths are made with very thin washcoats containing the noble metals. In order to convert 90% of the CO from the inlet stream at a residence time of no more than 0.01 sec, one needs a first-order kinetic rate constant of about 230 sec-1. When the catalytic activity is distributed uniformly through a porous pellet of 0.15 cm radius with a diffusion coefficient of 0.01 cm2/sec, one obtains a Thiele modulus y> = 22.7. This would yield an effectiveness factor of 0.132 for a spherical geometry, and an apparent kinetic rate constant of 30.3 sec-1 (106). 

Oxidation kinetics over platinum proceeds at a negative first order at high concentrations of CO, and reverts to a first-order dependency at very low concentrations. As the CO concentration falls towards the center of a porous catalyst, the rate of reaction increases in a reciprocal fashion, so that the effectiveness factor may be greater than one. This effectiveness factor has been discussed by Roberts and Satterfield (106), and in a paper to be published by Wei and Becker. A reversal of the conventional wisdom is sometimes warranted. When the reaction kinetics has a negative order, and when the catalyst poisons are deposited in a thin layer near the surface, the optimum distribution of active catalytic material is away from the surface to form an egg yolk catalyst. 

A hydrocarbon is cracked using a silica-alumina catalyst in the form of spherical pellets of mean diameter 2.0 mm. When the reactant concentration is 0.011 kmol/m3, the reaction rate is 8.2 x 10"2 kmol/(m3 catalyst) s. If the reaction is of first-order and the effective diffusivity De is 7.5 x 10 s m2/s, calculate the value of the effectiveness factor r). It may be assumed that the effect of mass transfer resistance in the. fluid external Lo the particles may be neglected. 

Many theoretical embellishments have been made to the basic model of pore diffusion as presented here. Effectiveness factors have been derived for reaction orders other than first and for Hougen and Watson kinetics. These require a numerical solution of Equation (10.3). Shape and tortuosity factors have been introduced to treat pores that have geometries other than the idealized cylinders considered here. The Knudsen diffusivity or a combination of Knudsen and bulk diffusivities has been used for very small pores. While these studies have theoretical importance and may help explain some observations, they are not yet developed well enough for predictive use. Our knowledge of the internal structure of a porous catalyst is still rather rudimentary and imposes a basic limitation on theoretical predictions. We will give a brief account of Knudsen diffusion. 

The concentration of gas over the active catalyst surface at location / in a pore is ai [). The pore diffusion model of Section 10.4.1 linked concentrations within the pore to the concentration at the pore mouth, a. The film resistance between the external surface of the catalyst (i.e., at the mouths of the pore) and the concentration in the bulk gas phase is frequently small. Thus, a, and the effectiveness factor depends only on diffusion within the particle. However, situations exist where the film resistance also makes a contribution to rj so that Steps 2 and 8 must be considered. This contribution can be determined using the principle of equal rates i.e., the overall reaction rate equals the rate of mass transfer across the stagnant film at the external surface of the particle. Assume A is consumed by a first-order reaction. The results of the previous section give the overall reaction rate as a function of the concentration at the external surface, a. ... 

The overall effectiveness factor for the first-order reaction is defined using the bulk gas concentration a. 

FIGURE 10.3 Nonisothermal effectiveness factors for first-order reactions in spherical pellets. (Adapted from Weisz, P. B. and Hicks, J. S., Chem. Eng. Sci., 17, 265 (1962).)... 

Consider a nonporous catalyst particle where the active surface is all external. There is obviously no pore resistance, but a film resistance to mass transfer can still exist. Determine the isothermal effectiveness factor for first-order kinetics. 

Suppose that catalyst pellets in the shape of right-circular cylinders have a measured effectiveness factor of r] when used in a packed-bed reactor for a first-order reaction. In an effort to increase catalyst activity, it is proposed to use a pellet with a central hole of radius i /, < Rp. Determine the best value for RhjRp based on an effective diffusivity model similar to Equation (10.33). Assume isothermal operation ignore any diffusion limitations in the central hole, and assume that the ends of the cylinder are sealed to diffusion. You may assume that k, Rp, and eff are known. 

With the method applied it is possible to take into account substitution effects both in the A and C monomers, as explained elsewhere (12). The substitution effect factor Kjj indicates the factor by wKTch the reaction rate between monomer I and any other monomer L is multiplied for each previous bond formed between monomers I and J (i.e. first-shell substitution effects (7)). For positive substitution effects Kjj is larger than 1, for negative effects it is smaller than 1. 

Figure 2.1 Dependence of the effectiveness factor on the Thiele modulus for a first-order irreversible reaction. Steady-state diffusion and reaction, slab model, and isothermal conditions are assumed.

The subscript refers to a spherical particle. One should also remember that we limited ourselves to a first-order irreversible reaction. Other expressions can be derived but are beyond the scope of this book. Nevertheless, Eq. (35) has important practical implications, since it is possible to discuss the effectiveness of the system by a single dimensionless parameter, (fig. Figure 5.35 shows the effectiveness factor as a function of O,. 

In this exercise we shall estimate the influence of transport limitations when testing an ammonia catalyst such as that described in Exercise 5.1 by estimating the effectiveness factor e. We are aware that the radius of the catalyst particles is essential so the fused and reduced catalyst is crushed into small particles. A fraction with a narrow distribution of = 0.2 mm is used for the experiment. We shall assume that the particles are ideally spherical. The effective diffusion constant is not easily accessible but we assume that it is approximately a factor of 100 lower than the free diffusion, which is in the proximity of 0.4 cm s . A test is then made with a stoichiometric mixture of N2/H2 at 4 bar under the assumption that the process is far from equilibrium and first order in nitrogen. The reaction is planned to run at 600 K, and from fundamental studies on a single crystal the TOP is roughly 0.05 per iron atom in the surface. From Exercise 5.1 we utilize that 1 g of reduced catalyst has a volume of 0.2 cm g , that the pore volume constitutes 0.1 cm g and that the total surface area, which we will assume is the pore area, is 29 m g , and that of this is the 18 m g- is the pure iron Fe(lOO) surface. Note that there is some dispute as to which are the active sites on iron (a dispute that we disregard here). 

The internal effectiveness factor is a function of the generalized Thiele modulus (see for instance Krishna and Sie (1994), Trambouze et al. (1988), and Fogler (1986). For a first-order reaction ... 

Figure 3.32. Interna effectiveness factor as a function of the generalized Thiele modulus for a first order reaction.

Fig. 5.4-14. Effectiveness factor versus Thiele modulus for first-order reaction.

Currently, benzene alkylation to produce ethylbenzene and cumene is routinely carried out using zeohtes. We performed a study comparing a zeohte Y embedded in TUD-1 to a commercial zeolite Y for ethylbenzene synthesis. Two different particle diameters (0.3 and 1.3 mm) were used for each catalyst. In Figure 41.7, the first-order rate constants were plotted versus particle diameter, which is analogous to a linear plot of effectiveness factor versus Thiele modulus. In this way, the rate constants were fitted for both catalysts. 

Quantitative analytical treatments of the effects of mass transfer and reaction within a porous structure were apparently first carried out by Thiele (20) in the United States, Dam-kohler (21) in Germany, and Zeldovitch (22) in Russia, all working independently and reporting their results between 1937 and 1939. Since these early publications, a number of different research groups have extended and further developed the analysis. Of particular note are the efforts of Wheeler (23-24), Weisz (25-28), Wicke (29-32), and Aris (33-36). In recent years, several individuals have also extended the treatment to include enzymes immobilized in porous media or within permselective membranes. The important consequence of these analyses is the development of a technique that can be used to analyze quantitatively the factors that determine the effectiveness with which the surface area of a porous catalyst is used. For this purpose we define an effectiveness factor rj for a catalyst particle as... 

In the laboratory, the measured rate constant for the first-order reaction would have to equal the product rjk if this constant were expressed per unit area of catalyst. This relationship then gives us an alternative interpretation of the effectiveness factor in terms of our model... 

The equations for effectiveness factors that we have developed in this subsection are strictly applicable only to reactions that are first-order in the fluid phase concentration of a reactant whose stoichiometric coefficient is unity. They further require that no change in the number of moles take place on reaction and that the pellet be isothermal. The following illustration indicates how this idealized cylindrical pore model is used to obtain catalyst effectiveness factors. 

Curve B of Figure 12.3 [adopted from Wheeler (38)] represents the dependence of the effectiveness factor on Thiele modulus for second-order kinetics. Values of r for first-order and zero-order kinetics in straight cylindrical pores are shown as curves A and C, respectively. Each curve is plotted versus its appropriate modulus. 

Plots of effectiveness factors versus corresponding Thiele moduli for zero-, first-, and second-order kinetics based on straight cylindrical pore model. For large hr, values of r are as follows ... 

The Effectiveness Factor Analysis in Terms of Effective Diffusivities First-Order Reactions on Spherical Pellets. Useful expressions for catalyst effectiveness factors may also be developed in terms of the concept of effective diffusivities. This approach permits one to write an expression for the mass transfer within the pellet in terms of a form of Fick s first law based on the superficial cross-sectional area of a porous medium. We thereby circumvent the necessity of developing a detailed mathematical model of the pore geometry and size distribution. This subsection is devoted to an analysis of simultaneous mass transfer and chemical reaction in porous catalyst pellets in terms of the effective diffusivity. In order to use the analysis with confidence, the effective diffusivity should be determined experimentally, since it is difficult to obtain accurate estimates of this parameter on an a priori basis. 

Effectiveness factor plot for spherical catalyst particles based on effective diffusivities (first-order reaction). 

The Effectiveness Factor Analysis in Terms of Effective Diffusivities Extension to Reactions Other than First-Order and Various Catalyst Geometries. The analysis developed in Section 12.3.1.3 may be extended in relatively simple straightforward fashion to other integer-order rate expressions and to other catalyst geometries such as flat plates and cylinders. Some of the key results from such extensions are treated briefly below. 

Effectiveness factor ratios for first-order kinetics on spherical catalyst pellets. 

Thus a zero-order reaction appears to be 1/2 order and a second-order reaction appears to be 3/2 order when dealing with a fast reaction taking place in porous catalyst pellets. First-order reactions do not appear to undergo a shift in reaction order in going from high to low effectiveness factors. These statements presume that the combined diffusivity lies in the Knudsen range, so that this parameter is pressure independent. 

Effectiveness Factors for Hougen-Watson Rate Expressions. The discussion thus far and the vast majority of the literature dealing with effectiveness factors for porous catalysts are based on the assumption of an integer-power reaction rate expression (i.e., zero-, first-, or second-order kinetics). In Chapter 6, however, we stressed the fact that heterogeneous catalytic reactions are more often characterized by more complex rate expressions of the Hougen-Watson type. Over a narrow range of... 

Effectiveness factor chart for first-order reaction in spherical pellets for y = 20. [From P. B. Weisz and J. S. Hicks, Chemical Engineering Science, 17 (265), 1962. Copyright 1962. Reprinted with permission of Pergamon Press.]... 

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