Heat transfer semibatch reactor

Emulsion Process. The emulsion polymerization process utilizes water as a continuous phase with the reactants suspended as microscopic particles. This low viscosity system allows facile mixing and heat transfer for control purposes. An emulsifier is generally employed to stabilize the water insoluble monomers and other reactants, and to prevent reactor fouling. With SAN the system is composed of water, monomers, chain-transfer agents for molecular weight control, emulsifiers, and initiators. Both batch and semibatch processes are employed. Copolymerization is normally carried out at 60 to 100°C to conversions of - 97%. Lower temperature polymerization can be achieved with redox-initiator systems (51). 

Semibatch Reactors. Semibatch reactors are the most versatile of reactor types. Thermoplastic injection molds are semibatch reactors in which shaped plastic articles are produced from melts. In mol ding thermoplastics, large clamping forces of up to 5000 metric tons are needed to keep molds together, while highly viscous polymers are forced into their cavities. Heat transfer is critical. If the molds are too cold, polymers soHdify before filling is completed if they are too hot, the time required for cooling delays production. 

In a batch reactor, the reaclants are loaded at once the concentration then varies with time, but at any one time it is uniform throughout. Agitation seiwes to mix separate feeds initially and to enhance heat transfer. In a semibatch operation, some of the reactants are charged at once and the others are then charged gradually. 

Therefore, many traditional designs, such as stirred tank reactors, incorporate heat transfer in the process (jacket, external or internal coil, etc.). However, in these devices, there is a significant distance between the heat transfer site and the site of the chemical reaction where heat is released. As a consequence semibatch mode is implemented while batch mode and/or systems are diluted. 

The main limitation of HEX reactors is the short residence time, typically from a few seconds to a few minutes. Indeed, the apparatuses are smaller than the traditional ones and fast flow velocities are necessary in order to maintain good level of heat-transfer coefficients. However, as described in the previous paragraph, the highlighted transfer properties of HEX reactors allow us to operate in a few minutes, whereas it takes many hours in batch or semibatch mode. 

In order to illustrate how the mode of operation can positively modify selectivity for a large reactor of poor heat-transfer characteristics, simulations of the reactions specified in Example 5.3.1.4 carried out in a semibatch reactor were performed. The reaction data and process conditions are essentially the same as those for the batch reactor, except that the initial concentration of A was decreased to cao = 0.46 mol litre, and the remaining amount of A is dosed (1) either for the whole reaction time of 1.5 h with a rate of 0.1 mol m s", or (2) starting after 0.5 h with a rate of 0.15 mol m " s". It is assumed that the volume of the reaction mixture and its physical properties do not change during dosing. The results of these simulations are shown in Fig. 5.3-15. The results of calculation for reactors of both types are summarized in Table 5.3-3. 

It is clear from the presented data that the yield and selectivity in a large semibatch reactor can be improved compared to those in a small batch reactor that has much better heat-transfer capability. This has been achieved by decreasing the rate of heat evolution, which has been obtained by lowering the instantaneous concentration of reactant A. The results also indicate that the dosing policy can have a very significant influence on reactor performance. 

In Illustration 10.7 we will consider how to meet the vast majority of the heat transfer requirements for operation of a semibatch reactor by a semiautothermal mode of processing. By... 

If one were to operate this semibatch reactor under a filling schedule, which for the first 11 hr is identical to that considered previously, and then proceed to feed A at the maximum rate of 400 lb/hr for an additional 2.875 hr, the same total amount of A would have been introduced to the reactor. However, in this case, the heat transfer requirements would change drastically. There would be a strong exotherm beginning at the moment the cold feed is stopped. The results for this case are presented in Table 10.1.3. 

Semibatch Reactors Some of the reactants are loaded into the reactor, and the rest of the reactants are fed gradually. Alternatively, one reactant is loaded into the reactor, and the other reactant is fed continuously. Once the reactor is full, it may be operated in a batch mode to complete the reaction. Semibatch reactors are especially favored when there are large heat effects and heat-transfer capability is limited. Exothermic reactions may be slowed down and endothermic reactions controlled by limiting reactant concentration. In bioreactors, the reactant concentration may be limited to minimize toxicity. Other situations that may call for semibatch reactors include control of undesirable by-products or when one of the reactants is a gas of limited solubility that is fed continuously at the dissolution rate. 

Bubble columns where a gas is dispersed through a deep pool of liquid are commonly used in industry as absorbers, strippers, or reactors when a large liquid holdup, large liquid residence time, or large heat transfer is needed. They may be operated either countercurrently, cocurrently, or semibatch. Other advantages of bubble columns are the absence of moving parts, minimum maintenance, small floor space, ability to handle sol-... 

Example 5-5 Hexamethylenetetramine (HMT) is to be produced in a semibatch reactor by adding an aqueous ammonia solution (25 wt % NH3) at the rate of 2 gpm to an initial charge of 238 gal (at 25°C) of formalin solution containing 42% by weight formaldehyde. The original temperature of the formalin solution is raised to 50°C in order to start the reaction. The temperature of the NH4.OH solution is 25°C. The heat of reaction in the liquid phase may be, assumed independent of temperature and concentration and taken as —960 Btu/lbbf HMT. If the reactor can be operated at a temperature of 100°C, the rate of reaction is very fast in comparison with the rate of heat transfer with the surroundings. Temperatures higher than 100°C are not desirable because of vaporization and increase in pressure. 

The influence of heat transfer on yield and selectivity in scaling up batch and semibatch reactors will be illustrated using a series reaction, taking place in an ideal jacketed stirred-tank reactor. This reaction is composed of two irreversible elementary steps, both exothermic and both with first order kinetics ... 

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