Integral reactor, catalytic reaction

Finally, it is worth mentioning that a successful integration of catalytic reaction steps with product separation and catalyst recovery operations will also be dependent on innovative chemical reaction engineering. This will require the widespread application of sustainable engineering principles [48].In this context process intensification , which involves the design of novel reactors of increased volumetric productivity and selectivity with the aim of integrating different unit operations to reactor design, and miniaturization will play pivotal roles [49, 50]. 

Tubular Reactors. The tubular reactor is exceUent for obtaining data for fast thermal or catalytic reactions, especiaHy for gaseous feeds. With sufficient volume or catalyst, high conversions, as would take place in a large-scale unit, are obtained conversion represents the integral value of reaction over the length of the tube. Short tubes or pancake-shaped beds are used as differential reactors to obtain instantaneous reaction rates, which can be computed directly because composition changes can be treated as differential amounts. Initial reaction rates are obtained with a fresh feed. Reaction rates at... 

Equation 8.3.4 may also be used in the analysis of kinetic data taken in laboratory scale stirred tank reactors. One may directly determine the reaction rate from a knowledge of the reactor volume, flow rate through the reactor, and stream compositions. The fact that one may determine the rate directly and without integration makes stirred tank reactors particularly attractive for use in studies of reactions with complex rate expressions (e.g., enzymatic or heterogeneous catalytic reactions) or of systems in which multiple reactions take place. 

For gas phase heterogeneous catalytic reactions, the continuous-flow integral catalytic reactors with packed catalyst bed have been exclusively used [61-91]. Continuous or short pulsed-radiation (milliseconds) was applied in catalytic studies (see Sect. 10.3.2). To avoid the creation of temperature gradients in the catalyst bed, a single-mode radiation system can be recommended. A typical example of the most advanced laboratory-scale microwave, continuous single-mode catalytic reactor has been described by Roussy et al. [79] and is shown in Figs. 10.4 and... 

For a more detailed analysis of measured transport restrictions and reaction kinetics, a more complex reactor simulation tool developed at Haldor Topsoe was used. The model used for sulphuric acid catalyst assumes plug flow and integrates differential mass and heat balances through the reactor length [16], The bulk effectiveness factor for the catalyst pellets is determined by solution of differential equations for catalytic reaction coupled with mass and heat transport through the porous catalyst pellet and with a film model for external transport restrictions. The model was used both for optimization of particle size and development of intrinsic rate expressions. Even more complex models including radial profiles or dynamic terms may also be used when appropriate. 

Monoliths exhibit a large flexibility in operation. They are well suited for optimal semibatch, batch, continuous, and transient processing. Catalytic conversion can be combined with in situ separation, catalytic reactions can be combined, heat integration is possible, and all lead to process intensification. In the short term, catalytic monoliths will be applied to replace trickle-bed reactor and slurry-phase... 

At first sight, adsorption and reaction are well-matched functionalities for integrated chemical processes. Their compatibility extends over a wide temperature range, and their respective kinetics are usually rapid enough so as not to constrain either process, whereas the permeation rate in membrane reactors commonly lags behind that of the catalytic reaction [9]. The phase slippage observed in extractive processes [10], for example, is absent and the choice of the adsorbent offers a powerful degree of freedom in the selective manipulation of concentration profiles that lies at the heart of all multifunctional reactor operation [11]. Furthermore, in contrast to reactive distillation, the effective independence of concentration and temperature profiles... 

The study of the deterioration of the hydroxil groups of the catalyst and the nature of the coke that is being deposited have been studied in situ in a catalytic chamber (Spectra Tech) connected in series with a Nicolet 740 FTIR spectrophotometer. The reaction has also been carried out in an automated isothermal fixed bed integral reactor [6], in cycles of reaction-regeneration, with the aim of obtaining partially deactivated catalyst samples under contrasted operation conditions (time on stream, temperature, contact time and number of regenerations of the catalyst). 

To derive the overall kinetics of a gas/liquid-phase reaction it is required to consider a volume element at the gas/liquid interface and to set up mass balances including the mass transport processes and the catalytic reaction. These balances are either differential in time (batch reactor) or in location (continuous operation). By making suitable assumptions on the hydrodynamics and, hence, the interfacial mass transfer rates, in both phases the concentration of the reactants and products can be calculated by integration of the respective differential equations either as a function of reaction time (batch reactor) or of location (continuously operated reactor). In continuous operation, certain simplifications in setting up the balances are possible if one or all of the phases are well mixed, as in continuously stirred tank reactor, hereby the mathematical treatment is significantly simplified. 

The case study of vinyl acetate synthesis emphasises the benefits of an integrated process design and plantwide control strategy based on the analysis of the Reactor / Separation / Recycles structure. The core is the chemical reactor, whose behaviour in recycle depends on the kinetics and selectivity of the catalyst, as well as on safety and technological constraints. Moreover, the recycle policy depends on the reaction mechanism of the catalytic reaction. 

The laboratory study of Fisher and Smith on methane and sulfur vapor reaction illustrates typical apparatus and procedures for differential and integral tubular-flow reactors. An example of a laboratory differential reactor for a homogeneous catalytic reaction has been given by Matsuura et al. ... 

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