Plug flow, temperature distribution

In the holding section of a continuous sterilizer, correct exposure time and temperature must be maintained. Because of the distribution of residence times, the actual reduction of microbial contaminants in the holding section is significantly lower than that predicted from plug flow assumption. The difference between actual and predicted reduction in viable microorganisms can be several orders of magnitude therefore, a design based on ideal flow conditions may fail. 

The control system must manipulate heat removal from the reactor, but what should be the measured (and controlled) variable Temperature is a good choice because it is easy to measure and it has a close thermodynamic relation to heat. For a CSTR. temperature control is particularly attractive since there is only one temperature to consider and it is directly related to the heat content of the reactor. However, in a spatially distributed system like a plug-flow reactor the choice of measured variable is not so clear. A single temperature is hardly a unique reflection of the excess heat content in the reactor. We may select a temperature where the heat effects have the most impact on the operation. This could be the hot spot or the exit temperature depending upon the design of the reactor and its normal operating-profile. 

The evaluation of catalyst effectiveness requires a knowledge of the intrinsic chemical reaction rates at various reaction conditions and compositions. These data have to be used for catalyst improvement and for the design and operation of many reactors. The determination of the real reaction rates presents many problems because of the speed, complexity and high exo- or endothermicity of the reactions involved. The measured conversion rate may not represent the true reaction kinetics due to interface and intraparticle heat and mass transfer resistances and nonuniformities in the temperature and concentration profiles in the fluid and catalyst phases in the experimental reactor. Therefore, for the interpretation of experimental data the experiments should preferably be done under reaction conditions, where transport effects can be either eliminated or easily taken into account. In particular, the concentration and temperature distributions in the experimental reactor should preferably be described by plug flow or ideal mixing models. 

This chapter discusses four methods of gas phase ceramic powder synthesis by flames, fiunaces, lasers, and plasmas. In each case, the reaction thermodynamics and kinetics are similar, but the reactor design is different. To account for the particle size distribution produced in a gas phase synthesis reactor, the population balance must account for nudeation, atomistic growth (also called vapor condensation) and particle—particle segregation. These gas phase reactors are real life examples of idealized plug flow reactors that are modeled by the dispersion model for plve flow. To obtain narrow size distribution ceramic powders by gas phase synthesis, dispersion must be minimized because it leads to a broadening of the particle size distribution. Finally the gas must be quickly quenched or cooled to freeze the ceramic particles, which are often liquid at the reaction temperature, and thus prevent further aggregation. 

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