Rate control temperature effect

Factors that influence growth of sucrose crystals have been listed by Smythe (1971). They include supersaturation of the solution, temperature, relative velocity of crystal and solution, nature and concentration of impurities, and nature of the crystal surface. Crystal growth of sucrose consists of two steps (1) the mass transfer of sucrose molecules to the surface of the crystal, which is a first-order process and (2) the incorporation of the molecules in the crystal surface, a second-order process. Under usual conditions, overall growth rate is a function of the rate of both processes, with neither being rate-controlling. The effect of impurities can be of two kinds. Viscosity can increase, thus reducing the rate of mass transfer, or impurities can involve adsorption on specific surfaces of the crystal, thereby reducing the rate of surface incorporation. 

Generally speaking, temperature control in fixed beds is difficult because heat loads vary through the bed. Also, in exothermic reactors, the temperature in the catalyst can become locally excessive. Such hot spots can cause the onset of undesired reactions or catalyst degradation. In tubular devices such as shown in Fig. 2.6a and b, the smaller the diameter of tube, the better is the temperature control. Temperature-control problems also can be overcome by using a mixture of catalyst and inert solid to effectively dilute the catalyst. Varying this mixture allows the rate of reaction in different parts of the bed to be controlled more easily. 

Computer controls are likewise used for stove operation, to control deUvery of the hot blast. High hot blast temperatures are generally desirable, as these reduce the coke rate. Control of the flame temperature in the raceway is effected by controlled additions to the hot blast, primarily of moisture. Injectants into the tuyeres such as coal, oil, and natural gas are often used to replace some of the coke. The effect of these injectants on flame temperature must be accounted for, and compensation is performed by lowering moisture or adding oxygen. 

Reaction 1 is the rate-controlling step. The decomposition rate of pure ozone decreases markedly as oxygen builds up due to the effect of reaction 2, which reforms ozone from oxygen atoms. Temperature-dependent equations for the three rate constants obtained by measuriag the decomposition of concentrated and dilute ozone have been given (17—19). 

Both control schemes react in a similar manner to disturbances in process fluid feed rate, feed temperature, feed composition, fuel gas heating value, etc. In fact, if the secondary controller is not properly tuned, the cascade control strategy can actually worsen control performance. Therefore, the key to an effective cascade control strategy is the proper selection of the secondary controlled variable considering the source and impact of particular disturbances and the associated process dynamics. 

Inert gas pressure, temperature, and conversion were selected as these are the critical variables that disclose the nature of the basic rate controlling process. The effect of temperature gives an estimate for the energy of activation. For a catalytic process, this is expected to be about 90 to 100 kJ/mol or 20-25 kcal/mol. It is higher for higher temperature processes, so a better estimate is that of the Arrhenius number, y = E/RT which is about 20. If it is more, a homogeneous reaction can interfere. If it is significantly less, pore diffusion can interact. 

This paper surveys the field of methanation from fundamentals through commercial application. Thermodynamic data are used to predict the effects of temperature, pressure, number of equilibrium reaction stages, and feed composition on methane yield. Mechanisms and proposed kinetic equations are reviewed. These equations cannot prove any one mechanism however, they give insight on relative catalyst activity and rate-controlling steps. Derivation of kinetic equations from the temperature profile in an adiabatic flow system is illustrated. Various catalysts and their preparation are discussed. Nickel seems best nickel catalysts apparently have active sites with AF 3 kcal which accounts for observed poisoning by sulfur and steam. Carbon laydown is thermodynamically possible in a methanator, but it can be avoided kinetically by proper catalyst selection. Proposed commercial methanation systems are reviewed. 

In other instances, reaction kinetic data provide an insight into the rate-controlling steps but not the reaction mechanism see, for example, Hougen and Watson s analysis of the kinetics of the hydrogenation of mixed isooctenes (16). Analysis of kinetic data can, however, yield a convenient analytical insight into the relative catalyst activities, and the effects of such factors as catalyst age, temperature, and feed-gas impurities on the catalyst. 

A cascade control system can be designed to handle fuel gas disturbance more effectively (Fig. 10.1). In this case, a secondary loop (also called the slave loop) is used to adjust the regulating valve and thus manipulate the fuel gas flow rate. The temperature controller (the master or primary controller) sends its signal, in terms of the desired flow rate, to the secondary flow control loop—in essence, the signal is the set point of the secondary flow controller (FC). 

All of these steps are rate processes and are temperature dependent. It is important to realize that very large temperature gradients may exist between active sites and the bulk gas phase. Usually, one step is slower than the others, and it is this rate-controlling step. The effectiveness factor is the ratio of the observed rate to that which would be obtained if the whole of the internal surface of the pellet were available to the reagents at the same concentrations as they have at the external surface. Generally, the higher the effectiveness factor, the higher the rate of reaction. 

The rate at which reactions occur is of theoretical and practical importance, but it is not relevant to give a detailed account of reaction kinetics, as analytical reactions are generally selected to be as fast as possible. However, two points should be noted. Firstly, most ionic reactions in solution are so fast that they are diffusion controlled. Mixing or stirring may then be the rate-controlling step of the reaction. Secondly, the reaction rate varies in proportion to the cube of the thermodynamic temperature, so that heat may have a dramatic effect on the rate of reaction. Heat is applied to reactions to attain the position of equilibrium quickly rather than to displace it. 

Diffusivities in liquids are comparatively low, a factor of 10 lower than in gases, so it is probable in most industrial examples that they are diffusion rate controlled. One consequence is that L-L. reactions are not as temperature sensitive as ordinary chemical reactions, although the effect of temperature rise on viscosity and droplet size sometimes can result in substantial rate increase. On the whole, in the presnt state of the art, the design of L-L reactors must depend on scale-up from laboratory or pilot plant work. 

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