Reactor design fundamentals mass transfer

A quantitative strategy is discussed herein to design isothermal packed catalytic tubular reactors. The dimensionless mass transfer equation with unsteady-state convection, diffusion, and multiple chemical reactions represents the fundamental starting point to accomplish this task. Previous analysis of mass transfer rate processes indicates that the dimensionless molar density of component i in the mixture I must satisfy (i.e., see equation 10-11) ... 

Kinetic and reactor modeling will always be a fundamental step in the design of chemical processes. The main objective of this task is to construct a computational tool for predicting product distribution and reactor behavior at various operating conditions. In this sense, modeling of heavy oil hydroprocessing is of extreme complexity because there are so many parallel physical and chemical processes inside the reactor phase equilibrium, mass transfer of reactants and products between the three phases present in the reactor (gas, liqnid, and solid), intraparticle diffusion, a vast reaction network, and catalyst deactivation, to name a few. Ideally, the contribution of all these events must be accounted for in order to increase prediction capability however, the level of sophistication of the model will generally depend on the pursued objectives. 

Designed to obtain such fundamental data as chemical rates free of mass transfer resistances or other complications. Some of the heterogeneous reactors of Fig. 23-29, for instance, employ known interfacial areas, thus avoiding one uncertainty. 

Volumes 1, 2 and 3 form an integrated series with the fundamentals of fluid flow, heat transfer and mass transfer in the first volume, the physical operations of chemical engineering in this, the second volume, and in the third volume, the basis of chemical and biochemical reactor design, some of the physical operations which are now gaining in importance and the underlying theory of both process control and computation. The solutions to the problems listed in Volumes 1 and 2 are now available as Volumes 4 and 5 respectively. Furthermore, an additional volume in the series is in course of preparation and will provide an introduction to chemical engineering design and indicate how the principles enunciated in the earlier volumes can be translated into chemical plant. 

However, each set of factors entering in to the rate expression is also a potential source of scaleup error. For this, and other reasons, a fundamental requirement when scaling a process is that the model and prototype be similar to each other with respect to reactor type and design. For example, a cleaning process model of a continuous-stirred tank reactor (CSTR) cannot be scaled to a prototype with a tubular reactor design. Process conditions such as fluid flow and heat and mass transfer are totally different for the two types of reactors. However, results from rate-of-reaction experiments using a batch reactor can be used to design either a CSTR or a tubular reactor based solely on a function of conversion, -r ... 

The selection and design of a catalysis reactor depends on the type of process and fundamental process variables such as residence time, temperature, pressure, mass transfer between different phases, the properties of the reactants, and the available catalysts [16]. 

Gas absorption and any associated chemical reaction is always accompanied by the simultaneous release of heat of solution and heat of reaction. The micro-scale phenomena taking place close to the interface therefore involve the generation and diffusion of heat as well as the diffusion and reaction of material species. In developing a fundamental appreciation of simultaneous mass and heat transfer in gas-liquid reactions it is important for the heat effects to be incorporated into the analysis of diffusion and reaction because the rates and pathways of chemical reactions are usually enormously sensitive to temperature. In particular, for the case of gas-liquid reactor performance, if the heat effects are such that the mass transfer with reaction zone adjacent to the interface is at a temperature significantly different from the bulk, the yield and the selectivity performance will be erroneously interpreted if reaction is assumed to take place at the bulk liquid temperature. In consequence, the basic conceptual design of a commercial gas-liquid reactor could incorporate fallacious reasoning leading to inefficient operation at sub-optimal yield. 

---