Recycle loop reactor/tank system

Recycling of partially reacted feed streams is usually carried out after the product is separated and recovered. Unreacted feedstock can be separated and recycled to (ultimate) extinction. Figure 4.2 shows a different situation. It is a loop reactor where some of the reaction mass is returned to the inlet without separation. Internal recycle exists in every stirred tank reactor. An external recycle loop as shown in Figure 4.2 is less common, but is used, particularly in large plants where a conventional stirred tank would have heat transfer limitations. The net throughput for the system is Q = but an amount q is recycled back to the reactor inlet so that the flow through the reactor is Qin + q- Performance of this loop reactor system depends on the recycle ratio qlQin and on the type of reactor that is in the loop. Fast external recycle has... 

Bath type reactors can also be used as a flow system. In this case the reacting liquids can be continuously fed into an ultrasonic tank with overflow over a weir toward the next process step. Such treatment could be intensified by recycling or by connecting a number of such sonicated tanks in line the number of tanks or the recycle loops will be strongly dependent on the irradiation time required for the application. 

Tanks-in-series reactor configurations provide a means of approaching the conversion of a tubular reactor. In modelling, systems of tanks in series are employed for describing axial mixing in non-ideal tubular reactors. Residence time distributions, as measured by tracers, can be used to characterise reactors, to establish models and to calculate conversions for first-order reactions. The reactor in this example has a recycle loop to provide additional flexibility in modelling the mixing characteristics. 

The simplest flow-sheet for the reaction Aj o Aj is the RD column sequence with an external recycling loop shown in Fig. 5.1. The system as a whole is fed with pure Aj. According to the assumed relative volatility of the two components a > 1, the reaction product A2 is enriched in the column distillate product whereas the bottom product contains non-converted reactant Aj, which is recycled back to the reactor (continuous stirred tank reactor, CSTR, or plug flow tube reactor, PFTR). The process has two important operational variables the recycling ratio cp = B/F, that is the ratio of recycling flow B to feed flow rate F, and the reflux ratio of the distillation column R = L/D. At steady-state conditions, D = F since the total number of moles is assumed to be constant for the reaction Aj A2. As principal design variables, the Damkohler number. 

Continuous flow stirred-tank reactors are normally just what the name implies tanks into which reactants flow and from which a product stream is removed on a continuous basis. CFSTRs, CSTRs, C-star reactors, and backmix reactors are only a few of the names applied to the idealized stirred-tank flow reactor model. We will use the letters CSTR in this book. The virtues of a stirred-tank reactor lie in its simplicity of construction and the relative ease with which it may be controlled. These reactors are used primarily for carrying out liquid phase reactions in the organic chemicals industry, particularly for systems that are characterized by relatively slow reaction rates. If it is imperative that a gas phase reaction be carried out under efficient mixing conditions similar to those found in a stirred-tank reactor, one may employ a tubular reactor containing a recycle loop. At sufficiently high recycle rates, such systems approximate the behavior of stirred tanks. In this section we are concerned with the development of design equations that are appropriate for use with the idealized stirred-tank reactor model. 

Pressure relief equipment includes relief valves, safety valves, rupture discs, piping, drums, vent stacks, pressure indicators, pressure alarms, pressure control loops, and flare systems. Pressure relief devices can be placed on pumps, compressors, tanks, piping, reactors, distillation columns, refrigeration systems, and many other kinds of equipment. Materials that cannot be released to the atmosphere are recycled back to the system, or sent to a scrubber or flare system. The discharge from pressure relief equipment is collected in a closed piping system and sent to a flare stack. Harmless gases are discharged at a safe distance from plant operations areas. 

Added productivity of lactic acid fermentations can be achieved by combining continuous systems with mechanisms that allow higher bacterial cell concentrationsResearch is concentrated on two mechanisms (1) membrane recycle bioreactors (MRBs) and (2) immobilized cell systems (ICSs). The MRB consists of a continuous stirred-tank reactor in a semiclosed loop with a hollow fiber, tubular, flat, or cross flow membrane unit that allows cell and lactic acid separation and recycle of cells back to the bioreactor. The results of a number of laboratory studies with various MRB systems demonstrate the effect of high cell concentrations on raising lactic acid productivity (Litchfield 1996). O Table 1.12 lists examples of published results employing various MRB systems. 

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