Residence time optimization

TABLE 1-2 Restricted Residence-Time Optimization for Two CSTRs in Series Operating at the Same Temperature ... 

How closely a design approaches minimum energy is largely determined by the raw materials and catalyst system chosen. However, if reaction temperature, residence time, and diluent are the only variables, there is still a tremendous opportunity to influence energy use via the effect on yield. Even given none of these, there is stiU wide freedom to optimize the heat interchange system (see Reactor technology). 

Batch readers—optimum residence time for series and complex reactions, minimum cost, optimal operating temperature, and maximum rate of reaction... 

Flow regimes, operability Residence time distribution Mixing Transport processes Screening Optimization Validation... 

The optimal network increases total residence time by 48 per cent when compared with an equivalent MSMPR of the same volume and throughput. This increase would translate into a similar increase in mean crystal size and a 78 per cent increase in yield. Exactly the same residence time as for the single crystallizer have been reported from simple cascade configurations previously designed for stage-wise crystallization processes for slight improvements in... 

The key to efficient destruction of liquid hazardous wastes lies in minimizing unevaporated droplets and unrcacted vapors. Just as for the rotary kiln, temperature, residence time, and turbulence may be optimized to increase destruction efficiencies. Typical combustion chamber residence time and temperature ranges arc 0.5-2 s and 1300-3000°F. Liquid injection incinerators vary in dimensions and have feed rates up to 1500 gal/h of organic wastes and 4000 gal/h of aqueous waste. 

Typically, the saponification is run with 10% sodium hydroxide solution in a reactor cascade at 95-98°C under stringent pH control. The saponification mixture is separated in a settler. The upper phase consists of alkanes with a small proportion of chloroalkanes, which is removed by oleum refining or dehydrochlorination and high-pressure hydrogenation. The refined alkanes can be recycled to the reactor. In the aqueous lower phase are alkanesulfonates, sodium chloride, and between 4 and 8 wt % hydrotropically dissolved alkanes. An optimal separation can be approached at 95 °C, and residence times of less than 60 min if Fe(III) ions are added and pH values of 3-5 are maintained. 

Short residence time of the product in the evaporator Close correlation between operating parameter and product specs Optimized energy consumption Easy startup/shutdown operations... 

Mixing Models. The assumption of perfect or micro-mixing is frequently made for continuous stirred tank reactors and the ensuing reactor model used for design and optimization studies. For well-agitated reactors with moderate reaction rates and for reaction media which are not too viscous, this model is often justified. Micro-mixed reactors are characterized by uniform concentrations throughout the reactor and an exponential residence time distribution function. 

The results of Example 5.2 apply to a reactor with a fixed reaction time, i or thatch- Equation (5.5) shows that the optimal temperature in a CSTR decreases as the mean residence time increases. This is also true for a PFR or a batch reactor. There is no interior optimum with respect to reaction time for a single, reversible reaction. When Ef < Ef, the best yield is obtained in a large reactor operating at low temperature. Obviously, the kinetic model ceases to apply when the reactants freeze. More realistically, capital and operating costs impose constraints on the design. 

In the design of optimal catalytic gas-Hquid reactors, hydrodynamics deserves special attention. Different flow regimes have been observed in co- and countercurrent operation. Segmented flow (often referred to as Taylor flow) with the gas bubbles having a diameter close to the tube diameter appeared to be the most advantageous as far as mass transfer and residence time distribution (RTD) is concerned. Many reviews on three-phase monolithic processes have been pubhshed [37-40]. 

The kinetic parameters associated with the synthesis of norbomene are determined by using the experimental data obtained at elevated temperatures and pressures. The reaction orders with respect to cyclopentadiene and ethylene are estimated to be 0.96 and 0.94, respectively. According to the simulation results, the conversion increases with both temperature and pressure but the selectivity to norbomene decreases due to the formation of DMON. Therefore, the optimal reaction conditions must be selected by considering these features. When a CSTR is used, the appropriate reaction conditions are found to be around 320°C and 1200 psig with 4 1 mole ratio of ethylene to DCPD in the feed stream. Also, it is desirable to have a Pe larger than 50 for a dispersed PFR and keep the residence time low for a PFR with recycle stream. 

Reactive distillation is one of the classic techniques of process intensification. This combination of reaction and distillation was first developed by Eastman Kodak under the 1984 patent in which methyl acetate was produced from methanol and acetic acid. One of the key elements of the design is to use the acetic acid as both a reactant and an extraction solvent within the system, thereby breaking the azeotrope that exists within the system. Likewise, the addition of the catalyst to the system allowed sufficient residence time such that high yields could be obtained, making the process commercially viable. Other examples in which reactive distillation may enhance selectivity include those of serial reactions, in which the intermediate is the desired product, and the reaction and separation rates can be systematically controlled to optimize the yield of the desired intermediate. ... 

The bulk of this chapter is devoted to a discussion of optimization with regard to selectivity considerations. In the sections that follow we will take 3 = 0 in order to concentrate on the primary effects and to simplify the discussion. Consequently, in this chapter, the terms space time, mean residence time, and holding time may be used interchangeably. 

Flow rate The limitations associated with the volume of flow cell can be overcome by accurately controlling the flow rate of each stream entering into the manifold. This experimental parameter controls the residence time of the chemiluminescent solution within the cell and can be easily optimized by the operator. How rates are directly proportional to the rate of the CL reaction. As the rate of the reaction increases, the flow rate should be increased but, at the same time, consumption of reagents increases. The flow rate also affects the shape and the height of the peak as well as the measurement rate (number of sample or standard solutions injected per hour). 

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