Semi flow reactor

Some batch reactions have the potential for very high energy levels. If all the reactants (and sometimes catalysts) are put into a kettle before the reaction is initiated, some exothermic reactions may result in a runaway. The use of continuous or semi-batch reactors to limit the energy present and to reduce the risk of a runaway should be considered. The term semi-batch refers to a system where one reactant and, if necessary, a catalyst is initially charged to a batch reactor. A second reactant is subsequently fed to the reactor under conditions such that an upset in reacting conditions can be detected and the flow of the reactant stopped, thus limiting the total amount of potential energy in the reactor. 

The influence of inhibitor on the performance of a semi-continuous reactor can be, in some ways, similar to both batch and continuous systems. A dead time is usually observed upon addition of the initial charge. When the secondary stream flow is started after some reaction of the initial charge, additional inhibitor flows into the reactor and the initiation rate drops. When this programmed addition is stopped the initiation rate increases sometimes enough to cause temperature control problems. 

The catalytic degradation of PS was carried out in a semi-batch reactor where nitrogen is continuously passed with a flow rate of 30 mL/min. A mixture of 3.0 g of PS and 0.3 g of the catalyst was loaded inside a Pyrex vessel of 30 mL and heated at a rate of 30 C/min up to the desired temperature. The distillate from the reactor was collected in a cold trap(-10 °C) over a period of 2 h. The degradation of the plastic gave off gases, liquids and residues. The residue means the carbonaceous compounds remaining in the reactor and deposited on the wall of the reactor. The condensed liquid samples were analyzed by a GC (HP6890) with a capillary column (HP-IMS). 

Key PFR = Plug Flow Reactor, BSTR = Batch Stirred-Tank Reactor, (S)BSTR = (Semi)Batch Stirred -Tank Reactor, SBSTR = Semibatch Stirred-Tank Reactor, CSTR = Continuous Stirred-Tank Reactor, TBR = Trickle-Bed Reactor. 

Generally, the temperature changes with time or, equivalently, with distance from the reactor inlet (for flow reactors). This change is usually controlled well in reaction calorimeters but can become uncontrolled in other conventional laboratory flow or (semi)batch reactors. The balance equations of a batch reactor for a single reaction of a-th order kinetics are given by ... 

In this chapter the simulation examples are described. As seen from the Table of Contents, the examples are organised according to twelve application areas Batch Reactors, Continuous Tank Reactors, Tubular Reactors, Semi-Continuous Reactors, Mixing Models, Tank Flow Examples, Process Control, Mass Transfer Processes, Distillation Processes, Heat Transfer, and Dynamic Numerical Examples. There are aspects of some examples which relate them to more than one application area, which is usually apparent from the titles of the examples. Within each section, the examples are listed in order of their degree of difficulty. 

In this chapter, we first consider uses of batch reactors, and their advantages and disadvantages compared with continuous-flow reactors. After considering what the essential features of process design are, we then develop design or performance equations for both isothermal and nonisothermal operation. The latter requires the energy balance, in addition to the material balance. We continue with an example of optimal performance of a batch reactor, and conclude with a discussion of semibatch and semi-continuous operation. We restrict attention to simple systems, deferring treatment of complex systems to Chapter 18. 

The choice of a reactor is usually based on several factors such as the desired production rate, the chemical and physical characteristics of the chemical process, and the risk of hazards for each type of reactor. In general, small production requirements suggest batch or semi-batch reactors, while large production rates are better accommodated in continuous reactors, either plug flow or continuous stirred tank reactors (CSTR). The chemical and physical features that determine the optimum reactor are treated in books on reaction engineering and thus are not considered here. 

Single Reactions—For all reactions of orders above zero, tire CSTR gives a lower production rate than the batch, semi-batch, or kinetically equivalent plug-flow reactor. 

Two Reactions, Different Orders—In the case of a desired second-order reaction and an undesired first-order reaction, such as A + B - C and A — D, where C is the desired product, the batch, semi-batch, or plug-flow reactor is preferred. 

An exothermic reaction involving two reactants is run in a semi-continuous reactor. The heat evolution can be controlled by varying the feed rate of one component This is done via feedback control with reactor temperature measurement used to manipulate the feed rate. The reactor is cooled by a water jacket, for which the heat transfer area varies with volume. Additional control could involve the manipulation of the cooling-water flow rate. 

Biological catalysts in the form of enzymes, cells, organelles, or synzymes that are tethered to a fixed bed, polymer, or other insoluble carrier or entrapped by a semi-impermeable membrane . Immobilization often confers added stability, permits reuse of the biocatalyst, and allows the development of flow reactors. The mode of immobilization may produce distinct populations of biocatalyst, each exhibiting different activities within the same sample. The study of immobilized enzymes can also provide insights into the chemical basis of enzyme latency, a well-known phenomenon characterized by the limited availability of active enzyme as a consequence of immobilization and/or encapsulization. 

Biochemical reactors can be operated either batchwise or continuously, as noted in Section 1.5. Figure 7.1 shows, in schematic form, four modes of operation with two types of reactors for chemical and/or biochemical reactions in Uquid phases, with or without suspended solid particles, such as catalyst particles or microbial cells. The modes of operation include stirred batch stirred semi-batch continuous stirred and continuous plug flow reactors (PFRs). In the first three types, the contents of the tanks arc completely stirred and uniform in composition. 

Figure 7.1 Modes of reactor operation (a) batch reactor, (b) semi-batch reactor, (c) continuous stirred-tank reactor, and (d) continuous plug flow reactor.

The semi-batch reactor produces 5 m3 of product solution every 2 hours. Therefore, in a continuous reactor, the flow rate must be 2.5m3h 1 or 6.94-10-4 mV1. 

A fast exothermal reaction is to be performed in a semi-batch reactor. In order to control the temperature course of the reaction, one of the reactants is added at a constant rate, producing a constant heat flow. The reactor is cooled with water from a river (at 15 °C in winter). The cooling water should not be rejected at a temperature higher than 30 °C. 

Of special attention is the work [24] in which kinetic regularities of ethane oxidation by oxygen performed at 600-630 °C in a flow reactor in the low transformation zone were successfully and semi-quantitatively explained by the radical-chain mechanism with H202 as a source of two active particles ... 

Knowledge of these types of reactors is important because some industrial reactors approach the idealized types or may be simulated by a number of ideal reactors. In this chapter, we will review the above reactors and their applications in the chemical process industries. Additionally, multiphase reactors such as the fixed and fluidized beds are reviewed. In Chapter 5, the numerical method of analysis will be used to model the concentration-time profiles of various reactions in a batch reactor, and provide sizing of the batch, semi-batch, continuous flow stirred tank, and plug flow reactors for both isothermal and adiabatic conditions. 

Importance of mixing in flow reactors having biochemical reactions has been studied in the past (1.-4). The results of these studies, are however, not applicable to fermentation systems operated in batch or semi-batch manner and very few publications have addressed themselves to such systems (2 ). On the other hand, fermentations are most commonly carried out in batch or semi-batch systems in which the role of mixing towards performances at different scales of operations is not well understood. Possible reasons for this lack of interest have been a presumption of perfect mixing in non-flowing reactors and the... 

A schematic diagram of the entrained flow reactor is shown in Figure 1. At the top of the reactor, a screw feeder and semi-venturi system is used to entrain the ground coal particles in the cold primary gas stream. The coal is then injected into the reactor where it is entrained in, and heated by, the preheated secondary gas. The pyrolyzing coal particles fall in a thin stream through the reactor and are collected by a movable water-cooled collector probe. The time which the particles spend in the reactor is controlled by moving the collector probe up and down the reactor axis. The pyrolysis reactions are rapidly quenched in the collector probe, and the particles are separated from the gas stream by a cyclone in the collection system. 

E.-Y. Hwang et al. [11] PP Semi-hatch reactor with nitrogen flow rate of 30 ml/min. A mixture of 3.0 g PS and 0.3 g catalyst was loaded inside a Pyrex vessel 10 Different clinoptilolites... 

Comparative tests have been performed in the semi-batch reactor system to evaluate the Ru/Ti02 cataly versus a more conventional nickel-based catalyst. These tests show that rutlienium at only 3% metal loading has about the same activity as nickel at S0% metal loading. This comparison is only for short-term activity of the catalyst. As demonstrated in the continuous flow tests, the nickel catalyst loses activity readily in tlie first hours on stream, while the ruthenium maintains its activity. 

Figure 6. Feed flow-rate profile with time to a semi-batch reactor.

Figure 10. Dynamic feed flow-rate profile in response to step change in monomer ratio in a controlled semi-batch reactor.

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