Steady continuous operation

Next we derive relationships between the species composition in chemical reactors to the chemical reactions taking place in them. For convenience, we distinguish between two modes of reactor operations batch operation (batch reactors) and steady continuous operation (flow reactors), shown schematically in Figure 2.1. In batch reactors, reactants are charged into the reactor and, after a certain period of time, the products are discharged from the reactor hence, the chemical reactions take place over time. In steady-flow reactors, reactants are continuously fed into the reactor, and products are continuously withdrawn from the reactor outlet hence, the chemical reactions take place over space. 

Although the continuous-countercurrent type of operation has found limited application in the removal of gaseous pollutants from process streams (Tor example, the removal of carbon dioxide and sulfur compounds such as hydrogen sulfide and carbonyl sulfide), by far the most common type of operation presently in use is the fixed-bed adsorber. The relatively high cost of continuously transporting solid particles as required in steady-state operations makes fixed-bed adsorption an attractive, economical alternative. If intermittent or batch operation is practical, a simple one-bed system, cycling alternately between the adsorption and regeneration phases, 1 suffice. 

The desirable operating characteristics of equipment include simplicity, convenience and low cost of maintenance simplicity, convenience and low cost of assembly and disassembly convenience in replacing worn or damaged components ability to control during operation and test before permanent installation continuous operation and steady-state processing of materials without excessive noise, vibration or upset conditions a minimum of personnel for its operation and, finally, safe operation. Low maintenance often... 

A run was carried out with an extract flow rate of = 8.64 niL min (and a raffinate flow rate of = 4.72 niL min ). Raffinate purity close to 100 % (PUR = 99.6 %) was obtained, but the extract purity was lower (PUX = 97.5 %). The internal concentration profiles were evaluated at cyclic steady state (after 20 full cycles of continuous operation). Also evaluated were the average concentrations of both species in both extract and raffinate during a full cycle. 

At the flood point, liquid continues to flow down the column, but builds up at a greater rate from tray to tray. Sutherland [69] demonstrated that flooding moves up the column from the point of origin. For this reason it is important to design perforated trays without downcomers with extra care, as changing internal rates are quickly reflected in performance if the proper hole requirements are not met. They are a usefiil tray for steady state operations. 

All processes may be classified as batch, continuous, or semibatch depending on how materials are transferred into and out of the system. Also, the process operation may be characterized as unsteady state (i.e., transient) or steady state, depending on whether the process variables (e.g., pressure, temperature, compositions, flowrate, etc.) are changing with time or not, respectively. In a batch process, the entire feed material (i.e., charge) is added instantaneously to the system marking the beginning of the process, and all the contents of the system including the products are removed at a later time, at the end of the process. In a continuous process, the materials enter and leave the system as continuous streams, but not necessarily at the same rate. In a semibalch process, the feed may be added at once but the products removed continuously, or vice versa. It is evident that batch and semibatch processes are inherently unsteady state, whereas continuous processes may be operated in a steady or unsteady-state mode. Start-up and shut-down procedures of a steady continuous production process are examples of transient operation. 

Achieving steady-state operation in a continuous tank reactor system can be difficult. Particle nucleation phenomena and the decrease in termination rate caused by high viscosity within the particles (gel effect) can contribute to significant reactor instabilities. Variation in the level of inhibitors in the feed streams can also cause reactor control problems. Conversion oscillations have been observed with many different monomers. These oscillations often result from a limit cycle behavior of the particle nucleation mechanism. Such oscillations are difficult to tolerate in commercial systems. They can cause uneven heat loads and significant transients in free emulsifier concentration thus potentially causing flocculation and the formation of wall polymer. This problem may be one of the most difficult to handle in the development of commercial continuous processes. 

Continuous Polymerizations As previously mentioned, fifteen continuous polymerizations in the tubular reactor were performed at different flow rates (i.e. (Nj g) ) with twelve runs using identical formulations and three runs having different emulsifier and initiator concentrations. A summary of the experimental runs is presented in Table IV and the styrene conversion vs reaction time data are presented graphically in Figures 7 to 9. It is important to note that the measurements of pressure and temperature profiles, flow rate and the latex properties indicated that steady state operation was reached after a period corresponding to twice the residence time in the tubular reactor. This agrees with Ghosh s results ). 

The experimental programme was mainly concerned with estimating kinetic parameters from isothermal steady state operation of the reactor. For these runs, the reactor was charged with the reactants, in such proportions that the mixture resulting from their complete conversion approximated the expected steady state, as far as total polymer concentrations was concerned. In order to conserve reactants, the reactor was raised to the operating temperature in batch mode. When this temperature had been attained, continuous flow operation commenced. This was... 

For an industrial application it is clear that flow cells will be highly advantageous since they allow continuous operation, the use of external heat exchangers and continuous monitoring of quality. In addition the reactant concentration remains invariant with time, allowing the cell to be run under true steady-state conditions, and the lower residence time of the products reduces further reactions. 

Most continuous plants are now designed for steady-state operation with little regard for the ease (or difficulty) with which the steady state can be maintained through control. Such a plant can be difficult to control once it deviates from the steady state. 

Continuous Stirred Tanks with Biomass Recycle. When the desired product is excreted, closing the system with respect to biomass offers a substantial reduction in the cost of nutrients. The idea is to force the cells into a sustained stationary or maintenance period where there is relatively little substrate used to grow biomass and where production of the desired product is maximized. One approach is to withhold some key nutrient so that cell growth is restricted, but to supply a carbon source and other components needed for the desired product. It is sometimes possible to maintain this state for weeks or months and to achieve high-volumetric productivities. There will be spontaneous cell loss (i.e., kd > 0), and true steady-state operation requires continuous purging and makeup. The purge can be achieved by incomplete separation and recycle... 

The fed-batch scheme of Example 14.3 is one of many possible ways to start a CSTR. It is generally desired to begin continuous operation only when the vessel is full and when the concentration within the vessel has reached its steady-state value. This gives a bumpkss startup. The results of Example 14.3 show that a bumpless startup is possible for an isothermal, first-order reaction. Some reasoning will convince you that it is possible for any single, isothermal reaction. It is not generally possible for multiple reactions. 

All the supported catalysts used gave TCE conversions less than 20% for the wet oxidation at 310 K, except for the 5 wt.% CoOx/Ti02, which had a steady-state conversion of 45% via a transient behavior in activity up to 1 h on stream (Fig. 1). Subsequently, there was negligible TCE conversion for the bare Ti02 during continuous operating hours near 6. 

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