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Reactor Volume Calculations in Engineering

The document outlines a tutorial on reactor engineering focusing on tubular reactors, covering various chemical reactions and calculations related to plug flow reactors (PFR) and continuous stirred-tank reactors (CSTR). It includes derivations for reactor volume equations, calculations for required reactor volumes to achieve specific conversions, and stoichiometric analyses for different reactions. Key topics include reaction rates, conversions, and the impact of operating conditions on reactor design.

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Shazni Ahamed
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17 views2 pages

Reactor Volume Calculations in Engineering

The document outlines a tutorial on reactor engineering focusing on tubular reactors, covering various chemical reactions and calculations related to plug flow reactors (PFR) and continuous stirred-tank reactors (CSTR). It includes derivations for reactor volume equations, calculations for required reactor volumes to achieve specific conversions, and stoichiometric analyses for different reactions. Key topics include reaction rates, conversions, and the impact of operating conditions on reactor design.

Uploaded by

Shazni Ahamed
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

CH3143 – Reactor Engineering

Tutorial – 2

Tubular Reactors

1. A B+C

the reaction is carried out in a plug flow reactor operated at steady state. The exit
concentration of A is 40 % of the entering concentration. Entering volumetric flow rate and
inlet concentration of A are 15 dm3/min and 6 mol/dm3, respectively (Volumetric flow rate
is constant, vin=vout). The rate of reaction is given by r = −kC and rate constant is 0.12
dm6mol-2min-1

i. Derive an equation for PFR volume relating volumetric flow rate, concentrations of
A and rate constant.
ii. Calculate the required PFR volume.
iii. Determine a CSTR volume required to achieve same exit concentration (Entering
conditions are same).

2. 𝐴 + 𝐵 → 𝐶 is an irreversible gas phase non elementary reaction. The feed stream to the
reactor at 1013 kPa and 500 K contains 33.3 mole% of A and 66.7 mole% of B. Each of
following reaction rates, measured in units of is observed at a particular conversion,
.
x.
Reaction rate (-rA) 0.010 0.005 0.002 0.001
Conversion (x) 0.0 0.2 0.4 0.6

i. Derive the equation for volume of a PFR relating flow rate, reaction rate and
conversion.
ii. Determine the volume of PFR required to achieve 30% conversion of A for an
entering volumetric flow rate of 2 m3/min.
iii. Estimate volume of a CSTR which takes the effluent from above PFR as inlet and
achieve 50 % total conversion.

∫ 𝑓(𝑥)𝑑𝑥 = 𝑓(𝑎) + 4𝑓 + 𝑓(𝑏) , ℎ =

3. N 2O5 vapour under goes the reaction 2 N 2O5  4 NO2  O2 and this is first order and
essentially irreversible. The N 2O5 vapour passes through a tubular reactor in which the
pressure and temperature are constant. The flow rate at the inlet is n0 mole per unit time. If
there is plug flow in the vessel, show that the fraction, F, of the N 2O5 which decomposes
during passage is given by:
CH3143 – Reactor Engineering
KV r 1
 2.5 ln  1 .5 F
V0 n 0 (1  F )

Where, Vr is the volume of the reactor, V0 is the molar volume at the prevailing temperature
and pressure and K is the rate constant for the reaction. Neglect the presence of N 2 O 4 .

4. Gas leaving an Ammonia oxidation plant is cooled rapidly to atmospheric temperature, in


order to remove the bulk of the water vapour. It then contains 9% NO 1% NO 2 and 8% O2
(all % s are by volume). The remainder of the gas is nitrogen. Before entering the absorption
tower for the production of nitric acid, this gas is allowed to oxidize until the NO: NO 2
molar ratio reaches 5:1. Cooling is efficient enough for the temperature of the reacting gas
mixture to remain constant at 20 0C.
The gas flow rate at the reactor inlet is 10,000 m3/hour, measured at 200C and 1 atm. Gas
pressure within the reactor is constant at 1 atm. Reaction order corresponds to its
stoichiometry and the overall order of the reaction is 3.0. The rate constant ‘k’ is 1.4×10 4
m6/kmol2.s at 200C.
i. Develop the stoichiometric table for the flow system using standard notations (Eg -
Ɵi, Fi)
ii. Calculate the final conversion of NO using the given data.
iii. Determine the required tubular reactor volume to achieve the above calculated
conversion in part b.

5. 𝐴 + 𝐵 ↔ 2𝐶 + 𝐷 is a gas phase reaction which is carried out in a tubular reactor to


produce C on large scale. The reaction takes place isothermally and reactor is maintained at
5270C. Further, the operating pressure is 5 bar and pressure drop through the reactor can be
neglected. The combined feed rate of A and B is 10 tons/hr and A:B mass flow ratio is 2:3.
The temperature and pressure in feed flows are equal to the reactor operating conditions.

The reaction is reversible with the rate equation;


-𝑟 = 𝑘 𝐶 𝐶 − 𝑘 𝐶 𝐶

The rate constant for forward reaction: 𝑘 = 2.5 and equilibrium constant: 𝑘 = 3.4.
.
The products will be discharged from the reactor when fractional conversion of A is 40 %
mole. Estimate the required reactor volume.
Note :
Molar mass of A and B are 52 g/mol and 85 g/mol respectively.

Common questions

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For a CSTR, the fundamental equation is V_CSTR = F_A0 * (X / -r_A), where X is the conversion needed, and r_A is constant throughout the reactor. The reaction rate -r_A is evaluated at the reactor outlet conditions. Assuming similar conditions as the PFR for an exit concentration of 2.4 mol/dm3, use r_A = -kC_A^3 for the outlet concentration of A. Solving F_A0 = v0C_A0, where v0 = 15 dm3/min, V_CSTR simplifies to (v0 * C_A0 / kC_A^3) * X. Calculating gives V_CSTR = (15 dm3/min * 6 mol/dm3 / 0.12 dm6mol-2min-1) * 0.6 = 125 dm3 .

For a reversible reaction A + B ↔ 2C + D occurring in a tubular reactor, influences on volume are centered on reaction equilibrium and kinetics. The reaction's volume is related to the molar flow rate of reaction components and the forward-reverse reaction kinetics. With isothermal conditions, set -r_A = k_f*C_A*C_B - k_b*C_C*C_D. Using equilibrium constraints (k_c = C_C^2 * C_D / (C_A * C_B)) and given mass flow ratios, solve for V such that the conversion of A fulfills the design constraint of 40% .

For the CSTR taking effluent from a PFR with a 30% conversion, we need to calculate V_CSTR based on the difference in conversion from 30% to 50% total. Use -r_A at the outlet condition, which is calculated at 50% conversion. Assuming v0 = 2 m3/min, concentrated equation, C_A = C_A0(1-X), and given the reaction characteristics, determine the rate of reaction at this conversion; thus, V_CSTR = (2 m3/min)(0.2) / (rate at 50% conversion), where detailed values would depend on the reaction rate data .

Develop a stoichiometric table for the NOx reacting system considering gas flow and stoichiometry. Given the reaction order is 3, apply rate law -r_NO = kc_NO^3 with k = 1.4 × 10^4 m6/kmol2.s. Integrate this rate law to find the conversion considering the total inlet moles and flow rate. The specific final conversion X can be calculated knowing initial concentrations and moles affected by the reaction, leading to particular conversion at which NO: NO2 molar ratio equals 5:1 .

To determine the PFR volume, calculate the concentration of A at 40% conversion, which is 2.4 mol/dm3 (40% of initial 6 mol/dm3). Use the rate of reaction -r_A = -kC_A^3 with k = 0.12 dm6mol-2min-1, and apply the integral of 1/C_A^2 to get the volume: V = 15 dm3/min * (0.6 / 0.12) * (1/(6^2) - 1/(2.4^2)) = 37.5 dm3. Thus, the required volume is 37.5 dm3 .

Molar ratios, particularly in gas phase reactions like the ammonia oxidation described, dictate reactant proportioning and product distribution, affecting reaction kinetics, equilibrium, and total conversion achieved. Maintaining an appropriate NO: NO2 ratio, for instance, ensures the reaction proceeds with optimal efficiency in converting reactants to desired products, enhancing production and reducing by-products. The design must adjust parameters such as feed flow rates and reactor volume to maintain these ratios, enabling a controlled, efficient reaction environment that yields the single desired product .

To determine the required tubular reactor volume, calculate the integration of the conversion-dependent reaction rate, accounting for the overall 3rd-order reaction. Start by constructing the mole balance across the tubular reactor: V = ∫ F_A0 dX / -r, where the rate -r is dependent on NO concentration. Use the design equations at specified conditions, assuming conversions align with maintaining reactor conditions: a consistent NO to NO2 molar ratio of 5:1 demands the final conversion data previously computed .

The volume of a PFR can be derived using the material balance for a differential element within the reactor. For a reaction with the rate equation -r_A = -kC_A^3 and a steady-state operation, the equation for the volume V of the PFR is obtained by integrating the rate expression over the length of the reactor: V = (F_A0 / (-r_A)) * (1 - X), where F_A0 is the molar flow rate of A at the inlet, X is the conversion, and r_A is the rate of reaction. This results in the integral form: V = F_A0 * ∫dX / (-kC_A^3), which can be solved provided the relationship between concentration and conversion is known .

To construct stoichiometric tables, define each reactant's and product's initial molar flow rates, conversion levels, and stoichiometric ratios in terms of inlet stream composition and flow rates. For complex gas reactions, such as NO oxidizing to NO2, track molar changes per conversion unit, apply reaction stoichiometry, and include all significant conserved quantities (e.g., total moles or energy considerations). These tables are useful as they provide a clear framework to quantify and track changes in concentration and composition across different sections of reactors, facilitating accurate reactor sizing and design .

Factors affecting plug flow assumption validity include the uniformity of reactant flow, axial mixing resistance, and radial distribution uniformity. For irreversible decomposition in a tubular reactor, as in 2O5N vapour breaking down, it is essential for flow to be virtually unmixed in the axial direction, maintain a uniform velocity profile across the reactor's cross-section, and have minimal radial variations in composition. Proper reactor design ensures the reaction progresses consistently with the mathematical simplification of the plug flow model .

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