Presentation Report

Of
Chemical Reaction Technology

SUBMITTED TO: Mr. Zohaib Atiq Khan

SUBMITTED BY:
Muhammad ALI 2010-BT-CHEM-10
Muhammad Shafique 2010-BT-CHEM-13
Topic:
………. Batch Reactor
Date: 29/11/2013
 Presentation report

Introduction:-
A type of Ideal reactor vessel widely used in the process industries. This
type are used for a variety of process operations such as solids dissolution,
product mixing, chemical reactions, batch distillation, crystallization,
liquid/liquid extraction and polymerization.
The basic characteristics of this reactor are:

 Unsteady state operation takes places in reactor.

 Composition changes w.r.to time.
 Uniform composition throughout reactor.

Construction:-
A typical batch reactor consists of

 Reactor vessel.
 Agitator.
 Baffles.
 Cooling/Heating system.
 Motor/ Shaft Drive Unit.

Kinds of Phases Present

1. Gas phase.
2. Liquid phase.
3. Liquid Solid.

Prepared By: Group# 3 Reg# 2010-BT-CHEM-10 & -13 Page 1

 Presentation report
1. Reactor Vessel:-
A type of Ideal reactor vessel used in the process may vary in size from less
than 1 liter to more than 15,000 liters. They are usually fabricated in steel,
stainless steel, glass lined steel, glass or exotic alloy. Feed Inlet

Liquids and solids are usually charged via connections

in the top cover of the reactor. Vapors and gases also
discharge through connections in the top.
Liquids are usually discharged out of the bottom.
Product
Outlet

2. Agitator:-
It is an apparatus for stirring liquid. The usual agitator arrangement is a
centrally mounted driveshaft with an overhead drive unit. Impeller blades
are mounted on the shaft.

A wide variety of blade designs are used and typically the blades cover
about two thirds of the diameter of the reactor. Where viscous products are
handled, anchor shaped paddles are often used which have a close
clearance between the blade and the vessel walls.

Motor

Shaft

Blade

Most batch reactors also use baffles. These are stationary blades which
break up flow caused by the rotating agitator. These may be fixed to the
vessel cover or mounted on the interior of the side walls.
Despite significant improvements in agitator blade and baffle design,
mixing in large batch reactors is ultimately constrained by the amount of
energy that can be applied.

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3. Heating/Cooling System:-
Products within batch reactors usually liberate or absorb heat
during processing. Even the action of stirring stored liquids generates heat.
In order to hold the reactor contents at the desired temperature, heat has
to be added or removed by a cooling jacket or cooling pipe. Heating/cooling
coils or external jackets are used for heating and cooling batch reactors.
Heat transfer fluid passes through the jacket or coils to add or remove heat.

Within the chemical and pharmaceutical industries, external cooling

jackets are generally preferred as they make the vessel easier to clean.

The performance of these jackets can be defined by 3 parameters:

 Response time to modify the jacket temperature.

 Uniformity of jacket temperature.
 Stability of jacket temperature.

Fast temperature control response and uniform jacket heating and cooling
is particularly important for crystallization processes or operations where
the product or process is very temperature sensitive.

There are several types of batch reactor cooling/Heating jackets:

1. Single external jacket.

2. Half coil jacket.

3. Constant flux cooling jacket.

1. Single external jacket:-

The single jacket design consists of
an outer jacket which surrounds the vessel.
Heat transfer fluid (H.T Fluid) flows around
the jacket and is injected at high velocity via External
nozzles. Jacket

The temperature in the jacket is regulated

to control heating or cooling.
Oldest design of external cooling jacket. Single external jacket system

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Limitations:-
The single jacket has some limitations.

1. On large vessels, it can take many minutes

to temperature of the fluid in the cooling
jacket. This results in sluggish temperature
control.
2. The distribution of heat transfer fluid is also External
far from ideal and the heating or cooling Jacket
tends to vary between the side walls and
bottom dish.

Single external jacket system

2. Half Coil jacket:-

It made by welding a half pipe the outside of the vessel to
create a semi circular flow channel. The heat transfer fluid passes through
the channel in a plug flow fashion. A large reactor may use several coils to
deliver the heat transfer fluid. Like the single jacket, the temperature in the
jacket is regulated to control heating or cooling.

The plug flow characteristics of a half coil jacket permits

faster displacement of the heat transfer fluid in the jacket (less than 1min).

This is desirable for good temperature control.

It also provides good distribution of heat transfer
fluid which avoids the problems of non uniform
heating or cooling between the side walls and
bottom dish.

Like the single jacket design however

the inlet heat transfer fluid is also vulnerable to
large oscillations (in response to the temperature
control valve) in temperature.

Half Coil jacket

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3. Constant Flux cooling jacket:-

The constant flux cooling jacket is a relatively recent development.

It is not a single jacket but has a series of 20 or more small jacket elements.
The temperature control valve operates by opening and closing these
channels as required. By varying the heat transfer area in this way,
the process temperature can be regulated without altering the jacket
temperature.

 The constant flux jacket has very fast temperature control response
(typically less than 5 seconds) due to
i. The short length of the flow channels.
ii. High velocity of the heat transfer fluid.
 Like the half coil jacket the heating/cooling
flux is uniform.
Because the jacket operates substantially
constant temperature the inlet temperature
oscillations other jackets are absent.

Operation:- Constant flux cooling jacket

Simple Batch Reactor is charged via two holes in the top of the
tank; while reaction is carried out, nothing else is put in or taken out until
the reaction is done; tank easily heated or cooled by jacket.

Liquids and solids are usually charged via connection in the top cover of
the reactor. Vapors and gases also discharge through connections in the
top. Liquids are usually discharged out of the bottom.

Feed Inlet

Product
Outlet

Batch Reactor

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Waste water treatment (SBR):-

Working procedure of batch reactor involved in waste water
treatment is:

1. Waste water inter into the reactor.

2. Bio oxidation of organic matter occurs in the SBR.

3. After mixing and settling the treated water is collected by decanter.

4. Biological solids or waste activated sludge is removed from bottom.

Startup:-
 Turn the main power supply ‘’ON’’

 Discharge valve should be close.

 Open inlet stream valve.

 Filling of tank, level should be maintained.

 Turn the stirrer ‘’ON’’ by mechanical means.

 Compress the air.

 Aeration of the mixed liquor.

Waste water treatment (SBR)

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Shut-down:-
After complete the procedure of batch reactor these steps are
involved in waste water treatment (SBR) shutdown:

 Stop air supply.

 “Off” agitation.
 “Off” power supply.
 Open decanting valve.
 Remove WAS.
 Clean the tank.

Trouble Shooting:-
 Excess Foam.
 Pumice-like foam (gray color).

 Due to solid returns from sludge.

 Improve the solids capture in the sludge processing scheme.

 Sulfide Bulking.
 Elemental sulfur present in waste water.

 addition of ferric chloride or ferrous sulfide to bind the sulfur

 Lowering of pH
 Very high sour.

 Affects the micro-organism.

 Adding lime, soda ash or sod-bicarbonate.

Prepared By: Group# 3

Reg# 2010-BT-CHEM-10

2010-BT-CHEM-13

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Advantages:-
1. High conversion per unit volume for one passes.
2. Flexibility of operation-same reactor can produce one product
one time and a different product the next.
3. Easy to clean.
4. Its cheaper to produce a whole batch instead of single,
machines can be used more effectively. It's lower cost, fewer
workers because going to use machines.
5. The batch reactor lies with its versatility. A single vessel can
carry out a sequence of different operations without the need
to break containment.
6. This is particularly useful when processing toxic or highly
potent compounds.

Disadvantages:-
1. High operating cost.
2. Product quality more variable than with continuous operation.
3. More time require.
4. Difficult to produce large scale production.

Applications:-
 Batch distillation.
 Crystallization.
 Liquid/Liquid extraction and Polymerization.
 Pharmaceutical.
 Fermentation.
 Waste water treatment.

Reference:-
High opera Jenkins, D., M. G. Richard and G. T. Daggers. 1993. Manual on
the Causes and Control of Activated Sludge Bulking and Foaming. Lewis
Publishers, Inc., Chelsea, MI

Prepared By: Group# 3 Reg# 2010-BT-CHEM-10 & -13 Page 8

Prepared By: Group# 3 Reg# 2010-BT-CHEM-10 & -13 Page 7