Introduction

Reactor is a device for the controlled release of nuclear energy (as for
producing heat) .
Reactors are vessels designed to perform chemical reactions that take
place in the presence of a catalyst between reactants in feedstock, or
reactants in multiple feed streams.
Type of reactor
The three classical generic chemical reactors are the batch reactor, the
continuous stirred-tank reactor (CSTR), and the plug flow tubular reactor
(PFR).
-Batch reactor
A batch reactor is a chemical reactor in which a non-
continuous reaction is conducted, i.e., one where the
reactants, products and solvent do not flow in or out of
the vessel during the reaction until the target reaction
conversion is achieved. By extension, the expression
is somehow inappropriately used for other batch fluid
processing operations that do not involve a chemical
reaction, such as solids dissolution, product mixing,
batch distillation, crystallization, and liquid/liquid
extraction. In such cases, however, they may not be
referred to as reactors but rather with a term specific to the
function they perform (such as crystallizer, bioreactor, etc.).
Many batch processes are designed on the basis of a scale-up from the
laboratory, particularly for the manufacture of specialty chemicals and
pharmaceuticals. If this is the case, the process development will
produce a recipe for the manufacturing process, which is not not unlike a
recipe used in cookery.[2] A typical batch reactor consists of a pressure
vessel with an agitator and integral heating/cooling system. The vessels
may vary in size from less than 1 L to more than 15,000 L. They are
usually fabricated in steel, stainless steel, glass-lined steel, glass or
exotic alloys. 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.
The advantages of the batch reactor lie with its versatility. A single
vessel can carry out a sequence of different operations without the need
to break containment. This is particularly useful when processing toxic or
highly potent compounds.
Batch reactors are often used in the process industry; in wastewater
treatment, as they are effective in reducing biological oxygen demand
(BOD) of influent untreated water;[3] in the pharmaceutical industry; in
laboratory applications, such as small-scale production, inducing
fermentation for beverage products, and for experiments of reaction
kinetics and thermodynamics; etc. Common issues ascribed to batch
reactors are their relatively high cost and unreliability in terms of product
quality.
-CSTR
A continuous stirred tank reactor (CSTR) is a reaction
vessel in which reagents, reactants, and solvents flow
into the reactor while the products of the reaction
concurrently exit the vessel. In this manner, the tank
reactor is considered to be a valuable tool for
continuous chemical processing.
CSTR reactors are known for their efficient mixing
and stable, uniform performance under steady-state
conditions. Typically, the output composition is the
same as the material inside the reactor, which depends on
the residence time and reaction rate.
In situations where a reaction is too slow, when two immiscible or
viscous liquids require a high agitation rate, or when plug flow behavior
is desired, multiple reactors can be linked together to create a CSTR
cascade.
A CSTR assumes an ideal back mixing scenario, which is the exact
opposite of a plug flow reactor (PFR).
Continuous stirred tank reactors (CSTRs) consist of:
 A tank reactor.
 Stirring system to mix reactants (impeller or fast-flowing introduction
of reactants).
 Feed and exit pipes to introduce reactants and remove products.
CSTRs are most commonly used in industrial processing, primarily in
homogeneous liquid-phase flow reactions where constant agitation is
required. However, they are also used in the pharmaceutical industry
and for biological processes, such as cell cultures and fermenters.
-PFR
The plug flow reactor is the second-
most primary ideal reactor and is
similar to the continuous stirred tank
bioreactor. Here polymerization and
conversion reactions are performed
in noncatalytic mode. The
polymerization of ethylene and the
conversion of naphtha to ethylene
are examples. A catalytic process is
used for the synthesis of ammonia
and SO2 combustion [10]. Currently, plug flow reactors are used in the
production of biodiesel and other biofuels with a recycle system [9]. The
plug flow reactor is mostly preferred for bioenergy production because of
its steady-state operation. In addition, the plug flow reactor does not
require any agitation or baffling. When high viscous reactants are used,
a high-pressure drop is developed, which may be considered as a
limiting factor in the usage of this reactor, and this reactor is more
complex than the continuous stirred tank bioreactor.
Plug flow reactors are unique in the sense that operation in parallel or
series give the same conversion if the space time is held constant. This
implies, for example, that if a 20-m reactor of fixed diameter is required
to achieve a given conversion, the same conversion and capacity can be
achieved by running ten 2-m reactors in series or ten 2-m reactors in
parallel. The split of the feed in the parallel case must be one tenth of
the total to keep the same space time. In industrial applications the
geometry chosen is a function of cost of construction, ease of operation,
and pressure drop. Parallel operation is normally preferred to keep the
pressure drop at a minimum.
CSTR vs Batch Reactor
In general, reactors can be classified as either continuous or batch
reactors. CSTRs are typically smaller in size and enable the seamless
addition of reactants and reagents while the product can flow out
continuously without interruption.
In contrast, a batch reactor is a chemical reactor that involves the
addition of a fixed amount of reactants to the reactor vessel, followed by
the reaction process until the desired product is obtained. Unlike a
continuous reactor, reactants are not added continuously, and products
are not removed continuously. Furthermore, batch reactors are not as
uniformly mixed, and the temperature and pressure conditions may vary
during the reaction.
CSTRs have the unique ability to handle higher reactant concentrations,
as well as more energetic reactions due to their superior heat transfer
properties in comparison to batch reactors. In this manner, a CSTR is
considered a tool supporting flow chemistry.
The Difference Between CSTR and PFR (plug flow reactor)
CSTRs and PFRs are both used in continuous flow chemistry. CSTRs
and PFRs can either function as standalone reaction systems or be
combined to form part of a continuous flow process. Mixing is a crucial
aspect of CSTRs, whereas PFRs are designed as tubular reactors
where individual moving plugs contain reactants and reagents, acting as
mini-batch reactors. Each plug in a PFR has a slightly different
composition, and they internally mix, but not with the nearby plug ahead
of or behind it. In an ideally mixed CSTR, product composition is uniform
throughout the entire volume, whereas in a PFR, product composition
varies depending on its position within the tubular reactor. Each type of
reactor has its own set of advantages and disadvantages when
compared to the others.
While a CSTR can produce substantial quantities of product per unit of
time and can operate for extended periods, it may not be the best choice
for reactions with slow kinetics. In such cases, batch reactors are
typically the preferred option for synthesis.
Plug flow reactors are generally more space-efficient and have higher
conversion rates compared to other types of reactors. However, they are
not suitable for highly exothermic reactions because it can be
challenging to control sudden temperature surges. Furthermore, PFRs
typically entail higher operating and maintenance costs than CSTRs.
Advantages of CSTR over PFR
 Temperature control is easily maintained
 CSTR behavior is well understood, including in mixing (ability to
handle solids and slurries), reaction calorimetry, dosing options, and
chemical kinetics
 Less expensive and easier to construct than dedicated specialty flow
systems
 The interior of the reactor is accessible for process analytical
technology (PAT)
 Multiple units can be easily joined for cascade operation or integration
in more complex flow systems with PFR, etc.
Disadvantages of CSTR over PFR
 Overall throughput per unit volume is typically lower than tubular flow
reactors
 A steady state needs to be maintained so the system needs to be
well understood
 Single units are not optimal for reactions with slow kinetics