UNIVERSITEIT VAN PRETORIA/UNIVERSITY OF PRETORIA

DEPARTEMENT CHEMIESE INGENIEURSWESE/DEPARTMENT OF CHEMICAL ENGINEERING

CRO 410 REACTOR DESIGN 410

TYD/TIME: 3 uur JUNIE 2013 BIng(Chem)IV

TOTAAL/TOTAL: {60}
Eksterne eksaminator/External examiner: Zita Harber

Interne eksaminator/Internal examiner: Elizbé Du Toit

Question 1 (10)

The figure below shows different layouts for two identical packed bed reactors. In scenario 1 the
reactors are operated in series and in scenario 2 the reactors are operated in parallel. In both cases
the reactors are operated isothermally. The mass flow rate and concentration of reactants to the
reactors in each of the flow schemes are identical. The reaction that is considered is first order with
regards to reactant A. Bed porosity for both reactors = 0.4. The conversion of reactant A in the
series reaction scheme is 75% (Configuration 1). The Thoenes-Kramer correlation accurately
predicts the external liquid solid mass transfer coefficient.

a) What will the conversion in configuration 2 be if it is assumed that the reaction rate is
controlled by external liquid solid mass transfer effects in both reactors? Plug flow
behaviour may be assumed and the catalyst particle diameter is the same in both scenarios.
b) What will the conversion in configuration 2 be if it is assumed that the reaction rate is
completely limited by internal mass transfer effects in both reactors? (Same particle
diameters and plug flow behaviour)
c) What will the conversion in configuration 2 be if the Peclet number for the series reactor
scheme (scenario 1 – see as one long reactor) is 8? In this case all mass transfer effects can
be assumed negligible and the catalyst particle diameter (same for both), is such that Rep <
20 in both reactor configurations. Bed porosity for both reactors = 0.4.
Question 2 (15)

A solid (non-porous) catalyst with a density of ρc = 2000 kg/m3 is used to catalyse a first order liquid
phase reaction in an isothermal CSTR. The stirrer speed is varied between different experimental
runs, and the catalyst concentration is varied in order to ensure a constant volumetric reaction rate
(based on reactant A) of -0.112 mol/m3/s. This ensures a constant outlet concentration of
component A of CA = 5000 mol/m3. The figure below shows how the catalyst concentration needs to
be varied with stirrer speed in order to ensure equal volumetric rates between different runs when a
uniform catalyst particle diameter of 2 mm is used. The correlation that describes the specific mass

transfer coefficient in this reactor shows that:
 ∝  

a) What is the intrinsic mass based reaction constant for the 2 mm particles? [3]
b) Catalyst particles with a diameter of 1 mm are now used in subsequent experiments.
Calculate the mass based intrinsic rate constant for the 1 mm particles if you may assume
that the area density of active sites (sites/m2) is independent of the particle diameter. [2]
c) Predict the catalyst concentration required with the 1 mm catalyst particles -if the
assumption in (b) holds - to ensure the same volumetric rate if the stirrer speed in the
reactor is set to 50 rpm [5]
d) The actual catalyst concentration required at 50 rpm for the 1 mm particles turns out to be
Ccat= 1.5 kg/m3. This implies that the sites/m2 is NOT independent of the particle diameter.
Determine the proportionality of the active site density to particle diameter (I.e. sites/m2 ∝
(dp)n, determine n) [5]
Question 3 (15)

The catalysed hydrogenation of a long chain olefin (O) to the paraffin (P) is carried out in an
isothermal slurry bed reactor that may be assumed to operate as a CSTR.
O + H2 → P
The reaction rate is second order in terms of the hydrogen concentration. Information on the
reactor and the reaction are given in the table below.

Volume of reactor 10000 liter

3
Catalyst concentration 4 kg/m
Olefin molar flowrate into reactor 2000 mol/hr
3
Henry constant of hydrogen in mixture 10 mol/m /bar
Operating pressure in the reactor 4 bar
Particle diameter (spherical) 1 mm
3
Particle density 1400 kg/m
2
Effective diffusivity of hydrogen in liquid filled catalyst 1.5E-09 m /s
Conversion of olefin 75%
kc Liquid solid mass transfer coefficient with 1 mm particles 4.25e-04 m/s
3
Hydrogen concentration in bulk liquid @ operating conditions 32 mol/m

a) Determine the overall gas liquid mass transfer coefficient (kLag) at the operating conditions
given in the table. [2]
b) What is the hydrogen concentration at the surface of the catalyst pellets? [2]
c) Calculate the intrinsic rate constant for the second order surface reaction. [5]
d) The particle diameter is now doubled but the same catalyst mass (Ccat) is used in the reactor.
Determine the steady state conversion of the olefin with the new catalyst particle diameter.
The gas liquid mass transfer coefficient are not influenced by particle diameter, but


 ∝  . (A trial and error procedure may be required. Clearly show all the
equations you use to solve this problem with numerical values for constants as far as
possible) [6]
 Question 4 (20)

An exothermic, irreversible liquid phase first order reaction where pure component A reacts to
form B was studied in a few different reactors (more detail given in the questions) where a
porous catalyst is used to catalyse the reaction. The information in the table below is the same
for all reactors. You may assume any external mass transfer effects to be negligible.
3
Pre-exponential rate constant 2 m /kg/s

Activation Energy 45 kJ/mol

Heat of reaction (exothermic) -50 kJ/mol

Specific heat capacity of A and B 250 J/mol/K

3
Inlet concentration of A 2000 mol/m

Catalyst Particle diameter (both reactors) 1 mm

3
Catalyst density 1800 kg/m

Effective diffusivity in liquid filled catalyst pores 1.0E-08 m2/s

Reactor inlet flow rate 1.4 l/min

a) What catalyst weight will be required if an adiabatic CSTR with an inlet temperature of 400
K is used and a conversion of 85% is required? [4]
b) What conversion can be achieved in an adiabatic PBR, with an inlet temperature of 300 K, if
it is required that the particle effectiveness factor, η, is such that the rate regime is such that
internal mass transfer effects may be assumed negligible over the entire length of the
reactor. [5]
In question 4 c) and 4 d) a non-adiabatic PBR is cooled using cooling oil with a constant temperature
of 330 K (Tu). The maximum temperature observed in the cooled PBR is 500 K. The bed density of
the PBR is 800 kg/m3, and the flow rates and reactor dimensions in the reactor are such that
Ua = 9.1 kW/K.
c) Show qualitatively how the particle effectiveness factor will vary with catalyst mass. Clearly
explain (using equations and graphs), the profile that you give. [4]
d) What is the conversion of component A at the observed maximum temperature? [7]