Lectures 2-6

Chapter 2

Conversion and Reactor Sizing

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 Reactor Mole Balance Summary
General Mole Balance:

2
 Reactor Sizing
• The Mole Balance equations are very
important, but in most cases may not be directly
used for reactor sizing, because:
-NA and FA are not what we commonly use for evaluation of
reaction’s progress. They are not intuitionistic terms as well;

- The term of conversion, X, is designated to describe a

reaction’s progress toward completion.

• The Mole Balance equations need to be

rewritten in terms of X for reactor sizing, which
are offen referred to as the design equations. 3
 2.1 Definition of Conversion
• Conversion, X, is a measure of the reaction’s
progress toward completion.
aAbB  c C  d D
Choose limiting reactant A as basis of calculatio n

b c d
A B
 C  D
a a a

moles A reacted
X
moles A fed

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 2.2 Batch Reactor Design Equations

Total amount of reacted

A after a time t:

Total amount of un-

reacted A after a time t:

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 2.2 Batch Reactor Design Equations

Mole Balance:
Combine with

Integral Form:

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 2.3 Flow Reactors Design Equations

Total molar flow rate of reacted A after a time t:

Total molar flow rate of un-reacted A after a time t:

 2.3.1 CSTR Design Equation
Mole Balance:
Combine with

CSTR Design
Equation:

Why is rA equal to (rA)exit? Characteristic of CSTR.

 2.3.2 PFR Design Equation
Mole Balance:
Combine with

PFR Design
Equation:

Integral Form:
 2.3.3 PBR Design Equation
Mole Balance:
Combine with

PFR Design
Equation:

Integral Form:
 Reactor Design Equation Summary

General Mole Balance: dX

General Design Equation: FA0 X   rA dV   N A0
dt
We can size reactor now if we are given -rA=f(X). 11
 2.4 Applications of Design Equations for
Flow Reactors
• Example 1:
Given reaction in a CSTR and , size the reactor.

CSTR design equation:

Combine both equations, we get direct correlation between V and X:

FA0 X
V
kC A0 (1  X )

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 2.4 Applications of Design Equations for
Flow Reactors
• Levenspiel Plot for Flow Reactors
Given rA=rA (X) is known, we can draw a Levenspiel Plot to size a reactor:

FA 0
rA

X
What are the advantage to use Levenspiel Plots?
CSTR: PFR: 13
 2.4 Applications of Design Equations for
Flow Reactors
• Levenspiel Plot for CSTR

Area = Volume of CSTR

FA 0
FA 0 
rA V   X1
rA X
1

X X1

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 2.4 Applications of Design Equations for
Flow Reactors
• Levenspiel Plot for PFR

FA 0 Area = Volume of PFR

rA X1 FA 0 
V 0  dX
rA 

X1

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 2.4 Applications of Design Equations for
Flow Reactors
• Comparison of Levenspiel Plots for CSTR and PFR

The resaon that the isothermal CSTR volume is

Given the specific -rA=f(X), the isothermal greater than the PFR volume is that the CSTR is
tubular reactor volume is smaller than the always operating at the lowest reaction rate.
CSTR for the same conversion. Why? The PFR starts at a high rate at the entrance
and gradually decreases to the exit rate.
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 2.5 Flow Reactors in Series
Levenspiel Plot for a CSTR-PFR-CSTR Reactor in Series:

FA0 X 1
V1 
 rA1
X2 F
V2   A0
dX
X1  r
A

FA0 ( X 3  X 2 )
V3 
 rA3

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 2.5 Flow Reactors in Series
• CSTR in series

For one single CSTR (V3) with

X2 conversioin:
F X
V3  A0 2
 rA 2

V1  V2  V3
CSTR in series can be more efficient than single CSTR.
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 2.5 Flow Reactors in Series
• PFR in series

X1 FA0
V1   dX
0  rA
X2 FA0
V2   dX
X1  rA

For one single PFR (V3) with X2 conversioin:

X2 FA0 X1 F X2 F
V3   dX   A0
dX   A0
dX  V1  V2
0  rA 0  rA X 1  r
A
There is no difference in the total volume comparing PFRs in series with one
PFR with same total conversion. 19
 2.6 Examples
• Example 1: Size a CSTR
Use rA=f(X) data listed in the table to calculate the V needed to achieve 80%
conversion in a CSTR. Inlet flow information: a gas mixture consisting of 50% A and
50% inerts at 10 atm and flowing at 6 dm3/s at 300 F (422.2 K).

CSTR design equation:

At X=0.8, we read –rA=0.00125;

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Take FA0 and rA value into the design equation, we get V needed for X=0.8 for a
CSTR.

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 2.6 Examples
• Example 2: Size a PFR using same parameters for CSTR as in Example 2
Use rA=f(X) data listed in the table to calculate the V needed to achieve 80%
conversion in a CSTR. Inlet flow information: a gas mixture consisting of 50% A and
50% inerts at 10 atm and flowing at 6 dm3/s at 300 F (422.2 K).

PFR design equation:

Ideal gas law

Appendix
for more
details.

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 Levenspiel CSTR plot

Vs.

VPFR < VCSTR for to achieve a same conversion, X.

Will VPFR always be smaller than VCSTR for a same X?
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Will VPFR always be smaller than VCSTR for a same X?

The answer is “No”. It depends on the curvature of rA as a function of X, i.e. the

shape of the Lavenspiel plots.

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• Example 3: Comparing volumes for CSTRs in series

CSTR design equation:

–1/rA=250

1st CSTR:

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2nd CSTR:

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• Example 4: Comparing volumes for PFRs in series
For two PFRs in series, 40% conversion is achieved in the first reactor.
What is total volume of the two reactors snecessary for 80% overall
conversion of the species A entering reactor 1?

PFR design equation:

1st PFR

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 2nd PFR

The volume necessary to achieve 80% conversion of species A for one signle PFR is:

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No benefits in volume to replace one single PFR with PFR in series.
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• Example 5: Combination of PFR and CSTR, and comparision of the
order of sequencing reactors

=0.5

=0.5

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=0.5

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=0.5

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 Some Further Definitions
• Space Time: τ (obtained by dividing the reactor volume by the
volumetric flow rate entering the reactor)

• Space Velocity: SV

Example: Calculate the space time, τ, and space velocities for a CSTR reactor with
V=6.4 m3 and entering volumetric flow rate of 2 dm3/s.

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Design Equations and Reactor Sizing Summary

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