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Reactors

A reactor is a vessel for controlled chemical reactions, essential in various industries like refineries and pharmaceuticals. Types of reactors include batch, continuous stirred tank, plug flow, packed bed, fluidized bed, and trickle bed, each suited for specific processes. Key design considerations involve reaction kinetics, heat transfer, mass transfer, catalyst selection, and safety, while common failure modes include catalyst deactivation, thermal runaway, and corrosion.

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4 views2 pages

Reactors

A reactor is a vessel for controlled chemical reactions, essential in various industries like refineries and pharmaceuticals. Types of reactors include batch, continuous stirred tank, plug flow, packed bed, fluidized bed, and trickle bed, each suited for specific processes. Key design considerations involve reaction kinetics, heat transfer, mass transfer, catalyst selection, and safety, while common failure modes include catalyst deactivation, thermal runaway, and corrosion.

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2022umt1946
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© © All Rights Reserved
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Reactors – Industrial Overview

1. Definition and Purpose


A reactor is a vessel or system in which a controlled chemical reaction takes place. Reactors
are designed to maintain the required conditions—such as temperature, pressure,
residence time, and mixing—for optimal conversion of reactants into products. They are
used extensively in refineries, petrochemical plants, pharmaceutical manufacturing, and
chemical processing units to carry out reactions such as hydrogenation, polymerization,
oxidation, and cracking.

2. Types of Industrial Reactors


Reactors are classified based on operating mode, flow patterns, phase interaction, and
catalyst usage. The most common types include:

Batch Reactor
Operates in a closed system where all reactants are loaded, allowed to react, and then
discharged. Common in specialty chemicals and pharma.

Continuous Stirred Tank Reactor (CSTR)


Reactants are continuously fed while products are removed; ensures uniform composition.
Suitable for liquid-phase reactions.

Plug Flow Reactor (PFR)


Reactants move through a tubular vessel with minimal mixing; ideal for high-speed or
exothermic reactions.

Packed Bed Reactor (PBR)


Gas or liquid flows through a packed bed of catalyst; used widely in fixed-bed catalytic
processes.

Fluidized Bed Reactor


Solid catalyst particles are suspended in upward-flowing fluids; excellent heat and mass
transfer. Used in fluid catalytic cracking (FCC).

Trickle Bed Reactor


Liquid trickles over a catalyst bed while gas flows concurrently; commonly used in
hydrotreating and hydrogenation.
3. Design Considerations
Designing a reactor involves balancing multiple factors to ensure performance, efficiency,
and safety. Key considerations include:

 - Reaction kinetics and expected conversion rate.


 - Heat transfer requirements, especially for exothermic or endothermic reactions.
 - Mass transfer limitations and mixing effectiveness.
 - Catalyst selection, loading method, and deactivation behavior.
 - Pressure drop across the reactor.
 - Selection of corrosion-resistant materials and proper lining.
 - Instrumentation for temperature, pressure, and flow control.

4. Common Failure Modes


Reactors operate under demanding thermal, chemical, and mechanical conditions. The
following are typical failure mechanisms:

 - Catalyst deactivation due to fouling, poisoning, or sintering.


 - Thermal runaway from uncontrolled exothermic reactions.
 - Corrosion, particularly in acidic or high-temperature service.
 - Overpressure leading to vessel rupture.
 - Mechanical fatigue or brittle fracture from thermal cycling.
 - Blockage or fouling affecting fluid flow and heat exchange.

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