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Overview
Define conversion (X)

Chapter 2: Conversion and

Reactor Sizing
Objectives:
Use conversion in design equations
Use a Levenspiel plot to size a reactor
Use a Levenspiel plot to understand the effects of reactors in series

Write reactor design equations in terms of

conversion
Determine the size of CSTRs and PFRs using the
design equations, X, and the rate of reaction
Determine the system conversion and individual
sizes of reactors in series

Conversion
Generic reaction:

Definition of Conversion
If A is the limiting reactant:

Rearranged:
Conversion:
What is the limiting reactant?
What is the conversion?

For example, in a flow reactor:

Or:

Remember these
definitions

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Batch Reactor Design Equation

Batch Reactor Design Equation

Previously:

From previous slide

Definition of conversion for a batch system:

Simplifying:
We can integrate this
numericallly, if needed

By substitution:

Integrating:

Batch Design Equation

Batch Example

AB+C
-rA = kCA (first order)
k = 0.005 s-1
V = 100 dm3
CA,0 = 0.1 mol/dm3
95% conversion of A XA = 0.95
Find the time, tf, needed for conversion

CSTR Design Equation

Previously:

Definition of conversion for a flow system:

By substitution:

Answer = 600 s
CSTR Design Equation

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CSTR Example

AB+C
-rA = kCA (first order)
k = 0.005 s-1
FA,0 = 5 mol/h
CA,0 = 0.1 mol/dm3
95% conversion of A XA = 0.95
Find the volume needed for conversion

Answer = 52.78 dm3

PFR Example

AB+C
-rA = kCA (first order)
k = 0.005 s-1
FA,0 = 5 mol/h
CA,0 = 0.1 mol/dm3
95% conversion of A XA = 0.95
Find the volume needed for conversion

PFR Design Equation

Previously:

Definition of conversion for a flow system:

By substitution:

PFR Design Equation

PBR Design Equation

Rewrite the PFR design equation in terms of
PBR Design Equation
catalyst weight:

Answer = 8.32 dm3

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Real Reaction-Rate Data

Reaction rate changes with concentration (except
for 0th-order reactions):

Real Reaction-Rate Data

Data from Fogler, Table 2-1:

Therefore, reaction rate changes with conversion.

We can measure this dependence experimentally.

Real Reaction-Rate Data

We can plot the reaction rate data, -rA:

Real Reaction-Rate Data

Plotting 1/-rA:
Asymptote
What does this mean?

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Levenspiel Plot

Sizing a Reactor Using the Levenspiel Plot

Plotting FA,0/-rA for FA,0 = 0.4 mol/s:

Find the CSTR volume for XA = 0.8:

All we need to know is
FA,0/rA at XA = 0.8

What does
this mean?

Sizing a Reactor Using the Levenspiel Plot

Find the PFR volume for XA = 0.8:

Sizing Reactors, Example

For XA = 0.8:

We need to know the integral

from XA = 0 to XA = 0.8

2 CSTRs in series, 2 PFRs in series, 1 CSTR, 1 PFR, 6 CSTRs in series

What is total conversion after each reactor?

What does
this mean?

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Sizing Reactors, Comments

If you have many small CSTRs in series, you
approximate a PFR
Some reactors come in standard sizes

Not All Reactions are the Same

For XA = 0.4, which is more efficient: CSTR or PFR?
How about XA = 0.8, 0.9?
What combination of CSTRs and PFRs would maximize efficiency?

How can you maximize the yield?

Sometimes you have to use a reactor that is already

purchased
How can you best use what you have?

PFRs always look more efficient, why would you use a

CSTR?

Further Definitions
These will be used later in the course:
Mean residence time (space time):
Space velocity:
This is the inverse of mean residence time
But it is often measured using different conditions than the reactor
(i.e. different T, P, or even different phase)