Академический Документы
Профессиональный Документы
Культура Документы
W REACTOR
hen planning the design of a
batch-type plant to produce
commercial quan-tities of a
product or a mix of
producís, every full-size reactor in the
plant will usually have a working
CONSIDER
volume that is some múltiple of the
ca-pacity of a pilot plant reactor.
Produc-tion capability of the larger
plant is often predicted from cycle times
expe-rienced in the small-scale
equipment. Process engineers usually
have little trouble maintaining the same
cycle time for production steps such as
the charging of liquids and sohds to the
The reactor This article develops the mathemat-
ics of reactor scale-up. We will show,
reactor. They are not so in control,
however, when it comes to the times
aspect ratio when the aspect ratio of the two reac-
tors is the same, the increase in heat
transfer área is only a fraction of the
required to complete temperature
adjustment steps in the larger units. in scale-up increase in volumetric capacity. We
Given the same vessel and jacket will also develop a shorteut to quickly
configurations and restricted to the NOMENCLATURE compute the aspect ratio required to
same operating conditions as at the factor for determining the capacity make the heat transfer área increase
small scale, the same steps take longer at (gal.) of tfie bottom head = 0.606 proportionally to the volume.
the larger scale because heat transfer for ASME Standard F & D heads
área does not scale-up at the same rate as (3fg2 - d2§)/g3, see Equation 15 The mathematics of scale-up
does reactor volume. aa = total heat transfer área, ft2 Consider the reactor in Figure 1; the
This series of four articles addresses A= Absolute valué of p, see Equation working volume in that vessel is given
ABV = 20 by the expression:
four issues. Two are presented this
(3Pg - 2ad§)/g3, see Equation 15
month and two next month. Part 1, Wy=F [aD3 + 7.48(n/4)D2L] (1)
bb (f3 - a2§)/g3, see Equation 15
below, explains how the geometry of with the conversión factor 7.48 gal = 1
= ce 5.875, see Equation 3 reactor
scale-up "short changes" the larger unit
= d inside diameter, ft. defined ft3. Next, define aspect ratio:
ofheat transfer área. Part 2 will show the = D Equation 19 t + [4a(F-l J/7.48], see R = L/D (2)
mathematics of scale-up to predict the = Equation 9 fraction of total volume and define the constant, d:
times for temperature adjustment steps DV = oceupied by working volume. irF, d = 7.48M4) = 5.875 (3)
at the larger scale. Part 3 introduces f = see Equation 9 straight side Substitute d and R into Equation 1:
changing the jacket to a zoned F= length covered by VW,ft. WV=F[aL)3 + dRD3] (4)
configura-tion. Part4 combines the aspect reactor straight side
ratiocor-rections to the zoned (tangent-to-tangent) length, ft.
Solving Equation 4 for reactor diame-
9= ter gives:
configuration to reduce prolonged cycle J= (f+gRl), see Equation 14 (a+dR]),
times. see Equation 14 defined -ÍW/-1/3
L= Equation 17 defined Equation 18
D= \ (5)
Considering the aspect ratio aspect ratio, L/D, dimensionless (a+dR)
Go to a meeting of process engineers to M= volume scale-up factor =
discuss scale-up. At least one oíd hand N= VWj/WV, Assume that the total área of the bot-
will remind others that scale-up P= heat transfer área scale-up factor tom head is effective for heat transfer.
geometry "short changes" the larger QV = = A2/A1 factor for determining The total surface área of the reactor in
reactor of heat transfer área. Next will R= the surface área (ft2) of the bottom Figure 1 that is avaüable for heating or
come the intuitive judgment, "Sure, but head = 0.931 for ASME Standard cooling the working volume is a sum:
SUFV = F & D heads working volume, gal.
if we make the new reactor skinnier A = tV2 + nDJ (6)
and taller..." Roots of the cubic equation 21
SUFA = (SUFVM3/N2), see Equation 14 Working volume can be defined as in
This státement is a suggestion to ma-
angle, see Equation 20, radians Equation 1 or it can be defined as
nipúlate the "aspect ratio" of the reactor. t=
Define that as "the tangent-to-tangent re-lated to the straight side length that
length of the reactor divided by the reac- it filis. Make this expression in "J"
tor diameter." It is usually not good equal to Equation 1 with the constants
as ex-pressed by Equation 3.
prac-tice to design reactors with large wv =
aspect ratios. Unfortunately, the YY¡ = F [aD3 + dD2L] = aD3 + dD^J (7)
mathematics of scale-up is too §=
0= Solving Equation 7 for J gives
complicated to permit even the old-hand
process engineer to offer an
instantaneous intuitive reply as to the
best ratio.
96 CHEMICAL ENGINEERING / DECEMBER 1997
Partí
</ =
DESIGN
(8) TABLE 1. THEEFFECTOF
SCALIN© UP VOLUME AT
CONSTANT ASPECT PATIO
SUFv SUFA VALUÉ SUFA Os %SUFV
2 1.59 79
3 2.08 69
ATIONS
Edward H. Steve 4 2.52 63
Day& 5 2.93 59
Zimmermann 6 3.30 55
International 10 47
4.65
JaD(F-l)
+ FL
———-—^-~-
SOLVING THE CUBIC EQUATION
An Excel 5.0 spreadsheet is the easy way fo solve Equation 15. Two key 9. Compute the angle 0 (ÁBV = the absoluto valué of the pararneter p]
constants based on ASME Standard F & D vessel heads are a= 0.606 and f
= 0.931 []]. It will be easy to find three roots for nu-merous inpuf valúes of R\,
QV2 0
the aspect ratio. Table 2 shows the example calculation for R] = 4. For this
= arceos
(20)
particular cubic equaiion, the following traditional solution method applies [2], ABV¿
Read the spreadsheet this way: 27
1. Design choice inputs: R, = 4, SUFV = 2, F = 0.8 10. Calcúlate the three roots, YY,, YY2 and YY3
2. Constants:.a = 0.606, t = 0.931
3. Calcúlate d, f and g
4. Calcúlate N, M and §
-f (21)
5. Calcúlate aa, bb and ce. These are the coefficients of the cubic equation eos 0 + 7t (22)
ó. p = j[3bb~aa2] ABV (
23)
(17): yys=-2^
References
1. Dimoplon, W., Jr., August 1974!
How to Determine the 2. Turna, J.J., "Engineering Mathematics Hand-
Geometry of Pressure
Vessel Heads, book," p.7, McGraw-HiB, New York, 1970.
Hydro-carbon
Process., pp. 71-74,
MORE
T
his is the second in a series of
ar-ticles that addresses selected
reactor design considerations. The
REACTOR
first (p. 96) discussed how the
geometry of scale-up "short changes"
the larger unit of heat transfer área.
This article will develop how the
math-ematics of scale-up can be used to
pre-dict the heat loads and times
required for completing temperature
CONSIDER
LMTD
ln
(t2-T) Predicting
adjust-ment steps at the larger scale.
(*x-n
Traditional Heat Transfer Model temperature
The figure shows the traditional model
used for unsteady-state heat transfer loads and times
analysis. Components are an agitated
reactor and a non-isothermal jacket
for scale-up
fluid. The mission is to cool or heat the
contents of the vessel from initial to NOMENCLATURE
final temperature.
Note 2 with the drawing All items below are introduced for Part 2. If
recom-mends including the weight of common to both parts, they will not be
the ves-sel in an analysis. The repeated.
temperature of the reactor walls must ai = UA]/wiC, see Equation 18
change along with the contents. For A= total heat transfer surface área =
simplicity, how-ever, this feature is not As + ABift2
included in the mathematics in this A¡j = heat transfer área on the bottom
article. The as-sumption is plausible head of the reactor, ft2
based on relative heat capacities and
A$ = heat transfer área on
weights.
the straight side of the reactor, ft2
Calculating the time required to
change the internal temperature of the b= (SUFv)2/3/k, see Equation 18
reactor starts with differential heat C= heat capacity of ¡acket fluid,
balance equations: Bfu/lb-°F
Cp|_ = heat capacity of mass of material in
Por Cooling:
the reactor, Btu/lb-"F
= wC(t2-t1) = UA(LMTD) (1) k= scale-up terrn for ¡acket How,
dimensionless
(b) (c)
LMTD= log mean temperature
-«**.% differ-ence, see Equations 3 and 4
(a) ML = mass of material in the reactor, Ib
For Heating: t] = ¡acket inlet temperature, °F
MLCpLd=
LMTD £ -= wC(.t1-t2) = UA(LMTD) (2) t2 = ¡acket outlet temperature, °F
■da T= temperature of mass of material
(d) (e) (í) in the reactor, °F
Then compute the log mean U= overall heat transfer coefficient,
tempera-ture differences Btu/hr-ft2-°F
(3) w= ¡acket flow, Ib/h
X= eUA/wC ¡ see Eauation 8. Sub-
scripts explained Equations 13,
14andl5.
For coohng: For fl = time required to complete the
(4) step, h
heating:
_ [(h-ry^-T)]
u>C(t2-t1)=UA temperature at the start of the coohng
ln (5) cycle, T¡, to the temperature at the end
We will retain the lower case "t" for Clearing and of the cooling cycle, T2.
representing jacket temperature and the rearranging... When cooling, T2 < T¡. The (g) form of
upper case "T" for representing internal Equation 8 shows clearly that the
ln ¡JA
reactor temperature. It will not matter if wC (6) pre-dicted t at the start of the cycle will
2
the temperature adjustment operation is (T-h), be larger than the predicted t2 at the end
for cooling or for heating. Another of the cycle. This is an important aspect of
simplification we will assume is that
(T-H)
un-steady state heat transfer. Don't
both U and A remain constant over the Therefore, in exponential form: overlook it when completing heat load
temperature adjustment cycle. (T-t1)ICT-t2) = eÜAIwC (7) calculations.
LettingX= eUA!wC and Equate parts (e) and (f) in Equation 2
Jacket Outlet Temperature substítuting gives and use the full definition of LMTD for
Equate parts (b) and (c) in Equation 1. the heating mode. The result will be
Use the definition of LMTD for the cool- t2 = mX-V+tJ/X =T + [(tj-T)IX] (8)
ing mode. This equation allows the (g) (h)
di-rect calculation of the jacket outlet The valúes for t¡ and X in
temperature, t2, in the figure. Equation 8 are constant.
Temperature T varíes from the
[T-tt)-(T-h
100 CHEMICAL ENGINEERING / DECEMBER 1997
(T-h)/
".
/(T-h)
Part2
DESIGN
TABLE . PARAMETERSFORTHi
AGITATED REACTOR
AB s75 ft2
■:■. As s188.9 (t2
= 1.0Btu/lb-°F
.c CpL = 0.516 Btu/lb-°F
ATIONS
Edward H. Steve ML = 29,962 Ib
Day& : ti = 104°F
T,
Zimmermann
.:•■
• = 221°F
International h = 158°F 2
u = 73.5 Btu/hr-ft -°F
w = ; 28,798 Ib/h
scale-up factor (SUFy), plug Equation 2 indicates the scaled-up reactor.) substituted into Equation 11.
18 into form (h) of Equation 8. 'SUFvjML1CpL~
ML2CpL _¡SUFV]ML1CpL
i,=T + Q=
h-T
H (19) To predict directly the expected
*J Tiz- (21)
3. Final Adjustment Time valué for the time required to complete ln
h
Equation 20 results because M¿¿ = a cooling step in a reactor scaled-up by T2-h rf-i
SUFy x Mi2 and u>2 = kwp (Subscript some volume scale-up factor {SUFy),
Equations 18 and 20 can be
Coade has raised the bar another notch with Calculation example No. 2 The
CAESAR II Versión 4.0, the new, native Plus you get all these tools ¡n one package: objective is to scale up the reactor to
Windows 95/NT versión of the world's most twice the volume. i.e., SUFy = 2.
CAESAR II
popular program for pipe stress analysis and
Versión
• Pipe stress analysis
As-sume U2 = Uj. Assume that the size
of the half-pipe jacket is identical at
4.0 both scales. In other words, k = 1,
therefore w2 = lXw}.
Pipe Stress Analysis Use Equation 18 and calcúlate a»
and b