Recycle reactors

For autocatalytic reactions, recycle reactors are suitable. In some cases, we want to
take the output (flue gas in coal combustion) and recycle part of it for variety of
reasons. In biological systems, we may want to use it as a way of introducing catalyst
(enzyme).

1 2
0 3

Here, recycle reactor is a PFR where a part of the output stream is split and routed
back to the inlet. The dotted line shows the entire recycle reactor. Input to the recycle
reactor is at location 0 and the net output is at location 3.

At location 1, the ‘fresh’ input and the ‘recycled’ input are mixed and given as a
combined input to the PFR. At location 2, the output of the PFR is split into a
‘recycled stream’ and ‘net product stream’. The ‘net product stream’ goes to location
3.

We can use two definitions of conversion.

X o = Overall conversion = fraction of fresh feed (location 0) converted

F − FA,3
= A,0
FA,0

The second conversion is the ‘single pass’ conversion or ‘conversion per pass’
F − FA,2
X s = A,1
FA,1
 FA, R
We define recycle ratio as R = . Note that there is only simple physical re-routing
FA,3
of the stream, there is no chemical separation (like distillation) at location 2. Thus, the
composition of the fluid in the streams 2, R and 3 are the same.

At steady state conditions, combined feed at location 1 has some ‘conversion’, (i.e. it
is a mixture of fresh feed and converted stream).

Determine XA,1, and the relationship between Xo and Xs.

FA,0 − FA,3
Xo = ----------(1)
FA,0

FA,1 − FA,2
Xs = ----------(2)
FA,1
FA, R
R= -----------(3)
FA,3

FA,1 = FA,0 + FA, R ------------(4)

FA,2 = FA, R + FA,3 ------------(5)

We want a relationship between FA,0, Xo, R and Xs. Eliminate FA,R, FA,1, FA,2 and FA,3
from the five equations.

(i) Eliminate FA,R. Given FA, R = R × FA,3

FA,0 − FA,3
a. FA,1 = FA,0 + RFA,3 , FA,2 = ( R + 1) FA,3 , X o = ,
FA,0
FA,1 − ( R + 1) FA,3
Xs =
FA,1
(ii) Eliminate FA,3. Given FA,3 = FA,0 (1 − X o )
a. FA,1 = FA,0 1 + R (1 − X o )  , FA,2 = ( R + 1) FA,0 (1 − X o ) ,
FA,1 − ( R + 1) FA,0 (1 − X o )
Xs =
FA,1
(iii) Eliminate FA,2 and FA,1.
FA,0 1 + R (1 − X o )  − ( R + 1)(1 − X o ) FA,0
Xs =
FA,0 1 + R (1 − X o ) 
a.
1 + R − RX o − ( R − RX o + 1 − X o ) Xo
= =
1 + R (1 − X o )  1 + R (1 − X o )
 b. Re-arranging, we get X o =
(1 + R ) X s
1 + ( RX s )

Note: When R = 0, Xs = Xo

Also note that FA,0 is automatically eliminated from the relationship because it comes
in the numerator and denominator.

Mass balance at location 1 would give XA,1.

FA,0 + FA,R is the ‘mixed or combined’ stream. If there were no reaction, concentration
of A would be higher. Also, FA,3 would be FA,0.

X A,1 =
(F
A ,0 + RFA,0 ) − ( FA,0 + FA, R )
=
RFA,0 − FA, R
(F A ,0 + RFA,0 ) FA,0 (1 + R )
But FA, R = RFA,3 = RFA,0 (1 − X o )
RX o
Therefore, X A,1 =
1+ R

We use this in the PFR section of the recycle reactor. We can write the feed as
( R + 1) FA,0 , but with some conversion (i.e. XA,1).
X A ,2
dFA dx
= rA can be written as ∫ dV = ( R + 1) FA0 ∫
dV X A ,1 − rA

But XA,2 = Xo. Therefore,

Xo
dx
V = ( R + 1) FA,0 ∫
RX o − rA
R +1
Graphical representation:

Consider a plot of 1 vs. x for an arbitrary kinetics.

−rA

Corresponding to
Some arbitrary kinetics

1
−rA

0 1

Conversion (x)
Ideal PFR: For a PFR, with an input stream consisting of reactant A (molar flow rate
= FA0) and a desired conversion of xf1, the volume of the reactor is given by
xf 1
dx
V = FA0 ∫ −r
0 A
= FA0 × Area under the curve between the points 0 and xf1.

Corresponding to
Some arbitrary kinetics

1
−rA

0 xf1 1

Conversion (x)

PFR. Inlet x =0, Outlet x = xf1

We can consider a second reactor, and say that the input to the second reactor is
reactant A, with a molar flow rate of FA0 but with an initial conversion of xf1. Now the
conversion (considering the original stream) at the outlet of the second reactor is xf2.
The volume of the second reactor is

xf 2
dx
V = FA0 ∫
xf 1 − rA
FA0 × Area under the curve between the points xf1 and xf2.

Corresponding to
Some arbitrary kinetics

1
−rA

0 xf1 xf2 1

Conversion (x)

Second PFR. Inlet x =xf1, Outlet x = xf2

Ideal CSTR: In a CSTR, the concentration at the outlet is the same as the
concentration in the reactor. The reactor volume is given by
1
V= FA0 ( x f 1 − 0 ) = FA0 ×Area of the rectangle bound by the four
−rA at the outlet conditions
lines (x=0,x=xf1,y=0,y=yf1).

To draw the rectangle, first draw a vertical line at inlet conversion (i.e. x=0), outlet
conversion (xf1), a horizontal line at y (i.e. 1 ) =0 and then the fourth line, a
−rA
horizontal line, corresponding to 1 = 1
−rA at the outlet conditions −rA x = x
f1

Corresponding to
Some arbitrary kinetics

1
−rA

0 xf1 1

Conversion (x)

CSTR. Inlet x =0, Outlet x = xf1

In case of a second reactor, we can say the conversion at the inlet is xf1 and the
conversion at the outlet is xf2. Therefore, the rectangle now is bounded by the lines
(x=xf1,x=xf2,y=0,y=yf2), as shown below.

Corresponding to
Some arbitrary kinetics

1
− rA

0 xf1 xf2 1

Conversion (x)

CSTR. Inlet x = xf1, Outlet x = xf2

Recycle reactor.

The PFR part of the recycle reactor has a ‘mixed’ stream at the inlet. The feed can be
though of as (R+1) FA0 with some conversion xA,1. Note that we denote the overall
conversion as xo.

The volume can be obtained by the formula

xo
dx
V = ( R + 1) FA0 ∫ =(R+1) × FA0 × Area under the curve between the points xA,1
Rxo − rA
R +1
and xo.

Rxo
Here xA,1 is given by xA,1 =
R +1
In the plot, we should divide the line segment from x=0 to x = xo into (R+1) parts. The
inlet conversion is given by the point xA,1 which comes after ‘R’ parts. The integration
Rxo
is performed between x = and x = xo . i.e. the area under the curve between the
R +1
Rxo
points x = and x = xo is measured and then multiplied by FA0 × (R+1).
R +1

R is roughly 1
R is roughly 0.5

Corresponding to Corresponding to
Some arbitrary kinetics Some arbitrary kinetics

1 1
− rA − rA
1 1
R R
R+1 segments R+1 segments
0 1 0 1
xA1 xo xA1 xo
Conversion (x) Conversion (x)

Recycle reactor. Inlet x =xA1, Outlet x = xo Recycle reactor. Inlet x =xA1, Outlet x = xo

R is roughly 2

Corresponding to
Some arbitrary kinetics

1
−rA
R 1

R+1 segments
0 1
xA1 xo
Conversion (x)

Recycle reactor. Inlet x =xA1, Outlet x = xo