TYPES OF PLUG FLOW REACTORS (PFR)

The PFR types are divided into adiabatic and polytropic PFRs either
with or without heat exchange through the tube wall:
1. The adiabatic reactors comprise the simple, single-stage base case
and some multistage configurations with heat exchange prior to
each individual stage.
2. The nonadiabatic or polytropic PFRs are types with coolant
surrounding the pipe wall and heat transfer through the pipe wall
surface area, which can be achieved with a jacketed or radiation-
heated PFR
1. Adiabatic PFRs

1) Single-Stage Adiabatic PFR

• Single stage adiabatic PFRs are attractive because of their simple and
cheap empty pipe construction, often without thermal insulation and
thus easily accessible from the outside
• A minimum feed temperature must be exceeded to attain a suitable
initial reaction rate to reduce the reactor volume.
• A maximum feed temperature should not be exceeded to prevent
overheating with decomposition reactions and equipment damage.
2) Multistage PFRs with Interstage Heat Exchange

The multistage configuration allows a higher overall average reaction

temperature with a higher average reaction rate and with a lower
reactor volume
3) Stepwise Cold Shot Cooling
• The PFR is subdivided into smaller adiabatic PFRs. Stepwise cooling
is achieved by injecting unconverted cold feed before each
individual PFR-stage
• Multistage cooling (or heating) can also be obtained by stepwise
injection and mixing an inert gas, liquid or solid heat carrier feed
stream
2. Polytropic PFRs
1) Jacketed PFRs
• In nonadiabatic PFRs, heat is transferred through the tube wall into a
heating or cooling medium surrounding the tubes
• The smaller the tube diameter, the higher is the specific surface area for
heat transfer. The increased pressure drop in the tubes has to be
considered and more energy is needed for pumping.
• Coolant flow in the jacket is cocurrent, countercurrent, or crosscurrent
with the same temperature at each axial point.
 2) Tubular Loop Reactor

• This configuration should not be confused with recycling of

unconverted feed after product separation. The whole reaction
mixture is recycled together with the products
• heat exchange in the loop section allows precise temperature control
of the reactor temperature.
3. Multitubular PFR Configurations
• The reactor design corresponds
to a shell-and-tube bundle heat
exchanger, with a cocurrent or
countercurrent (crosscurrent)
heat exchange medium on the
shell side
• A convenient method with a
good overall heat transfer is a
shell-side liquid, boiling at a
controlled temperature and
pressure