Packed Bed Reactors

Types of Catalytic Reactors

We can divide the catalytic reactors into two broad
varieties
• Packed (Fixed)-bed reactors
• Fluidized-bed reactors
Fixed-bed Fluidized-bed
Advantages • Plug-flow can be • Small size catalyst can be
approximated used due low pressure
• Effective drop
contacting • Good T control
• Easy regeneration

Disadvantag • Low heat • Far from plug-flow with

es conductivity and bypassing
poor T control
• High ΔP
• Small particle size
 Types of Catalytic Reactors (continued)
Ammonia synthesis
(highly exothermic rxn.)
SO2 to SO3 conversion
(mild exothermic rxn.)

Pseudo homogeneous model for

packed bed Multi tubular reactor
(Ammonia Synthesis)
Types of Catalytic Reactors (continued)

Low Conversion
Types of Catalytic Reactors (continued)
Types of Catalytic Reactors (continued)
Types of Catalytic Reactors (continued)
 Heat and Mass movement in a PB

For detailed simulation of this situation we need to solve

coupled partial differential equation of heat and mass
transfer.
Basically we are discussing here, about effect of
temperature and pressure on the rate of reactions

• Equilibrium composition, rate of reaction, and product

distribution are affected by changes in operating temp

• Heat of reaction: which determine heat requirement

during reaction and exchange of heat

Pseudo homogeneous model for

packed bed
Thermodynamics gives two important information's

• Heat liberated or absorbed for given extent of reaction

• Maximum possible conversion

 1. Heat liberated or consumed:

Where

2. Equilibrium conversion:
 3. Thermo. Equilibrium Constant:

• The thermodynamic equilibrium constant is unaffected by the pressure, inert and kinetics,
but is affected by temp. of system

• Though “K” is unaffected by pressure and inerts, but the equilibrium composition,
conversion of reactants is influenced by these variables

• K >> 1 reaction is irreversible’ if K<<1 indicates that reaction will not reach to completion

• Increase in ‘T’ equilibrium conversion increases for endo. and for exo. decreases
Graphical Representation of Design Eqns.
Temp., composition, reaxn. Rate for non isothermal
case
Graphical Representation of Design Eqns.
• Irreversible (Exo. and Endo)
• Reversible Exothermic
• Reversible Endothermic

𝑡h
  𝑐𝑜𝑛𝑠𝑖𝑑𝑒𝑟   n   order   IRREVERSIBLE    Rxn .
𝑛
¿− r 𝐴 =𝑘  𝐶 𝐴             where ,   n   = 1 
𝐸
− 
𝑅𝑇
− r 𝐴 =𝑘 0   e  𝐶 𝐴 0 (1− X 𝐴 )        consider   𝜀 𝐴 =0
𝐸
 

¿ 𝑋 𝐴 =1− (
−𝑟 𝐴   e
𝑘 0  𝐶 𝐴 0  
𝑅𝑇

)
At what extent Temp. should be Tmax
increased

1. When vol. is minimum and

maximum rate
• Reversible Exothermic /Endo. Rxn.

ΔHr = E1 –E2
ΔHr = +ve (endo)
ΔHr = -ve (exo)
If E2 > E1 exothermic; E2 < E1 endothermic
 Equilibrium 𝑋𝐴
 
𝑊 𝑑 𝑋𝐴
conversion =∫
XA decreases as 𝐹𝐴0 0
−𝑟 𝐴
Temp increases

XA

Tmax
What Tmax value should be considered
1. Tmax at which matl. of construction should be safe
2. Catalyst should not be spoiled
3. No side Rxn. Beyond certain Tmax
 Now, to get the vol. of reactor ENERGY BALANCE eqn.
XA = f(T)

The line equation obtained from above balance eqn. will intercept all those
RATES
It can be any arbitrary line as shown below non adiabatic condition (heat
can be removed by any means)   ρ𝐶 ∆ 𝑇 −𝑄 𝑃
𝑋 𝐴 = 
This plot gives entire − ∆ 𝐻 𝑟 . 𝐶𝐴 0 Heat
DESIGN information
removal
Q = U A (T-TC)

XA -rA 1/-rA
0 0.05 20
0.2 0.02 50
0.3 0.01 100
0.5 0.02 50
0.8 0.01 100
 This is for DESIGNING
PFR

For MFR
In case of MFR to calculate volume one should know the conversion,
say 80% conversion
 Extend this to RECYCLE REACTOR:

The size of reactor required for a given duty and for a given temperature
progression is found as follows:

1. Plot Rxn. path on the XA versus T plot. This is the operating line
for the operation.
2. Find the rates at various XA along this path.

3. Plot the 1/(-rA) versus XA curve for this path.

4. Find the area under this curve. This gives V/FAo.

Graphical Representation of Design Eqns.
MFR PFR
Graphical Representation of Design Eqns.
Recycle Reactor
Adiabatic Operations Eqn. for Exo. Rxn.

𝑇   = T0+𝛽 X𝐴 ρ.𝐶𝑝

¿ 1/𝛽 =  𝐶 (∆𝐻 )
¿ 𝐴0 𝑟
 Reversible Endo.

Reversible Exo.

Exo. Mixed Flow

T-X Plots and Optimum Temperature
Progression
Irreversible Reversible, Exo Reversible, Endo
Best location for the adiabatic operating line (Optimal T0).

• for plug flow, a trial and error search is needed to find this line;

• for mixed flow, no search is needed.

The best reactor type, that which minimizes V/F A0 can be found
directly from XA vs. T graph

If the rate progressively decreases

with conversion, then
use…………reactor
For endo. Rxn.
And close to isothermal exo. Rxn.

For such autocatalytic reactions,

…………reactor/operations are
best
 2

 The slope of the operating line, Cpwill determine which reactor is best
Cpis Small which reactor is best?
Large Cpwhich reactor is best?
T-X Plots and Optimum Temperature
Progression
Irreversible Reversible, Exo Reversible, Endo
Staged Packed Beds with Intercooling
Optimum Two-Stage Packed Bed Reactor

Rev. Exo. Rxn

Three variables: Ta = i/p temp; amt. of cata. = pt. b; amt. of intercooling = line bc
Optimum Two-Stage Packed Bed Reactor
Procedure:
1. Guess Ta
2. Use the slope of
adiabatic line Amt.
cata.

3. Cool to point c

4. Repeat Step 2 to reach point d

5. If point d is not a desired point then repeat the
search with a different Ta
 Staged Mixed Flow Reactor

• in this case the reactors should operate on the line of optimum

temperature progression
Rev. Exo. Rxn
Staged Packed Beds with Recycle
 Staged Packed Beds with Recycle

• Flexibility of approaching mixed flow

• Could avoid regions of low rates
Staged Packed Beds with Recycle
 Staged Packed Beds with Recycle

• The best location depends on the convenience and HT

coeff.
Cold Shot Cooling
 Cold Shot Cooling

• We can eliminate the inter-stage heat exchangers

• The extent of Inter stage cooling should
-rA,leaving reactor = -rA,entering next reactor
 -rA,leaving reactor = -rA enerting next reactor

For exothermic reaction slope of the adiabatic line determines

which contacting scheme is best
 Choice of Contacting System
• For endothermic reactions (rate decreases with
conversion) plug flow with no recycle is always
preferable
• For exothermic reversible reactions:

The cold shot cooling is feasible if:

 Choice of Contacting System (continued)
The slope of the adiabatic line decides the flow pattern
• If the slope is high (for dilute gas or a liquid): use PFR
• If the slope is low (for pure gas): use MFR
 Example Problem - I

• Type of reactor: plug, recycle, or mixed (infinite recycle)

• Amount of catalyst needed
• Heat duty ahead of the reactor, at the reactor itself, and
after the reactor
• The temperature of all flowing streams

Adiabatic line slope: