CHE516 - Lab Report On Plug Flow Reactor PDF
CHE516 - Lab Report On Plug Flow Reactor PDF
Remarks:
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Date: Date:
TABLE OF CONTENT
2.0 INTRODUCTION......................................................................................................... 3
11.0 RECOMMENDATIONS............................................................................................ 22
The goals of the experiment is to investigate the effect of residence time towards the conversion
of the saponification process between Sodium Hydroxide, NaOH and ethyl acetate, Et(Ac).
The saponification process is done using the SOLTEQ Plug Flow Reactor BP – 101. The
product sample is taken for every flowrate of sodium hydroxide, NaOH and ethyl acetate,
Et(Ac) which is at 250mL/min, 200mL/min, 150mL/min, 100mL/min and 50mL/min for
titration process in Experiment 2 for the manual conversion determination. The residence time
for each flowrate is 8 min, 10 min, 13.3333 min, 20 min and 40 min, respectively. The
conversion of the reactant to product is 68%, 64%, 57.2%, 56.8% and 54.4%, respectively. The
reaction rate constant, k is 2.6563 L/mol.min, 2.2222 L/mol.min, 1.6706 L/mol.min, 1.6435
L/mol.min and 1.4912 L/mol.min, respectively. The rate of reaction, -rA is 0.002720
mol/L.min, 0.002879 mol/L.min, 0.003060 mol/L.min, 0.003067 mol/L.min and 0.003100
mol/L.min, respectively. The rate of reaction decreases as the reaction rate constant decreases.
Higher flowrate of reactant increases the rate of reaction and thus, increasing the conversion
rate of the reactant to product.
In the industry, reactors are one of the most important equipment to create a desired products
from the raw materials. The design of a certain reactors are crucial. There are three types of
basic reactor which is Batch Reactor, Continuous Stirred Tank Reactor (CSTR), and Plug Flow
Reactor (PFR).
Plug flow reactor (PFR) or Tubular flow reactor consist of long hollow tube in which
the reactant would flow in an axial direction in the shape of plug (Cylindrical shape) as shown
in Figure 1. These tube usually encased inside the tank to maintain the temperature of the
system. In the PFR, we would consider the reactant is perfectly mixed and the composition of
the reactant is different along the tube. The streams are opposite of a batch reactor, which is a
reactor that has a constant volume and has no incoming or outgoing streams.
Figure 1 - Plug Flow Reactor Where the Reactant Flow In an Axial Direction in the
Shape of Plug
PFR become main choice for certain chemical process in the industry due to its non-
mixing property of the reactors. It is also very helpful in the continuous production of the
product. Flow of plug flow reactor is laminar, as with viscous fluids in small-diameter tubes,
and greatly deviate from ideal plug-flow behaviour.
1) To carry out a saponification reaction between sodium hydroxide, NaOH and ethyl
acetate, Et(AC).
2) To determine the reaction rate constant.
3) To determine the effect of residence time on the conversion.
Plug Flow Reactor (PFR) is one of the ideal reactor in industry. Many plants and company used
PFR as the site for their reactants to react in producing valuable desired product. This reactor
mainly famous for process that involves gas or fast reactions process. This is because, in PFR
the reactants are fed continuously and products are also continuously removed. PFR becomes
favourable because it is easy to maintain, as it does not have any moving parts. Additionally,
the most favourable reason is it has the highest conversion per reactor volume of flow reactor.
In designing and modelling a PFR, an ideal condition are assumed in order to ease the
calculation. The PFR behaviour are assumed to be perfect mixing at all times without dead time
occurs in any corner or area in the PFR. This composition is a function of residence time and
rate of reaction.
𝐯
𝐝𝐍𝐀
= 𝐅𝐀𝟎 − 𝐅𝐀 + ∫ 𝐫𝐀 𝐝𝐕 (𝐞𝐪. 𝟏)
𝐝𝐭 𝟎
Assumption made:
dNA
1. In steady state condition, = 0 but only in the radial direction (Rodgers, 2013).
dt
2. No axial mixing.
3. For a flow system, FA can be given in terms of entering molar flow rate FA0 and the
conversion, X.
FA = FA0 − FA0 X
−𝑟𝐴 𝑑𝑉 = 𝐹𝐴0 𝑑𝑋
𝑋
𝑣
𝑑𝑋
∫ 𝑑𝑉 = 𝐹𝐴0 ∫
0 −𝑟𝐴
0
4. In this experiment, the reaction order is second order thus it depends on concentration of
both solution 𝐶𝐴0 and 𝐶𝐵0 (Engineering). However, to ease the calculation and analysis, the
concentration being fed to the reactor in in equimolar. Thus, the initial concentrations of
reactants is CA0 = CB0 . The rate law can be written as follow:
−rA = kCA CB = kCA2
𝟐
−𝐫𝐀 = 𝐤𝐂𝐀𝟎 (𝟏 − 𝐗)𝟐 (𝐞𝐪. 𝟑)
X X
dX dX
V = FA0 ∫ = v0 CA0 ∫ 2
−rA kCA0 (1 − X)2
0 0
X
v0 dX
V= ∫
kCA0 (1 − X)2
0
v0 X
V= ( )
kCA0 1 − X
𝐕 𝟏 𝐗
𝛕= = ( ) (𝐄𝐪. 𝟒)
𝐯𝟎 𝐤𝐂𝐀𝟎 𝟏 − 𝐗
For constant PFR volume, flow rate and initial concentrations, the reaction rate constant is,
𝐯𝟎 𝐗
𝐤= ( ) (𝐄𝐪. 𝟓)
𝐕𝐂𝐀𝟎 𝟏 − 𝐗
5.1 Materials
1) 0.25M Hydrochloric Acid, HCl
2) 0.1M Sodium Hydroxide ,NaOH
3) 0.1M Sodium Acetate, Na(Ac)
4) Deionized Water, H2O
5.2 Apparatus
1) Burette
2) Conductivity Meter
3) Plug Flow Reactor
Plug flow
reactor
4) The water jacket B4 and preheater B5 is filled with a clean water. The valves V13
and V18 is opened. Pump P3 is switch on to calculate the water through pre-
heater B5.
5) A stirrer motor M1 is switched on and the speed is set for about 200 rpm.
6) Valve V2, V4 and V10 is opened. Pump P1 is switched on. P1 is adjusted to flow
rate of 150 ml/min at flow meter, FI-01. Valve V10 is closed and pump P1 is
switched off.
7) Valve V6, V8, V12 is opened. Pump P2 is switched on. P2 is adjusted to flow rate
150 ml/min at flow meter FI-02. Valve V12 is closed and pump P2 is switched off.
8) The unit is now ready for the experiments.
Solution Mixture
Concentration Conductivity
Conversion 0.1 M 0.1 M H2 O
of NaOH (M) (mS/cm)
NaOH Et (Ac)
0% 100 mL - 100 mL 0.0500 23.6000
25% 75 mL 25 mL 100 mL 0.0375 14.9000
50% 50 mL 50 mL 100 mL 0.0250 9.2100
75% 25 mL 75 mL 100 mL 0.0125 4.2300
100% - 100 mL 100 mL 0.0000 0.0654
y = -0.0424x + 0.9406
R² = 0.9783
y = -0.0424x + 0.9406
R² = 0.9783
Conductivity (ms/cm)
Initial Flowrate Of
Solutions Inlet Conductivity, Q1 Outlet Conductivity, Q2
(mS/cm) (mS/cm)
(mL/min)
❖ Information added:
13
Conversion vs. Residence Time
50
45
40
Conversion, X (%)
35
30
25
20
15
10
5
Residence Time, τ (min)
0
0 10 20 30 40 50
Figure 5 - The graph of Conversion, X, against Residence time, τ, obtained from the
calculations in experiment 3.
The graph shows the plot of conversion versus residence time. The curve shows a
decreasing pattern until t = 20 min, before increasing as the curve approaching to t = 40 min.
14
8.0 CALCULATIONS
1. Total flowrates of sodium hydroxide, NaOH, and ethyl acetate, Et (Ac) are,
= 500 mL/min
= 0.5 L/min
4L
Thus, Residence Time, τ = 0.5 L/min = 8 min
CNaOH,f
CNaOH,o =
2
0.1 M
=
2
= 0.05 M
CNaOH,s
V2 = × V1
CHCl,s
0.1 M
= × 17.0 mL
0.25 M
= 6.8 mL
V3 = VHCl,s − V2
= (10 − 6.8) mL
= 3.2 mL
n1 = CHCl,s × V3
mol 1L
= 0.25 × 3.2 mL ×
L 1000 mL
= 0.0008 mol
n2 = n1
= 0.0008 mol
n2
CNaOH =
Vs
0.0008 mol 1000 mL
= ×
50 mL 1L
= 0.016 M
CNaOH
Xunreacted =
CNaOH,o
0.016 M
= = 0.32
0.05 M
Xreacted = (1 − Xunreacted ) × 100%
= (1 − 0.32) × 100%
= 68%
vo X
k= ( )
VTFR CAo 1 − X
❖ All the values above are substituting into the rate constant equation where,
L
0.5 min 0.68 L
k=[ ]( ) = 2.6563
(4 L)(0.1 M) 1 − 0.68 mol. min
−rA = kCA CB
CA = CAo (1 − X)
CB = CBo (1 − X)
L mol 2 mol
−rA = (2.6563 ) (0.1 ) (1 − 0.68)2 = 0.002720
mol. min L L. min
NOTE: The same way of calculations was used to evaluate the residence time, conversion,
reaction rate constant and rate of reaction for different flowrates of 200 mL/min, 150 mL/min,
100 mL/min and 50 mL/min.
In this plug flow reactor (PFR) experiment it is primarily to carry out a saponification reaction
between NaOH and Et(Ac). At the end of the experiment, the reaction rate constant is
determined by using formula and the effect of residence time on the conversion in the PFR.
This experiment are conducted using the SOLTEQ Plug Flow Reactor (Model BP 101) where
NaOH and Et(Ac) solution are fed into the reactor by varying the feed flow rates to obtain
several residence time and the effect of each one is studied.
Besides, a calibration curve for conductivity versus conversion is also prepared for
saponification reaction of ethyl acetate Et(Ac) and sodium hydroxide NaOH. For the
calibration curve of conductivity versus conversion, the slope and y-axis intercept value is
determined from the equation of the curve yield using excel. Based on Figure 4, the slope = -
0.0424, while the y – axis intercept = 0.9406.
In this experiment, different initial feed flowrates, conductivity value and the volume
of NaOH used in the titration process is organized in Table 3. From the data, the residence
time, conversion of the reactions and the reaction rate constant is determined through a series
of calculation by using formula for plug flow reactor experiment.
A graph of conversion against residence time is plotted and it is shown in Figure 5. The
residence time and the conversion of the reaction is obtained from the calculation using
formula. The reactors residence time is defined as the reactor volume divided by the total feed
flow rates while conversion is a property that shows how much of the reaction take place which
is the number of moles of A that reacted per mole of A fed to the system.
From the graph plotted in Figure 5, the conversion of the reaction is inversely
proportional to the residence time of the reactant in the reactor. It shows that when the residence
time of the reactor increases, the conversion of the reactant will decreases. Residence time
shows the average amount of time that a particle spends in a particular system and conversion
is a direct function of time spent for reaction. Apparently, the higher the residence time, the
higher conversion. This may be due to the error of total feed flowrate of solutions occurred
while conducting the experiment.
The reaction rate constant, k for every different initial feed flowrate is 2.6563
L/mol.min for flow rate 250 mL/min. For flow rate 200 mL/min the k-value is 2.2222
L/mol.min and reaction rate constant for 150 mL/min is 1.6706 L/mol.min. For flow rate 100
The rate of reaction, -rA is also determined after the rate of reaction has been calculated.
The rate of reaction for 250 mL/min is 0.0002720 mol/L.min while 0.002879 mol/L.min is the
rate of reaction for 200 mL/min. For flow rate 150 mL/min, the rate of reaction is 0.003060
mol/L.min, 0.003067 and 0.003100 mol/L.min is the rate of reaction for flow rate 10 and 50
mL/min. It indicates that when the reaction rate constant is decreases, the rate of reaction is
also decreases. The specific rate constant is proportionally constant relating the rate of the
reactions to the concentrations of reactants. A rate law is an expression showing the relationship
of the reaction rate to the concentrations of each reactants.
From the experiment above, the flowrate of the sodium hydroxide, NaOH and ethyl acetate,
Et(Ac) is 250mL/min, 200mL/min, 150mL/min, 100mL/min and 50mL/min. The residence
time for each flowrate is 8 min, 10 min, 13.3333 min, 20 min and 40 min, respectively. The
conversion of the reactant to product is 68%, 64%, 57.2%, 56.8% and 54.4%, respectively. The
reaction rate constant, k is 2.6563 L/mol.min, 2.2222 L/mol.min, 1.6706 L/mol.min, 1.6435
L/mol.min and 1.4912 L/mol.min, respectively. The rate of reaction, -rA is 0.002720
mol/L.min, 0.002879 mol/L.min, 0.003060 mol/L.min, 0.003067 mol/L.min and 0.003100
mol/L.min, respectively. The rate of reaction decreases as the reaction rate constant decreases.
Higher flowrate of reactant increases the rate of reaction and thus, increasing the conversion
rate of the reactant to product.
There are several precautions and recommendations that we can do to ensure more accurate
and reliable results. Which is:
1) Repeat the trials at least three times and calculate the average results to get a more
accurate data.
2) Always make sure that the start-up procedure and shut down procedure was done
correctly to prevent damage at the equipment.
3) The flow rates of the inlet need to be kept constant by monitor it at all times because
the flow rates will affect the collected data.
4) Glass apparatus need to be handle carefully to prevent it from broken while conducting
experiment.
5) Make sure to wear the Personal Protective Equipment (PPE) while conducting the
titration as we handling the chemicals.