CHEMICAL REACTION
ENGINEERING
A. SARATH BABU
1
Course No. Ch.E – 326 CHEMICAL REACTION ENGINEERING
Periods/ Week : 4 Credits: 4
Examination Teacher Assessment: Marks: 20
Sessionals: 2 Hrs Marks: 30
End Semester: 3 Hrs Marks : 50
1. KINETICS OF HOMOGENEOUS REACTIONS
2. CONVERSION AND REACTOR SIZING
3. ANALYSIS OF RATE DATA
4. ISOTHERMAL REACTOR DESIGN
5. CATALYSIS AND CATALYTIC RECTORS
6. ADIABATIC TUBULAR REACTOR DESIGN
7. NON-IDEAL REACTORS
2
TEXT BOOKS
1. Elements of Chemical Reaction Engineering - Scott Fogler H
2. Chemical Reaction Engineering - Octave Levenspiel
3. Introduction to Chemical Reaction Engineering & Kinetics, Ronald
W. Missen, Charles A. Mims, Bradley A. Saville
4. Fundamentals of Chemical Reaction Engineering – Charles D.
Holland, Rayford G. Anthony
5. Chemical Reactor Analysis – R. E. Hays
6. Chemical Reactor Design and operation – K. R. Westerterp, Van
Swaaij and A. A. C. M. Beenackers
7. The Engineering of Chemical Reactions – Lanny D. Schmidt
8. An Introduction to Chemical Engineering Kinetics and Reactor
Design – Charles G. Hill, Jr.
9. Chemical Reactor Design, Optimization and Scaleup – E. Bruce
Nauman
10.Reaction Kinetics and Reactor Design – John B. Butt
3
Without chemical reaction our world would be a
barren planet. No life of any sort would exist.
There would be no fire for warmth and cooking,
no iron and steel to make even the crudest
implements, no synthetic fibers for clothing, and
no engines to power our vehicles.
One feature that distinguishes the chemical
engineer from others is the ability to analyze
systems in which chemical reactions occur and to
apply the results of the analysis in a manner that
benefits society.
4
Automotive catalytic converter
The largest market for chemical reactors is the
automotive catalytic converter (ACC), both in number of
reactors in existence (many million sold/year) and in
amount of reactants processed (millions of tons/year).
There are >50 million automotive catalytic converters
operating throughout the world, and everyone owns one if
he or she has a car less than 10 years old.
The catalytic converter is a
tube wall reactor in which a
noble-metal impregnated wash
coat on an extruded ceramic
monolith creates surface on
which reactions occur.
5
FCC Reactor
The FCC reactor is
without question the
most complex and
important equipment in
chemical engineering.
It is only second to ACC
in amount of reactants
processed.
6
The human reactor
HCl and enzymes (E)
catalyze most reactions.
The food mixes in the stomach (volume 0.5 liter), but its feed is
semibatch: - a transient CSTR.
Next the acidified food passes into the small intestine (a reactor 3/4
in. in diameter and 20 ft long), where it is neutralized and mixed with
more enzymes from the pancreas. This is the primary chemical reactor
of the body, operating with secreted enzymes and with E. coli bacteria
catalysts.
REACTORS occupy a
central role in every
chemical process
It is inside reactors a bulk
of chemical transformations
take place
Introduction 8
• In typical chemical processes the capital and
operating costs of the reactor may be only 10 to
25% of the total, with separation units
dominating the size and cost of the process.
• Yet the performance of the chemical reactor
totally controls the costs and modes of
operation of these expensive separation units,
and thus the chemical reactor largely controls
the overall economics of most processes.
• Improvements in the reactor usually have
enormous impact on upstream and downstream
separation processes.
9
CHALLENGES ?
Chemical engineer never encounters a single reaction in an
ideal single phase isothermal reactor.
Real reactors are extremely complex with multiple
reactions, multiple phases, and intricate flow patterns
within the reactor and in inlet and outlet streams.
An engineer needs enough information to understand the
basic concepts of reactions, flow, and heat management and
how these interact.
The chemical engineer almost never has kinetics for the
process she or he is working on. The problem of solving the
batch or continuous reactor mass-balance equations with
known kinetics is much simpler than the problems
encountered in practice.
10
Reaction rates in useful situations are seldom known, and
even if these data were available, they frequently would
not be particularly useful.
Many industrial processes are mass-transfer limited so
that reaction kinetics are irrelevant or at least
thoroughly disguised by the effects of mass and heat
transfer.
Questions of catalyst poisons and promoters, activation
and deactivation, and heat management dominate most
industrial processes.
We usually encounter an existing reactor that may have
been built decades ago, has been modified repeatedly, and
operates far from the conditions of initial design. Very
rarely we have the opportunity to design a reactor from
scratch. 11
REACTION RATES?
Unfortunately, there are no tables of chemical reaction
rates listed in literature.
Useful data tables and correlations can be found in areas
like: thermodynamics, heat and mass transfer, or
separations.
Reaction-rate data do not exist for most technologically
interesting processes.
If someone claims to have a general correlation of reaction
rates, the prudent engineer should be suspicious.
This is the fun (and frustration) of chemical reaction
engineering.
12
Thermodynamics, mass and heat transfer, and separations
can be said to be “finished” subjects for many engineering
applications, whereas every new reaction system must be
examined from first principles.
Most of the process units can be modeled and simulated
using sophisticated computer programs such as ASPEN, but
for the chemical reactors in a process these programs are
not much help unless the kinetics are provided by the user.
The chemical reactor is the least understood and the most
complex “unit” of any chemical process.
Its operation usually dominates the overall operation and
controls the economics of most chemical processes.
13
Systems in which chemical
reactions takes place are
called reactors
Chemical Reaction Engineering
is the engineering activity
concerned with exploitation of
chemical reactions on a
commercial scale
Introduction 14
Objective:
To design a reactor:
• that produces the desired product
safely
• without any adverse environmental
effects
• in an economical manner
• and to a desired specification
15
• Chemical reaction engineering involves the
application of basic chemical engineering principles
to the analysis and design of chemical reactors.
• Many of the operations in a chemical plant –
support the chemical reactor.
• Heat exchange, separations etc. may be used to
pre-treat the reactor feed and then to separate
the reactor effluent into constituent parts.
• A complete understanding of reactor analysis
require – knowledge & understanding of all the
basic chemical engineering principles.
16
Scope
Design & operation of reactors
How fast reactions occur
Chemical Kinetics
Maximum possible yields -TD
Scale of operation
Calvin,Melvin
The true student will seek evidence to establish fact rather than confirm
his own concept of truth, for truth exists whether it is discovered or not.
17
Design of reactors involve:
Choosing the best type of
reactor for a given reaction
Choosing the optimum
operating conditions
Determining the Size of the
reactor
18
The choice of reactors depends on:
• safety
• environment
• profit
Profit depends on:
• raw materials
• initial and operating costs
• market value of the finished
products
19
Physical Chemical Physical
treatment steps treatment steps treatment steps
Chemical Plant – Our
CRE deals with Chemical treatment steps
Choice of the reactor dictates:
• Pre and post treatment steps
Chemical reactor is the place in the process where the
most value is added: lower-value feeds are converted
into higher-value products. 20
Reactor design require
(all most all core areas of chemical engineering)
Thermodynamics
Chemical Kinetics
Fluid Mechanics
Heat & Mass transfer
Mathematics:
Economics
Introduction 21
Thermodynamics
• Feasibility of a reaction
• Heat of reaction, effect of temperature
• Equilibrium yields, constant, composition
Chemical Kinetics
• Quantitative studies of the rates at which
chemical processes occur
• Factors on which these rates depend
• Reaction mechanism
A description of a reaction in terms of its
constituent molecular acts is known as the
mechanism of the reaction.
Chemical Kinetics & Thermodynamics
• Time is a variable in kinetics but not in
thermodynamics; TD does not deal with respect to
time; equilibrium is a time-independent state.
• Information about the mechanism of chemical change
can be obtained from kinetics but not from
thermodynamics.
• The rate of chemical change is dependent on the path
of reaction; thermodynamics is concerned with “state”
and change of state of a system.
• Chemical kinetics is concerned with the rate of
reaction and factors affecting the rate, and chemical
thermodynamics is concerned with the position of
equilibrium and factors affecting equilibrium.
23
24
Liquid phase over the gas phase operation
Advantages:
• For the desired product the reactor may be smaller
• The heat capacities and thermal conductivities are
greater for liquids - factors which increase the heat
transfer
• The equipment size is small resulting in lower power
requirements and capital costs.
Disadvantages:
• corrosion and catalyst losses.
• In considering a liquid system, all operating conditions
must fall within the two-phase region
• high operating pressures are potentially hazardous and
expensive to contain 25
How to say a chemical reaction has occurred ?
A chemical species is said to have reacted when it has
lost its chemical identity. The identity of a chemical
species is determined by the kind, number, and
configuration of that species' atoms.
Three ways a chemical species can lose its chemical identity:
1. Decomposition
2. Combination
3. Isomerization
Quiz
26
During a Chemical Reaction
Is mass conserved ?
Are moles conserved ?
Is energy conserved ?
Is volume/density conserved ?
27
Homogenous
Heterogeneous
Chemical Reversible
Biochemical Irreversible
Constant Density Elementary
Variable density Classification Non-elementary
of
Reactions
Isothermal Exothermic
Nonisothermal Endothermic
Single Catalytic
Multiple Noncatalytic
Introduction 28
Classification
Of reactors
Batch / Isothermal / Ideal / Homogenous/
Continuous Non-isothermal Non-ideal Heterogeneous
Introduction 29
Non–Ideal
Non-isothermal
Heterogeneous React
Multiple Reactors
Multiple Reactions
Uphill Task
Variable density
Constant density
Isothermal Reactors
Homogen. Reactors
Single Reactions
Ideal Reactors
Introduction 30
Type of Reactors
Homogeneous Heterogeneous Special
Batch Packed bed Slurry
Moving bed Trickle bed
Plug Flow
Bubble column
CSTR Fluidized bed
Laminar flow Ebullating Flow
Recycle
Introduction 31
Time line ….
• 1777 Wenzel - first quantitative data on rates of reactions
• 1796 Van Narum – first to recognize catalysis
• 1867 Guldberg & Waage – law of mass action for
homogeneous reactions
• 1877 Van’t Hoff – extended to heterogeneous reactions
• 1889 Arrhenius – concept of activation energy
• 1902 Ostwald – definition of catalyst
• 1920 Taylor – active site catalytic action
• 1923 Lewis & Ries – use of reaction kinetics in the design
of reactors
• 1950 Dankwerts – structure of RTD for analysis
32
Any Questions?
“There is an important question that must be asked when approaching any
difficult project for the first time, and that question is, “Why bother?”
33
