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    Chapter No.5 Reactor Design

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    michsantos
    This document discusses the design of a fluidized bed reactor. It begins by comparing fixed bed and fluidized bed reactors, noting advantages of fluidized beds include excellent gas-solid contact and easy temperature control. It then provides details on the construction and operation of a fluidized bed reactor used to produce acrylonitrile. The document concludes by outlining the design procedure for a multi-tube fixed bed reactor, including calculations for mass transfer coefficients, reactor dimensions, catalyst weight, and total reactor height.

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    Chapter No.5 Reactor Design

    Uploaded by

    michsantos
    81 views8 pages
    This document discusses the design of a fluidized bed reactor. It begins by comparing fixed bed and fluidized bed reactors, noting advantages of fluidized beds include excellent gas-solid contact and easy temperature control. It then provides details on the construction and operation of a fluidized bed reactor used to produce acrylonitrile. The document concludes by outlining the design procedure for a multi-tube fixed bed reactor, including calculations for mass transfer coefficients, reactor dimensions, catalyst weight, and total reactor height.

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    This document discusses the design of a fluidized bed reactor. It begins by comparing fixed bed and fluidized bed reactors, noting advantages of fluidized beds include excellent gas-solid contact and easy temperature control. It then provides details on the construction and operation of a fluidized bed reactor used to produce acrylonitrile. The document concludes by outlining the design procedure for a multi-tube fixed bed reactor, including calculations for mass transfer coefficients, reactor dimensions, catalyst weight, and total reactor height.

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    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    81 views8 pages

    Chapter No.5 Reactor Design

    Uploaded by

    michsantos
    This document discusses the design of a fluidized bed reactor. It begins by comparing fixed bed and fluidized bed reactors, noting advantages of fluidized beds include excellent gas-solid contact and easy temperature control. It then provides details on the construction and operation of a fluidized bed reactor used to produce acrylonitrile. The document concludes by outlining the design procedure for a multi-tube fixed bed reactor, including calculations for mass transfer coefficients, reactor dimensions, catalyst weight, and total reactor height.

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    DESIGN OF

    REACTOR

    CHAPTER No.5
    REACTOR DESIGN

    FLUIDIZED BED REACTOR

    5.1 INTRODUCTION

    Reactors:-
    Reactant gas can be made to contact solid catalyst in many ways, and each has its specific
    advantages and disadvantages. There are two broad types of Reactors.
    1:- Fluidized Bed Reactor.
    2:- Fixed Bed Reactors.
    The moving bed reactor is an intermediate case which embodies some of the advantages
    and some of the disadvantages of Fixed Bed and Fluidized Bed Reactors.
    Fluidized-bed catalytic reactors have been characterized as the workhorses of process
    industries. For economical production of large amounts of product, they are usually the
    first choice, particularly for gas-phase reactions. Many catalyzed gaseous reactions are
    amenable to long catalyst life (1-10 years); and as the time between catalyst changes outs
    increases, annualized replacement costs decline dramatically, largely due to savings in
    shutdown costs. It is not surprising, therefore, that fluidized-bed reactors now dominate
    the scene in large-scale chemical-product manufacture.

    47
    Production of Acrylonitrile
    DESIGN OF
    REACTOR

    5.2 COMPARISON OF FIXED & FLUIDIZED BED


    REACTORS:-

    FIXED BED REACTORS:-


    Used for Solid/Liquid or Solid/Gas Contact.
    Gases approximate plug flow while passing through Fixed Bed Reactor.
    Effective temperature control of large Fixed Bed is difficult.
    In highly exothermic reactions hot spots are developed which ruin catalyst.
    Cant use very small size of catalyst due to high pressure drop.
    FLUIDIZED BED REACTORS:-
    Excellent Solid/Gas contact.
    Rapid mixing of solids allows easily controlled practically isothermal, operations.
    No hot spots even in highly exothermic reactions.
    Good gas to particle and bed to wall heat transfer
    Small size catalysts can be used. Thus, preferred in fast reactions.
    Preferred when catalyst has to be treated frequently as it deactivates rapidly.

    5.3 CONSTRUCTION AND OPERATION OF


    FLUIDIZED BED REACTOR:-
    The reaction takes place in a specific vessel at the base of which a mixture of air
    compressed to between 0.15 and 0.310 6 Pa absolute and fertilizer grade ammonia is
    introduced, previously vaporized and preheated to between 150 and 200 oC by passage
    through heat exchangers. This feed first crosses a distribution plate and then reaches the
    catalyst bed, which it fluidizes. Chemical grade propylene (> 95 % weight) is introduced
    separately above the previous distributor, after first having been vaporized and preheated
    to around 200 oC. The fluidization height is 7 to 8 m.
    Because of the necessity of removing or adding heat, it may not be possible to use a
    single large-diameter tube packed with catalyst. In this event the reactor may have a set
    48
    Production of Acrylonitrile
    DESIGN OF
    REACTOR
    of immersion tubes with internal boiler feed water circulation placed within the catalyst
    bed. This serves to remove the heat generated by the reaction and to control the
    temperature at between 420oC and 480 oC, while producing high pressure steam (over
    3106 Pa absolute).The energy exchange with the surroundings is obtained by circulating,
    or perhaps boiling, a fluid in the space between the tubes. Cyclone separators are installed
    in the upper part of reactor to retain catalyst particles entrained in the gaseous effluents.

    49
    Production of Acrylonitrile
    DESIGN OF
    REACTOR

    5.4 DESIGN PROCEDURE FOR MULTI TUBE


    FIXED BED REACTOR:-

    Input Stream

    Weight Moles
    Components Weight% Mole%
    (kg/hr) (kmol/hr)
    Propylene 14280 12.5 340 8.5
    Air 93024 81.4 3230 81.2
    Ammonia 6936 6.1 408 10.3
    Total 114240 100 3978 100
    Feed Rate of Propylene = 340 Kmol/hr
    Total Gas Flow Rate = 3978 Kmol/hr
    Total mass Flow rate = 114240 kg/hr
    Volumetric Flow rate = 102918.9 m3/hr
    Superficial Gas Velocity = 1800 m/hr
    Relative Bubble Velocity:-
    g = gravitational constant = 12.7 107 m/hr2
    db= bubble diameter = 0.1m
    Relative bubble velocity Ubr = 0.711 (g db) 0.5
    Ubr =4740 m/hr
    Bubble Velocity:-
    Uo = Superficial Velocity = 1800 m / hr
    Umf = Velocity at minimum fluidization =9 m / hr
    Ub = Bubble Velocity = Uo Umf + Ubr
    Ub =6531 m/hr

    Mass Transfer Coefficients:-

    50
    Production of Acrylonitrile
    DESIGN OF
    REACTOR
    From Bubble to Interchange Zone,

    U
    D 0.5 g1/4
    Kbc 4.5 mf 5.85 AB

    db d 5/4

    b

    Kbc = 4537 hr -1
    DAB = 0.14 m2 / hr
    Where DAB is diffusivity of A in B.

    From Interchange to Emulsion phase,

    1/2

    D U

    Kce 6.78 mf

    AB b


    d 3


    b

    Where f is void of bed at fluidization and Kce is interchange coefficient


    f = 0.5
    Kce = 4584 hr -1

    Fraction of Bed Volume:-

    U o U mf
    fb
    Ub
    fb = 0.223

    Volume Fraction of solids in bubble:-


    Volume fraction of solids in bubble = b = 0.015 (1 mf) (1 fb)/ fb
    b = 0.01

    Volume Fraction of Solids an Clouds and Wakes:-


    Volume Fraction of Solids an Clouds and Wakes= c
    51
    Production of Acrylonitrile
    DESIGN OF
    REACTOR
    c = (1 mf)[3 Umf / mf + ]
    Ubr-Umf/ mf
    c = 0.2

    Volume Fraction of Solids in Emulsion :-


    Sum of fraction = 1
    So,
    Volume Fraction of Solids in Emulsion = 0.79

    Diameter of Reactor:-
    Cross sectional Area of Reactor is,
    A = m / s Umf
    s = 1500 kg/m3
    A = 8.46 m2
    From which the Diameter of reactor is calculated is,
    D = (4 A / ) 0.5
    D = 3.28 m

    Evaluating KR:-

    b Kr+ 1

    1/Kbc + 1 HFBRUo total

    ln(CA/CAo)= cKr + 1

    1/Kce + 1

    e Kr

    ..equation 1

    Weight Of Catalsyt :-
    ln(CA/CAo) = e (1.44K(W/F)) .. equation 2

    52
    Production of Acrylonitrile
    DESIGN OF
    REACTOR

    Height Of Bubbling Fluidized Reactor :-


    HFBR = W/ s total .. equation 3

    Iteration between eqs. 1, 2 and 3 we get

    Conversion = 0.8
    Weight = 145808.1kg
    Bed Height = 11.5 m

    Using graph of TDH/D Vs D,


    Trans disengagement height = TDH =3.63 m

    Total height = 11.5 + 3.63


    = 15.13m

    Volume of Reactor:-
    Volume of Fluidized Bed Reactor V = /4 * D2 *Lf
    = 129 m3
    5.5 Specification Sheet:

    Identification

    Item Reactor
    Type Fluidized bed
    No. of item 1
    Function
    Conversion of propylene
    Design Specification

    53
    Production of Acrylonitrile
    DESIGN OF
    REACTOR
    Operating temperature 420oC
    Operating pressure 200 kPa
    Design temperature 500oC

    Design pressure 250 kPa


    Diameter 3.28 m
    Height 15.13 m
    Wall thickness 0.0075 m
    Material Carbon Steel 81 B 45
    Volume 129 m3
    Pressure Drop 10.3 kPa
    Distributor
    Type Gas Sparger orifice type
    Material Nickel
    Insulation Ceramic
    Catalyst
    Size 60 m

    Porosity 50 %

    Type Mixed oxide composition

    Cooling mechanism

    Cooling media Water

    Cooling arrangement coil

    54
    Production of Acrylonitrile

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