document-1700092808-000_Chemical_reaction_engineering

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1 Chemical reaction engineering (50% of a 15-credit module) R. I. Slavchov, r.slavchov@qmul.ac.uk version: November 2023 Maple installation links to download the 2023 version: from Maplesoft license code: 4XZM9MVGAK65FMRR Coursework assignments problems (note that there are hyperlinks) deadline CW 2a. Revision, multiple reactions, mechanisms Group A: sec1-6c 45 and sec3-4 55 ; Group B: sec1-7a 45 and sec3-7c 55 ; Group C: sec2-11 55 and sec3-2 45 ; Group D: sec2-10 55 and sec3-3a..d 45 . 15 Nov 21 Feb CW 2b. Nonisothermal reactors Group A & C: sec5-6; Group B & D: sec4-5. 22 Nov CW 2c. Non-ideal reactors Groups A and C: sec7-6; Groups B and D: sec7-7. 29 Nov Coursework rules: 1. Some of the questions are intended to be done manually, others are for Maple, but most are for either option (up to you). Submissions without detailed comments, names of symbols, units etc. will be given less points. Upload .mw, .pdf or .pptx files on the submission point. No images, please (.jpg, .png, .tif) put your images in a .pdf or .pptx before uploading. 2. If you feel confident in using another software for the computations, you are welcome to do so. In this case, the solutions should be submitted as executed code printed in pdf format, with detailed comments. However, technical mistakes related to the syntax will not be corrected by the tutor in this case. 3. Students are supposed to work alone. If similar errors are found in two submitted courseworks, both offenders will be disqualified (0 points from coursework). If you help each other, then follow the two rules: (i) d on’t share files and paper with your colleagues; (ii) don’t write things you don’t understand in your coursework, especially if someone else did them. 4. Bonus problems: these require more effort. They are not obligatory, but correct solutions will be marked and can compensate for mistakes in your coursework. 5. Despite my efforts, the lecture notes contain mistakes. You are kindly asked to report all problems and mistakes to me via e-mail (anything from language to a minus in the derivation, and notes such as “this paragraph uses concepts we have not been taught previously”). The reported errors will be counted as bonus-problems. Last year, some colleagues of yours could get a 15% top-up of their coursework mark just by proof-reading the notes! You have even more errors to find in the Maple files. Examination rules: The exam will be in two parts. You will be given 6 questions. You choose 5 of them to solve. You will be allowed to use all lecture materials. Minimum requirements: if you know how to formulate the governing equations for CSTR and BR, you will receive around 25% of the marks. Thus, to solve one and a half problem and write the balances (without solving them) for the others is enough to pass the exam.
2 This module’s exam is such that plagiarism is particularly easy to catch. Marks: The recommended mean mark in UK universities is 60 ± 20. You will probably have around 65±15 for the coursework and 55±25 for the exam, as this is what the higher education agency that allows QMUL to give you engineering degree asks for. I know you are used to higher grades, but CRE has been and will remain a university-level engineering module.
3 Contents Maple installation 1 Coursework assignments 1 List of symbols 6 Introduction: basic chemistry, mathematics and Maple 9 1 A review of the material for simple reactions in simple reactors 15 1.1 Refresh and extend basic chemical kinetics for one homogeneous reaction 15 1.2 Temperature dependence of rate and equilibrium constants 22 1.3 Simple reactors and their mole balances 23 2 Multiple reactions 35 2.1 Two reactions 35 2.1.1 Parallel reactions (branching reactions). Formulation in terms of component concentrations/amounts 35 2.1.2 Consecutive (series) reactions: formulation in terms of yield 41 2.2 Many reactions in a batch, PF or CST reactor 44 3 Reaction mechanisms and reactive intermediates 52 3.1 Active intermediates 52 3.2 Rate of the overall process 55 3.3 Quick equilibria 57 3.4 Figuring out the mechanism from experimental data 58 3.5 Chain branching & reactor safety 61 4 Energy balance. Adiabatic reactors 68 4.1 Brief introduction 68 4.2 Irreversible reaction in an adiabatic reactor 72 4.3 Reversible reaction in an adiabatic reactor 77 5 Heat exchange and external work 86 5.1 Batch reactor 86 5.2 Plug flow reactor with thermal fluid jacket 87 5.3 Continuous stirred-tank reactor 95 5.4 Radiator coil heat exchanger 95 6 Residence time distribution 103 6.1 Brief introduction to probability 103 6.2 The distribution of the residence time and how to measure it 106 6.3 Ideal reactors 109 6.4 Using the residence time distribution for diagnostics 113 7 Mixing models for nonideal reactors 118
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4 7.1 Complete segregation model 119 7.2 Complete mixedness 121 Exam formulae 127 Mock exam 128 Solutions to the mock exam problems 130 References 140
5 Legend Red text: under construction; skip it. Example X-X Solution to a problem Additional information Rusty: solved with Maple, look in the Examples.mw file. Green: problem given as a homework. Purple: question given as a bonus problem. Orange: problems from the mock exam (solved in the final section). Yellow : learning outcomes Blue : questions to answer. Gray : a hint. Italic is usually introducing a term or a common expression. u ultraeasy problem e easy problem n normal d difficult y yeah you’re a legend if you solve that Maple use software to solve this problem on paper do not use software for this problem if neither Maple nor on paper whether you use software is up to you
6 List of symbols A area, m 2 A m specific surface area, m 2 /kg a activity, mol/m 3 (concentration-based) or dimensionless (molar fraction-based) C concentration, mol/m 3 C p total heat capacity at constant pressure c p molar heat capacity at constant pressure E activation energy, J/mol F total flow rate, mol/s (total molar flow rate) or kg/s (total mass flow rate) j molar flux, mol/m 2 s H enthalpy, J/mol (reaction enthalpy) or J (heat) K equilibrium constant K I association constant of an inhibitor-enzyme complex K M Michaelis constant (for enzymes), or Monod ’s constant (for cell growth) k rate constant, various units m mass, kg n amount of substance, mol p pressure, Pa p i partial pressure, p i = x i p R gas constant, 8.314 J/molK S AB overall selectivity of A with respect to B, S AB = BA n A / n B = B n A / A n B = B C A / A C B s AB instantaneous selectivity of A with respect to B, s AB = | BA d n A /d n B | = | BA r A / r B | r rate of a reaction, V 1 d /d t , mol/m 3 s, or rate of production of a component, V 1 d n /d t T temperature, K t time, s V volume V m i molar volume of a component, V m i = d V /d n i v volume flow rate, m 3 /s w i weight fraction, w i = m i / m X conversion, X = / x i mole fraction, x i = n i / n Y overall yield fraction, Y = | l | n u / u ( n l0 n l ), u useful, l limiting y instantaneous yield fraction, y = l d n u / u d n l = l r u / u r l , u useful, l limiting length of the radical chain ji stoichiometric coefficient of the i th component in the j th reaction reaction yield, mol V reaction yield per unit volume, mol/m 3 density space-time, residence time volume fraction of voids, porosity A fraction of useful area of the catalyst Indices and brackets: X 0 initial value of X X 1/2 value at half-reaction (half-life) X value of X after a complete irreversible reaction, until the key component is exhausted X e equilibrium value of X
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7 X f referring to the forward reaction in a reversible process; formation reaction X r referring to the reverse reaction in a reversible process X value of X at standard pressure (1 atm) X value of X at room temperature (298 K) X i index i usually refers to all possible components in a mixture X j index j usually refers to all possible reactions in a mixture X Y superscript index is used to indicate the phase [X] concentration of X, mol/m 3
8 Preface The reactor design is central for any process design, because the chemical reactor determines what other processes would be needed, and the production rate of the reactor controls the size of all other units. These notes covers (i) reaction mechanisms and multiple reactions; (ii) non-isothermal reactors; (iii) statistical distribution of the residence time and nonideal reactors. You are supposed to have as prerequisite knowledge the basics of the main ideal reactors batch, plug flow, continuous stirred-tank. As with any engineering course, the problem-solving is the most important component of your studies. Therefore, the solved examples and the Maple tutorials provided should be scrutinized, and the lecturer and tutors should help you working your way through the list of problems in the end of each chapter. Your measure of success is neither the exam mark, nor the amount of text you have read it is the easiness with which you solve these problems. Nowadays, a softwareless engineer is as odd as a chimney sweep or a clock winder. Therefore, a fraction of the problems is intended to be solved with engineering packages such as Maple, Mathematica, Python. Most of the problems can be solved either manually or with software. With them it is best first to sketch the solution manually, and then to do it with a software. The more they sweat in practice, the less they bleed in battle --General Suvorov
9 Introduction: basic chemistry, mathematics and Maple Your job is to: fundamentals revise basic chemistry (units, moles, concentration, ideal gas, pH); skills refresh your Maple skills (syntax, analysis of a function). This section is for your own use. Problems i) basic chemistry should cause no difficulty whatsoever and are there for you to just check whether you are on the page you need to be. Some of these are solved in the Maple examples file. The second set, Problems ii) mathematics and Maple , summarize the mathematical apparatus we will use in the course. There should be nothing new to you in this section in terms of mathematics. It, however, also teaches you how to use Maple on a basic level, so it is recommended to try and solve the problems with Maple. Read more Check the introduction sections in Examples.mw on QMplus. In Maple, read Help menu > Maple Help > Manuals > 1…11. Problems 1. Which are the SI units for: a) activation energy E ; b) entropy S ; c) molar fraction-based activity a x ; d) molality based activity, a m ; e) volume V ; d) mass m ; e) molar mass M ; f) mass fraction w ; g) molar concentration C ; h) Avogadro’s 1 number; i) gas constant R ; j) heat capacity C p of an object at constant pressure; k) temperature T ; l) rate of a reaction r ; m) enthalpy of a reaction. u 2. Switch to SI units: a) M = 18 g/mol; b) r H = 13 kcal; c) C = 0.3 mol/L; d) p = 2.4 atm; e) = 24 g/L; f) v = 3 L/min; g) T = 18.2 °C. u 3. Harmonizing units: a) What mass of water is contained in 1 gallon of 460 mM NaCl solution of density 1.03 g/cm 3 ? b) A heater delivers 343 kcal of heat to 300 lbs of iron of heat capacity 25 J/molK. What is the resulting increase in temperature? e c) Component A in a liquid mixture degrades, due to a reaction of constant rate of 0.015 mol·pint -1 ·min -1 , in a vessel of volume 1 barrel. The vessel initially contained 0.010 lb-mol of A; how much of A will be left after 2 h 55 min 12 s? n 4. Molar mass computations a) What is the weight of 0.001 mmol Pb? b) What is the weight of 30 atoms of Cl? c) What is the weight of an oxygen molecule? d) How many atoms are there in 6 kg of iron? e) How many moles contain 10 g of ethanol? e 1 /av ɔˈ g ɑː dr ɔ /
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10 f) A mixture of Pb and Sn weighs 10 g and is 0.05 mol overall. What is the mass and the amount of substance of each element? n 5. Mole and mass fraction, x and w а) What are the mole fractions of O 2 and N 2 in a mixture of 1 mol O 2 and 3 mol N 2 ? b) A 250 kg/min flow of water is mixed with a 5 kg/min flow of glucose before entering a bioreactor. What is the molar fraction of the glucose of the flow at the entrance of the reactor? c) What is the weight percent of Pb in the compound PbS? u d) The mole fraction of KI in aqueous solution is х KI = 0.12%. Find the mass fraction. e) The mass fraction of KI in aqueous solution is w KI = 0.12. Find the mole fraction. f) A human being contains 0.2 weight percent ( w %) sulfur. Compute the mass, the mass concentration, the moles and the mole concentration of the sulfur atoms in a 70-kg person. The average density of the human body is approximately 950 kg/m 3 . What is the maximum amount of 2M sulfuric acid that can be produced from a single human? g) What is the mole fraction of the salt in a 0.3 M aqueous NaCl? e 6. Density, molarity, molar volume a) The density of some kind of gas is 2 kg/m 3 ; what is the mass of 3 m 3 of the gas? b) What is the number of molecules in 1 L of water? What is the molar concentration of water (at 4 °С)? c) 1 mg U(SO 4 ) 2 is dissolved in 1 L of water; find the molar concentration of the obtained solution. d) What is the molar volume of iridium? Density: = 22500 kg/m 3 . u e) What is heavier, the Earth or 100 m 3 of a neutron degenerated fluid? The neutron fluid is the hypothetical material from which the neutron stars are made. Its density is of the order of that of the atomic nucleus, = 10 18 kg/m 3 . What is the molar concentration of the neutrons in the neutron fluid? f) How many moles and how many molecules of water are there in the world ocean? The approximate volume of the ocean is V = 1.3 10 9 km 3 ; assume average density of = 1080 kg/m 3 . Take into account that a fraction of the mass of the ocean is due to dissolved electrolytes (average salinity: 3.5 w %). e g) We all know the story of the naked Archimedes screaming “ εὕρηκα! ” when he discovered his method to measure density of solids. But how does it work? You put a silver coin in a 100 mL flask, and weigh it; its mass is 13.432 g. You fill it with water to the mark, and weigh it again; the total mass of the water and the coin is 111.81 g. What is the density of the coin? Can it be pure silver (check its density online)? n 7. Dilute or concentrate a solution a) 1 М solution is diluted 3 -fold. What is the final concentration? b) We add 100 mL water to 500 mL 0.5 М solution of HCl. What is the new concentration of the acid? c) You have a 100 mL flask, a measuring cylinder, a bottle of 1M NaOH and distilled water. How will you prepare 100 mL 0.15 М NaOH? u d) Two streams are mixed: 30 m 3 /h of 0.1 M NaOH and 10 L/min of water. What is the composition of the resulting mixed stream? e) Take 1 L of 0.001 М NaOOCCH 3 and add to it 2.201 g crystals of the same salt. What is the resulting concentration of the solution? f) 10 mL of 2 M NaNO 3 are added to 150 mL 0.01 M Na 2 SO 4 . What is the final concentration of each ion in the solution (Na + , SO 4 2- , NO 3 - )?
11 g) 2 g CaCl 2 are added to 1 L 0.02 M HCl. What is the final concentration of each ion in the solution (H + , Ca 2+ , Cl - )? e h) Nearly all cells maintain increased acidity inside ( in the lumen of ) some digestive organelles (lysosomes, endosomes, vacuoles) the pH there is 4.5, compared to 7 in the cytoplasm. This is thanks to a machinery called V-class proton pump (a transmembrane protein swimming in the membranes of these organelles). Every cycle of the pump consumes one ATP from the cytosol in order to insert two protons in the liposome. What is the amount of ATP needed by the pump to produce pH = 4.5 in a spherical lysosome of radius 0.2 m? The transport of H + is going to charge the organelle positively. How can it return to electroneutral state? n 8. Negative decimal logarithm a) An acidic rain has pH 3.8. If the acidity is due to nitric acid, what is its concentration? b) pH in the stomach of a human is between 1.5 and 2. In what limits vary the concentration of HCl in the stomach? c) The activity of OH - in a basic solution is 1.1 M. What is pH? d) What is pOH in a solution with activity of the H + ions of 1.8 M? e) The dissociation constant of an acid is K a = 1.4 10 -6 . What is p K a ? f) p K b = 12.5. What is K b ? u 9. Ideal gas a) Find the mass of the gas in your living room (4×4×2.5 m 3 or so). b) A cycle wheel has radius of 30 cm. The tyre has cross-section diameter of 3 cm. You use a hand pump that pumps 30 g of air per cycle into the tyre. You do 30 pumps. What is the pressure in the tyre? c) A meteorological balloon full of He at the surface of Earth (1 atm, 86 °F) has volume of 100 m 3 . It is let into the atmosphere, and reaches the tropopause where T = -66 °F and p = 96 hPa. What will be the balloon’s volume there? e d) (unknown T) 10. Partial pressure a) Oxygen, nitrogen, CO2 in air what are the pressures from mole fraction b) what are the mole fractions from pressures c) vapour pressure of water and kg water in saturated vapours, Clausius-Clapeyron d) equilibrium with partial pressures 11. Heating a material a) Find the heat effect, Q p , from the isobaric cooling of 1 mol of steam from 160 °C to 130 °C. The molar heat capacity of steam is с р ,m = 36 J mol 1 K 1 . b) Find the heat Q required to heat 1 mol of water from 20 °C to 90 °C. The heat capacity of water is с р = 4.14 kJ kg 1 K 1 . Ans . 5.2 kJ/mol. c) Find the heat U required to heat isochorically 2 mol of ideal monomolecular gas from 300 K to 600 K. Find c V ,v at 300 K and at 600 K (standard pressure). u Ans . 7.5 kJ/mol; 507 and 253 J∙m -3 ∙K -1 .
12 12. Maple Analysis of a general function For each of the following functions, answer the questions: - What values of x produce a real value of y ? - What is the value of y ( x = 0), and where y ( x ) = 0? Plot the function and its zeros. - Find the extrema and the inflections of the functions. Plot them as points together with the function. a) y = sin( x )/ x (solved example); b) 2 2 ln( 1) y x x = (solved in part); c) e x x (| x | is written as abs( x ) in Maple); d) 3/4 x x + ; e) 1 1 1 x x x + + + . e 13. Analysis of functions that chemical engineers actually care about a) The rate of an enzymatic reaction changes with temperature following the equation / / e 1 e a b E RT E RT aT r b = + . Here, r [mM/h] is rate of the reaction, T [K] is temperature, R [J∙K 1 ∙mol 1 ] is the gas constant, E a [J/mol] is the activation energy of the enzymatic reaction, E b is the activation energy for denaturation of the enzyme, a [mM∙h 1 ∙K 1 ] and b [1] are kinetic parameters 2 . At low temperatures, this formula corresponds to the Arrhenius equation. At high temperatures, however, the enzyme partially denatures which leads to a fall in rate. There is an optimal temperature at which the rate has an extremum, and this is the temperature at which we want to operate our bioreactors. Plot r as a function of T , in the range 0…100 °C (careful with the units!). Mark on the plot the position of the extremum and the two inflection points. Parameters: a = 1.8×10 15 mM∙h 1 ∙K 1 ; b = 2.2×10 20 ; E a = 91 kJ/mol; E b = 120 kJ/mol; R = 8.314 J∙mol 1 ∙K 1 . Careful with the units use SI! b) The Arrhenius equation for the rate constant reads ( ) 0 a exp / k k E RT = , T = 0…∞ K. It predicts an inflection point of k ( T ) at a certain temperature. Find this point analytically. Use the values k 0 = 1 s 1 , E a = 38 kJ/mol to plot k ( T ). Mark the position of the inflection point on the picture. c) If you pick a random molecule in a gas, the probability it to have velocity v is proportional to the so-called probability density v of the Maxwell distribution , 2 2 /2 e Mv RT v v = , v = 0…∞ m/s. Here, M is the molar mass of the gas, T is the temperature of the gas (25 °C), R is the gas constant. - Plot v vs. v for oxygen and nitrogen at room temperature, on the same plot. - The dependence v ( v ) has a maximum corresponding to the most probable velocity v m of the molecules. Find its value for oxygen and nitrogen. Mark the position of the maximum with a point. Careful, the SI units for M are kg/mol, for T kelvin! e 2 Units [1] mean that b is dimensionless.
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13 d) The internal energy of butane as a function of the internal rotation angle that we use for Newman structures is given by the function ( ) ( ) ( ) 1 2 3 1 cos 1 cos2 1 cos3 u u u u = + + + + , = − . Find all extrema, plot the function and mark the extrema. Parameters: u 1 = 0.120 kcal/mol, u 2 = 0.012 kcal/mol, u 3 = 0.319 kcal/mol. n 14. Maple Analysis of the equation of state of a van der Waals fluid The ideal gas equation becomes inaccurate above 10 atm and erroneous above 100 atm, so it does not work for high-pressure reactors. One simple upgrade to account for the non-ideality of a fluid (the interaction between the molecules) is the v an der Waals’s equation of state : ( ) ( ) 2 p av v b RT + = . Here, p [Pa] is pressure, v [m 3 /mol] is molar volume (a common measure of density, related to the mass density m as v = M / m , where M is molar mass), T [K] is temperature, R [J∙mol 1 ∙K 1 ] is the gas constant, a [Pa∙m 6 /mol 2 ] is van der Waals’ attraction constant , and b [m 3 /mol] is van der Waals’ repulsion constant. a) Find p as a function of v . Plot it for T = 500 K, in the range v = b …25 b . b) Find the two extrema of p ( v ), v min and v max . Mark them with points in the plot for T = 500 K. The region between the extrema (the spinodal region ) corresponds to unstable state as the mechanical condition for stability is violated: there, d v /d p > 0, so the fluid expands upon compression which is impossible. Therefore, between the extrema, the fluid can only exist as two co-existing phases, liquid and gas. The low- v region before the minimum corresponds to stable liquid phase. The high- v region corresponds to stable non-ideal gas phase. Find the highest pressure at which you can still have gas, and the lowest pressure at which you can still have liquid. c) The compressibility T [Pa 1 ] of the fluid is, by definition, T = v 1 (∂ v /∂ p ) T = v 1 (d p /d v ) 1 . Plot it in the range b v min for the liquid, and in v max …25 b for the gas at T = 500 K. Put the two curves on the same plot. Find the molar volume and the pressure at which the gas has the lowest compressibility, and mark it on the plot. d) Now change the value of the temperature set it to T = 8 a /27 bR (careful with the fraction in Maple! this is written as T:= 8*a/27/b/R ). This is the critical temperature of van der Waals’ fluid , at which the spinodal region and the phase transition disappear. The function p ( v ) now has no extrema, only a horizontal inflection (where both d 2 v /d p 2 and d v /d p are zero). Find its position, and mark it on the plot of p ( v ) in the range b …25 b . The inflection corresponds to the critical point of the fluid; the respective pressure and molar volume are called critical pressure and volume . e) Plot the compressibility of the fluid as a function of v . Find all extrema and inflections in the range b …25 b , and put them on the plot. f) Finally, consider a van der Waals fluid at temperature T = 600 K ( supercritical fluid, as T > T cr ). Plot p ( v ) in the range b …25 b , and mark all extrema and inflections. Do the same for T ( v ). d g*) Animate p ( v ) using T as an animation parameter (check the function animate in Maple’s help pages). Put on top of the animated plot the spinodal curve the location of the two extrema at all temperatures (a certain curve p spinodal ( v )). The final result should be an animated plot where the moving curve p ( v ; T ) should have its extrema always remaining onto the spinodal curve p spinodal ( v ). y Parameters: b = 0.16 L/mol; a = 2.6 Pa∙m 6 /mol 2 ; R = 8.314 J∙mol 1 ∙K 1 . Careful with the units use SI!
14 15. Ordinary differential equations, separation of variables Solve the following equations: a) d ( ) ( ) d f t f t t = , with initial condition f (0) = f 0 . b) d ( ) d f G f t = , with initial condition f = 1 when t = 1. c) 2 d d f t f t = , with initial condition f = 1 when t = 0. Sketch/plot the solution. d) 2 2 d 1 d f t f t f t = + , with initial condition f = 2 when t = 0. Sketch/plot the solution. e) 2 1 2 d d d d f f t t t = , with initial conditions 1 d (1) 1 d t f f t = = = . f) The system d ( ) ( ) exp[ ( ) ( )] d f t g t f t g t t = , d ( ) ( ) exp[ ( ) ( )] d g t f t f t g t t = − , with initial conditions f (0) = g (0) = 1.
15 1 A review of the material for simple reactions in simple reactors Your job is to: fundamentals… revise and extend basic chemical kinetics, revise basic reactor engineering (batch, PFR, CSTR); skills design a one-reaction reactor. You have already been introduced to chemical reactors, mostly with examples where only one chemical reaction is taking place. In part one of CRE-II, we will focus on simultaneously occurring interdependent reactions. However, we will first introduce several new concepts on a couple of familiar examples. 1.1 Refresh and extend basic chemical kinetics for one homogeneous reaction Yield; stoichiometric 3 coefficients. Let us mix n A0 moles of a chemical species A and n B0 moles of B. Assume that the following reaction between A and B is possible: 2A + B ½C. (1-1) We say that moles of the reaction (1-1) took place when 2 moles of the reagent A and moles of B reacted to form ½ of the product C. This can be written as: n A = n A0 2 , n B = n B0 , n C = ½ . (1-2) The quantity is called the yield or extent of the reaction (1-1), and is a function of time: right after A and B were mixed, ( t = 0) = 0 (zero moles of reaction at the beginning of it), and then the reaction proceeds to completion ( ) or to equilibrium ( e ). The relations (1-2) can be written concisely as: n i = n i 0 + i , (1-3) or per unit volume, C i = C i 0 + i V , (1-4) where V [mol/m 3 ] are the moles of reaction per m 3 of mixture. Here, i = A,B,C; n i 0 is the initial amount of component i (where n C0 = 0); i is the stoichiometric coefficient of i . The stoichiometric coefficients of the reagents are, by definition, negative for the reaction (1-1), A = 2, B = 1, C = + ½. (1-5) The stoichiometric coefficients of any inert species present in the mixture (a solvent, an inert carrier gas, or an admixture) is null. One standard way to write a chemical reaction (the second most common after the one you know) is  i i 0, (1-6) where i is the i th component. For example, eq. (1-1) can be written as 2A B + ½C 0. (1-7) This is the default way to input chemical equations in many chemical engineering software packages. 3 / ˌstɔɪkɪəʊˈmetrɪk / 4 better /ksai/, although /sai/ and /zai/ are more common; is capital
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16 The yield has the micromechanical meaning of number of successful events , and V is events per unit volume. The particular event depends on the type of reaction. For radioactive -decay of 238 U, it would be the number of times a He 2+ particle is emitted from the nucleus. Note that is strictly neither the same thing as the observed decrease in number 238 U atoms, nor the produced amount of 234 Th or -particles, because other nuclear processes take place simultaneously (consummation or production of 238 U, 234 Th and especially He 2+ ). Another example: most reactions between two radicals (2R R 2 ) proceed without an energy barrier, so all collisions between R lead to the formation of R 2 . In this case, V is simply the number of collisions between particles R per unit volume. For a short period of time t (so short that the concentration C does not change), a small number of hits, V , will take place; Maxwell has shown that V is given by the formula 2 2 B vdW π δ 8 δ V k T R C t m = , where R vdW is the van der Waals radius of an R particle, m is its mass, C is its concentration, t is time, k B is the Boltzmann constant. The collisions per unit time and unit volume , r = V / t , are, of course, the rate of the reaction (unless V is function of t then we need to use the proper definition r = V -1 d /d t ). If there is an energetic barrier for the reaction, then not all collisions lead to a reaction event, and is only the number of effective collisions e.g., those collisions that break a bond (compared to r , which is effective collisions per unit time and unit volume ). Irreversible reactions, limiting component, conversion. An irreversible reaction is one that proceeds to completion. Completion of the reaction means that either A or B is exhausted, i.e. either n A = 0 or n B = 0 after sufficient time. In case that both n A and n B reach zero, we say that the initial mixture is stoichiometric . For the reaction (1-1), a stoichiometric mixture will have n A0 = 2 n B0 . Most generally, the stoichiometric mixture is of initial composition n i 0 = | i | , (1-8) where is the maximum yield of the reaction. In the other case, where A disappears before B, we say that A is the limiting component and B is in excess . For the limiting reagent A, upon completion, it will be valid that n A = n A0 2 = 0. (1-9) Eq. (1-8) holds true for the limiting component (or components) only. The excess of B, n B∞ , is the amount left after completion, n B∞ = n B0 = n B0 n A0 /2. (1-10) The yield nondimensionalized with the maximum yield is called the conversion X : = X , X = / . (1-11) The amount of limiting components can be related to the conversion as n i = n i 0 + i = n i 0 −  i | X = n i 0 (1 X ). (1-12) To derive this formula, we first made use of the fact that the limiting component is always a reagent (so i = | i |), then we used eq. (1-11) for and eq. (1-8) for | i | . For the components in excess , the relationship between n i and the conversion X is more complicated: n i = n i + ( n i 0 n i )(1 X ). (1-13) Reversible reaction and equilibrium. In theory, no reaction can be completely irreversible the principle of micromechanical reversibility states that if the molecular process A 2B is possible, so is the reverse process 2B A. The forward and the reverse reactions together correspond to one reversible reaction , A 2B. (1-14) A reversible reaction proceeds until equilibrium is reached. Consider a mixture of initial composition C A0 and C B0 . After V mol/L reaction takes place, the composition will be, according to eq. (1-4),
17 C A = C A0 V , C B = C B0 + 2 V . (1-15) Note that for a reversible reaction V can have a negative value (when the reaction proceeds backwards, with A being formed from B). A reversible reaction always proceeds in direction towards chemical equilibrium. For ideal gases or ideal solutions, the condition for equilibrium reads: C 2 Be / C Ae = K , (1-16) where K is the concentration-based equilibrium constant of the process (1-14). Eqs. (1-15) relate the equilibrium concentration to the equilibrium yield V e as C Ae = C A0 V e , C Be = C B0 + 2 V e . Substituting these in eq. (1-16) leads to one equation for one unknown, V e : ( C B0 + 2 V e ) 2 /( C A0 V e ) = K . (1-17) The reversible reaction (1-14) proceeds from initial V = 0 to the final value V e (which is what towards equilibrium means). If V e is positive, we say that the initial conditions are left of equilibrium , meaning that A in the initial mixture is in excess compared to its equilibrium value, and the reaction (1-14) has to proceed to the right with formation of B. On the opposite, if V e is negative, we say that the initial conditions are right of equilibrium . Which reactions are irreversible, and which are reversible? In theory, all reactions are reversible. In practice, there are three classes of reactions that proceed to completion: (i) highly exothermic reactions at low temperature; (ii) highly endothermic reactions at high temperature; (iii) reactions in which the product is removed completely from the mixture by a phase separation process. For example, if A in eq. (1-14) is in solution and B is very volatile so that it leaves the solution, the reaction can proceed to completion (but this might not be the case at increased pressure, or for small volume of the gas phase). Likewise, the reaction will proceed to completion if the product B forms an insoluble crystal, or A is a gas while B forms a non- volatile liquid, and so on. Rate of the reaction, rate of component production. By definition, the total rate of the reaction, r n [mol s -1 ], is the time derivative of : r n = d /d t . (1-18) The specific or volumetric rate of the reaction is defined as 1 d d r V t = . (1-19) This r is the quantity that is commonly referred to as rate of a reaction, and is of units [mol m -3 s -1 ]. The rate may be alternatively defined per unit mass of the mixture [mol kg -1 s -1 ], per unit mass of the catalyst [mol (kg-cat) -1 s -1 ], per total moles of the mixture [s -1 ] etc. For reactions proceeding under constant volume conditions (isochoric 5 reactions), we can bring V under the differential in eq. (1-19) to simplify it to r = d V /d t , (1-20) where we used the relation = V V . However, if the volume changes, the relationship between the rate and the yield per unit volume is more complicated: d 1 d d d V V V r t V t = + . (1-21) The rate of the reaction r n = d /d t is simply related to the rates of consumption/production of the involved components, r ni = d n i /d t , as it follows from the differentiation with respect to t of both sides of eq. (1-3): d d ν d d i i n t t = , i.e. 5 / ˌaisəˈkɔːrik /
18 r ni = i r n , and after dividing by V , r i = i r . (1-22) For example, for the reaction 2A + B ½C, this corresponds to r A = 2 r , r B = r , r C = ½ r . (1-23) Very often, people speak of rate of a reaction with respect to component A, B or C . This corresponds to the rates of the equivalent reactions A + ½B ¼C, 2A + B ½C, and 4A + 2B C, respectively, i.e. rate with respect to component i refers to a formulation where | i | = 1. The three formulations refer to three definitions of yield: A , B , and C . The three yields are related as 4 A = 2 B = C . Rate law and mass action law. The rate of every reaction is a well-defined function of the conditions in the mixture the composition, the temperature etc. The relationship between rate and composition, r = f( C A , C B, C C …), (1-24) is called the rate law that the reaction follows. Nearly all elementary (single-stage) reactions follow a simple power law dependence on the concentrations of the components, called the mass action law . For the irreversible elementary reaction A A + B B C, (1-25) the mass action law states that: A B ν ν A B r kC C = . (1-26) Here, k is the rate constant of the reaction. The quantity | A + B | is the order of the reaction; just | A | is the order with respect to A. Reactions that follow the mass action law are called simple . The elementary reactions are almost always simple, but the simple reactions are often multi-staged, and their rate constant k is usually a combination of several elementary rate constants. The elementary rate constants can often be predicted theoretically via micromechanical modelling of chemical reactions, e.g., via the transition state theory of Eyring 6 . Reactions that do not follow a simple rate law may still proceed according to a power law dependence. For example, if the reaction (1-25) is complex, it can follow a rate law of the sort A B C D r kC C C C = , (1-27) where and are the orders with respect to the reagents A and B, is the order with respect to the product C, and is the order with respect to a catalyst or inhibitor D. Unlike the stoichiometric coefficients, the reaction orders , , and can have values that are positive or negative, integer or fraction. In addition, the rate law might be more complicated than a power law polynomial fractions are especially common (see sec. 3 below). An important limitation of power laws for the rate of chemical reactions is that they are inaccurate for strongly non-ideal mixtures and solutions, especially where the dependence of the activation energy on the concentration is significant; reactions involving formation of a new phase are often such. Consider now a reversible elementary reaction, of equilibrium constant K : A A + B B C C + D D, C D A B ν ν Ce De ν ν Ae Be C C K C C = . (1-28) This condition for equilibrium is only an approximation ideal mixture is assumed. Generally, activities a i have to be used instead of concentrations C i , and then the equilibrium condition alters to ν e i i a K = . (1-29) 6 / ˈ airing/
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19 If the ideal mixture approximation is used, the concentrations of the solvent molecules or of any pure solid participating in the reaction are skipped in the product, e.g., if D is a solvent or a solid, it should not be present in eq. (1-28) (but will remain in (1-29)). The total rate r of the reversible reaction (1-28) is the rate of the forward reaction, r f , minus the one of the reverse reaction, r r . If this is a simple reaction, the mass action law reads A B C D ν ν ν ν f r f A B r C D r r r k C C k C C = = . (1-30) At equilibrium, this rate is 0, i.e. r fe = r re and A B C D ν ν ν ν f Ae Be r Ce De k C C k C C = . By comparing this relation to the equilibrium condition (1-28), we find that k r = k f / K . (1-31) Substituting this relation back into eq. (1-30), we obtain for the rate the expression ( ) A B C D ν ν ν ν f A B C D / r k C C C C K = , (1-32) which is the form we will usually use. Note that this form is again limited to ideal mixtures. In non-ideal mixtures, the following form is often used: ( ) A B C D ν ν ν ν f A B C D / r k a a a a K = . (1-33) However, as a rule, k f in this equation has a significant dependence on the concentrations of the components, so eq. (1-33) is not sufficient to determine the evolution of the composition of the mixture one has to add to it an equation for k f ( C i ), which is difficult to obtain in practice. The rate law of a simple reaction follows directly from the kinetic equation of this reaction. Eqs. (1-25)&(1-28) are kinetic if the rate laws (1-26)&(1-30) are valid. Often, several kinetic equations may correspond to the same chemical equation. For example, the 1 st order reaction A B, the 2 nd order 2A 2B, the 3 rd order 3A 3B, the catalytic reaction A + C B + C, the autocatalytic reaction 2A + B 3B all these proceed according to the same chemical equation (A B) but follow different rate laws ( r = k [A], k [A] 2 , k [A] 3 , k [A][C], k [A] 2 [B]). A chemical equation is one that reflects correctly the stoichiometry of the process only; a kinetic chemical equation gives you more than that it specifies the form of the rate law. The rate equations (1-32) for the reversible reaction and (1-26) for the irreversible one are ordinary differential equations (ODEs) for the respective s. This ODE can be written explicitly by using the relations (1-21) between r and and (1-4) between C and . For example, consider the isochoric elementary reaction 2A B, for which eq. (1-4) gives C A = C A0 2 V and C B = C B0 + V . The rate law then leads to the equation ( ) ( ) ( ) 2 2 f A B f A0 B0 d / 2 / d V V V r k C C K k C C K t = ⎯⎯→ = + . (1-34) This is an ordinary first-order differential equation for V ( t ). As all first-order ODE, it requires one initial condition for V . This condition is simply V (0) = 0. A reaction that represents specific 1-stage molecular process is called elementary . There are many simple reactions that are not elementary but multistaged. On the other hand, an elementary reaction may not follow the mass action law accurately (as a rule, deviations occur both at very low and very high concentrations). Almost all elementary gas-phase reactions are of the 2 nd order; 3 rd order is very rare. 1 st order reaction is possible with large molecules, and is usually an interaction between two parts of the molecule, such as the following intramolecular hydrogen abstraction: C H 3 CH 3 O H O C H 3 CH CH 3 O O H In solution, 1 st order reactions are more common, but usually solvent molecules are involved in the process, and one should strictly speak of a pseudo-first order process. Nuclear decay follows
20 1 st order kinetics. Only non-elementary simple reaction can be of order different from 1, 2 and 3 (non- integer, ≥3 etc.) . Example 1-1. Consider the elementary reaction A 2B taking place in gaseous phase, under isobaric-isothermal conditions. Analyse the evolution of the amount of A and B. What is the time for half-reaction? Solution. This is a non-isochoric batch reactor problem. First, write the relationships between n i and : n A = n A0 , n B = 2 ; total moles n = n A + n B = n A0 + . Since there is only one reagent, A, it is the limiting component. The maximum yield corresponds to complete depletion of A, n A = n A0 = 0, so for and the conversion of the reaction we get = n A0 ; X = / = / n A0 . (1-35) Under isobaric conditions, the volume of the system increases proportionally to n , according to the ideal gas law: V = nRT / p = ( n A0 + )/ C A0 , (1-36) where C A0 = n A0 / V 0 = p / RT is the initial concentration of A, and V 0 is the initial volume (and initially V 0 = n A0 RT / p as p and T are constant). Now we can convert the concentrations to reaction yield: A0 A A A0 A0 n n C C V n = = + ; B B A0 A0 2 n C C V n = = + . (1-37) The rate law reads r = kC A , and can be written as an explicit equation for using the definition (1-19) of rate, the result (1-37) for C A , and eq. (1-36) for V : ( ) A0 d d k n t = . (1-38) This is solved by separation of variables. We first multiply both sides of the equation by -1 and then use that d = d( ) = d( n A0 ); after that we integrate: eq. (1-38) ( ) ( ) ( ) 0 A0 A0 A0 d dln d d t t n k n n k t t = ⎯⎯→ = − ⎯⎯→ = − ⎯⎯→ A0 A0 ln n kt n = − . (1-39) In the last step, we used that = 0 at t = 0. The solution to eq. (1-39) for is: ( ) A0 1 e kt n = . (1-40) The evolution of the composition with time is obtained by substituting this in eqs. (1-37) A A0 e 2 e kt kt C C = ; B A0 1 e 2 2 e kt kt C C = . (1-41) Finally, the time for half-reaction t 1/2 is the one at which = /2 = n A0 /2 (where is the “full reaction”). From eq. (1-39) we then find: A0 A0 1/2 A0 / 2 1 ln 2 ln n n t k n k = − = . (1-42)
21 Fig. 1. Trajectories of the amounts of substance and the reaction yield of the gas-phase reaction A 2B under constant pressure and temperature, in nondimensionalized coordinates. Example 1-2. Consider the elementary reversible reaction A B in liquid phase; neglect any change of volume and assume isothermal conditions. Analyse the evolution of the amount of A and B. Find the time for half-reaction. Solution. As stated, the problem implies again a batch reactor system. Since the process is isochoric, we will work with V [mol/L] instead of [mol]. The relationships between C i and V are: C A = C A0 V , C B = V . (1-43) Let us first find the composition after equilibrium has been reached. The equilibrium condition for the reaction A B reads: Be Ae C K C = , or e A0 e V V K C = . (1-44) The equilibrium yield (the full reaction , the moles per litre of reaction until equilibrium is reached) is the solution to eq. (1-44), namely: e A0 1 V K C K = + , so e e 1 V K X K = = + , (1-45) where = C A0 . The rate law for A B reads ( ) ( ) f A B f A0 f e d 1 1 / d V V V V K K r k C C K k C k t K K + + = = = = . (1-46) Here, we first substituted C A and C B with eqs. (1-43) and simplified, and then used (1-45) to get rid of C A0 . This is solved by separation of variables similarly to the previous problem: ( ) e f f r e 1 ln V V V K k t k k t K + = − = − + ; (1-47) ( ) f r e 1 e k k t V V + = , or after division by = C A0 , ( ) f r e 1 e k k t X X + = . (1-48) The time for half-reaction (where = V e /2) is easiest to obtain from eq. (1-47): 1/2 f r ln 2 t k k = + . (1-49) n i / n A0 t / t 1/2 X = / t / t 1/2 half- reaction half- reaction
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22 Fig. 2. Trajectories of the concentrations and the reaction yield of the liquid-phase reaction A B, in nondimensionalized coordinates; K = 3. 1.2 Temperature dependence of rate and equilibrium constants In the simplest case, the rate constant follows the Arrhenius 7 equation ( ) f f 0 f exp / k k E RT = , (1-50) where E f [J/mol] is the activation energy of the forward reaction; the preexponential factor k f0 is the collision frequency of molecules in the correct orientation. Similarly, for the reverse reaction, ( ) r r0 r exp / k k E RT = . (1-51) Chemical engineers often use these equations in their equivalent forms f f f 1 1 exp E k k R T T = ; r r r 1 1 exp E k k R T T = , (1-52) where k is the value of k at one standard temperature T (usually 298 K). E f and E r are positive, and therefore, the rate constants rapidly increase with T . Some radical reactions are of zero activation energy (and are very fast); for them, k = k 0 may drop with the increase in T , due to a weak power law dependence of k 0 on the temperature ( k 0 ~ T n , where n = 2…+3) . For the equilibrium constant K = k f / k r , an equation of similar form holds: Δ 1 1 exp H K K R T T = , (1-53) where K = k f / k r is the equilibrium constant at room temperature, and H = E f E r is the heat of the reaction. This is van ’t Hoff’s 8 equation. The relation between heat of reaction and activation energies is often illustrated with the dependence of the energy U of a system on the reaction coordinate a certain molecular geometric characteristic, such as distance between two atoms or an angle, that changes continuously upon a reaction event. For example, for the 7 / ɑ:ˈrenius / 8 / vɑ:n ə t ˈhɔf /, note the spelling of van ’t X = V / V t / t 1/2 half- reaction C i / C A0 t / t 1/2 C Be C Ae
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23 decomposition AB A + B of a diatomic molecule AB, this would be the distance d AB between the two atoms A and B, see Fig. 3. As the distance increases from the equilibrium bond length (state AB) to infinity (state A + B), the system is forced to pass through a maximum energy state, corresponding to the so-called transition complex [A---B] (elongated unstable configuration of the two atoms). The energy of [A---B] is by E f higher than that of the stable molecule AB, and by E r higher than that of two free atoms A + B. The difference between the energies of the initial state AB and the final A + B is equal to the heat of the reaction (approximately, as U and H differ by a small term RT due to the expansion of the system). Fig. 3. Relationship between activation energies and heat of a reaction (Polanyi-Wigner diagram). Derive from Maxwell distribution 1.3 Simple reactors and their mole balances Most of our module is dedicated to the question how the reactor type and the reaction nature determine the performance of the reactor, or more specifically, what is the performance equation of the reactor: output = f( input ; design ). Here, input means feed characteristics (composition, temperature, feed flow rate); design means reactor type, size, heat exchange system etc.; output means outflow composition, temperature, flow rate. The performance equation depends on two broad features of the process: the chemistry (i.e. reactions, reaction rates, mixture composition) and the mixing pattern (i.e. reactor design, flow parameters, heat transfer). Let us now briefly summarize what you already know about the basic types of reactors. The main thing the reactor type determines is the way the amount of a given component is delivered or removed from the system, i.e. the reactor type determines the mole balance in the system. The most general mole balance of the i th component in a reactor reads: amount amount change of amount flowing in flowing out produce from in the reactor with feed with product reactions 0 d d d i i i i V n F F r V t = + , (1-54) where n i is the amount of component i in a volume V of the reactor, F i 0 is the inflow of i (mol/s), and F i is the outflow; r i is the production rate. For one reaction of rate r taking place in the mixture, we know that r i = i r . Eq. (1-54) is the integral (total) form of the mole balance. One useful differential (local) form reads 1 i i i i C F C r t t V = − + ; (1-55) A─B [A---B] A + B d AB [Å] AB bond transition complex free A and B U [kJ/mol] E r E f H
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24 it assumes simple dependence of F on V (as in a plug flow reactor). The general mole balance (1-54) is valid for any reactor. Different types of reactors allow for various simplifications of eqs. (1-54) and (1-55). Eq. (1-54) is actually a very general count balance and can be applied to anything. An example: the population n of the UK changes for 4 reasons, - immigration ( F 0 = 600,000 y -1 ); - emigration ( F = 350,000 y -1 ); - the formation reaction, 2 humans 3 humans, of rate r birth d A = 680,000 y -1 ; - the consumption reaction, 1 human being free soul, of rate r death d A = 350,000 y -1 . The integrals are over the area of the UK. This example is actually with two reactions in the reactor. The total rate of population change is 1 0 birth death d d d 580000 y d A A n F F r A r A t = + + = , (1-56) A under the integral denotes that the integration is over the whole available area (not an integration limit). The data are rough averages for 2005-2015. Based on the equation, you can estimate the population and the structure of the UK society based on sociological models (e.g., Brexit will supposedly restrict the immigration from the EU, so F 0 will decrease by ~ 5-10%). Batch reactor , gas or liquid. A batch reactor is filled with the reactant mixture and then closed. There are no flows in or out of the batch reactor, therefore, F = F 0 = 0. In addition, let us assume that the reactor is well-mixed and therefore, homogeneous ( r i under the integral in eq. (1-54) is independent of the location). Under these assumptions, the mole balance eq. (1-54) simplifies to d d i i n Vr t = . (1-57) This is a trivial result the mass balance coincides with definition of reaction rate. The balance can be simplified further in case that the volume of the reactor is constant (liquid phase reaction, or a gas phase reaction in a bomb) in such case, it holds true that d n i /d t = V d C i /d t , so d d i i C r t = . (1-58) Using here eqs. (1-4)&(1-22), we obtain d d V r t = . (1-59) For isochoric-isothermal reaction, where the rate law specifies a dependence of r on , this equation is integrated to: 0 1 d ( ) V V V t r = . (1-60) For example, for a second order reaction A + B C, the mass action law gives r = k ( C A0 V )( C B0 V ). Substituting this in eq. (1-60) and integrating gives immediately the time at which a reaction should be quenched in order to obtain a specified yield see question 6c). For a single non-isochoric isothermal reaction, eq. (1-57) can be re-written using eqs. (1-3) as d /d t = Vr . If V and r here depend on only, we can again integrate: 0 1 d ( ) ( ) t V r = . (1-61)
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25 Compared to the isochoric case, eq. (1-60), there are three complications. The first is that is in [mol] and should refer to a specified initial amount of the mixture; if this initial amount is not specified, you should specify it yourself i.e. consider 1 mole in total of the initial mixture, or 1 kg, or 1 mol of the key (most expensive) reagent. The second is that V is changing with , and the dependence has to be specified by an additional condition. For example, for isobaric reaction in an ideal gas, V = nRT/p = RT n i / p = RT n i 0 / p + RT  i / p = V 0 + ( RT  / p , (1-62) where  =  i is the change in the number of moles in the reaction. For liquid phase reactions, V is again linear function of : V = n i v i = n i 0 v i +  i v i = V 0 + , (1-63) where 9 v =  i v i is the change in volume for mole of the reaction, and v i is the partial molar volume of the i th component (roughly a constant equal to the volume of the i th molecule times N A ). The final complication is that the mass action law is sensitive to the change in density. For example, for the reaction A + B C, the mass action law has to be used in the form r = kC A C B = kn A n B / V 2 = k ( n A0 )( n B0 )/ V ( ) 2 . The batch reactor is the most widely used experimental reactor: nearly every new industrial process is born in small laboratory batch reactors. The reason is that we cannot really make a small plug flow or continuous stirred-tank reactor that consumes less than a barrel of feed per experiment. Batch reactors are fairly common for small-scale pharmaceutic and speciality chemical productions, as they allow for better quality control each batch can be analysed and confirmed to be suitable for use. Natural/household examples for batch reactors: cooking soup in a pot. An engine cylinder can be thought as a batch reactor, but a very untypical one: cycle times are very small; the volume is fixed but time dependent; reactions do not produce useful products, only useful free energy. Semi-batch reactor is one in which some components are continuously added in the mixture, mostly to avoid excess heat production or to increase selectivity when multiple reactions are possible. Therefore, F i 0 in the general balance (1-54) is not zero for one or more components, and the mole balance reads 0 d d i i i n Vr F t = + . (1-64) Fig. 4. A typical batch or semi-batch reactor ( stolen from essentialchemicalindustry.org ). Semi-batch reactors are fairly common for small-volume chemical production and for bioreactions. Natural/household examples for semi-batch reactors: the stomach. Once food is delivered to the stomach, acid and enzymes are secreted continuously. After residence time of about 30 min, the mixture is transported to another reactor joint in series the intestines. 9 Be careful (the Greek letter nu) is stoichiometric coefficient; v (the English vee) is molar volume, say IUPAC.
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26 Plug flow tubular reactor (PFR). These reactors are normally operated under steady state conditions, so d n i /d t = 0 in the general balance (1-55). The differential mole balance reads d F i = r i d V , or ( ) d d d d i i i vC F r V V = = ; (1-65) here, v is the volume flow rate, and F i = vC i . If the density of the mixture does not change along the length of the reactor, then v = v 0 (the volume flow rate at the entrance) and the mole balance simplifies to: 0 d d i i C v r V = , or d d i i C r = . (1-66) Here, = V / v 0 is the space-time of the reactor . Note that eqs. (1-58) for a batch reactor and eq. (1-66) for PFR differ only by the name of the variable ( t in the former case, in the latter). This means that C i ( t ) for isochoric-isothermal batch reactor and C i ( ) for isothermal PFR with incompressible flow are the same functions. Therefore, we can write for PFR: d ( ) d V V r = , 0 d ( ) V V V r = , (1-67) analogously to eqs. (1-59)&(1-60). The plug flow reactor mole balance for a mixture that changes density is easiest to deal with if a yield of units mol/s is introduced. If there were no reaction, the mole flow rate of component i through each cross-section of the reaction would be constant, F i = F i 0 . Due to the reaction, it changes by stoichiometric coefficient times the yield t of the reaction, 0 ( ) ν ( ) i i i t F V F V + , (1-68) where t is in mol/s, i.e. it is a production rate . This is how many moles of reaction take place in a part of the reactor of volume V for one second. The general mole balance d F i = r i d V is valid; substituting F i in it with eq. (1-68) and rearranging gives α d ν ν ν d i t i i i i i r r k C V = = = . Note that d t /d V turns out to be equal to the rate of the reaction r . Now we need to express the concentrations through the new quantity t : ( ) 0 / ν / i i i i t C F v F v = = + , and then also the volumetric flow rate v through t : 0 0 Δ Δ i i i i t t v v F v F v v v = = + = + , where v 0 is the volumetric flow rate of the feed, v i is the partial molar volume of the i th component, and v =  i v i is the change of the partial molar volume due to the reaction. For liquid phase reaction, this is usually a constant; for an ideal gas, v i = RT / p , and it could be the case that pressure p or the temperature T change along the length of the PFR. Combining the last three equations leads to a single equation for t ( V ): ( ) ( ) α α 0 0 α 0 0 ν d ν d Δ Δ i i i i i t t i i t t t F F r k k V v v v v + + = = = + + . (1-69) If v is constant, this is easily integrated to obtain the design equation:
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27 ( ) ( ) α 0 α 0 0 0 Δ d d ( ) ν i t t i t t t t i i t v v V r k F + = = + . It tells us what should the reactor volume be in order to achieve production rate of t . However, v is a constant only for most liquid-phase reactions and for gas-phase isobaric-isothermal reactions. In gas-phase fixed-bed reactors, the pressure drop is important and v =  RT / p ( V ) has to be used, with p ( V ) specified by a flow model (or sometimes assumed linear). When this is the case, the separation of variables above does not work. For non-isothermal gas-phase reactions, T (and therefore k ) become functions of V as well. In such situations, your non- explicit design equation is really the differential equation (1-69), which has to be solved numerically. PFRs are the most commonly encountered reactors in the chemical industry, because of a long list of advantages. They allow for continuous, fast, reliable, large-scale production; PFRs work well with gaseous, liquid and heterogeneous mixtures; residence times can be very short; the heat exchange system is very easy to design; high pressures can be achieved etc. Membrane plug flow reactor . The normal plug flow reactor has impermeable walls. The membrane plug flow reactor is one in which a component from the reaction mixture is added or removed selectively through the walls. In such case, the total molar flow rate F i in the general eq. (1-54) has two components: one for the cross-section flow F cs and a second for the flow through the walls: cs, d d d i i i F j A r V + = ; (1-70) here, A is the area of the membrane, and j i is the molar flow per unit area of component i through the membrane, in direction out of the reactor. Eq. (1-70) per unit volume of the reactor reads d d d d i i i F A j r V V + = . (1-71) If the reactor is a cylindrical tube of radius R r , d A /d V is simply equal to 2/ R r . Fig. 5. Typical membrane reactor designs. In the first one, the product C is removed from the mixture through the membrane (used with reversible reactions to increase conversion). In the second design, one of the reactants is delivered through the membrane (used to increase selectivity when the rate of a side reaction is minimized at low concentration of A). Stolen from Fogler [2]. An example for a natural membrane tubular flow reactor (although laminar flow, not plug flow) are our intestines. Continuous stirred-tank reactor (CSTR) , or mixed flow, or vat, or backmix reactor. In stationary state, d n /d t = 0, and the mixture is homogeneous, which simplifies the general mole balance (1-54) to 0 0 i i i F F rV = + . (1-72) If flow rate is v , so F i 0 = vC i 0 , F i = vC i and V = v , this equation simplifies to the familiar form 0 0 i i i C C r = + , i.e. 0 i i i C C r = . (1-73) Using eqs. (1-4)&(1-22), we can write this as an equation for V : / V r = . (1-74)
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28 (stolen from Wikipedia) Natural examples: the surface of the Ocean is a sort of CST bioreactor light, CO 2 and minerals are constantly flowing in, and O 2 and organic material is constantly flowing out. The human liver is an inflow-outflow tank type reactor, but not a well-stirred one. Example 1-3. Consider the elementary reversible reaction A B in liquid phase, CSTR. Analyse the composition of the reactor as a function of its space-time. Find the space-time for half-reaction. Find the production rate of B, F B = vC B , as function of the flow rate. Solution. The relationships between C i and V and the equilibrium composition are unchanged compared to the previous example 1-2: C A = C A0 V , C B = V ; (1-75) e A0 1 V K C K = + . (1-76) The rate law for A B still reads ( ) f e 1 V V K r k K + = . (1-77) The mole balance (1-74) reads simply ( ) f e 1 V V V K k K + = , which is a linear equation for V . To obtain the solution, we solve that for V and simplify using that K = k f / k r : ( ) f e e 1 1 f r f 1 1 1 1 V V V K k K K k k k K + = = + + + + . This is the design equation for the reaction A B in CSTR it allows computing the conversion V at any flow rate and volume of the reactor (i.e. any = V / v ). Combining reactors. Reactors are often used in series or in parallel. Well-designed assemblies of reactors are able to combine the advantages of two or three types of reactors. Assemblies are especially useful when multiple reactions take place.
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29 Fig. 6. Nature- inspired reactors in series in artwork: “Cloaca” by Wim Delvoye . A room-sized assembly in Hobart, Tasmania, that replicates the journey of food through our gastrointestinal tract. This art-piece shares one thing in common with industrial reactors: as a rule, they are smelly! Judging from the photo, what type of reactors have been immortalized? Picture stolen from ABC News. The main parameters optimized when a reactor is designed: safety, selectivity, yield, temperature control and cost. Minimum volume. Typical advantages, disadvantages and features of the main reactors (based on table 3-1 of Schmidt) BR CSTR PFR reactor size for given conversion (typically) + - + simplicity and cost + + - continuous? - + + easy to clean? + + - on-line analysis - + + product certification + - - typical residence times hours from 10 min to 10 h s to tens of min
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30 Read more Levenspiel’s ch. 1 -6 [1]. Fogler’s ch. 1 -7 [2]. Supafastquiz A reaction follows the rate law r = k [A] 2 /( K + [B]). What are three ways to accelerate it? A reversible reaction 2A B is slow and exothermic. What temperature would be optimal for its rate: the highest achievable, the lowest achievable, or somewhere in the middle? Which of the following processes will be approximately isothermal, and which adiabatic? a) synthesis of an organic molecule in dilute aqueous solution; b) an explosion of H 2 + O 2 ; c) a liquid phase reaction of enthalpy r H = 10 J/mol; d) a slow exothermic reaction taking place for 24 h in a well-cooled batch reactor; e) compression of air in the engine cylinder for 10 ms during the intake stroke. Three reactors that allow components to be added to the mixture after the start of the reaction? A CSTR is of volume 5 L and flow rate is 10 L/h. What is the residence time? A batch reactor is of volume 5 L and residence time 10 h. What is the flow rate? The following three reactions are completely equivalent: A → ½B, r 1 = k 1 A 3/2 ; 2A → B, r 2 = k 2 A 3/2 ; 3/2 A → ¾ B, r 1.5 = k 1.5 A 3/2 . However, k 2 = k 1 /2, and therefore, the rate of the second reaction is slower than the rate of the first reaction. Now how is that possible? If the rate is not invariant to the way we choose to write the reaction, then what is invariant? What is the realationship between k 1.5 and k 2 ? PS are H 1 , H 2 , H 1.5 . Problems 1. Easy questions a) What are the stoichiometric coefficients of each component in the following reactions: 3C 2 H 2 → C 6 H 6 ; H 2 Cl 2 + 2HCl → 0; Ca 2+ + SO 4 2- → CaSO 4 (S) and Ca 2+ + SO 4 2- + 2H 2 O → CaSO 4 ·2H 2 O (S) . b) Are the following reactions different? (i) A ½C and (ii) 2A C. Is their yield different? How are i and ii related? c) Are the following reaction different?
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31 (i) 2A 3C and (ii) 3C 2A. How are i and ii related? 2. Derivations a) Derive eq. (1-13) from eq. (1-3). b) The relation (1-3) between amount of substance and yield, n i = n i 0 + i , can be thought of as a particular case of the mole balance eq. (1-54). Derive (1-3) from (1-54) for batch reactor. Derive the same for CSTR. Show that for any homogeneous reactor (semi-batch, non-stationary CSTR), instead of n i = n i 0 + i , it is true that ( ) 0 0 0 ν d t i i i i i n n F F t = + + . c*) Space time is V / v 0 ; if the volumetric flow rate v changes along the length of a PFR, then the space time is not equal to the mean residence time of the mixture in the reactor. Can you relate the function v ( V ) to ? Can you relate to v ( )? Ans. 1 0 d V v V = ; ( ) 1 1 0 0 Δ d t t t v v r = + . 3. Basic irreversible reactions a) Consider the irreversible reaction 4A + 3B 2C in liquid phase. The initial composition of the mixture is [A] 0 = 0.3 M, [B] 0 = 0.25 M, [C] 0 = 0.001 M. Find the composition of the mixture after completion of the reaction. b) In an engine cylinder, 10 mg isooctane react completely with 0.195 g of air (excess!). What will be the composition of the final mixture (give mole fractions of each component)? Air is 21:79 O 2 :N 2 by mole. c) The electrochemical reaction Zn + Cu 2+ Zn 2+ + Cu consists of two conjugated half- reactions, Zn Zn 2+ (aq) + 2e (zinc anode), Cu 2+ (aq) + 2e Cu (copper cathode). The two electrons are transported from the anode to the cathode through an external circuit. Let the mass of the anode be 10 g, and the electrolyte solutions be of very large amount. What is the maximum yield of the reaction? What amount of Cu will be deposited on the cathode? What amount of electricity will pass through the external circuit? One mole of electrons corresponds to F coulombs, where F is Faraday’s constant. 4. Basic equilibria a) The following equilibrium has been established in aqueous solution: 2Fe 3+ + 2I 2Fe 2+ + I 2 . The concentration of iodine is determined via titration: [I 2 ] e = 0.0032 M. We also know the initial concentrations of Fe 3+ and I : [Fe 3+ ] 0 = 0.0150 M, [I ] 0 = 0.0110 M. Determine the equilibrium yield of the reaction, the conversion and the equilibrium constant of the process. n b) Gaseous HCl and O 2 are mixed in ratio 1:1 at 870 K, 1 bar. The following reaction takes place under constant pressure: 4HCl (G) + O 2 (G) 2Cl 2 (G) + 2H 2 O (G) . The molar part of the Cl 2 is 0.238 when equilibrium is reached. Find the molar fraction-based equilibrium constant K x , the pressure based equilibrium constant K p , and the concentration- based equilibrium constant K C .
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32 c) Consider the heterogeneous reaction A (G) + 2B (S) 2C (G) (B is solid, A and C are gases). It takes place under constant pressure of 100 kPa; its equilibrium constant is K p = 1.3 (st. state 101325 Pa). The initial partial pressures of A and C are p A0 = 9.5 kPa and p C0 = 12.5 kPa (the rest is inert gas). Find the equilibrium composition of the mixture (the molar fractions and the partial pressures). d) Dimethyl ether, CH 3 OCH 3 or Me 2 O, is used as fuel, refrigerant, aerosol propellant, precursor for dimethyl sulfate, Me 2 SO 4 , and as solvent for some low-temperature pharma reactions. It is produced from methanol (one of the many useful products that stems from syngas): 2CH 3 OH CH 3 OCH 3 + H 2 O. Your boss told you to investigate the possibility to produce Me 2 O in a gas phase reaction at increased temperature (above the boiling point of methanol, 65 °C), and your first job is to find the yield of the process as function of T . The equilibrium constant as function of temperature is given by K p = 0.0000196× T 1.18 exp(3226/ T ), where T is in units K; standard conditions do not matter. Plot the equilibrium conversion, X e = e / , as function of T up to 800 °C. Plot also the equilibrium partial pressures and mole fractions of all components as function of T , if the total pressure is 1 atm. What will be the conversion of methanol at 150 °C? Hint: two solutions, only one is physical! 5. Post-Arrhenius kinetics a) k = k 0 T n exp( E / RT ) 6. An irreversible reaction in batch or PF reactor a) The liquid-phase reaction A + 2B 2C follows the rate law r = k [A]. If the initial concentrations are [A] 0 = [B] 0 , find the time of completion of the reaction in a batch reactor (when [B] = 0). What is the time for completion of the reaction if [B] 0 = 3[A] 0 ? b) Maple The reaction ½ A + ½ B C is simple. Let it take place in PFR; the density of the fluid is constant. Unless [A] 0 = [B] 0 , this reaction is completed for a finite residence time fin . Find fin as function of the ratio [A] 0 /[B] 0 . What happens when [A] 0 = [B] 0 ? Find the evolution of the concentrations in this case. c) The gas phase reaction A + B 3C, which is simple, takes place in a batch reactor under constant volume (bomb). Find t ( ) using eq. (1-60). Plot the composition of the mixture and the pressure in the reactor against time using parametric plot. Parameters: n A0 = 1.5 mol, n B0 = 4 mol, V = 100 L, k = 0.01 m 3 ·mol -1 ·h -1 , T = 300 K. 45 d) The liquid-phase reaction A 2B follows the rate law r = k [A] 2 . Find the composition of the mixture along the length of a PFR reactor (use the space-time as a variable), and plot it/sketch it. Find the time for half-reaction. Parameters: [A] 0 = 0.1 M, k = 0.01 M -1 ·h -1 . e) Maple The simple reaction 3A 2B takes place in gaseous phase under constant pressure and temperature; no inerts. Find the evolution of the composition and the volume as function of time and the time for half-reaction first analytically, and then plot/compute them. What should be the quenching time needed to obtain 90% conversion? Parameters: p = 1 atm, k = 1×10 -4 m 6 ·mol -2 ·h -1 . Hint: use eq. (1-61). f) The photochemical reaction C 2 Cl 4 + Cl 2 C 2 Cl 6 follows the rate law r = k [Cl 2 ] 3/2 . If the initial concentrations are [C 2 Cl 4 ] 0 = ½[Cl 2 ] 0 , and the reaction takes place under isochoric- isothermal conditions, find the time of completion of the reaction (when [C 2 Cl 4 ] = 0). 7. A reversible reaction in batch or PF reactors
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33 a) The reaction A B is second-order ( not first! not simple! ) and reversible. It takes place in PFR under constant T without change in density. Find the equilibrium yield. Find the relationship between the equilibrium constant K and the rate constants k f and k r ; use it to get rid of k r . Find the dependence of on using eq. (1-67), and the time for half-reaction. Plot [A] and [B] vs. . Find the flow rate needed to produce 60% conversion. Parameters: K = 2, [A] 0 = 1 M, k f = 0.003 M -1 ·s -1 , V = 300 L. 45 8. A reaction in CSTR a) The simple reaction 2A B takes place in CSTR. Find [A], [B], , X , and the specific production rate F B V = [B]/ as a function of . Plot for [A] 0 = 1 M. What initial concentration of A is needed to produce 85% conversion? Parameters: V = 100 L, v = 5 L/min, k = 1 M -1 ·min -1 . b) The same for the simple reversible reaction 2A B. 9. Autocatalytic reaction a) Consider the simple reaction A + B 2B in a PFR. If the density of the system is constant, express the concentrations C A and C B through the yield V . Write the rate law, and the explicit differential equation for V ( ). Solve it. Plot the results for V , C A , C B and for the rate r as functions of the space-time for C A0 = 1 M, C B0 = 10 -6 M, k = 0.1 M -1 min -1 . The rate r has a maximum at a specific space-time, called the initiation time in of the autocatalytic reaction. Find it. Ans. for conversion: ( ) ( ) 0 0 0 0 [A] [B] [A] [B] 0 0 1 e [A] 1 e [B] + + = + kt kt X . b) Consider the same reaction in a CSTR. Plot C A and C B as function of . c) Consider 2A + B 2B in a PFR. 10. Reactions used as clocks: dating rocks When a volcano erupts, it throws out a mixture of molten rocks. Due to the high temperature, the inorganic ions mix well in this mixture. However, as it cools down, various minerals phase- separate from it. Two common volcanic minerals that phase-separate from the lava are the plagioclase (a mixture of NaAlSi 3 O 8 and CaAl 2 Si 2 O 8 ) and the quintessence (FeTiO 3 ). Both minerals contain significant amount of impurities. In particular, small amounts of ions of Sr and Rb from the lava are included in the two minerals as admixture defects. Rb has a much higher affinity to the quintessence. Millions of years ago, the two ions, Sr and Rb, were well-mixed in the lava; in result, the lava had a well defined isotopic ratio 87 Sr/ 86 Sr. However, Rb started to mess up the isotopic ratio once the phase separation occurred, because 87 Rb is a little bit radioactive and produces 87 Sr, according to the nuclear reaction 87 87 37 38 Rb Sr k e ⎯⎯→ + , a 1 st -order process with half-life of 87 Rb of t 1/2 = 48 10 9 y. As Rb is accumulated preferentially in the quintessence, there the isotopic ratio 87 Sr/ 86 Sr increases more quickly than in the plagioclase. A geologist or an astronaut dug out probes from the two rocks (when rocks are dated, two phases of the same age are called isochron ) and brought them to you. Your laboratory analysed the isochron and gave you the following concentration ratios: 87 Rb/ 86 Sr 87 Sr/ 86 Sr
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34 Plagioclase 0.004 0.699 Quintessence 0.180 0.707 When did the lava solidify? Hint : use the results from Example 1-1.
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35 2 Multiple reactions Your job is to: fundamentals predict the yields in multi-reaction mixture; skills formulate and solve a system of algebraic/ordinary differential equations, optimize selectivity/yield. Figuring out which are the important reactions taking place in the reactor and what are their rates is a significant chunk of the job of the reactor engineer. In particular, process optimization is often all about increasing conversion and selectivity, or avoiding certain undesirable or dangerous reactions by purifying the feed or altering the temperature and the pressure. Moreover, no major industrial chemical process is single-step; instead, you would usually have complicated mechanism with many consecutive stages and side reactions. This section is about the alphabet of multiple reactions; the next one will be about reaction mechanisms and the rates of non-simple reactions. 2.1 Two reactions There are only a handful of ways in which two reactions can be interconnected 10 : consecutive: A B C; parallel: A ← B C; independent: A B ← C; and A B; C D. (2-1) Under isochoric-isothermal conditions, the independent reactions are treated as simple 1-stage reactions; the first reaction does not affect the second in any way and the two just sum up. However, th e “independent” processes suddenly start to interact if we have gas-phase reactions where the volume changes (due to dilution effects) or under non-isothermal conditions (where T is altered by the heats of both reactions simultaneously). We will not consider this sort of interactions here, which leaves us with just two types. 2.1.1 Parallel reactions (branching reactions). Formulation in terms of component concentrations/amounts Parallel reactions are extremely common in organic chemistry as a rule, in any synthesis, a number of isomers are produced together with the main product. An example is substitution reactions with arenes and alkanes. Whenever organic molecules and oxygen are co-existing at high temperature, oxidation takes place in parallel to the main process. If there is no O 2 , then another nasty side reaction might take place coking, the production of carbonaceous material. Quantifying selectivity. The main problem that has to be solved by the engineer is to minimize the formation of the side products and make the process more selective . One everyday example: when we cook meat, we would like to minimize the oxidation reactions leading to aromatization and carbonization (producing foul-smelling carcinogenic chemicals) simultaneously with the desired partial hydrolysis, protein denaturation and esterification. There are several characteristics of the reaction that are commonly used as parameters to optimize. All of these are measuring how much desirable product D is formed in comparison 10 A reaction scheme is a type of graph , having vertices (the components) and edges (the reactions). The analysis of complicated reaction schemes utilizes the mathematical graph theory .
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36 with various undesirable ones. Especially “undesirable” are those side products that can poison the catalyst, and products that are hard to separate from D. The first set of characteristics in use is conversions of the main (most expensive) reagent A to desirable product D and undesirable U: D A DA A0 Δ n X n = , where D n A = AD n D ; U A UA A0 Δ n X n = , where U n A = AU n U . (2-2) Here, D n A is the amount of A consumed to produce D, and AD is the stoichiometric ratio for A and D (how many moles of A are needed to produce 1 mole of D if no side reactions take place), and similarly for D n A and AU . For uncomplicated reaction schemes, AD = | A |/ D . If one desirable and several undesirable products are formed, the sum X DA + X U 1 A + X U 2 A + … will be equal to the total conversion of the reagent A, X A = n A / n A0 = ( n A0 n A )/ n A0 . Table 1. Standard characteristics of selectivity of multiple reactions. The stoichiometric coefficients are skipped for clarity. conversion X A (amount of A converted)/(initial amount of A) ~(A 0 A)/A 0 ~ (D+U)/A 0 desirable conversion X DA (amount of A converted to D)/(initial amount of A) ~D/A 0 overall yield fraction Y D (amount of A converted to D)/(amount of A converted) ~D/(A 0 A) ~ D/(D+U) overall selectivity S DU (amount of A converted to D)/(amount of A converted to U) ~D/U instantaneous yield fraction y D (rate of conversion of A to D)/(rate of conversion of A) ~ r D /| r A | ~ r D /( r D + r U ) instantaneous selectivity s DU (rate of conversion of A to D)/(rate of conversion of A to U) ~ r D / r U Two other common characteristics are the instantaneous and the overall selectivities (Table 1). The instantaneous selectivity s DU is defined as D D DU UD UD U U d ν ν d n r s n r = = , (2-3) where r D V -1 d n D /d t and r U V -1 d n U /d t are the rates of production of the two components D (desirable) and U (undesirable), and UD = UA / DA ( DA is how much D is produced by a mole of A if no side products are formed; same for UA ). For simple reaction schemes, UD = U / D . The other selectivity in use is called the overall selectivity , defined as DU UD D U ν / S n n = . (2-4) For CSTR, S DU = s DU (where does that follow from?) . If multiple undesirable products are formed, the definition of selectivity has to be modified accordingly, e.g., 1 2 1 2 U U D DU D U U ... ν ν ν n n n S = + + . (2-5) The higher this selectivity, the lower the cost of the reagents per unit mass of useful product (as no feed is lost to produce side products), and the lower the cost of the separation procedures needed to remove U 1 , U 2 etc.
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37 The final two common characteristics are the instantaneous yield fraction : D D D AD AD A A d ν ν d n r y n r = = , (2-6) and the respective overall yield fraction : D D D AD AD A A0 A ν ν Δ n n Y n n n = = . (2-7) Here, n A is the total amount of A consumed (spent on both desirable and undesirable products). The last equation can be written as 1 2 1 2 U U D D D D D U U ... ν ν ν ν n n n n Y = + + + . (2-8) Unfortunately, there is no firmly established terminology for these fractions. Your colleagues might call the yield Y D selectivity and overall conversion , and use the letter S for it; our desirable conversion X DA is often called a yield . You might also see the stoichiometric factors dropped out in the definition. Therefore, always doublecheck. Example 2-1. Analysis of parallel reactions in a batch reactor. Consider the following two reactions occurring in the same liquid mixture: (2-9) Analyse the evolution of the mixture composition and characterize the selectivity. Solution. These reactions consume A simultaneously. Let the initial concentration of A be C A0 . After V 1 moles per litre of the 1 st and V 2 of the 2 nd reaction have taken place, the mixture content will be C A = C A0 2 V 1 2 V 2 ; C B = V 1 ; C C = 3 V 2 . (2-10) Differentiation of these three equalities with respect to time t gives us the relation between the rates of production of A, B and C and the rates r 1 = d V 1 /d t and r 2 = d V 2 /d t of the two reactions: r A = 2 r 1 2 r 2 ; r B = r 1 ; r C = 3 r 2 . (2-11) For the two reactions, two similarly looking rate laws hold true (just different k ’s) : 2 1 1 A r k C = and 2 2 2 A r k C = . (2-12) The substitution of eq. (2-12) in eq. (2-11) leads to 3 differential equations for the 3 unknown concentrations: ( ) 2 A 1 2 A d 2 d C k k C t = − + ; 2 B 1 A d d C k C t = ; 2 C 2 A d 3 d C k C t = . (2-13) The initial conditions for these ordinary differential equations are C A (0) = C A0 ; C B (0) = C C (0) = 0. This is the first common formulation of a chemical kinetic problem: in terms of unknown concentrations. The first of eqs. (2-13) can be integrated immediately by separating the variables: ( ) ( ) 0 A 1 2 1 2 2 A A A0 d 1 1 2 d 2 t t C k k t k k t C C C = = − + + = − + ; 2A B 3C 1 2
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38 ( ) A0 A 1 2 A0 1 2 C C k k C t = + + . This result is substituted in the second of the eqs. (2-13) for B: ( ) 2 A0 B 1 1 2 A0 d d 1 2 C C k t k k C t = + + , and the integration from t = 0 to t gives ( ) ( ) ( ) ( ) 2 1 2 A0 A0 1 A0 B 1 2 1 2 A0 1 2 0 0 1 2 A0 d 1 2 d 1 2 2 1 2 t t k k C t C k C C k t k k C t k k k k C t + + = = = + + + + + ( ) ( ) ( ) 2 1 A0 1 A0 1 2 1 2 A0 1 2 A0 0 1 2 1 2 1 2 t k C k C t k k k k C t k k C t = = + + + + + . (2-14) Likewise, ( ) 2 2 A0 C 1 2 A0 3 1 2 k C t C k k C t = + + . (2-15) Fig. 7. Evolution of the concentrations of A, B and C for two parallel reactions, liquid phase, batch reactor ( k 1 = 0.4 M -1 ·h -1 , k 2 = 0.15 M -1 ·h -1 , C A0 = 1 M). Let B be the desired product. The ratio S BC = 3 C B / C C is the overall selectivity of B with respect to the undesired product C, eq. (2-4); the coefficient CB = 3 is used to account that 3 moles of C are formed from the amount of A that is needed to produce a mole of B. The selectivity for the considered reaction scheme turns out to be constant independent of the time of the reaction (but dependent on temperature): B 1 BC C 2 3 C k S C k = = . (2-16) The ratio Y B = 2 C B /( C A0 C A ) is the overall yield fraction of B; the stoichiometric ratio AB = 2 stands for 2 moles of A required to produce a mole of B. Using the results for C B and C A : B 1 B A0 A 1 2 2 ... C k Y C C k k = = = + . The maximum yield of B (the maximum possible moles or concentration of B in the product) is achieved at infinite time where 1 in the denominator of eq. (2-14) becomes negligible: A0 1 B 1 2 2 C k C k k = + . (2-17). C i / C A0 t / t 1/2 C B C C 2A B 3C 1 2
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39 It is useful to make a distinction between side products and by-products . For example, consider the following production of a desirable product D from reagent R, with two by- products and two side products: 1 1 1 R S B ⎯⎯→ + , 2 1 2 S D B ⎯⎯→ + , 3 2 R S ⎯⎯→ . Reactions 1 and 2 are consecutive, and correspond to the overall reaction R D + B 1 + B 2 . Ideally, we want R to be completely converted to D. However, reaction 2 might be too slow and some of the side product S 1 will inevitably be present in the outflow. In addition, the side reaction 3 is going to produce a second side product S 2 . A clever reactor design can decrease the amount of side products, down to [S 1 ] = [S 2 ] = 0 (i.e. overall yield fraction of D with respect to S 1 and S 2 of Y D = 100%). In contrast to S 1 and S 2 , the by-products are unavoidable: the stoichiometry of the desired reaction demands 1 mol of B 1 and B 2 for each mole of D produced. It is always the task of the chemical engineer to (i) minimize the amount of side products, and (ii) find use for the by-products. In the rare case where the by-products are waste , the chemical engineer has to safely get rid of them for many industrial processes, this is very expensive and might even be the price-controlling factor. Let us now consider a couple of simple rules to maximize selectivity of parallel reactions. Role of the dilution. You know from CRE-I that methods for dilution (pressure decrease, addition of inert gas or solvent, recycle) or concentration are often used to alter the rate of a reaction. An important use of dilution is to maximize the selectivity when parallel reactions take place. Consider the reaction scheme Let the reactions d and u follow two different rate laws: d d d A r k C = and u u u A r k C = . (2-18) The instantaneous selectivity is, from the definition (2-3), equal to d u d d DU A u u r k s C r k = = . (2-19) We want to improve the selectivity by decreasing or increasing the concentration of A in the reactor. Case 1 : d > u , i.e. the “good” reaction is of higher order with respect to C A . In this case, the dilution mitigates the desirable reaction, so s DU is higher when A is more concentrated. Therefore, the reactor should be designed in such a way that A is as concentrated as possible. If the reactions in question are gas-phase, then pressure should be increased and the fraction of inert gases should be kept at minimum. In the liquid phase, it is better not to use solvents or other inert materials. A CSTR is a bad choice for reactions where selectivity increases with the concentration of a reagent, because CSTR operates at the outlet concentration (which is the lowest possible for the reagents). Batch or PF reactors are preferable, since during some of the reaction time the reaction will proceed under increased reagent concentration (compared to the outlet conditions). Case 2 : d < u , i.e. the desirable reaction is of lower power of C A . In this case, dilution mitigates the undesirable reaction, so s DU is higher when the concentration is lower. One has to keep the concentration of A as low as possible. CSTR is appropriate here. A PFR with recycle is also an option. Inert gases or more solvent should be considered. A D U d u
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40 The last case, d = u , is making the selectivity independent of the dilution. Consider now another process that involves two reagents and two parallel reactions: Let the two reactions follow the rate laws d d d d A B r k C C = and u u u u A B r k C C = . (2-20) The respective instantaneous selectivity is d u d u d d DU A B u u r k s C C r k = = . (2-21) Case 1 : the desirable reaction is of higher power of both C A and C B , relative to the undesirable. As in the previous example, we need to keep the mixture as concentrated as possible (do not use inert gases or diluting solvent; do not use CSTR; pressurize if gas-phase process). Case 2 : the desirable reaction is of relatively low power of both C A and C B . Keep the system as dilute as possible (use inerts; use CSTR, or PFR with recycle; keep pressure low if gas-phase reaction). Case 3 : the desirable reaction is of relatively high power of C A , but of low power of C B , compared to the undesirable reaction. In this case, to increase selectivity, the engineer aims to keep A concentrated but B as dilute as the process allows. For such situations, a common solution is semi-batch reactor where B is fed at low rate to a concentrated solution of A. Another option is a membrane reactor with A fed from the entrance, and B fed through the walls of the membrane, thus keeping the ratio C B / C A low throughout the length of the reactor. The opposite solution (A slowly fed to concentrated B) will be the right option in the last case, where d < u , but d > u . Role of the temperature. Substitution of the Arrhenius equation (1-50) in eq. (2-19) for the selectivity leads to d u d0 d u DU A u0 exp k E E s C k RT = , (2-22) and similarly for eq. (2-21). Again, there are several options. The first variant, (i) , is the one where the desirable reaction has higher activation energy than the undesirable one ( E d > E u ) here, the increase in temperature will accelerate r d more than r u , improving selectivity. Temperature should be increased as much as possible (usually, T is limited by the stability of the reagents, so keep it at the limit). In the second case, (ii) , the desirable reaction is of relatively low activation energy. In this case, temperature should be kept low. This option is also limited at too low a temperature, the reactions may become so slow that the process requires enormous size of the reactor. Also, the decrease in temperature is often limited by phase changes in the mixture (we do not want our reagent to phase separate as crystals in the reactor); viscosity of liquids can increase so much that mixing becomes impossible. The final option (iii) is with E d E u , where the temperature has little effect on the selectivity. Chemical means to increase selectivity of parallel reactions: orienting groups. Ortho-, para- and meta- orienting substituents. Resonance and steric effect. Effect on reactivity: m- orienting substituents decrease reactivity; o- and p- usually increase, but often decrease reaction rate. A+B D U d u
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41 Catalyst. Ortho-, para- and meta- orienting substituents. Resonance and steric effect. Effect on reactivity: m-orienting substituents decrease reactivity; o- and p- usually increase, but often decrease reaction rate. 2.1.2 Consecutive (series) reactions: formulation in terms of yield These are typical for reactions involving polyfunctional compounds, polymerization etc. A common problem with series reactions appears in the production of polysubstituted compounds, where one often aims at producing an intermediate product, and not the completely substituted compound. An example is the production of diethanolamine (an important corrosion inhibitor), which is produced by ethoxylation of NH 3 : ( ) ( ) 2 3 side produ d 1 2 3 3 EtO Et t 2 main pro uc e t d O EtO ct sid pro uc HOEt HOEtNH HOEt N N NH H + + + ⎯⎯⎯→ ⎯⎯⎯→ ⎯⎯⎯→ . The reaction has to be quenched before the third step consumes significant amount of the desirable product, but after the second reaction did its job. Example 2-2. Analysis of series reactions in a batch reactor. Consider the following two reactions occurring in the same liquid mixture in a batch reactor: 1 2 A B 2C ⎯⎯→ ⎯⎯→ . (2-23) Analyse the evolution of the mixture composition, and optimize the reactor. Solution. The relationship between concentrations and yields, and between rates of production and reaction rates read: C A = C A0 V 1 , r A = r 1 ; C B = V 1 V 2 , r B = r 1 r 2 ; C C = 2 V 2 , r C = 2 r 2 ; (2-24) If the reactions are simple, the two rate laws read: ( ) 1 1 1 A 1 A0 1 d d V V r k C k C t = = = ; ( ) 2 2 2 B 2 1 2 d d V V V r k C k t = = = , (2-25) where we substituted the concentrations with the respective sum of yields from eq. (2-24). This results in two equations for the two unknown yields (i.e. the problem is formulated in terms of unknown ’s , cf. example 2-1 and eqs. (2-13) for unknown concentrations). The first of these equations is not different from eq. (1-38) for the single reaction A B, i.e. the second reaction B 2C does not affect the rate of the first one in any way. As a result, we can write immediately the solution for 1 just by changing indices in eq. (1-40): ( ) 1 1 A0 1 e k t V C = . (2-26) We substitute this result in the second eq. (2-25) ( ) 1 2 2 A0 2 2 d ( ) 1 e ( ) 0 d k t V V t k C k t t + = . (2-27) To integrate this equation, we observe that one fraction of the exp( k 1 t ) term can be moved under the differential to obtain the “high symmetry” form (i.e. a form that has similar expression under the differential and outside of it): ( ) ( ) 1 1 A0 2 ? 2 A0 2 ? d e e 0 d k t V k t V C c k C c t + = . (2-28) This is the same equation as (2-27). The value of the constant c ? we introduced is found by comparing (2-27) and (2-28) executing the differentiation in eq. (2-28), we obtain
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42 1 1 2 1 ? 2 A0 2 ? 2 2 d e e 0 d k t k t V V k c k C k c k t + + = . This is equivalent to eq. (2-27) when 1 1 1 2 2 A0 1 ? 2 ? ? A0 2 1 e e e k t k t k t k k C k c k c c C k k = = . We finally substitute c ? back in eq. (2-28), which is then easily solved by separation of variables: 1 2 A0 2 A0 2 1 2 2 A0 A0 2 1 e ln k t V k C C k k k t k C C k k  = − . The resulting algebraic equation is finally solved for V 2 , 1 2 2 1 2 A0 2 1 2 1 1 e e k t k t V k k C k k k k = + . (2-29) The evolution of the concentrations of A, B, and C with time is obtained by substituting the two yields (2-26) and (2-29) into eqs. (2-24): 1 A A0 e k t C C = ; 1 2 B 1 A0 2 1 e e k t k t C k C k k = ; C C = 2 V 2 . (2-30) Fig. 8. Evolution of the yields of the two series reactions (left) and the concentrations of A, B, and C (right). Liquid phase, batch reactor; k 1 = 0.4 h -1 , k 2 = 0.15 h -1 , C A0 = 1 M. An important feature of consecutive reactions is that the concentration of the intermediates passes through a maximum. To find the position of this maximum, we use that there d C B /d t = r B = r 1 r 2 = 0, i.e. k 1 C A = k 2 C B . This is an equation for t : 1 2 1 1 2 collecting the exponents ln... and solve for 1 A0 1 2 A0 1 2 2 1 e e e e e k t k t k t k t k t t k C k k C k k k k = ⎯⎯⎯⎯⎯⎯⎯→ = ⎯⎯⎯⎯⎯⎯→ 2 max 2 1 1 1 ln k t k k k = . (2-31) The time to reach the maximum of the intermediate product is often called the induction time of the second reaction , as at this point the rate of the second reaction ( r 2 = k 2 C B ) reaches a maximum together with C B . Note that t max is independent of the concentration; this is the case when the reactions are of the 1 st order only. The only practical way to accelerate or decelerate the induction in this case is by altering temperature. The respective optimal conversion to B is obtained by substituting eq. (2-31) back into C B ( t ) from eq. (2-30): C i [M] t [h] B t [h] i [M]
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43 ( ) ( ) ( ) ( ) 1 2 1 2 2 1 / / B,max 1 2 1 2 B,max 1 A0 2 1 / / k k k k k k C k k k k X k C k k = = . (2-32) If B is the desired product, this quantity will be independent of C A0 again, a feature of 1 st -order reactions only. X B,max depends on the temperature, however, and eq. (2-32) and variants of it are often use to optimize the temperature of a reactor. Example 2-3. Series reactions in a CSTR. Consider the same two reactions as in the previous example, A B 2C, but in a CSTR. Optimize. The mole balances in this case are given by eq. (1-72), and read A A0 A 1 F F Vr Vr = = − ; ( ) B B 1 2 F Vr V r r = = ; C C 2 2 F Vr Vr = = . (2-33) Substituting here F i with vC i (volumetric flow rate times concentration), V with v (volumetric flow rate times space-time of the reactor), and r j with the respective rate laws ( r 1 = k 1 C A , r 2 = k 2 C B ), we obtain: A A0 1 A C C k C = − ; B 1 A 2 B C k C k C = ; C 2 B 2 C k C = . (2-34) These are three algebraic equations for the three unknown concentrations: C A , C B and C C . We first solve the first equation for C A ; then C A is substituted in the second equation, which is then solved for C B ; the solution for C B goes into the third equation and we solve that one for C C . The result is: A0 A 1 1 C C k = + ; A0 1 B 2 1 1 1 C k C k k = + + ; A0 1 C 2 2 1 2 1 1 C k C k k k = + + . (2-35) These equations determine how the product composition changes with the volume of the reactor and the inflow rate. The results are plotted in Fig. 9.
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44 Fig. 9. Dependence of the concentrations of A, B and C on the space-time of a CSTR (A B 2C); k 1 = 0.4 h -1 , k 2 = 0.15 h -1 , C A0 = 1 M. If the mixture ’s residence time in the reactor is too long, B will react to form C; on the opposite, if the space-time is too small, the reagent A will be unable to produce much B. Therefore, there exist a space-time that maximizes C B , as evident in Fig. 9. To determine it, we need to find the maximum of C B ( ). To make our life easier, we can instead minimize 1/ C B , as it is simpler to differentiate: ( ) 2 1 2 1 1 2 B 1 2 2 1 A0 1 A0 1 A0 1 d d 1 d d k k k k C k k k C k C k C + + + = = − + . (2-36) This is equal to 0 when max 1 2 1/ k k = . (2-37) The respective value of C B is ( ) 2 B,opt A0 2 1 / 1 / C C k k = + . (2-38) 2.2 Many reactions in a batch, PF or CST reactor Let us assume you know the mechanism of a reaction, and you want to choose the best reactor for it. The 3 abilities that this module is supposed to teach you are: (stage 1) to formulate the problem for predicting the outcome of a reaction given the chemical mechanism and the reactor characteristics i.e. write down all the governing equations; (stage 2) to solve the formulated problem, using approximations where required, with appropriate analytic or numerical methods, and put the solution in a form one can operate with; (stage 3) to know what to do with the solution , how to use it to choose or optimize a reactor. We will now demonstrate the technique behind step 1, the formulation of the chemical kinetic problem for composition evolution with multiple reactions in the mixture, using an example. (i) You would normally start with a reaction scheme . Consider the following set of reactions taking place in a batch reactor: 1 2 A B 2C 2D E ⎯⎯→ + ⎯⎯→ + ⎯⎯ ; 3 C E F + ⎯⎯→ ; 4 5 1 H 3F G 2B 2 ⎯⎯ ⎯⎯→ + . (2-39) In real-world problems, it is you who has to come up with an idea of what the important reactions are in the mixture you study, under the conditions you study, and also to collect the C i [M] [h] B
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45 parameters you need (but this is the subject of another module). Here, we focus on what to do with the scheme once it is there. (ii) Elementary reactions and rate laws. For each elementary step in your scheme (2-39), write down the rate law: (1) A + B 2C: r 1 = V 1 d 1 /d t = k 1f C A C B k 1r C C 2 ; (2) 2C 2D + E: r 2 = V 1 d 2 /d t = k 2 C C 2 ; (3) C + E F: r 3 = V 1 d 3 /d t = k 3 C C C E ; (4) 3F ½H: r 4 = V 1 d 4 /d t = k 4 C F 3 ; (5) 3F G + 2B: r 5 = V 1 d 5 /d t = k 5 C F 3 . (2-40) The last two steps are unlikely to be elementary reactions (why?) ; still, we assume they are simple reactions. One note aside: in reaction schemes, it is often the case that some of the steps have a multistage mechanism themselves. Such reactions would follow, accordingly, a complex rate law e.g., you might know empirically that reaction 3 actually follows rate law r 3 = k 3 C C /( K 3 + C E ) under controlled laboratory conditions, suggesting that reactive intermediates are formed from the component C + E before producing the “end” product F. It is always dangerous to apply a complex laboratory rate law to the real reactor the reactive intermediate is a high-energy molecule that, by definition of “reactive” , can react with many of the species present in the real mixture. As a result, the empirical rate law determined in a laboratory mixture of C + E might alter significantly in the reactor mixture of A + B + C + E. (iii) Relate the concentration of each component to the five reaction yields: n A = n A0 1 ; n B = n B0 1 + 2 5 ; n C = n C0 + 2 1 2 2 3 ; n D = n D0 + 2 2 ; n E = n E0 + 2 3 ; n F = n F0 + 3 3 4 3 5 ; n G = n G0 + 5 ; n H = n H0 + ½ 4 ; general formula: n i = n i 0 + j ji j , (2-41) where v ji is the stoichiometric coefficient of the i th component in the j th reaction. For constant volume conditions (e.g., bomb reactor or liquid phase reactions), the respective concentrations are simply C i = n i / V . (2-42) However, for gas reaction proceeding under constant pressure, the dilution factor has to be accounted for. If the ideal gas equation is valid, then the concentrations are given by i i n p C n RT = , (2-43) where n are the total moles in the system, 0 4 0 0 2 3 ν Δν i i ji j i j j i i j i j n n n n n = = + = + = + . (2-44) The factors  j are the sums of the stoichiometric coefficients for the j th reaction (  1 =  1 i = 0,  2 =  2 i = +1,  3 =  3 i = 1 etc.). Both eqs. (2-42) and (2-43) are valid also for time- dependent p and V (but are not immediately leading to explicit ready-to-solve equations in this case). (iv) Formulation of the ODE problem for j . The substitution of eqs. (2-42) or (2-43) in eq. (2-40), with n i given by eq. (2-41), yields a system of 5 ODEs for the five unknown
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46 functions j ( t ). The initial conditions for these ODEs are j (0) = 0, j = 1…5 . For example, for an isochoric reaction, the first equation (2-40) in explicit form is ( )( ) ( ) A 1 2 2 2 0 1 B0 1 5 2 C0 1 2 3 C A 2 B 1f 1r 2 1f 1r d 1 2 2 – 2 d n n t n n n n k V V V V k V k k + + = = , or using concentrations instead of moles, ( )( ) ( ) 2 1f A0 1 B0 1 5 1 0 1 1 r C 2 3 2 2 d d 2 V V V V V V V k C C k t C + + = . (2-45) The other 4 explicit equations are written similarly. (v) Formulation of the ODE problem for the unknown functions C i ( t ). Differentiation of eqs. (2-41) with respect to t and subsequent substitution of the rate laws (2-40) leads to: d n A /d t = Vr 1 V 1 d( VC A )/d t = k 1f C A C B + k 1r C C 2 ; d n B /d t = V ( r 1 + 2 r 5 ) V 1 d( VC B )/d t = k 1f C A C B + k 1r C C 2 + 2 k 5 C F 3 ; d n C /d t = V (2 r 1 2 r 2 r 3 ) V 1 d( VC C )/d t = 2 k 1f C A C B 2 k 1r C C 2 k 2 C C 2 k 3 C C C E (2-46) and likewise for D, E, F, G and H. The result is a system of 8 ODEs for 8 unknown concentrations. Another equation is required for V (e.g., V = const for isochoric or V = nRT / p for isobaric reactions). Initial conditions: C i (0) = C i 0 , i = 1…8. (vi) A very similar formulation is used for PFR. Limiting ourselves to the case of constant volume processes, one only has to change the derivatives of the batch reactor formulation following the rules d d d d Vj Vj t ⎯⎯→ for the j -formulation (2-45), d d d d i i C C t ⎯⎯→ for the C i -formulation (2-46), where is the space-time of the reactor ( = V / v ). If the density of the gas changes along the length of the PFR, we have to use the generalization of eq. (1-65) to multiple reactions: ( ) d d ν d d i i i ji j vC F r r V V = = = ; (2-47) here, r i is the production rate of i , and r j are the rates of all reactions according to, e.g., the mass action law. An additional equation is needed to define v ( t ). (vii) For CSTR, we can again easily obtain the governing equations from the batch reactor formulation, by applying the rules d d Vj Vj t ⎯⎯→ for the j -formulation (2-45), 0 d d i i i C C C t ⎯⎯→ for the C i -formulation (2-46), Thus, in CSTR of a given space-time, the equations that determine the concentrations are ( C A C A0 )/ = k 1f C A C B + k 1r C C 2 ; ( C B C B0 )/ = k 1f C A C B + k 1r C C 2 + 2 k 5 C F 3 ; ( C C C C0 )/ = 2 k 1f C A C B 2 k 1r C C 2 k 2 C C 2 k 3 C C C E …, compare to eqs. (2-46). (viii) Matrix representation. For more complicated reaction mechanisms (fancy name complex reaction networks ), the setup of the problem becomes increasingly cumbersome. Consider a mixture of n species with m possible reactions. The j th reaction is
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47 ν Ψ 0 ji i = , where i is the i th component. The reaction is fully characterized just by the vector of the stoichiometric coefficients { j } = ( j 1 , j 2 , …, jn ); all vectors comprise an m n matrix { ji }. The mass action law that corresponds to this matrix is: ν i 1 d 1 d ji n j j i k C V t = = , or in matrix representation { ν} = -1 k r C ln . Relationship between C i and j : 0 1 ν m i i ji j j n n = = + , or 0 { ν} = + n n ξ . Read more Fogler’s ch. 8 [ 2]; Levenspiel’s ch. 7 & 8 [ 1]; Schmidt’s ch. 4 [ 14]. Supafastquiz Can 20 be a value for the overall selectivity S DU of a process? Can 20 be a value for the instantaneous yield y D ? Or for the desirable conversion? The 1 st order reaction A D produces a desirable product. In parallel, the 0 th order reaction A U produces a side product. To dilute or not to dilute? Three methods for dilution/concentrating the mixture? The chlorination of methane is multi-staged: 2 2 2 2 1 2 3 4 4 3 2 2 3 4 Cl Cl Cl Cl CH CH Cl CH Cl CHCl CCl + + + + ⎯⎯⎯→ ⎯⎯⎯→ ⎯⎯⎯→ ⎯⎯⎯→ . Correct the following statements: a) In a batch reactor, [CH 3 Cl] increases monotonously with time. b) In a PFR, [CH 4 ] drops with time. c) In a CSTR, [CCl 4 ] passes through a maximum as feed flow rate increases. d) The induction times of the second and the third reactions are equal. e) If chloroform, CHCl 3 , is the desired product, then CH 2 Cl 2 is a by-product. Problems 1. Easy questions a) Consider a gaseous mixture of N 2 , O 2 , NO and NO 2 . How many reactions can you write between these components? How many of these are independent? Write the stoichiometric coefficients of the reactions in a table, with four columns (one per component) and several rows (one per independent reaction). This table is the stoichiometry matrix ji of your mixture. b) Identify the side products and the by-products of the synthesis of D from A and B for the following scheme: 2A B + 2C; 2B + C D + B;
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48 A + C E. What are the overall reactions? Can you distinguish between intermediate side products and side products proper ? c) Identify the side products and the by-products of the synthesis of D from A: A B + 2B 0; − A B + 2C + D 0; C A + D + E 0. 2. Maximum yield of multiple irreversible reactions a) Consider two irreversible reactions taking place simultaneously: eq 1 : 2A B; eq 2 : A + 2B C. Assume that the initial amount of A is n A0 . Can you predict the final state of the mixture? Solution: in this case, there are two reaction yields, 1 and 2 , or after the end of both reactions, 1∞ and 2∞ . The moles of A, B and C are related to them if 1∞ moles of the 1 st reaction and 2∞ of the 2 nd took place, then the composition of the mixture will be n A∞ = n A0 2 1∞ 2∞ ; n B∞ = 1∞ 2 2∞ ; n C∞ = 2∞ . There are two yields that specify the final compositions, and we need two equations to define them. One is obviously the condition for the limiting component A, so the first equation we need is n A∞ = 0, i.e. n A0 2 1∞ 2∞ = 0. (2-48) C is obviously not limiting, but can B be limiting? The answer is, not always. If the 1 st reaction is much faster than the second one, it will consume the whole A quickly and, in the absence of A, the second reaction will produce only a minor amount of C. In this case, 1∞ >> 2∞ , and the product will be B, of amount n A0 /2; n C will be close to zero. On the other hand, if the second reaction is very fast, then B reacts as soon as it is formed so it never accumulates in large quantities (it is a reactive intermediate ); in such case, it can be treated as a limiting component, leading to the condition 1∞ = 2 2∞ . Substituting this in eq. (2-48), we obtain 2∞ = n A0 /5; therefore 1∞ = 2 n A0 /5, and n C∞ = n A0 /5. b) Consider two irreversible reactions taking place simultaneously in a solution: eq 1 : 3A 2B; eq 2 : 3B 2C + A. Assume that the initial concentration of A is [A] 0 . Predict the final state of the mixture. c) Acetone, CH 3 COCH 3 , is sometimes used as fuel and fuel blend. Consider the incomplete combustion of acetone. If the initial mixture is [acetone]:[O 2 ] = 1:3, then acetone is in excess and the products will be CO 2 , CO and H 2 O. Find the fraction of each product in the exhaust. Ans. 1:3:2 CO 2 :H 2 O:CO. 3. Equilibrium yield of multiple liquid-phase reactions a) The following reversible reactions take place in a batch reaction: A B, K 1 = 0.5; 2A C + D, K 2 = 0.1, st. state 1 M. The initial concentration of A is [A] 0 . Find the equilibrium composition of the mixture. 4. Equilibrium yield of multiple gas-phase reactions
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49 a) Syngas is one of the most important products in chemical industry, and is used to synthesize a long list of materials. It is produced from natural gas: CH 4 + H 2 O → CO + 3H 2 . One particularly important application is production of methanol via the reaction: 1: CO(G) + 2H 2 (G) CH 3 OH(G), at 50 atm and 250 °C, in the presence of catalyst (a mixture of Cu and Zn oxides). However, the syngas is 1:3 CO:H 2 , so the hydrogen is in excess. Therefore, CO 2 is injected in the syngas to convert the excess hydrogen to some more methanol: 2: CO 2 (G) + 3H 2 (G) CH 3 OH(G)+H 2 O(G). At 250 °C, the equilibrium constants of this to processes are K 1 = 9400 and K 2 = 0.22 (st. state 1 atm). Assume the initial mixture is stoichiometric syngas + CO 2 . Find the equilibrium composition and the two conversions of the two reactions. The process is isobaric. b) Vinyl chloride is used in large quantities to produce polyvinyl chloride, PVC. It is made from 1,2-dichloroethane (which on its turn is produced by C 2 H 6 and Cl 2 ) via the elimination reaction: 1: ClCH 2 CH 2 Cl CH 2 =CHCl + HCl, usually under 500 °C and 1.5 MPa. However, there are several side reactions that can affect the yield, among them another dehydrohalogenation step to ethyne (acetylene): 2: CH 2 =CHCl CH≡CH + HCl, and hydrohalogenation of the vinyl chloride to 1,1-dichloroethane, 3: CH 2 =CHCl + HCl CH 3 CHCl 2 . At 500 °C, the equilibrium constants of these three processes are K 1 = 680, K 2 = 1.56, and K 3 = 0.0013 (standard state 10 5 Pa = 1 bar). Find 1 , 2 and 3 for n 0 (ClCH 2 CH 2 Cl) = 1 mol. What is the composition of the mixture upon reaching equilibrium? Which is the main side product, which is the by-product? How will the conversion to vinyl chloride change if pressure is increased to 30 MPa? 5. Selectivity and stoichiometric coefficients a) One mole of A underwent the parallel reactions 2A B and 3A 2C. As a result, 0.33 moles of B and 0.02 moles of C have been formed. What is the overall selectivity S BC achieved, and what is the overall yield fraction Y B ? b) One mole of A underwent the consecutive reactions 2A 3B and 2B 3C. As a result, 1.1 moles of B and 0.13 moles of C have been formed. What is the overall selectivity S BC achieved, and what is the overall yield fraction Y B ? 6. Selectivity for consecutive reactions Using the results from examples 2-2 and 2-3, show that the selectivity C B / C C under optimal conditions is always greater for an isothermal batch reactor than for isothermal CSTR. 7. Instantaneous selectivity and Trambouze reactions Consider the following reaction scheme (Fogler [2], p. 287): B is the desirable product. The three reactions follow three different rate laws: A X Y 1 3 2 B
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50 r 1 = const (zero-order reaction); r 2 = k 2 C A ; 2 3 3 A r k C = . (2-49) Parameters: r 1 = 0.0001 M/s, k 2 = 0.0015 1/s, and k 3 = 0.008 1/sM at 350 °C. The activation energies of the three processes are 40, 60 and 80 kJ/mol. a) Optimize the instantaneous selectivity s B/XY = r 2 /( r 1 + r 3 ) with respect to the concentration of A. b) Let A enter a CSTR at flow rate of 0.8 mol/s (molar) and 2 L/s (volume). What is the optimal volume of the reactor? c) Assume that a CSTR is operated at the optimal concentration C A,opt that maximizes s B/XY . Optimize s B/XY with respect to temperature. d) Qualitatively, how can the conversion be increased while the selectivity is kept high? 8. on paper Formulation of a chemical kinetic problem batch reactors a) Invent your own scheme having 4 reactions in a 7-component system, similar to eq. (2-39). Let it have branching, series and reversible reactions, and let it have various stoichiometric coefficients. Avoid physically impossible reactions (A B 2A cannot be, as it allows production of A from nothing). b) Write down the relationships between yields j and amounts of substance n i of each component. Assume that the mixture is gaseous and ideal and the processes proceed isobarically; express the concentrations C i with j . c) Write down the relationship between rates of production r i and rates of the reactions r j . d) Write down the rate laws; assume that 2 of your reactions are simple (including a reversible step); for the other 2, choose a rate law of your choice. e) Write the explicit 4 differential equations for the yields j . f) Write the explicit 7 differential equations for the amounts n i . g*) Maple Try to solve this system of ODEs numerically using Maple’s dsolve(..., numeric) (for parameters values between 0.5 and 2 for k and n i 0 of the reagents, in whatever units as long as they are self-consistent; n i 0 = 0 for the products, including the intermediates; 1 atm, 300 K). 9. on paper Formulation of a chemical kinetic problem CSTR a) is the same as 8a). b) Write down the relationship between rates of production r i and rates of the reactions r j . c) Write the rate laws; assume that 2 of your reactions are simple; for the other 2, choose a rate law of your choice. d) Write the mole balances for the 7 components, as 7 explicit equations for the 7 unknown concentrations C i . e*) Maple Try to solve this system of algebraic equations numerically using Maple’s fsolve (for parameter values between 0.5 and 2 for k and F i 0 of the reagents, in whatever units; F i 0 = 0 for the products and the intermediates). 10. Series reactions in PFR 55 The following liquid-phase process takes place in a PFR: 1 2 A 2B 3/2 C ⎯⎯→ ⎯⎯→ . (2-50) The first reaction is simple, but the second one is of the 0 th order (not second!), i.e. r 2 = k 2 . a) Analyse the evolution of the mixture along the length of the reactor.
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51 b) If B is the desired product, what space-time of the reactor will optimize the yield (this is also the induction time)? What is the maximum conversion? What is the overall selectivity of B with respect to C at the optimal space time? c) Plot the concentration profiles until the point where [B] = 0. Parameters: k 1 = 1.1 min -1 ; k 2 = 0.2 M·min -1 ; [A] 0 = 0.4 M. 11. Parallel reactions in CSTR 55 The following reactions take place in a CSTR: 1 A 3/2 B ⎯⎯→ ; 2 A 1/2 C ⎯⎯→ . (2-51) The first one follows the rate law r 1 = k 1 [A] 1/2 (i.e. it is not 1 st -order!); the second one is simple. a) Analyse the dependence of the composition of the reactor on its space-time . b) B is the desired product. What space-time corresponds to desirable conversion of 90%? What is the undesirable conversion under these conditions? c) Plot the dependence of the composition on the space-time of the reactor. Use units minutes for the space-time axis. d) The undesired product C has a maximum as a function of . Find its position and magnitude, and mark it on the plot. Parameters: k 1 = 8.1×10 -4 M 1/2 s -1 ; k 2 = 6.6×10 -4 s -1 ; [A] 0 = 0.45 M. 12. Consider the reaction mechanism 1 A 2B ⎯⎯→ ; 2 A B 2C + ⎯⎯→ . These reactions take place in a CSTR. The feed contains A only, of concentration [A] 0 . a) Find [A], [B] and [C] in the reactor as function of the reactor space-time . b) Find the selectivity S BC and the yield ratios Y B and Y C . How are S BC and Y B affected by the temperature of the mixture and the residence time ? c) B is the desired product, and the specific production rate F B V = v [B]/ V has to be maximized. What is the selectivity at the optimal residence time? 13. Using concentration vs. time data to determine the rate laws in a complex mixture relation (C), batch and CSTR 14. Packed bed reactor E2-1 par 2A B, 2A 3C (L) B E2-2 ser A B 2C (L) B E2-3 ser A B 2C (L) CST
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52 3 Reaction mechanisms and reactive intermediates Your job is to: fundamentals connect a mechanism to a non-simple (overall) rate law, apply pseudo-steady state and quick equilibrium approximations; skills figure out a rate law for the reaction you engineer; extras revise radical and S N &E chain reactions, say hi to initiation and termination and understand the role of light/ultrasound/walls in it. A simple reaction is a rare occasion in real-life chemical processes; even more so an elementary rate law. Nearly all reactions in nature and technology follow instead a complex mechanism and rate laws of non-integer and negative powers. For example, the decomposition of acetaldehyde at 500 °C proceeds according to the following chemical equation: CH 3 CHO CH 4 + CO. (3-1) Were this a kinetic equation, it would suggest a 1 st -order process. However, the experimental order of this reaction is 3/2, r = k [CH 3 CHO] 3/2 . (3-2) This expression is obviously not an elementary mass action law as there is no way 1.5 molecules to collide in the elementary act of the reaction. Such unusual dependences indicate a complex multi-stage process involving active intermediates high-energy molecules that react with much higher probability than the actual reagents. 3.1 Active intermediates An active intermediate is one that, once formed, reacts very quickly . For example, consider the schematic process: d d f [C*] A B C* products r k r = + ⎯⎯→ ⎯⎯⎯⎯→ , including f ormation of C* with rate r f and d ecomposition of the reactive intermediate with rate r d . By “ very quickly ” we mean that in the mole balance f d d[C*] [C*] d r k t = (3-3) the rate constant k d is so large that k d [C*] >> |d[C*]/d t |. Let us formulate the above equation in terms of an order-of-magnitude balance . If the concentration [C*] is a monotonous function of t , the derivative d[C*]/d t is of the order of [C*]/ t , which we write as d[C*]/d t ~ [C*]/ t (this relation becomes an equality if [C*] drops linearly with time to zero). Eq. (3-3) corresponds then to the following order-of-magnitude equation : f d [C*] ~ [C*] r k t . There is one large number in this balance: k d (according to the definition of an active species). It is either the 1 st or the 2 nd term, [C*]/ t or r f , that compensates for the k d [C*] so that the equation is fulfilled. However, [C*]/ t ~ k d [C*] is possible only if t ~ 1/ k d , and for a reactive radical 1/ k d can be of the order of ns- s, while for an unstable activated complex it can go down to femtoseconds. This means that 10 s after the beginning of the reaction, t >> 1/ k d will hold and d[C*]/d t will be negligibly small compared to k d [C*]. Neglecting d[C*]/d t is called the quasi- steady (or pseudo- , or - stationary ) approximation : f d 0 [C*] r k = [C*] = r f / k d . (3-4)
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53 In many textbooks, a formulation of the quasi-steady state can be found as time-independence of [C*] which still agrees with d[C*]/d t = 0. This is, however, incorrect. Actually, since both r f and k d in eq. (3-4) are usually time dependent, we will often plot [C*] as a function of t . What the pseudo-steady approximation says is that, although [C*] is a function of t , the derivative d[C*]/d t is small compared to k d [C*] a couple of milliseconds after the start of the reaction, i.e. this is an approximation for high reactivity, not for constant [C*]. The time dependence of [C*] is the reason why the approximation is called quasi- steady (instead of just steady). Often, the mechanism of reactions involving reactive intermediates proceeds in three distinct stages. First, there is a slow formation of active intermediates ( initiation , A A*). Second, A* wreaks havoc in its immediate surroundings via several consecutive reactions, each of which has as a product another reactive intermediate ( chain propagation , e.g., A* + B C + D*, D* E + F* etc.; note how energy the * is transferred from one particle to another). Finally, the reactive species recombine or dissipate their energy to form stable molecules ( chain termination 2F* E or quenching F* + X F + X). Nature of the reactive intermediates and ways to study them. The active intermediate can be simply a highly energetic molecule (at the high-energy end of the Maxwell distribution, or produced by non-Maxwellian collisions e.g., by radiation); or an active complex; a radical; a reactive ion. The reactive intermediates are of very low concentration (since k d in eq. (3-4) is large) and can be detected experimentally only in special cases, such as: - when they are luminescent . Unfortunately, these are exceptional cases. - Even very short-lived radicals can be detected with electron spin resonance spectroscopy (should have been a Nobel Prize for Yevgeny Zavoisky 11 ). - Ultrafast laser pump-probe pulse spectroscopy. In this technique, first, a large amount of reactive species is formed by a pump laser pulse that excites (or even breaks into pieces) the studied molecules. Second, their decay is detected by a follow-up probe pulse some femtoseconds later (Nobel Prize in chemistry for Ahmed Zewail 12 , 1999). The pulse corresponds to a large value of the formation rate r f for a short period of time; the detection stage takes place before the pseudo-steady state is established. Example 3-1. The active particle can be a molecule at the high-energy end of the Maxwell distribution. One known case of such mechanism is the decomposition of azomethane 13 : 2 2 3 2 2 3 3 2 Me N (CH ) N CH CH N + . (3-5) The process has two stages (1) a formation of activated azomethane and (2) its decomposition: 1 * 2 2 2 2 2 2 2Me N Me N Me N ⎯⎯→ + ⎯⎯ , 2 * 1 1f 2 2 1r 2 2 2 2 [Me N ] [Me N ][Me N ] r k k = ; 2 * 2 2 2 6 2 Me N C H +N ⎯⎯→ , * 2 2 2 2 [Me N ] r k = . (3-6) Find the overall rate law for the process (3-5). Solution. Let us write the mole balances for the products. The balance for the activated Me 2 N 2 can be simplified as the quasi-stationary approximation holds: * 2 2 d[Me N ] d t 1 2 r r = 2 * 1f 2 2 2 2 1r 2 2 2 [Me N ] [Me N ] [Me N ] k k k = + . (3-7) We used eqs. (3-6) for r 1 and r 2 . We can then write the rate law of ethane production as: 11 /jev ˈ geni z ʌˈ v ɔ iski:/ 12 / ˈæħmæd zeˈweːl / 13 better /æz əʊ -/, although /eiz əʊ -/ is more common
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54 2 2 6 1f 2 2 2 1r 2 2 2 d[C H ] [Me N ] d 1 [Me N ] k r k t k = = + . (3-8) The result is due to Lindemann [7]. In a very dilute gas ( p < 7 kPa), the concentration in the denominator is small and eq. (3-8) simplifies to r 2 = k 1f [Me 2 N 2 ] 2 = r 1f (i.e. the overall rate is the rate of the rate-determining process 1; r 1r is small). For high pressure/concentration ( p > 100 kPa), the concentration term in the denominator of eqs. (3-7)-(3-8) dominates; then [Me 2 N 2 * ] is at its equilibrium value, [Me 2 N 2 * ] = k 1f [Me 2 N 2 ]/ k 1r = K 1 [Me 2 N 2 ], and d[C 2 H 6 ]/d t = k 2 K 1 [Me 2 N 2 ] i.e. reaction 1 is quick so transient equilibrium is established, while the second process is slow and rate-determining (and slowly alters the composition of the mixture, together with the location of the transient equilibrium 1). The pressure dependence predicted by eq. (3-8) holds true for many gas-phase reactions involving intrinsically unstable molecules such as azomethane. Strictly, the activated particles in example 3-1 are just the unstable high-energy fraction of the Maxwell distribution of the Me 2 N 2 molecules. Were the Maxwell distribution valid, the fraction of molecules with energy above a certain threshold a would be ( ) a B a B B a / / 1/2 a B a 3/2 B a B 2 2 ( ) e d e π π k T k T k T k T P k T k T  + = ⎯⎯⎯⎯→ . Here, = mv 2 /2 is the kinetic energy of the molecule, and k B is Boltzmann’s 14 constant. Therefore, the equilibrium concentration of activated molecules having energy above a is [A*] eq = P ( > a )×[A], i.e. K 1 = k 1f / k 1r = P ( > a ). The parameters k 1f and k 2f determine how quickly an ensemble of molecules relaxes to equilibrium Maxwellian distribution. The characteristic time of this relaxation is the mean time between two collisions, ~ m 1/2 R vdW 2 k B 1/2 T 1/2 / p , where R vdW is the van der Waals radius of the molecule. This time increases with the decrease in pressure p , and for pressures low enough it starts to control the overall rate of the chemical reaction. Fig. 10. Schematic Maxwell distribution of the kinetic energies of the molecules in a material. The shaded area corresponds to the equilibrium constant K 1 . If a reaction consumes high-energy molecules, it may disturb the equilibrium distribution (the red line). 14 / ˈbɔl tsman/ [mol/kJ] [kJ/mol] a an out-of-equilibrium drop due to the reaction
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55 3.2 Rate of the overall process To find the evolution of the mixture composition with time, we will follow the algorithm developed in the previous chapter, sec. 2.2, with the quasi-stationary approximation for all reactive intermediates. Example 3-2: the reactive intermediates are radicals . There are several oxidative radical chain reactions of extreme importance to human life among them combustion, DNA oxidation, and a large number of industrial processes. The typical features of the low- temperature autoxidation (open-air oxidation of organic matter with formation of peroxides) can be illustrated with the oxidation of liquid isobutane, (CH 3 ) 3 CH, or RH for short, in the presence of air and diisobutyl peroxide, (CH 3 ) 3 COOC(CH 3 ) 3 , or i 2 for short. The process proceeds in three stages: initia- i 2 ½i i ⎯⎯→  , i r const = ; tion ia i RH iH+R + ⎯⎯→ , ia ia [i ][RH] r k = ; propagation o 2 2 R O RO + ⎯⎯→ , o o 2 [R ][O ] r k = ; loop a 2 2 RO RH RO H R + ⎯⎯→ + , a a 2 [RO ][RH] r k = ; termination t 2 2 2 2RO i O  ⎯⎯→ + , 2 t t 2 [RO ] r k = . (3-9) The initiation rate is proportional to [i 2 ], r i = k i [i 2 ], but it is usual to use r i as variable. In the initiation stage , the peroxide i 2 decomposes to produce the active alkoxy radicals (CH 3 ) 3 CO· for which we use the symbol . These are extremely reactive and attack the most abundant molecule, RH, abstracting the hydrogen from the weakest CH bond of the isobutane (the ternary one). Two reactions, o xidation and a bstraction of hydrogen, repeat several times during the propagation stage . First, the alkyl radical R· reacts readily with the oxygen present (why not with RH?) , reaction o , forming alkylperoxyl radical RO 2 ·. RO 2 · abstracts another hydrogen from the isobutane and returns the radical chain to R·. The propagation continues until two radicals meet and recombine in a t ermination reaction. Solution: the reactions (3-9) follow simple rate laws (although the first and the last are actually multi-staged). We first write the mole balances for production of each reactive species using the approach from sec. 2.2. Reactive intermediates: d[i ]/ d t i ia r r = ; d[R ]/ d t ia o a r r r = + ; 2 d[RO ]/ d t o a t 2 r r r = . (3-10) Together with the rate laws (3-9), these provide 3 linear equations for the concentrations of the 3 reactive intermediates. The quickest way to solve them is eq. (3-10) /i· ia i i ia [i ] / [RH] r r r k =  = ; eq. (3-10)/ + R·+ RO 2 · i t 2 i t 2 [RO ] / 2 r r r k =  = ; eq. (3-10) /R· a i i i o a o 2 o 2 t [RH] [R ] [O ] [O ] 2 k r r r r r k k k =  = + . (3-11) The equation r i = 2 r t is a noteworthy one. All reactions apart from the initiation and the termination conserve the number of radicals (produce as many radicals as are consumed). Therefore, r i = 2 r t is simply what is left from the mole balance for the total number of radicals in the system:
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56 ( ) 2 i t d [i ] [R ] [RO ] d[radicals] 2 d d r r t t  +  + = = . Of course, the quasi-steady approximation holds true for the sum of the radicals as well as for each radical, so d[radicals]/d t can be neglected in this balance. This equation is of quite general validity. We continue with the mole balances of all of the remaining species involved in the process (3-9) relatively stable: 2 i t d[i ]/ d / 2 0 t r r = − + = ; ia d[iH] d r t = ; 2 a d[RO H]/ d t r = ; 2 o t d[O ]/ d t r r = − + ; ia a d[RH]/ d t r r = − . (3-12) From the 1 st equation it follows that the process restores the initiator i 2 , and its concentration does not change with time therefore, i 2 is acting as a catalyst ; this is not a general result, however. The hydrocarbon RH is in great excess (liquid isobutane is ~5 M, compared to ~10 mM O 2 ) so we can assume [RH] = [RH] 0 while integrating the rate laws. The explicit rate of consumption of oxygen is obtained by substitution of eqs. (3-11) in the fourth eq. (3-12): 2 i i i i a 2 2 0 a t t d[O ] [RH] [O ] [O ] [RH] d 2 2 2 2 r r r r k k t t k k = − = + . (3-13) This is the most important result from our computations, because (i) the oxygen is very easy to monitor and thus we can use the formula to test our mechanism against data; and (ii) the oxygen consumed is a straightforward characteristic of the extent of the oxidation process. The rate of oxygen consumption follows a 0 th order rate law, which is rather non-intuitive: oxidation does not depend on [O 2 ]?! This means that even very small amount of O 2 will cause the same damage to organic matter, as long as the initiation rate is the same. Only at trace concentrations of O 2 will r O 2 drop to zero (see problem 5). The square root term is usually an order of magnitude higher than r i /2, so d[O 2 ]/d t ~ r i 1/2 is normally valid, not only for the considered initiator, but also for any other source of radicals (e.g., for initiation with UV radiation, d[O 2 ]/d t ~ I 1/2 ). Let us return to the second of eqs. (3-11) the balance for the total amount of radicals in the system, r i = 2 r t . It says that only initiation produces radicals, and the termination consumes them. Each initiator radical i· produces a radical chain (consecutive reactions that do not change the number of radicals in the system); each radical chain ends up with termination. The length of the radical chain is the number of hydrocarbon molecules reduced to R· per one i·; its average value is simply the rate of consumption of RH over the initiation rate: ia a a 2 a i i i t i [RO ][RH] [RH] d[RH] 1 1 d 2 V r r k k r r k r + = − = = + = + , (3-14) where we used eqs. (3-9) & (3-11) for r a & [RO 2 ·]. Thus, the length is inversely proportional to r i 1/2 : if the source of radicals is weak, the total radical density in the mixture will be small, so the rate of termination ( [radical] 2 ) will be small, and each radical has time to degrade RH before meeting another radical to recombine. On the opposite, if the radical source is very strong, the radical chain length will approach = 1, i.e., only one propagation step will occur to produce RO 2 ·, and it will immediately have plenty of other RO 2 · around to terminate. The real mechanism has several side reactions which can also be taken into account, see Fig. 11. When enough RO 2 H has accumulated, it can become an additional source of radicals. In addition, the alkoxy radical i· decay s to CH 3 COCH 3 and CH 3 ·, which produces CH 3 O 2 H. The latter process becomes an important route at increased temperature. At 100 °C and increased pressure, the rate of the initiation reaction ½ i 2 i follows rate law r i = k d [i 2 ] with k d = 0.0000816 min -1 . The second parameter of our kinetic model is the ratio
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57 k a /(2 k t ) 1/2 , which has the value 0.0176 min -1/2 M -1/2 . Note that the rate constants k a and k t are difficult to measure separately, so usually the ratio is used for characterization of the oxidation processes. From the density of the liquid isobutene, [RH] = 7.46 M. Eqs. (3-13)&(3-14) now allow us to determine the radical chain length and the rate of oxygen consumption: [i 2 ], mM r i = k d [i 2 ], mM/min , eq. (3-14) d[O 2 ]/d t , mM/h 0.5 0.0000408 651 -1.6 5 0.000408 207 -5.0 50 0.00408 66 -16.0 As can be seen, 100-fold increase in initiation rate causes approximately a 10-fold decrease in radical chain length and a 10-fold increase in rate of oxidation. C O O O 2 H O 2 O OH O + CH 3 O O O 2 H O + O H C C C Fig. 11. Mechanism of decomposition of isobutane. For brevity, only the carrier of the radical chain is given, except for the termination and initiation steps. 3.3 Quick equilibria Very often, there are reversible reactions in your mechanism that are so quick that the equilibrium condition is essentially fulfilled at all times. For example, most protolitic equilibria in aqueous solution are quickly established. Example 3-3. Consider the S N 1 reaction between ammonia and 2-bromomethylpropane, (CH 3 ) 3 C Br or RBr for short, which leads to tert -butylamine overall: (CH 3 ) 3 CBr + NH 3 (CH 3 ) 3 CNH 3 + + Br . (3-15) The reaction produces the protonated form of the amine. The process passes through a reactive intermediate the carbocation (CH 3 ) 3 C + . It takes place in a buffer solution that maintains the pH constant. The mechanism is: 1) (CH 3 ) 3 CBr (CH 3 ) 3 C + + Br , r 1 = k 1 ([RBr] [R + ][Br ]/ K 1 ); 2) (CH 3 ) 3 C + + NH 3 (CH 3 ) 3 CNH 3 + , r 2 = k 2 [R + ][NH 3 ]; 3) NH 4 + NH 3 + H + , r 3 = k 3 ([NH 4 + ] − N  + / K a ). (3-16) What is the effect of pH on the rate of this reaction, in view of the fact that the protonated form of the reagent NH 4 + is unreactive?
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58 Solution: the carbocation (CH 3 ) 3 C + is a reactive intermediate , therefore, 1 2 1 2 3 1 d[R ] [R ][Br ] 0 [RBr] [R ][NH ] 0 d r r k k t K + + + = = = 1 2 3 1 1 [RBr] [R ] [NH ] [Br ]/ k k k K + = + . The rate r of the overall process (3-15) must be equal to the rate r (RNH 3 + ) of production of RNH 3 + . From the mechanism, r (RNH 3 + ) = r 2 , i.e. 1 3 2 3 3 1 2 1 [RBr][NH ] [R ][NH ] [NH ] [Br ]/ k r k k k K + = = + . (3-17) The new concept here appears with the 3 rd process (3-16), a reversible protolytic reaction so quick that it leads to immediate equilibrium between NH 3 and NH 4 + , i.e. fast equilibrium: r 3 = 0, so [NH 3 ][H + ]/ N +  = K a , (3-18) where K a is the acidity constant of NH 4 + . The reaction results in deactivation of the ammonia since the concentration of the reactive form, [NH 3 ], is smaller than the total concentration of ammonia that we control, C amm = [NH 3 ] + [NH 4 + ]. From eq. (3-18), we find that N + = [NH 3 ][H + ] K a ; therefore, C amm = [NH 3 ] + [NH 3 ][H + ] K a amm 3 a [NH ] 1 [H ]/ C K + = + . Substituting this into the rate equation (3-17), we obtain the final result rate as a function of C amm , [RBr] and [H + ] (rather than rate vs. [NH 3 ] which we cannot control directly): amm 1 1 amm a 2 1 [RBr] [H ] 1 [Br ] C r k k C K k K + = + + . (3-19) A chemical engineer who designs a reactor normally wishes to maximize this rate. To do so, one can put a great excess of ammonia and keep [Br ] as low as possible this leads to C amm dominating in the denominator and r = k 1 [RBr] (i.e. (3-15) is a first order process; that is why we call it S N 1 ). In this case, the rate is completely independent of the ammonia concentration and the pH. On the other hand, a material scientist often wishes to stabilize a compound (probably not RBr in ammonia, but the principle is the same). In such case, you would keep r small either (i) by minimizing the ammonia concentration, or (ii) by dissolving excess of NaBr in the mixture to increase [Br ]. The second term in the denominator dominates then: ( ) 2 1 amm a [RBr] 1 [H ]/ [Br ] k K C r K + = + . (3-20) In this case, the stability of RBr will be strongly dependent on pH if you make [H + ] >> K a (i.e. pH < p K a ) the reaction rate will decrease dramatically. Of course, there is always a “but”. If pH approaches 1 -2, some low level of protonation of RBr appears, and RBrH + is very reactive… 3.4 Figuring out the mechanism from experimental data The detailed mechanism of the reaction is always of invaluable benefit to the chemical engineer knowing the mechanism means being able to control the process. Can we deduce the mechanism based on the rate law observed experimentally? The answer is no, not quite, as there are multiple mechanisms that lead to similar rate laws. What one usually does is to formulate several plausible possibilities based on sound chemical logic, and test which one
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59 agrees best with the experimental reaction rate data, and how reasonable are the values of the rate parameters. Yet, the empirical rate law gives important hints for the underlying mechanism. Some basic rules for proposing a mechanism based on empirical rate law are: Rule 1. If the concentration of a species S appears in the denominator of the rate law, the species probably collides with the active intermediate A* (there is an elementary step S + A* …). Rule 2. If the denominator is concentration-independent instead, the active intermediate probably decomposes spontaneously (A* …). Rule 3. If the concentration of a species S appears in the numerator, it probably produces the active intermediate (S A*). Rule 4. [S] to the power of ½ indicates a 2 nd order termination (2A* B) between active species that originate from S. Rule 5. Do not forget the principle of microscopic reversibility. A reaction that forms a high energy species (e.g., S A*) is reversible as a principle (i.e. A* S is also possible). Moreover, since A* is an unstable entity, the reverse reaction is normally of significant rate. The decomposition of A* to products can often be considered irreversible. However, a single irreversible step in your mechanism means that the overall process is irreversible. If you know that the overall process is reversible, then every step of the mechanism must be reversible. Rule 6. Reaction order 2 is the rule for elementary reactions. Order 1 is (rigorously said) rare, but pseudo-first order is typical for unstable species decomposing in a solution upon interaction with the solvent molecules. Order 3 is exotic and should be considered only in case all other options are unsatisfactory. Orders different from 1, 2 and 3 are almost impossible. This is true for both the forward and the reversible reaction, e.g., 2A 4B cannot be an elementary process because 4B 2A is impossible. Also, an elementary reaction can break 1-2 bonds at most; and elementary step where more than 2 bonds are broken simultaneously is unlikely. There is one exception: conjugated double bonds. Example 3-4: proposing a mechanism to explain the Stern-Volmer 15 equation [4]. When aqueous solution of CS 2 or CCl 4 is subjected to high-intensity ultrasound, it emits light ( here is a video). The process is called sonoluminescence , and involves cavitation formation of microsized gas bubbles at the time-locations where the pressure is at a minimum. The bubbles are then suddenly compressed (suddenly means adiabatically means heated up) and collapse with highly localized release of energy. Thus, the multiphase system dissipates the energy of the sound wave in highly heterogeneous manner, with hot-spots. Two features of the sonoluminescence process are indicative of the involved stages. First, the intensity I of the sonoluminescence is empirically known to be proportional to the concentration [CS 2 ]. Second, I decreases when certain quenchers , such as alcohol ROH, are added to the mixture; the quenching follows the linear Stern-Volmer dependence: I 0 / I = 1 + a [ROH], (3-21) where I 0 is the sonoluminescence intensity in the absence of alcohol. Can you propose a mechanism that agrees with these features, and can you relate the empirical constant a to the rate parameters? Solution: the emission process produces a photon from an exited molecule A*, i.e. A* A + h . The intensity of the sonoluminescence is proportional to the rate of this reaction. As I [CS 2 ] is empirically known, it can be assumed that A* is produced by CS 2 ( rule 3 ); the simplest possible initiation process is ultrasound * 2 2 relaxation CS CS ⎯⎯⎯⎯→ ⎯⎯⎯⎯ , r e = k e [CS 2 ] k r [CS 2 * ]; (3-22) 15 / ʃtern - ˈ f ɔ lm ʌ /
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60 Note that we assumed that the initiation reaction is reversible ( rule 5 ). The experimental rate law does not indicate this in any way, but the chemical logic does on the right side of this equation we have a high-energy product, which is not leaving the system as a gas or a precipitate, so it is impossible this reaction to be irreversible. Next, the activated carbon disulfide can emit a photon, * 2 2 CS CS h + , I = k I [CS 2 * ]. (3-23) Finally, the rate of the emission reaction, I , is empirically known to be inversely proportional to 1 + a [ROH], suggesting a quenching reaction between ROH and CS 2 * ( rule 1 ). We assume the following process: q * * 2 2 CS ROH CS ROH + ⎯⎯→ + deactivated products, r q = k q [CS 2 * ][ROH]. (3-24) In the first step, the excess energy of CS 2 * is transferred to ROH, which is able to dissipate it to the medium without luminescence. This process is called scavenging ; the alcohol behaves as a scavenger or quencher this terminology is used for many other processes involving intermediates (e.g., radical scavengers such as vitamin C protect your body against a group of pathogens called reactive oxygen species producing radicals). We are now ready to write the production rate equation of our reactive intermediate, CS 2 * . From eqs. (3-22)-(3-24) it follows: * 2 d[CS ] d t * e 2 e q 2 r q [CS ] [CS ] [ROH] I k r I r k k k = = + + ; (3-25) we used the pseudo-steady state approximation as CS 2 * is a reactive molecule. The intensity with and without alcohol now follows from eqs. (3-23)&(3-25): e 2 r q [CS ] [ROH] I I k k I k k k = + + ; e 2 0 r [CS ] 0 I I k k I k k = + + (note the units moles of photons produced by a litre of the solution). The ratio of the two gives q 0 r 1 [ROH] I k I I k k = + + , i.e. the Stern-Volmer equation. Thus, the empirical constant a in eq. (3-21) is given by a = k q /( k r + k I ). Note that the consistency of the mechanism with the shape of the experimental rate laws is not sufficient to claim it is correct. The real thing would involve computation or estimation of k q , k r and k I from first principles, and comparison of k q /( k r + k I ) with experimental values for a . Let us finish this section with several features of chemical reactions initiated by light, radiation, sound, and some reaction-quenching materials, as this is important for the business of both material scientists and chemical engineers. As demonstrated in the examples above, light and intensive sound can initiate a reaction by activating a stable molecule. This can be formally written as: A A* h + , r = kI [A]. (3-26) Here, I is the intensity of the light source (proportional to the concentration of photons in the illuminated sample). It is important to remember that, for all photochemical reactions, the rate constant k is always a function of the wavelength. In addition, the linear dependence r I is often of limited validity at high intensity, negative deviations from linearity occur. Similarly, for ultrasound, ultrasound A A* ⎯⎯⎯⎯→ , r = kI US [A]. (3-27) Electromagnetic radiation can also be produced by a reaction (we call this luminescence ): A* A h + , I = k I r = k I k [A*]. (3-28)
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61 The process is essentially the reverse of (3-26). In this case, the intensity of the produced light is proportional to the rate of the reaction r . The linear dependence I = k I r is again of limited validity, and again, the intensity of the produced light is function of the wavelength (defined by the emission spectra). Another important family of processes that involves reactive intermediates is the interaction between these intermediates and the wall. One especially common case is the quenching of radicals by metal walls: R +M M P + , r = kA M [R ]. (3-29) Here, “M” denotes the metal wall, P is an inactive product, and A M is the area of the metal surface available. It is often the case that the detailed chemistry of the quenching reaction is unknown, but the quenching effect of the walls of the vessel in which the reaction mixture is contained is well-documented. Especially important case is the quenching of explosions, see problem 12. 3.5 Chain branching & reactor safety Schmidt’s ch. 10 Scaleup of chain reactions Explosion; H2 and chain branching Flammability 2H 2 + O 2 → 2H 2 O Simplified: initiation H 2 → 2H∙ branching H∙ + O 2 → HO∙ + O∙ O∙ + H 2 → HO∙ + H∙ propagation HO∙ + H 2 → H 2 O + H∙ termination H∙ + HO∙ → H 2 O Read more Levenspiel’s sec. 2.1 & 2.3 [ 1]. Fogler’s ch. 9a [ 2] but careful! Many mistakes! Schmidt’s ch. 4 [ 14] but careful, some of the examples given for chemical mechanisms in this chapter are of messed-up chemistry. Supafastquiz Which of the following are reactive intermediates? a) An alkoxy radical. b) A transition complex. c) A carbocation. d) A protonated form of a base. An initiator i 2 breaks in two radicals and produces 12 oxidation events per i 2 , on the average, before termination. What is the radical chain length?
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62 The elementary photochemical reaction 2A + h A 2 * produces an activated intermediate. What is the rate law? What is the rate of the elementary process A + A* A 2 + h ? Problems 1. Pyrolysis of acetaldehyde The pyrolysis of acetaldehyde at around 500 °C is assumed to proceed via the following mechanism: CH 3 CHO 1 ·CH 3 + ·CHO; CH 3 CHO + ·CH 3 2 ·CH 3 + CO + CH 4 ; CH 3 CHO + ·CHO 3 ·CH 3 + 2CO + H 2 ; 2·CH 3 4 C 2 H 6 . a) Indicate the stages of the process as initiation, propagation, or termination reactions. Can you write an overall reaction? b) Derive the rate of consumption of acetaldehyde as function of [CH 3 CHO]. Under what conditions does it reduce to eq. (3-2)? c) Define the radical chain length for the considered reaction pathway (by analogy with eq. (3-14)) and express it as function of [CH 3 CHO]. 2. Decomposition of N 2 O 5 45 N 2 O 5 decomposes according to the following mechanism: N 2 O 5 NO 2 + NO 3 ; NO 3 NO + O 2 ; NO 3 + NO 2 NO 2 . In the studied temperature range, NO 2 is not reactive although it is a radical (i.e. quasi-steady state approximation does not hold for it). a) What is the overall reaction? b) What are the production rates of all reactants and products under the pseudo-steady assumption? c) What is the rate of the overall reaction? What is the effect of the presence of the product on the rate of the reaction? d) Simplify the overall rate for the two limiting cases of low and high concentration of ·NO 2 . Discuss the temperature dependence of the rate in the two cases. 3. Photo-induced dissociation of 1,2-diiodoethane to ethene 45 1 2 I 2I h + ⎯⎯→ ; 2 2 2I wall surface-bound I + ⎯⎯→ ; 3 2 4 2 2 4 2 C H I I C H I I +  ⎯⎯→ + ; 4 2 4 2 4 C H I C H I  ⎯⎯→ +  . a) What stage of the radical chain corresponds to these reactions: initiation, termination, or propagation? b) Find the rate of consumption of I 2 , and the rate of production of ethene. Assume that all radical species are very reactive. How would you define the length of the radical chain?
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63 c) How much will the rate of ethene production change if the gas pressure is increased twice? If the light intensity is increased twice? How will this rate change qualitatively if you add to the mixture an aerosol of the same material from which the wall is made? d) Let the initial concentration of I 2 be significantly lower than that of C 2 H 4 I 2 , so that for the initial period of the reaction [C 2 H 4 I 2 ] can be assumed constant. Integrate the production rate of I 2 to find [I 2 ]( t ). Sketch your solution. e*) Under the considered conditions, the reaction is autocatalytic. Based on your solution for [I 2 ]( t ), try to find the induction time of the reaction (the time at which the rate of production of I 2 reaches a maximum). Try to find the induction time without using the assumption for constant [C 2 H 4 I 2 ]. 4. Competition between E 1 and S N 1 reactions A classical engineering chemistry problem is the competition between 1 st -order nucleophilic substitution reactions (S N 1) with parallel 1 st -order eliminations (E1). An example is the production of 2-methyl-2-butene, (CH 3 ) 2 C=CHCH 3 (used in agriculture and as intermediate for many pharmaceutical syntheses). One way to produce it is by dehydration of 2-methyl-2-butanol, (CH 3 ) 2 COH CH 2 CH 3 , in the presence of an oxoacid HOA. The process follows the mechanism (1) Me 2 COH CH 2 Me + H + Me 2 COH 2 + CH 2 Me, (2) Me 2 COH 2 + CH 2 Me Me 2 C + CH 2 Me + H 2 O, (3) Me 2 C + CH 2 Me + OA Me 2 C = CHMe + HOA. Me is short for methyl. The mechanism corresponds to H + -catalysed E1 reaction; the anion OA is always bulky (e.g., C 6 H 5 SO 3 ), because otherwise it will bind the carbocation Me 2 C + CH 2 Me directly to produce the adduct Me 2 COA CH 2 Me. Another adduct, an ether, is nevertheless produced, in the following S N 1 reaction: (4) Me 2 C + CH 2 Me + Me 2 COH CH 2 Me Me 2 C(OH + R) CH 2 Me; (5) Me 2 C(OH + R) CH 2 Me Me 2 C(OR) CH 2 Me, where R stands for OC(CH 3 ) 2 CH 2 CH 3 . a) Carefully choose a sensible key for each species in the reactions above (e.g., Me 2 COH CH 2 Me ≡ ROH; Me 2 COH 2 + CH 2 Me ≡ ROH2 etc.), as otherwise your equations will be impossible to read or operate with. b) Assume that [ OA] = [H + ] = constant (i.e. the equilibrium HOA H + + OA is quickly established). Assume that the protonated alcohol Me 2 COH 2 + CH 2 Me, the carbocation Me 2 C + CH 2 Me, and the protonated ether Me 2 C(OHR) + CH 2 Me are reactive intermediates and the pseudo-steady approximation holds for them. Find the rates of production of the two major products, the alkene and the ether, as function of the concentration of the alcohol and [H + ]. c) Find the instantaneous selectivity s alkene-ether . How much will the selectivity change if you: - increase pH with one unit? - add an inert solvent to dilute the reagent Me 2 COH CH 2 Me twice? d) Assume that the process takes place in CSTR. Formulate the mole balances and solve them for the alcohol, the alkene and the ether as functions of the space-time of the reactor. Sketch the solution, or plot it, if using Maple. What space-time would you recommend to increase the selective production of the 2-methyl-2-butene? Parameter values for the Maple plot: K 1 =10 -1 (standard state 1 M); [H + ] = 10 -3 M; [alcohol] 0 =2 M; k 1 = 10 6 M -1 min -1 ; k 2 = 0.5×10 3 min -1 ; k 3 = 1.5×10 3 M -1 min -1 ; k 4 =1 M -1 min -1 ; k 5 =10 6 min -1 . 5. How low should [O 2 ] be for the oxidation to stop?
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64 At very low concentrations of [O 2 ], the concentration of the hydrocarbon radicals increases as [R ] [O 2 ] -1 , see eq. (3-11). When it reaches values comparable with those of the relatively stable hydroperoxide radical [RO 2 ], the cross-termination reaction becomes important: t-cross 2 2 RO R i +  ⎯⎯⎯→ . At even lower concentrations of [O 2 ], the hydrocarbon radicals start to terminate between each other: t-R 2 2R R  ⎯⎯→ (what compound is R 2 ?) The last reaction has similar rate constant to the 2RO 2 -termination, while the cross reaction is twice as fast, i.e. k t-cross = 2 k t-R = 2 k t . a) Derive the rate of oxygen consumption for the reaction scheme (3-9) with the two additional termination reactions above. Find its limit at high initiation rate. b) Integrate the result and sketch the dependence of [O 2 ] on time. c) Derive an expression for the radical chain length , and sketch it as a function of [O 2 ]. 6. Antioxidants in fuels and lubricants Any oil phase, from cooking oil to crude oil, tends to autoxidize following a variant of the mechanism (3-9). With fuels and lubricants, the oxidation process is especially problematic, as it is accelerated when they are exposed to the increased temperature of the engine parts (up to 160 °C in modern injectors). The oxidation leads to formation of gum, insoluble sticky matter that stuffs the orifices of the fuel injection system and the fuel filters. It results in inaccurate measurement of the injected mass of fuel in the cylinder, and therefore, very sooty combustion (if more fuel than optimal is injected) or too much NO x produces (if less fuel is injected). Solving the gum problem might reduce the emissions of soot by 50% and those of CO 2 by 2% worldwide! To stabilize the fuel, food, lubricants etc., chemical engineers use antioxidants. The most common ones are phenolic radical scavengers. They can take the radical “torch” from a peroxide to form a resonantly stabilized phenoxy radical, e.g. OH CH 3 +RO 2 -RO 2 H . O CH 3 CH O CH 3 C O CH 3 The phenoxy radical is much more stable than RO 2 · and cannot abstract hydrogens from hydrocarbons. Even better it tends to terminate with another RO 2 ·: O CH 3 +RO 2 -RO 2 H . O CH 2 Thus, a single p-cresol 16 is able to deactivate two radicals. It does even more than that an addition reaction can take place between the double bonds in the produced quinonic 17 structure (p-quinomethane) and peroxides present in the fuel, thus removing a source of radicals from the mixture. Add these two reactions to the mechanism (3-9). What are these reactions (initiation, propagation, termination)? Derive the final rate of consumption of RH, and the length of the 16 /ˈpær.ə ˈkresɒl/ 17 quinone /ˈkwɪnəʊn/ , /kwɪˈnəʊn/
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65 radical chain in the presence of p-cresol. Assume that the concentration of p-cresol is small (expand the results in series). What is the qualitative result, does increase or decrease with [p-cresol]? What happens with in the other limit of high concentration of cresol? 7. Guess the mechanism of the following reactions based on their rate laws a) Gas-phase oxidation of nitric oxide, NO, to nitrogen dioxide, NO 2 . The chemical reaction and the empirical rate law are: 2NO + O 2 2NO 2 ; 2 2 [NO] [O ] r k = . (3-30) Thus, the reaction is simple, and has once been thought to be an example for a 3 rd order elementary reaction. However, it later turned out that the rate constant k has an inverse Arrhenius dependence on temperature ( k decreases exponentially as T increases). This is impossible for elementary reactions the activation energy is always non-negative. Inverse dependence of k on T is possible only for barrierless reactions (such are most radical-radical reactions), but this is always a weak power law dependence, not exponential. Use the rules formulated before example 3-3 to propose a mechanism of the reaction. Derive the rate law using the pseudo-steady approximation for all reactive intermediates, and compare it with (3-30). If the two do not agree, check if they will under certain limiting conditions (low or high [NO] or [O 2 ]); if still not, try another mechanism. Indicate the stages as initiation, propagation, or termination. Express the empirical rate parameter k with the rate constants of the elementary steps; does your expression allow inverse temperature dependence? Under what conditions the rate law (3-30) can be expected to fail? General chemical knowledge you need: (i) many redox reactions of NO proceed through a reactive intermediate NO 3 ; (ii) if a reaction produces a relatively unstable molecule from a stable one, it is definitely reversible; (iii) all reactions where two radicals bind are of small or zero energy barrier; (iv) NO 2 , NO and O 2 are radicals (although quite stable ones). b) 55 The same for the production of phosgene from CO and Cl 2 : 2 2 CO Cl COCl + ; 3/2 2 [CO][Cl ] r k = . (3-31) Again, propose a mechanism; indicate the stages; derive the rate law; compare to the experimental one (if needed, assume low or high concentration of CO or Cl 2 ); express k with the rate constants in your mechanism (where possible with the equilibrium constants of the elementary reactions). New hints you need from general chemistry: (v) halogens X 2 are a source of radicals X·; (vi) hint (ii) is essential here. c) 55 Hydrogen bromide is produced industrially by combining H 2 and Br 2 at increased temperatures. In the absence of catalyst, the process follows the experimental rate law 2 2 H Br 2HBr + ; 3/2 2 2 2 [H ][Br ] [HBr] [Br ] k r K = + . (3-32) As in the previous points, propose a mechanism; indicate the stages; derive a rate law; compare to the experimental one; express k and K with the rate constants in your mechanism. Also, express the equilibrium constant of H 2 + Br 2 2HBr with your rate constants. New hints you need from general chemistry: (vii) the equilibrium H 2 + Br 2 2HBr is strongly shifted to the right as the bond H Br is of lower energy than both H H and Br Br. 8. H 2 + O 2 + h H 2 O 2 If a mixture of hydrogen and oxygen is illuminated, they react with formation of hydrogen peroxide. The hypothetical mechanism is: 1 2 H 2H h + ⎯⎯→ ;
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66 2 2 2 H O HO + ⎯⎯→ ; 3 2 2 2 2 2HO H O O  ⎯⎯→ + ; 4 2 2 2 2 HO H H O H + ⎯⎯→ + . a) What stage of the radical chain corresponds to these reactions: initiation, termination, or propagation? b) Assume that all radical species are very reactive. Find the rate of consumption of O 2 and H 2 , and the rate of production of H 2 O 2 . Define a rate of the overall reaction H 2 + O 2 H 2 O 2 . How would you define the length of the radical chain? c) Assume that the light intensity is very low and expand the rate of the overall reaction in a respective series. If only the leading term in this series matters, how much will the rate of the reaction increase if: - the pressure is increased from 1 atm to 1.5 atm? - the irradiance of the probe is increased from 10 W/m 2 to 20 W/m 2 ? d) Integrate the obtained rate law (in the low light intensity limit) to obtain [H 2 ] as function of time (assuming a homogeneous isothermal isochoric batch reactor). 9. Oxidation of iodide to hypoiodite The ionic oxidation-reduction reaction of oxidation of iodides to hypoiodites by hypochlorites in aqueous solution follows the chemical equation I ClO IO Cl + + . This process is supposed to follow the mechanism 1 2 ClO H O HClO OH ⎯⎯→ + + ⎯⎯ ; 2 HClO I HIO Cl + ⎯⎯→ + ; 3 2 HIO OH IO H O + ⎯⎯→ + . Assume that HClO and HIO (hypoclorous and hypoiodous acids) dissociate very quickly. a) Find the rate of IO production. b) What is the order of reaction with respect to [I ] at high and at low pH? What does your result suggest, can you stabilize a mixture of I and ClO (i) by adding HCl, (ii) by adding NaOH? 10. Consider the equilibrium liquid-phase reaction 1 2 A B C ⎯⎯→ ⎯⎯→ ⎯⎯ ⎯⎯ . a) What is the relationship between concentrations and reaction yields if the initial concentrations are C A = C A0 ; C B = C C = 0? Find the total concentration C A + C B + C C of A, B and C. b) Assume that all the reactions are 2 nd -order. Formulate the batch reactor problem for the evolution of the composition in terms of reaction yields (ODEs for the unknown i ) and in terms of concentrations (ODEs for [A], [B], [C]). c) Find the concentrations of C A , C B and C C at equilibrium, and the equilibrium yields of the two reactions. Find the equilibrium values of the overall selectivity and the overall yield fraction. There are three equilibrium constants for the above process the ratios of each two equilibrium concentrations. How are these equilibrium ratios related to the rate constants? d) Now assume that C is reactive intermediate. Assume further that A is in large excess at all times ( C A C A0 ). Find the dependence C B vs. time t . Sketch your solution. 11. S N 1 reaction (exam paper, 2020)
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67 Tert -amylchloride (2-chloro-2-methylbutane, (CH 3 ) 2 CCl-CH 2 -CH 3 , or ClRH for short) is an odorizing agent of minor importance and an essential intermediate for several industrial syntheses. It can be produced from a mixture of 3-methylbutan-2-ol ((CH 3 ) 2 CH-CHOH-CH 3 , or HROH) and 2-methylbutan-2-ol (CH 3 ) 2 COH-CH 2 -CH 3 , or HORH), via a reaction with HCl in methanol solution. The chlorination of 3-methylbutan-2-ol produces (CH 3 ) 2 CH-CHCl-CH 3 , or HRCl, as a side product. The mechanism of the reaction is first-order nucleophilic substitution (S N 1) with intramolecular transfer of hydrogen: 1 2 HROH H HROH + + ⎯⎯→ + ⎯⎯ , 2 2 2 HROH HR H O + + ⎯⎯→ + ; 3 HR Cl HRCl + + ⎯⎯→ ; 4 + HR RH + ⎯⎯→ ; 5 RH Cl ClRH + + ⎯⎯→ . where HR + stands for the carbocation (CH 3 ) 2 CH-CH + -CH 3 , and the fourth reaction transfers a hydrogen atom from the third to the second position to produce the more stable tertiary carbocation + RH, i.e. (CH 3 ) 2 C + -CH 2 -CH 3 . a) The hydrochloric acid is in excess, and it can be assumed that [H + ] = [Cl ] = C HCl , and that C HCl does not change as the process advances. Find the rate of consumption of the reagent HROH and the rate of production of the two products, HRCl and ClRH, as functions of the rate constants of the elementary processes, the concentration C HCl , and the concentration of HROH. Assume that the ions HROH 2 + , HR + and + RH are reactive intermediates, and that the processes 1-5 are elementary. b) Integrate the rate expressions (first order with respect to HROH) to find the concentrations of HROH, HRCl and ClRH as functions of the space-time of a plug flow reactor. Sketch the profiles of the three concentrations along the length of the reactor. c) Find the overall and the instantaneous selectivities, S HRCl-ClRH and s HRCl-ClRH , as functions of the concentration C HCl . What conditions favour the product ClRH, more acidic or less acidic? Reaction 3 proceeds almost without barrier, while reaction 4 has a significant activation energy (as a C-H bond has to be broken). What temperature will favour the production of HRCl? Parameters: K 1 = 0.4 M -1 (equilibrium constant); k 1 = 0.3 M -1 ·s -1 ; k 2 = 0.01 s -1 ; k 3 = 0.1 M -1 ·s -1 ; k 4 = 1.9 s -1 ; k 5 = 0.1 M -1 ·s -1 . 12. Branching reactions and explosion
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68 4 Energy balance. Adiabatic reactors Your job is to: fundamentals revise thermochemistry and adiabatic flame temperature, say hi to heat balance for reactive mixtures; skills design an adiabatic reactor using numeric integration; extras… ammonia and Haber-Bosch process 1 st level; carbon deposition and Boudouard. 4.1 Brief introduction In this section, we will add a new level of complexity to the general reaction engineering problem: heat production. As a rule, chemical reactions produce or consume large amounts of heat, and this is actually how children learn about chemistry for the first time (FIRE!...). A mole of the reaction A B produces not only a mole of B, but also a well-defined amount of heat, H , measured in J/mol, and called enthalpy of the reaction . Reactions that produce heat are called exothermic ( H < 0), and those that consume heat are endothermic ( H > 0). A quick summary of thermochemistry. We use the heats of a family of special kinds of reactions (formation, combustion, neutralization etc.) to compute the heats of any reaction through Hess’s law. The reaction of formation of a compound AB is, by definition, the reaction A + B AB between the stable forms of the native elements that constitute AB (the elements A and B in their standard states ). Thus, the formation reaction of CO 2 is C(graphite) + O 2 (gas) CO 2 (gas). The formation heat of CO 2 , f H (CO 2 ), is the enthalpy of this reaction. The standard formation heat, f H (CO 2 ), is the heat of this reaction under standard pressure (1 atm). The standard formation heat at room temperature , for which we are going to use the symbol f H (CO 2 ), is f H at room temperature ( T = 298 K). It is often the case that the formation reactions are actually impossible, or are so slow that one can never measure their reaction heats, especially so at room temperature. Nevertheless, f H can still be worked out from suitable combinations of real reactions using Hess’s law (check question 3), together with Kirchhoff’s 18 equation that relates the temperature dependence of a reaction heat to the heat capacities of the reactants. To give an example: the combustion of CH 4 follows the chemical equation CH 4 + 2O 2 CO 2 + 2H 2 O. (4-1) Both the reactants (CH 4 + 2O 2 ) and the products (CO 2 + 2H 2 O) can be produced in formation reactions from the native elements C(graphite) + 2H 2 + 2O 2 : (A) C + 2H 2 + 2O 2 1 2 CH 4 + 2O 2 3 CO 2 + 2H 2 O. (B) (C) In this diagram, state (A) is an initial state (arrows start there), state (B) is intermediate (an arrow in and an arrow out), and (C) is final (arrows end there). One can produce C from A either directly through reaction 2, or indirectly, via reactions 1&3 through the intermediate CH 4 . According to Hess’s law, the heat is independent of the reaction pathway, so H 2 = H 1 + H 3 . 18 / ˈkɪ r hɔf /
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69 On the other hand, reaction 1 has heat H 1 = f H (CH 4 ) (how much is the formation heat of O 2 ?) ; reaction 2 has heat H 2 = f H (CO 2 ) + 2 f H (H 2 O). Combining the three formulae, one obtains for the enthalpy of the reaction (4-1) the expression H H 3 = H 2 H 1 = f H (CO 2 ) + 2 f H (H 2 O) f H (CH 4 ). All heats in this equation are functions of the temperature T . However, in any handbook, it is only the standard room-temperature formation heats that are tabulated, and this allows one to compute only the respective standard heat of a reaction (the heat produced by a mole of this reaction at 25 °C and 1 atm), i.e. H = f H (CO 2 ) + 2 f H (H 2 O) f H (CH 4 ). Generalizing this idea to the reaction  i i 0, we obtain for the standard room-temperature enthalpy of any chemical process H =  i f H i . (4-2) On the other hand, the heat of the same process can be computed from the absolute molar enthalpies h i of each reactant: H =  i h i . (4-3) The absolute enthalpy h i of a molecule in a given mixture is the sum of the enthalpies of all chemical bonds (i.e. the enthalpy of the reaction producing an ideal gas of the compound from atoms) plus the interaction enthalpy of the molecule with its surroundings. Unlike f H , the enthalpies h i are not easy to tabulate; however, eq. (4-3) allows analysis of the function H ( T , p ) that eq. (4-2) does not. Differentiation of eq. (4-3) with respect to T at constant pressure leads to Kirchhoff’s law: ( H / T ) p =  i c pi c p . (4-4) Here, c pi = ( h i / T ) p is, by definition, the molar heat capacity of component i , and the sum c p =  i c pi is called the heat capacity of the reaction (compare with the formula (4-3) for the enthalpy, and that for the Gibbs energy of the reaction, G =  i i ). Kirchhoff’s law is a differential equation for H . Together with eq. (4-2) (used as a boundary condition), it determines the temperature dependence of H at a fixed pressure: Δ Δ Δ d = + T p T H H c T . (4-5) Usually, c p is of the order of 10-50 J·mol 1 ·K 1 , and its integral of the order of 10-50×( T T ) J/mol. The room-temperature reaction heat H is, on the other hand, of the order of 100-500 k J/mol. Therefore, in first approximation, it can be assumed that H H . If T T is several hundred degrees, or the reaction in question is of particularly low enthalpy, as a better approximation, it is often sufficient to assume that c p is temperature-independent, which yields ( ) Δ Δ Δ = + p H H c T T . (4-6) If even this is insufficiently accurate, the formula (4-5) has to be used without approximations, with c pi ( T ) either from handbook data (given usually as the coefficients of polynomial formulae for c pi vs T ) or from molecular models. Chemical equilibrium and reaction enthalpy. The reaction heat is important for the chemical reaction engineer for two reasons. First, it is the major term in every energy balance of a reaction mixture. Second, it determines the temperature dependence of the equilibrium constant K of the reaction through the Gibbs-Helmholtz relation: Δ G 2 / Δ p T H T T = − , (4-7) where G = RT ln K is the standard Gibbs energy of the reaction . Integration of this equation from T = T ° to T leads to
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70 2 Δ ln d = T T K H T K RT . (4-8) If H H , the integral Gibbs-Helmholtz formula (4-8) yields van ’t Hoff’s equation (1-53). If the linear dependence (4-6) is used instead for H vs. T , one obtains Δ / Δ Δ 1 1 exp = p c R p H c T T K K T R T T . (4-9) This equation is known as Kirchhoff’s equation for the equilibrium constant . The equilibrium constant K at standard pressure and room temperature is related to the standard room-temperature Gibbs energy of the reaction, G = RT ln K . Hess’s law is valid for the standard Gibbs energy of a reaction in the same form as for the reaction enthalpy, and it is used to relate K ° to the standard Gibbs energies of formation (compare to eq. (4-2)): G =  i f G i ; f ν Δ Δ exp exp i i G G K RT RT = = . (4-10) The results (4-2) for H , (4-10) for G and K , (4-4) for c p , (4-6) for H ( T ), and (4-9) for K ( T ) are probably the most widely used equations in chemical engineering. The involved parameters ( f H , f G , c p ) are tabulated for tens of thousands of compounds in numerous printed (CRC [10]) and web-based ( NIST ) handbooks and databases. You will meet with these formulae repeatedly in your careers. Example 6-1: calculate the equilibrium constant and the heat of the gas-phase reaction of synthesis of ammonia at 150 °C: N 2 + 3H 2 2NH 3 . (4-11) Find the equilibrium mole fraction of NH 3 if the pressure of the mixture is p = 10 bar and it is stoichiometric. Plot the equilibrium composition as function of T . You need the following handbook parameters (from CRC [10], where the standard state refers to 10 5 Pa): f H (NH 3 ) = 45.9 kJ/mol; f G (NH 3 ) = 16.4 kJ/mol; c p (NH 3 ) = 35.1 J·mol 1 ·K 1 ; c p (N 2 ) = 29.1 J·mol 1 ·K 1 ; c p (H 2 ) = 28.8 J·mol 1 ·K 1 . Solution. The standard heat of the considered reaction is trivial our reaction differs from the formation reaction just by the fact that it produces 2 moles of NH 3 (the formation reaction is 1/2 N 2 + 3/2 H 2 NH 3 instead). Therefore, H = 2 f H (NH 3 ) = 91.8 kJ/mol. The same result is obtained from Hess’s law (4-2), by taking into account that N 2 and H 2 are, of course, of zero formation enthalpy. Similarly, the standard Gibbs formation energy and the equilibrium constant at 25 °C are G = 2 f G (NH 3 ) = 32.8 kJ/mol; K = exp( − G / RT ) = 558 10 3 bar 2 . Question : should K have units, if exp( − G / RT ) is dimensionless, but the fraction K = p (NH 3 ) 2 / p (N 2 ) p (H 2 ) 3 is [Pa 2 ]? What are the units of K and where is the error? The heat capacity of the reaction is c p = 2 c p (NH 3 ) c p (N 2 ) 3 c p (H 2 ) = 45.3 J·mol 1 ·K 1 . Now Kirchhoff’s eq. (4-6) tells us that the heat of the reaction at 150 °C is ( ) Δ Δ Δ = + p H H c T T = 97.5 kJ/mol. Next, t he other Kirchhoff’s eq . (4-9) tells us the equilibrium constant at 150 °C is
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71 Δ / Δ Δ 1 1 exp = p c R p H c T T K K T R T T = 7.34 bar 2 . The condition for equilibrium is 2 3 3 2 2 (NH ) (N ) (H ) p K p p = ; moreover, we know that p (H 2 ) = 3 p (N 2 ) (stoichiometric mixture) and p (N 2 ) + p (H 2 ) + p (NH 3 ) = p = 10 bar (Dalton’s law). We then solve the three equations step by step: from stoichiometry and equilibrium, 2 4 3 2 (NH ) 27 (N ) p Kp = ; Dalton’s law with substituted p (H 2 ) & p (NH 3 ): 2 2 2 4 (N ) 27 (N ) p K p p + = ; solving a quadratic equation for p (N 2 ): 2 2 4 16 4 27 4 (N ) 2 2 27 K p b b ac p a K + = = + ; ammonia’s partial pressure : 3 8 27 4 4 27 (NH ) 27 K p K p p K + + = ; molar fraction of NH 3 : 3 NH ,e x = p (NH 3 ,150 °C)/10 bar = 71.5 %; equilibrium conversion : 3 3 2 NH e NH N 1 2 1 2 p X p p = + = 83.4 % at 150 °C. The ½ in the conversion is due to the stoichiometric coefficient of NH 3 in eq. (4-11) (two NH 3 are obtained from one N 2 ). The temperature dependence of the equilibrium partial pressures and the molar fraction x e of the ammonia is illustrated in the following figures. In the second figure, two approximations are used for K ( T ): the cruder van ’t Hoff’s and the improved Kirchhoff’s. A final note: we solved the problem by formulating it for the unknown “concentrations” (partial pressures); it is somewhat easier to formulate it for a single unknown , as we did in the previous sections (yet having another approach in your arsenal is always good). p i e , bar T , K H 2 N 2 x e = p e (NH 3 )/ p tot T , K
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72 4.2 Irreversible reaction in an adiabatic 19 reactor Let us return once again to the good old first-order reaction A B, and to the equations that determine the evolution of a reaction mixture. Until now, we were using: (i) the mole balances (equations for n i ): A A0 A d d n Vr F F t = − + , B B d d n Vr F t = ; (4-12) (ii) the rate law (equation for r ): r = k [A], 1 1 exp = E k k R T T ; (iii) the equation of state ( V ): V = ( n A + n B ) RT / p ; (iv) a mechanical constraint on the system ( p ): e.g., V = const , or p = const , or another These equations still do not solve the general reactor problem, as one unknown is left: the temperature. Until now we always assumed that T is constant (isothermal reactor), so this was not a problem. However, when moles of the reaction take place, they produce H moles of heat, which is usually pretty large and alters the mixture temperature. In this chapter, we will assume that this heat does not leave the mixture ( adiabatic reactor). A reactor is adiabatic when the heat transfer through its walls is much slower than the reaction rate, i.e. either the insulation slows down the heat transport from the reactor to the surroundings or the reaction is very quick (explosions are adiabatic reactions, combustion is also approximately adiabatic). In contrast, in the next section, we will consider the case where part of the reaction heat leaves through the reactor walls (i.e. it is transferred to an external body, usually the coolant). Let us first assume that the reaction heat capacity c p is negligible. This means, first, that H does not change with temperature, see eq. (4-6); and second, the total heat capacity C p [J/K] of the mixture does not change as the reaction proceeds (i.e. C p is function neither of nor of T ). This leads to the simplest possible form of the new equation we need, the heat balance : C p ( T T 0 ) = H . (4-13) Here, C p = n i c pi is a sum over the heat capacities of all components that are heated (which may include parts of the reactor). This equation states that the heat H produced by the reaction is spent on changing the temperature of the mixture (and maybe the reactor), C p ( T T 0 ). If the reaction is exothermic ( H < 0), the temperature will rise as the reaction advances. Usually, both C p and H vary with both T and , in which case the differential form of the heat balance has to be used: C p d T = − H d , or per unit time (v) the heat balance (equation for T ): d Δ d Δ d d p p T H V H r t C t C = − = − . (4-14) This equation has to be used instead of eq. (4-13) whenever the temperature and composition of the reaction mixture change significantly (e.g., | T | > 50-100 K). The value of the total heat capacity C p is often dominated by a solvent or an inert carrier gas and depends little on ; however, the temperature dependence of C p can be significant. Let us now consider a couple of examples. 19 /ædiəˈbætɪk/ is closer to the original Greek word, /ˌeɪ.daɪ.əˈbæt.ɪk/ is more common
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73 A B in an adiabatic isochoric batch reactor (see also the solved Maple examples file) . Isochoric batch reactor means that V = const and F i = F i 0 = 0. Both mole balances (4-12) simplify to the same equation, ( ) A0 d d V V k C t = . The rate constant here is temperature dependent. Using for this dependence the Arrhenius equation, we obtain ( ) A0 d 1 1 exp d = V V E k C t R T T . (4-15) The temperature T is, on its turn, dependent on V . The relationship between the two is set by the heat balance; in the simplest case, the linear equation (4-13) is valid. We will use it in the form 0 0 Δ Δ V p p H V H T T T C C = = . (4-16) Here, V is the volume of the mixture ( / V = V ), and C p is the capacity of what is heated up. For a batch reactor, it is not only the mixture that receives the heat, but also parts of the reactor itself (the metal wall below the insulation; the impeller; the catalyst pellets present). Therefore, C p = n i c pi + C p ,reactor wall + C p ,impeller + C p ,catalyst ; (4-17) here, c pi are the molar heat capacities of each component in the mixture, and C p ,part are the total heat capacities of the different parts of the reactor (where part wall, impeller, catalyst...) that are in thermal equilibrium with the mixture. Substitution of eq. (4-16) into the rate law (4-15) results in an explicit equation for V : ( ) A0 0 d 1 1 exp Δ d = V V V p E k C V H t R T T C . This equation is integrated via a separation of the variables; the explicit solution for t ( V ) is ( ) 0 A0 0 d 1 1 exp Δ / = V V V p V E t R T V H C T k C . Some nondimensionalization yields the simpler form 1 0 0 0 A0 0 d exp 1 Δ 1 X p C T E X k t RT V HC X X = , (4-18) where X = V / C A0 is the conversion, and k 0 = k exp[ ER 1 (1/ T 0 1/ T )] is the value of the rate constant k at the initial temperature T 0 . The integral (4-18) is not analytic, but is easily computed numerically. Case 1: exothermic reaction. If H < 0, the heat released by the reaction accelerates it, resulting in a characteristic inflection point of the X vs. t curve, corresponding to a respective maximum of the rate of the reaction, Fig. 12. A feature of the adiabatic exothermic reactions that the chemical engineer must always keep in mind is that the temperature may easily surpass a certain limit, T lim , beyond which various disasters would occur: (i) decomposition of the reactant or the reagents, which will not only result in low yields, but can also produce deposits, gases poisonous for people or for the catalyst etc. (ii) Boiling of the solvent, which can increase the pressure in the reactor and cause uncontrolled release of steam/vapours.
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74 (iii) Conditions might surpass a flammability or explosion limit, or a material strength limit. If the limiting temperature is T lim , then from eq. (4-16) we can find the respective limiting conversion for an adiabatic reactor: X lim = C p ( T lim T 0 )/ V| H|C A0 . Many fast reactions are of limited conversion for reasons like flammability, and we compute the maximum allowed conversion via the heat balance. Fig. 12. Adiabatic exothermic 1 st -order reaction, A B; H = 50 kJ/mol. Dependence of the temperature of a batch reactor, the conversion, and the rate of the reaction on time t . These are parametric plots of eqs. (4-16)&(4-18), with parameter X varied between 0 and 1. Parameter values: V = 100 L, C A0 = 1 M, T 0 = 40 °C, E = 70 kJ/mol, C p = 65 kJ/K, k 0 = 0.2 h -1 . If this is an aqueous solution, the line indicates where a limiting temperature (boiling point of the solvent) has been reached. Case 2: endothermic reaction. In this case, the reaction decelerates significantly after moderate conversion, due to the drop in temperature, Fig. 13. It is again possible that a limiting temperature is reached where the gases condense, or the liquid freezes, or where the viscosity of the solution becomes too high (which will occur at conversion X lim = C p ( T 0 T lim )/ V HC A0 ). Note that the final temperature cannot fall below 0 K, and therefore, X can never surpass C p T 0 / V HC A0 . In reality, long before that, the rate will become so sluggish that chemical engineers use the term reaction freezing . This phenomenon is especially common when multiple reactions take place, and also whenever the process involves a new phase formation step (nucleation). Fig. 13. Adiabatic endothermic 1 st order reaction, A B; H = + 0 kJ/mol. Dependence of the temperature in a batch reactor and the conversion on time. If this is an aqueous solution, the line indicates where a limiting temperature (freezing point) has been reached. t [h] X t [h] T [ C] t [h] r [M/h] t [h] X t [h] T [ C]
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75 A B in an adiabatic PFR. The differential mole balance for the PFR reads ( ) A d d V V k C = . All other equations remain the same, and therefore, the solution of the PFR problem differs from the one for batch reactor only by (i) being the variable instead of t , and (ii) the nature of the heat capacity C p . For a batch reactor, C p involves parts of the reactor, eq. (4-17); in a packed-bed batch reactor, for example, C p is often dominated by the heat capacity of the catalyst. For a PFR, C p is the heat capacity of the mixture only, i.e. C p = n i c pi . Once the PFR reactor is in steady state, the catalyst and the walls of the reactors are already at the stationary temperature and do not further exchange heat with the mixture. A B in an adiabatic CSTR. In this case, the temperature of the reactor is fixed, so the mole balances are decoupled from the heat balance. The mole balances read as usual A0 A A C C r kC = = ; B A C r kC = = . (4-19) The only thing we need the heat balance for is to answer the question: what is the relation between the inflow temperature T 0 and the operational temperature of the reactor T ? To achieve the optimal reactor temperature T , the inflow is usually preheated to an optimal temperature T 0 . The power of the reaction (rate of heat production) is given by HVr , in units [W]. In an adiabatic CSTR, this heating power is spent on warming up the inflow from its initial temperature T 0 to the reactor temperature T , which requires, in the absence of solvent, a heat of c p A ( T T 0 ) F A0 = c p A ( T T 0 ) vC A0 per second. Equating the power delivered to the power consumed gives us the heat balance of an adiabatic CSTR: 0 A A0 Δ p T T c C Hr = − . (4-20) We assumed here that the heat capacity c p A is independent of temperature. If it is not, we have to integrate it: 0 A0 A d Δ T p T C c T Hr = − . (4-21) Eqs. (4-19)&(4-20) define the state in the reactor ( C A , C B and T ) as function of the feed characteristics ( C A0 and T 0 ). However, it is more usual to predefine the reactor temperature, and to use these three equations to work out what the initial temperature should be (i.e. to solve for C A , C B and T 0 ). This task is straightforward to do, and gives A0 A 1 C C k = + ; A0 B 1 k C C k = + ; 0 A Δ 1 p H k T T c k = + + . (4-22) The last equation is the sought relation between the inflow temperature T 0 and the operational temperature T of the adiabatic CSTR. If the reaction is exothermic, T 0 is, of course, lower than T . If it is endothermic, the feed has to be heated up to avoid a drop in temperature (though it is unlikely that an endothermic reaction would be carried out in an adiabatic reactor). The chemical engineers use the value of T 0 from eq. (4-22) to design the heat exchanger preceding the CSTR Adiabatic temperature of the mixture. The temperature of a reaction mixture under adiabatic conditions upon 100% conversion is called the mixture’s adiabatic temperature . It corresponds to all of the reaction heat used to heat up the products. The actual way in which this process takes place might be complicated, e.g., for an exothermic reaction A B,
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76 temperature and conversion would increase simultaneously and continuously until the final state (100% B at the final temperature T ) is reached: A(25 °C) 0.9A + 0.1B (30 °C) 0.8A + 0.1B (36 °C) B( T ). (4-23) Since A and B have different heat capacities, the reaction heat and its effect will also be changing during the process. We can compute the adiabatic temperature using a differential balance, see problem 1c. However, Hess’s law tells us that the way in which we got from the initial state A(25 °C) to the final state B( T ) is not important for the total heat of the process (4-23) (which is zero, as it is adiabatic). For example, we can alternatively reach the final state in two steps: A(25 °C) B(25 °C) B( T ). Unlike the actual process (4-23) where each small step is adiabatic, in this alternative path from A(25 °C) to B( T ), the two steps are not adiabatic: step one, A(25 °C) B(25 °C), produces the room-temperature reaction heat H ; the second is just heating, and requires c p B ( T T ) joules of heat. Since we still want the overall process to be adiabatic, the total heat has to be zero, i.e. H + c p B ( T T ) = 0, so T = T H / c p B . (4-24) This is easily generalized for a general process reagents( T 0 ) products( T ): T = T 0 H 0 / c p ,products , (4-25) where c p ,products =  k c pk is the heat capacity of the products of 1 mol reaction the sum is over all products; H 0 is the heat of the reaction at the initial temperature T 0 . Example 6-2: adiabatic temperature of a flame. The torch burners are constructed to produce different flame temperature depending on the application. Here’s a work for a chemical engineer: if one needs a flame that is 1333 K hot, what should the torch be using as a fuel? The flame of the torch burner can be modelled as an adiabatic chemical reactor, with fuel and air feeds meeting at the flame front to produce CO 2 , H 2 O and heat. a) Consider a methane torch that uses the reaction CH 4 + 2O 2 CO 2 + 2H 2 O to produce heat. Assume that the combustion is adiabatic, and the heat released by the reaction is spent entirely to heat the products of the reaction and the inert N 2 from the atmosphere (starting from room temperature). What will be the flame temperature? b) An exquisite torch would burn not methane, but a 1:2 mixture of methane and oxygen. In this way, the heat produced by the reaction in the core of the flame is not spent on heating inert N 2 from the air. What is the maximal temperature this torch will be able to produce? Parameters: standard state: 1 bar, 25 °C f H [kJ/mol] c p [J/molK] CH 4 -74.6 36 O 2 29 CO 2 -393.5 50 H 2 O (gas) -241.8 33 N 2 29 Solution to a). The standard heat of the reaction follows from Hess’s law: H = f H (CO 2 ) + 2 f H (H 2 O) f H (CH 4 ) = -802.5 kJ/mol. To solve the problem, we will use Hess’s law for the imaginary two-step process isothermal reaction heating from 4 2 2 2 2 2 2 2 2 at 298.15 K 298.15 to K cold hot CH 2O 7.5N CO 2H O 7.5N CO 2H O 7.5N T + + ⎯⎯⎯⎯→ + + ⎯⎯⎯⎯⎯→ + + .
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77 We used that since [O 2 ]:[N 2 ] = 21:79, two moles of O 2 come with 2 79/21 = 7.5 moles of N 2 . This process has the same initial and final state as the combustion we consider, and therefore, has the same enthalpy. The enthalpy of the first process is H , and the one of the second is n i c pi ( T T ), where i is CO 2 , H 2 O or N 2 . The heat capacity of the products is n i c pi = 334 J/K. Since the process we consider is adiabatic, the total enthalpy should be zero, i.e. H + n i c pi ( T T ) = 0, so T = T − H / ( n i c pi ) = 298 + 802500/334 = 2700 K. Of course, this is just a form of the general equation (4-25) for the adiabatic temperature T . b) If oxygen is fed together with the fuel and does not come with the inert N 2 , we need to modify slightly the process above: isothermal reaction heating from 4 2 2 2 2 2 at 298.15 K 298.15 to K cold hot CH 2O CO 2H O CO 2H O T + ⎯⎯⎯⎯→ + ⎯⎯⎯⎯⎯→ + , i.e. the only thing that changes is that we do not spend the reaction heat on heating N 2 now, and the sum n i c pi is over CO 2 and H 2 O only. The heat capacity of the products is n i c pi = 116 J/K, so the adiabatic temperature is computed as T = 7200 K. This result is erroneous the actual flame temperature is some 4000 K less. The main reason is that above 3000 K, water starts to homodissociate to radicals, H 2 O H · + HO · , consuming a large fraction of the heat, i.e. the final state of the adiabatic combustion is not really hot H 2 O. Another large error stems from the assumption for constant heat capacities. 4.3 Reversible reaction in an adiabatic reactor With reversible reactions, there appears the additional complication of the equilibrium composition changing with temperature. If the reaction is endothermic, as it proceeds, the temperature of the mixture decreases; according to the Le Châtelier-Braun 20 principle, this shifts the equilibrium composition to the left (to the reagents). Therefore, for an endothermic reaction, an adiabatic reactor is a lose-lose situation: both the equilibrium conversion and the rate with which it is approached drop with the increase of the residence time . This is why we do not use adiabatic batch and PF reactors for endothermic reversible reactions we heat up instead. However, if the reaction is exothermic, as it advances, temperature increases, and so does the rate. The Le Châtelier-Braun principle, however, still tells us that the equilibrium will shift to the left, i.e. the equilibrium conversion again drops with . Designing a reactor that is able to maintain the rate reasonably high while achieving a reasonably high yield with an exothermic reaction is an age-old challenge faced by generations of reaction engineers. Let us consider this question directly with an example. Example 6-3. The isomerization of butane to isobutene takes place in liquid phase at increased pressure in (a) an adiabatic PFR; (b) an adiabatic CSTR. The process is reversible, C 4 H 10 i-C 4 H 10 , and follows a simple 1 st -order rate law. Some inert isopentane is present in the mixture. Calculate what the reactor volume should be in order to achieve conversion of 70%. Plot the change of the composition, X , X e , T and r down the length of the PFR reactor, or as a function of the CSTR flow rate. For the CSTR, plot the production rate as function of and find the interesting points. 20 /lə ʃɑtlˈ je-braun/. Did you know that Braun shared the Nobel Price with Marconi for the invention of the radio?
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78 Thermodynamic data : H = 6900 J/mol; K (60 °C) = 3.03; c p (butane) = 141 J/molK, c p (i-butane) = 141 J/molK, c p (i-pentane) = 161 J/molK. Rate data : k f (360 K) = 31.1 h -1 ; E = 54.7 kJ/mol. Inflow : T 0 = 330 K; F butane,0 = 163 kmol/h; [butane] 0 = 9.3 M; 10% inert i-C 5 H 12 . Solution to a) PFR. The reaction heat capacity is zero, c p = 0, so the capacity of the mixture and the heat of the reaction remain constant. Both k f and K depend on temperature (the Arrhenius and van ’t Hoff’s equations). Let us first write the equilibrium composition as a function of the temperature. The condition for equilibrium is: e e e 0 e [i] [b] [b] V V K = = , (4-26) and the equilibrium yield varies with the temperature together with K . The solution to eq. (4-26) for V e reads 0 0 e 1 1 0 0 [b] [b] 1 Δ 1 1 1 exp V K H K R T T = = + + , (4-27) where we used van ’t Hoff’s eq. (1-53), and we assumed that the standard temperature is conveniently chosen to be equal to the initial one. The set of equations we need is similar to the one we used for the irreversible reaction A B in the previous subsection, namely a mole balance + a rate law: ( ) f d [b] [i]/ d V k K = , (4-28) where [b] = [b] 0 V is the concentration of the butane, and [i] = V is the concentration of the isobutane. The second equation the heat balance is unchanged compared to (4-16), apart from C p being the capacity of the mixture only, C p = n i c pi , without reactor bits: 0 0 0 Δ Δ Δ V V V p i pi pV V H H H T T T T C C c c = = = ; (4-29) here we used that the concentration of the i th component is n i / V = C i , and that c pV = C i c pi is the heat capacity per unit volume of the mixture. Substitution of eq. (4-29) in the mole balance (4-28) leads to a single equation for a single unknown the yield V : 1 1 0 0 f0 0 0 0 0 d Δ exp 1 [b] exp 1 d Δ Δ pV pV V V V V V c T c T E H k RT H K RT H = . (4-30) This is integrated by separation of variables, 1 0 0 f0 1 0 0 0 0 0 exp 1 d Δ Δ [b] exp 1 Δ V pV V V pV V V V c T E RT H k c T H K RT H = , (4-31) compare with the respective result (4-18) for irreversible reaction. The results are plotted in Fig. 14 as parametric plots: X = V /[b] 0 against ( V ) according to eq. (4-31); V e ( V ) from eqs. (4-27)&(4-29) against ( V ); T ( V ) according to eq. (4-29) against ( V ); r ( V ) according to eq. (4-30) against ( V ).
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79 The parameter V is varied from 0 to the theoretical yield V e ( question: how would you find V e numerically? ). Fig. 14. Conversion, equilibrium conversion, temperature of the mixture, and rate of the reaction along the length of an adiabatic PFR. The final question is, what is the volume of the reactor needed for 70% conversion? Note that you could not know whether the conversion can surpass 70% at all before you solved the problem: the temperature could have increased so much that the final equilibrium yield is lower than 70%. This is not the case, according to the results in Fig. 14. Now, to obtain the space- time at which V = 0.7[b] 0 , we simply substitute this value in eq. (4-31) and integrate numerically using Maple: 0 1 0 0.7[b] 0 1 70% f 0 1 0 0 0 0 0 exp 1 d Δ Δ [b] exp 1 Δ pV V V pV V V V c T E RT H k c T H K RT H = = 9.5 min. The volumetric flow rate is v = [b] 0 F butane0 = 17.53 m 3 /h, and the volume of the reactor required for 70% conversion is therefore V 70% = v 70% = 2.77 m 3 . b) The operation of the CSTR is defined by two mole balances and the heat balance: ( ) 0 f [b] [b] [b] [i]/ r k K = = ; ( ) f [i] [b] [i]/ k K = ; ( ) ( ) 0 f Δ Δ [b] [i]/ pV c T T Hr Hk K = − = − , (4-32) compare to eq. (4-20). These equations can be solved for T , [b] and [i] in the reactor as functions of , but only numerically. It is again easier to change the variables, as in a), and to solve for , [b] and [i] as functions of T , and then analyse the results as parametric dependences. The solution is straightforward: first, we can divide the first and the second equation by the third (to get rid of r ). The results are, after rearrangement, ( ) 0 0 [b] [b] Δ pV c T T H = + ; ( ) 0 [i] Δ pV c T T H = − . (4-33) Substituting these in the 3 rd equation and solving for gives ( ) ( ) 1 0 0 0 f 1 [b] 1 Δ Δ pV pV c T T c T T Hk H K = − + + , (4-34) [min] T [ C] [min] r [M/h] [min] V /[b] 0
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80 where, of course, k f and K are exponential functions of T (Arrhenius, van ’t Hoff). The result for the conversion X = [i]/[b] 0 is plotted parametrically in Fig. 15, and is compared with the equilibrium conversion X e = [i] e /[b] 0 = 1/(1+ K 1 ), see eq. (4-27). Fig. 15. Conversion and equilibrium conversion vs. residence time of a CSTR. Parametric plot of eq. (4-33) vs. eq. (4-34), with parameter T . Let us now calculate the volume of the reactor that will allow for 70% conversion. From eq. (4-33), 70% conversion will be obtained at a temperature of 70% 0 70% 0 0 Δ [i] Δ [b] 0.7 pV pV H H T T T c c = = = 360 K. (4-35) At 360 K, from the Arrhenius and van ’t Hoff’s formulae, k f = 31.9 h -1 and K = 2.5. From eq. (4-34) we then obtain residence time 70% = 1 h 3 min. The resulting volume of the CSTR is V = v 70% = 18.25 m 3 , 6-7 times larger than the respective PFR volume. The specific production rate per unit volume of the reactor is, by definition, F i V = [i] v / V = [i]/ ; according to the second eq. (4-32), it is true that F i V = r , i.e. the specific production rate in the considered case is simply equal to the rate of the reaction: ( ) 0 i f 0 [i] 1 [b] 1 Δ pV V c T T F r k H K = = = + + . The rate is plotted as function of T and in Fig. 16. As demonstrated, there is an optimal operation temperature that can be achieved at a certain optimal . The maximum can be determined only numerically (consult the Maple examples file) it is at T opt = 346 K, corresponding to opt = 3.5 min and V opt = 1030 L. However, at these conditions, the conversion is very low (only X opt = 37.4 %). Fig. 16. Rate of the reaction (equal to the specific production rate of [i]) vs. T in a CSTR reactor. Note that the composition changes simultaneously with T , according to eq. (4-33). [min] [i]/[b] 0 T [K] r [M/h] T opt
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81 What a chemical engineer would recommend the entrepreneur with such a reaction is a CSTR and a PFR combined in series. As you know from your CRE introduction module, if a reaction is accelerating, CSTR is preferable to PFR and vice versa (remember the Levenspiel plot? if not, consult refs. [2,1]). For a reaction rate passing through a maximum at a certain conversion X opt , it is best to use CSTR until X opt is reached, and then use PFR to convert further the mixture from X opt to, e.g., 0.95 X e . We will further elaborate on this combination in the 8 th problem. Read more Levenspiel’s ch. 9 [ 1]; Fogler’s ch. 11 [ 2]. Schmidt’s ch. 5 [ 14]. Supafastquiz What is the heat capacity c p of the reaction 2A 3B? What does it mean if c p < 0? Link the relation to name(s) that match it: between heat capacity C p of a reactive mixture and heat r H of a reaction Kirchhoff between heat capacity c p and enthalpy r H of a reaction van ’t Hoff between equilibrium constant K and heat r H Gibbs-Helmholtz between adiabatic flame/reactor temperature and heat of the reaction heat balance between heat capacity c p and equilibrium constant K of a reaction Hess Which of these reactors is likely to be approximately adiabatic? - a chemostat; - a cooled gas-phase PFR; - a burner; - a cooking pot; - a tubular reactor with a vacuum jacket. Problems 1. Derivations a) Derive eq. (4-9) from the Gibbs-Helmholtz equation. b) At what conversion and temperature will occur the extremum of the rate of the exothermic reaction in Fig. 12? c) For a small interval of time d t , a small amount d of the reaction A B takes place to produce a small amount of heat, d H = H d . This heat is delivered to the mixture (of heat capacity C p = n A c p A + n B c p B ) to increase its temperature by d T . The differential heat balance reads
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82 d H = C p d T . Assume that c p A and c p B are constants. Separate the variables T and (you will need Kirchhoff’s equation (4-6) for H ( T ), the relation (1-3) between n i and ; use also that c p B = c p A + c p , which follows from eq. (4-4), to get rid of c p B ). Integrate from = 0 to the maximum yield to obtain T , the adiabatic temperature of the mixture. Compare with the formula obtained from Hess’s law, eq. (4-24). d) Let a mixture of composition n i 0 , i = 1… N , enter a reactor at temperature T 0 , and exit it at T , composition n i , i = 1… N . The reactions j = 1… M took place, of extents j and standard heats H j . Use Hess’s law to show that 0 0 d Δ d 0 T T i i j j i i i j i T T n c T H n c T + + = . 2. Basics (i): heat balance, production rates a) A 70-kg human consumes per day food containing a total of 2000 kcal on the average. Assume the food is glucose (standard combustion heat c H 298 = 2820 kJ/mol). Find the metabolic rate of this human in terms of rate of oxygen consumption in N-mL·kg 1 ·min 1 (normal volume of oxygen per kg of human per minute). (after Levenspiel [1]) b) 0.00340 mol naphthalene has been burned in a calorimeter of heat capacity 10283 J/K. As a result, the temperature of the system increased by 1.707ºС. Determine the heat of combustion of naphthalene (in J/mol)? e Ans. 5160 kJ/mol (probably a bomb calorimeter, so this is c U ). c) 1 L of water is boiling. What amount of cold water (3ºC) has to be added to it so that the temperature after mixing is 30 °C? e-n d) You put a hot spoon (90 °C, 30 g, steel) in a glass of cold water (5°С, 100 mL). What is the final temperature of the system, if the heat exchange with the surroundings is minimal? What if the spoon was golden? Parameters: c Fe = 0.45 J/gK, c Au = 0.13 J/gK, c H 2 O,m = 75.3 J/molK. n Ans. 7.7 °C; 5.8 °C. 3. on paper Basics (ii): Hess’s law a) Find the heat of the reaction CaC 2 2H 2 O + Ca(OH) 2 + C 2 H 2 0. Handbook data for the heats of formation of these compounds: CaC 2 H 2 O Ca(OH) 2 C 2 H 2 f H °  , kJ/mol 62.700 285.565 985.644 226.514 b) In any handbook, one can find the standard formation heat of PCl 5 at room temperature. However, if one mixes P and Cl 2 at room temperature, they will not produce PCl 5 at all. The product will be PCl 3 instead, and lots of heat: 2P + 3Cl 2 2PCl 3 , H = 634.52 kJ/mol. The produced PCl 3 can be converted to PCl 5 only under special conditions (increased pressure, appropriate temperature): PCl 3 + Cl 2 PCl 5 , H = 137.15 kJ/mol. What is, then, the formation heat of PCl 5 ? c) It is much easier to measure heats of combustion than heats of formation. Consider, for example, the infamous carbide of tungsten: if you mix solid W and C, you will have to wait ages until WC is formed. However, all three of them can be easily burned and the heat produced is measured as: C + O 2 CO 2 , c H = 393.51 kJ/mol;
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83 W + 3/2 O 2 WO 3 , c H = 837.47 kJ/mol; WC + 5/2 O 2 WO 3 + CO 2 , c H = 1195.8 kJ/mol. What is the formation heat of WC? d) You needed for something the standard combustion heat of gaseous hexane. You open the handbook and you find that it contains everything but the combustion heat of the gas! You can see the heats of formation of liquid and gaseous hexane, f H (G) = -167.2 and f H (L) = -198.7 kJ/mol; you found even a combustion heat, but for the liquid: c H (L) = -4163 kJ/mol. Only c H (G) is missing! Good that you can work it out… e) Find the equilibrium constant K p at room temperature of the reaction 3C 2 H 2 (G) C 6 H 6 (G) . The standard Gibbs energies r G °  of formation of the acetylene and the benzene are 209.2 and 124.52 kJ/mol, respectively. f) Find the room-temperature equilibrium constant of the process CO (G) + H 2 O (G) CO 2 (G) + H 2 (G) . The standard Gibbs energies of formation of CO, H 2 O and CO 2 are 137.26, 394.38 and 228.59 kJ/mol, respectively. 4. Equilibrium composition varying with temperature: heterogeneous reactions a) In chemical processes involving CO at high temperature, there takes place Boudouard ’s 21 reaction 2CO C + CO 2 . The produced “graphite” (better said , carbon nanoparticles or soot) tends to deposit on the reactor walls, the pipework, and the catalyst ( coking ) to cause undesired insulation, decrease in reactor volume, and foul the catalyst. Assume that a reactor produces exhaust fumes of 2 atm containing 5 mol% CO and 2 mol% CO 2 . The temperature in the chimney drops from 1100 K to 800 K. At what temperature the soot production will start? What fraction of CO will be converted to soot before the exit? Parameters: see table below. b) Many engine lubricants contain CaCO 3 nanoparticles. Inside the engine cylinders, these form an aerosol in the cylinder, and decompose to CaO and CO 2 : CaCO 3 CaO + CO 2 . Find the equilibrium vapour pressure p eq of CO 2 (equal to the equilibrium constant of the above process) near a solid composite particle made of a mixture of CaCO 3 (calcite) and CaO crystals. Plot it as a function of the temperature. What will happen with a single CaO particle in gas containing carbon dioxide if p (CO 2 ) > p eq and if p (CO 2 ) < p eq ? How much heat will be released by 1 g of CaO particles if they are cooled down from 1000 °C to 100 °C in a gas containing 5% CO 2 at 2 atm? At what temperature will the reaction start? Sketch schematically how the temperature of one CaO/CaCO 3 particle vary with time during cooling with constant power 22 . Parameters: standard state: 1 bar, 25 °C f H [kJ/mol] f G [kJ/mol] c p [J/molK] calcite -1207.6 -1129.1 83.5 calcium oxide -634.9 -603.3 42.0 carbon 8.5 carbon oxide -110.5 -137.2 29.1 carbon dioxide -393.5 -394.4 37.1 21 /bud ˈ wa/ 22 The heat stored by the hot CaO particle is blamed for the early ignition of the fuel causing engine knock that sometimes causes terrible damage to the cylinders.
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84 5. The simple reversible liquid-phase reaction A 2B takes place in a plug flow reactor a) Calculate the standard reaction enthalpy, the standard free energy, the heat capacity change of the reaction, and the value of the equilibrium constant at room temperature. b) The concentration of A at the entrance of the reactor is 0.5 M, and there is also 11 M of an inert solvent. Neglecting the volume change, find the equilibrium yield of the reaction as a function of the temperature. Plot or sketch the respective equilibrium composition vs T . c) The temperature of the outflow is specified as 400 K; the yield at the exit is specified as 80% of the equilibrium yield. If the reactor is adiabatic, what should the feed temperature be to fulfill the specifications? (Neglect the effect of the thermal expansion of the system on the concentration.) d) Express the temperature along the length of the reactor as a function of the reaction yield, and use it to write the rate law as an explicit function of . Write the space time of the reactor as an explicit integral function of . If using Maple, plot vs. , and compute the space- time of the reactor needed to obtain the specified 80% of the equilibrium yield. Parameters: f H (A) = 130 kJ/mol, f H (B) = 45 kJ/mol; f G (A) = 145 kJ/mol, f G (B) = 70 kJ/mol (standard state 1 M); c p (A) = 70 J/molK, c p (B) = 30 J/molK; c p (solvent) = 17 J/molK; k = 180×exp( E A / RT ) min -1 M -1 , where E A = 30 kJ/mol. 6. Simple reversible liquid-phase reaction in adiabatic batch reactor The reaction is 2A B. a) Find the equilibrium yield V e as a function of the temperature, and sketch it. At what temperature shall the equilibrium conversion be X e = 50%? b) Find the dependence of the temperature of the reactor on the reaction yield. Sketch this dependence on the same plot as a). Mark on this plot the reactor temperature and yield after very large residence time (when equilibrium is reached). c) The reactor uses an organic catalyst that cannot withstand temperature above 130 °C, so the temperature of the reactor at quenching is specified as 125 °C. What is the equilibrium reaction yield and the equilibrium conversion at this temperature? What should be the respective initial temperature of the feed entering the reactor, assuming that the outflow is at equilibrium? d) The real conversion is specified as 90% of the one found in c) (and final temperature is still specified as 125 °C). What should the initial temperature be in this case? Express the time at which the reaction has to be quenched to obtain the specified yield as an explicit integral (and calculate this integral, if you use Maple). Do not forget that the temperature of the reactor varies with V . Parameters: k 0 = 10 -3 h -1 ; E = 66 kJ/mol; H = -35 kJ/mol; K =15 M -1 T 0 = T = 300 K; [A] 0 = 8 M; V = 300 L; heat capacity of the filled reactor: C p = 240 kJ/K. 7. Endothermic reaction in adiabatic CSTR The simple endothermic reaction 2A 3B takes place in an adiabatic CSTR. a) Find [A] and [B] as functions of the space time of the reactor. Sketch/plot your solution.
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85 b) If the mixture temperature is specified as T = 350 K, what should be the feed temperature? Sketch the dependence of T 0 on . c) The conversion of A is specified as 83 %. Calculate the reactor space-time and the feed flow rate. Calculate the composition of the outflow and the required initial temperature of the feed. Parameters: f H (A) = -336 kJ/mol, f H (B) = -201 kJ/mol; k = 210 exp(- E A / RT ) m 3 /mol h, where E A = 34.1 kJ/mol. c p (feed) = 1800 Jkg -1 K -1 , density of the feed = 690 kg/m 3 ; [A] 0 = 4.3 M; reactor volume 100 L. 8. Maple Adiabatic reactors in series Analyse the reaction C 4 H 10 i-C 4 H 10 in a series of adiabatic CSTR and PFR reactors. Conversion of 70% with minimum total reactor volume is required. Illustrate the process in a Levenspiel plot. Parameters as in E6-3.
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86 5 Heat exchange and external work Your job is to: fundamentals say hi to cooling and heating of reactors; skills design the heat exchanger/cooling jacket of a reactor, simulate a non-isothermal reaction by solving numerically differential equations. The heat balances (4-13)&(4-14) for adiabatic reactors, which we analysed in the previous section, are rarely realistic models for the reactors used in practice. Real reactors are always equipped with means of controlling the temperature: various heat exchangers, cooling or heating jackets, electrical heating devices (as in the case of the mundane batch reactor called cooking pot ). Some reactors utilize also infrared or microwave heating. In addition, real reactors are never perfectly insulated, i.e. heat is exchanged with the air and the ground. Finally, both batch and CST reactors are heated to an extent by the mixing devices. In this section, we analyse how these common sources/sinks of heat affect the chemical processes taking place in the reactor. 5.1 Batch reactor The heat delivered to the mixture inside our batch reactor for a small time interval d t includes three contributions: (i) the reaction produces heat − H d (where d is the amount of reaction that took place for the period t t + d t ); (ii) heat will be delivered to the mixture from the heat exchanger / the electrical heating system / the ambient medium, with a specified heat rate J Q [J/s]. The amount of this heat is d Q = J Q d t . Cooling corresponds to negative value of J Q . ( iii) If the mixture is stirred by a stirrer or any other mechanical device, the power J W driving the device is dissipated as heat by friction against the flow of the mixture, which delivers additional J W d t joules to the reactor. This contribution is known as the shaft work . The sum of these three contributions will heat up or cool down the reactor by d T ; the heat balance reads C p d T = − H d + J Q d t + J W d t , where C p is the heat capacity of the reactor (the sum of the heat capacities of the mixture, the catalyst, and the pieces of the reactor that are heated or cooled, eq. (4-17)). Dividing this balance by d t , we obtain a differential equation for the temperature T ( t ) of the reactor: d Δ d p Q W T C V Hr J J t = − + + , (5-1) J W J Q 1 J Q2 J Q3
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87 where d /d t Vr , by definition of reaction rate. If there are several reactions that produce heat simultaneously, the heat balance has to take into account all of them: d Δ d p j j Q W T C V Hr J J t = − + + . (5-2) Normally, the shaft work is small compared to the other terms (though rarely negligible). The main new thing in this equation compared to the previous section is the external source of heat coming with J Q . Each specific heat source comes with a different expression for J Q . We will consider in more detail some variants in sec. 5.4. 5.2 Plug flow reactor with thermal fluid jacket One of the most common problems faced by us chemical engineers is the design of the cooling system for a PFR in which an exothermic reaction takes place. As a rule, PFRs are used for fast reactions; without cooling, a PFR is approximately adiabatic, and we already know from sec. 4.2 that this is troublesome the exothermic adiabatic reactions are self-accelerating and most of the heat is delivered within a short section of the tubular reactor (called the hot zone/the hot spot of the reactor). Such a peak in the heat flux is undesirable it can lead to poor selectivity, poor yield (especially for reversible reactions), carbon formation, local deactivation of the catalyst, corrosion, poor control of the reactor. Let us derive the heat balance for a cooled plug flow reactor. The most common cooling system is that of jacketed PFR the mixture passes through the central tube, often through the immobilized catalyst pellets. The thermal fluid is passed through the outer compartment. Many important processes take place in such a reactor, especially exothermic reversible reactions, e.g., the synthesis of ethylene oxide from ethane: C 2 H 4 + ½ O 2 C 2 H 4 O, which takes place together with the even more exothermic parallel combustion process, C 2 H 4 + 3O 2 2CO 2 + 2H 2 O. For you to have a proper picture of this process, the steel PFR used for it is 25 mm in diameter of the central tube, 5 m long. The thermal fluid is a boiling hydrocarbon i.e. the heat of the reaction in the central tube is consumed by the vaporization process in the jacket. Phase transitions are widely used for cooling and heating purposes, but dealing with a boiling thermal fluid is complex and here we consider the most common and simpler case, where the heat of the reaction is spent on heating up the thermal fluid. Consider a small cylindrical volume of moving liquid in a tubular reactor, with circular cross-section R c 2 , of volume V = R c 2 L (see the figure above). The symbol Y here means very small and proportional to the length L , where the quantity Y can be volume V , side area A , heat capacity C p . R c is the radius of the cylindrical tube. (1) For a small residence time d , this small volume produces reaction heat of amount H d , where d = r V d (5-3) are the moles of reaction that took place for the period of residence times +d inside the small volume V ( d Y means quantity Y proportional to both d V and d ). (2) For the same period, an amount of heat d Q will be transported through the wall from the fluid in the cooling jacket to the mixture, and
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88 d Q = j h A d , where j h = k h ( T F T ). (5-4) Here, j h is the heat flux through the wall [J/m 2 s], T F is the temperature of the thermal fluid, and k h is the heat transfer coefficient of the wall. If the fluid is a coolant ( T F < T ), the heat flux will be negative. These two sources of heat result in an increase in temperature of the mixture by d T degrees (“d” , because it is proportional to d ). If the heat capacity of the liquid of volume V is C p , the heat balance reads δ d δd Δ δd p C T Q H = . Substituting here eqs. (5-3)&(5-4), and using that the contact area with the wall is A = 2 R c L (area of the side wall of a cylinder), we obtain ( ) F c δ d δ d Δ δ d p h C T k T T R L Hr V = . Now we divide by d and V and rearrange: ( ) F c δ 2 π d Δ δ d δ / δ p h C R T k T T Hr V V L = . Here C p / V = c pi C i is the heat capacity per unit volume of the mixture (the parts of the reactor and the catalyst should not be counted, as we consider stationary state of the PFR; c pi is specific heat capacity of the i th component [J/mol K], and C i is its concentration [mol/m 3 ]). The derivative V / L is equal to R c 2 (volume of the cylinder / height of the cylinder). This leads us to the final form of the heat balance: ( ) ( ) F d Δ d reaction exchange with heat mixture heating thermal fluid pi i h T c C T T Hr = , where h = 2 k h / R c . (5-5) The new “overall” heat transport coefficient h is in units J/K m 3 s, and unlike k h , it varies with the size of the tube (tubes of small diameter have higher h and exchange heat with the thermal fluid more efficiently). Note that in this equation d is the differential of the real residence time d = v 1 d V , and not the effective residence time, v 0 1 d V , which we used here and there in the previous sections. Therefore, in the equation above, the flow rate v may vary along the length of the reactor. Eq. (5-5) can be compared to its adiabatic variant (4-16). Another useful form of this equation is with variable L instead of : since d = v 1 d V = R c 2 v 1 d L , eq. (5-5) can be written as reactor: ( ) ( ) F 2 c c d 2 π π Δ d pi i h T v c C R k T T R Hr L = . (5-6) This equation is convenient as we can immediately apply it to the thermal fluid (which is not as straightforward with eq. (5-5), because the thermal fluid is of different residence time F compared to the mixture, i.e. we will end up with two variables, and F , instead of just L ). To do this, we note that there is no reaction inside the thermal fluid to produce heat, so the last term disappears. Also, the heat 2 R c k h ( T F T ) leaves the thermal fluid to arrive at the mixture, so the sign of this term changes. Finally, the flow rate and the heat capacity of the thermal fluid are, of course, different. This leads to the balance thermal fluid: ( ) F F F F F c d 2 π d p h T v c C R k T T L = − . (5-7) We can now easily return to the mixture’s residence time as variable using d = R c 2 v 1 d L to get rid of d L : ( ) F F F F F d d p h v T c C T T v = − . (5-8) Here, v F / v is positive when the direction of the mixture flow is the same as the direction of the thermal fluid flow then we speak of co-current double-pipe heat exchange . If v F / v is negative,
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89 this means that the two currents flow in opposite directions this is the case of counter-current double-pipe heat exchange . As we shall see, the two variants correspond to very different reaction rates and yields. Example 7-1. Consider the isomerization of butane with heat transfer in a PFR. The reaction is the same as in Example 6-3, C 4 H 10 i-C 4 H 10 , and is exothermic. Inert isopentane is present. Simulate four variants of this reaction: a) with co-flow double-pipe heating/cooling; b) with counterflow double-pipe heating/cooling; c) with constant temperature of the cooling liquid (high flow rate v F ); d) adiabatic, as a limit of variant a). Plot the composition, X , X e , T , T F and r as they change down the length of the PF reactor. It is desired to keep the temperature below a limiting value of T lim = 55 °C, due to side reactions. Shall the conditions specified below lead to mixture temperature above T lim ? Thermodynamic data : H = 6900 J/mol; K 60 °C = 3.03; c p (butane) = 141 J/molK, c p (i-butane) = 141 J/molK, c p (i-pentane) = 161 J/molK. Rate data : k f (360 K) = 31.1 h -1 ; E = 54.7 kJ/mol. Reactor’s space time: = 2 h. Inflow : T 0 = 305 K; F butane0 = 163 kmol/h through 10 tubes; [butane] 0 = 9.3 M; 10% inert i-C 5 H 12 . Thermal fluid : T 0 F = 315; mass-specific heat capacity of the fluid c m F = 6 kJ/kg K; mass flow rate of the thermal fluid F m F = 500 kg/h per tube; h = 5000 kJ/m 3 hK. Solution. The solution of this problem is numerical. The explicit equations we solve are, first, the mole balance: d V /d = r , where ( ) f [b] [i]/ r k K = , [b] = [b] 0 V ( ), [i] = V ( ), (5-9) f f 1 1 exp ( ) E k k R T T = , Δ 1 1 exp ( ) H K K R T T = . We use [b] for the concentration of butane, [i] for isobutane and [p] for pentane. The other two equations are the heat balances for the mixture and for the thermal fluid, eqs. (5-5)&(5-8): ( ) ( ) F d ( ) ( ) Δ d pi i h T c C T T Hr = , (5-10) ( ) F F F F d ( ) ( ) d m m h c F T T T v = − , where we used that F F F F F p m m v c C c F = . (5-11) The sum in eq. (5-10) is the heat capacity per unit volume of the mixture: ,b ,i ,p ,b 0 ,p [b] [i] [p] [b] [p] 1478 J/KL pi i p p p p p c C c c c c c = + + = + = , where the relation (5-9) between [b], [i] and V was used. The initial conditions for the three equations are V (0) = 0; T (0) = T 0 ; T F (0) = T 0 F . By typing the equations and substituting all the values in Maple (see the solved .mw example) , we obtain the following results: a) Co-flow heating/cooling.
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90 At the entrance ( = 0), the thermal liquid has higher temperature than the reaction mixture and thus it heats the mixture up, accelerating the onset of the reaction. However, after residence time of ~15 minutes, the reaction has produced so much heat that the mixture becomes hotter and now the thermal fluid acts as a coolant. As it follows from eq. (5-11), the point where T F and T ( ) cross is always an extremum of T F ( ) this is the point dividing the cooling zone from the initial heating regime. Initially, the reaction rate increases (due to the Arrhenius dependence of r on the temperature), but then it decreases to zero as the equilibrium is approached. The thermal fluid is successfully keeping the mixture’s peak temperature below the limiting 55 °C. If the reactor is long enough, the mixture and the thermal fluid equilibrate to the same temperature. It is interesting to compare the reaction at several different values of the thermal fluid flow rates F m F this is done in the following figure: At very low F m F , the heating/cooling is insignificant and the reaction yield and temperature profiles in the reactor are unchanged compared to the adiabatic case. At very high F m F , the temperature of such large amount of coolant remains unaffected by the heat produced by the mixture and T F is of almost constant this is the excess coolant limit. b) Counterflow heating/cooling. There are only two changes in the equations we solve compared to a). The first change in our equations is that now the coolant flow is in the opposite direction, so a minus sign appears in eq. (5-11): ( ) F F F F d ( ) ( ) d m m h c F T T T v = − . [min] V [M] [min] T [ C] r [M/h] [min] T [ C] mixture thermal fluid 500 kg/h 125 kg/h 2500 kg/h
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91 We could, of course, simply use a negative value of the thermal fluid flow rate F m F . The second change is that the boundary condition is different the temperature of the thermal fluid is fixed at the exit of the reactor (as there is the entrance of the thermal fluid in counterflow double-pipe setup): T F ( ) = T 0 F ; (5-12) here, is the value of the residence time at the exit of the reactor. Unfortunately, the numerical procedures of Maple are likely to fail if you solve a system of ODE for three functions, with two of the boundary conditions imposed at = 0 and one at = . 23 Therefore, instead we need to guess the temperature at the entrance of the reactor (the exit of the thermal fluid) so that the condition T F ( ) = T 0 F is fulfilled. That is, we need to solve our problem with boundary condition T F (0) = value many times with a different value , until the computed fluid temperature T F ( ) at the other end of the reactor gives the right result. For the problem we solve, the value obtained by trial and error in the Maple code is 58 °C. The results for V ( ), T ( ) and T F ( ), together with the equilibrium yield V e , eq. (4-27), and the reaction rate, are plotted in the following figure: As demonstrated, the counterflow of thermal fluid has a very different effect from the co-flow. At the exit of the reactor, the fluid is cooling the mixture for a significant length of the reactor (say, = 30-120 min). This has two positive effects: first, the cooling of the mixture shifts the equilibrium to higher yields, and some precious few percent of conversion can be gained (the “won by cooling” arrow in the first figure). Second, the thermal fluid uptakes the heat produced by the reaction and stores it, until it reaches the entrance (the zone = 0…15 min), where it delivers it to the entering mixture, accelerating the onset of the reaction. Thus, a counterflow double-pipe heat exchange is an elegant way to use the heat of the reaction efficiently to heat the feed. However, a comparison between the co-flow and the counterflow curves will show that in the counterflow case, the main amount of reaction takes place much faster than with the co-flow, i.e. the counterflow is not very efficient at cooling the mixture in the first 0-30 min of the residence time. This results in a much higher peak of the mixture temperature, around 76 °C, well above the specified limiting temperature. Let us again consider several different values of F m F : 23 The standard methods to solve ODEs numerically (Newton, Runge-Kutta etc.) are working out the values of the function in each next node from the values in the previous node, i.e. from T 0 , T 0 F and V 0 , the numerical procedure will find the values T ( ), T F ( ) and V ( ) by substituting the derivatives in the three ODEs with divided differences , and then treating them as algebraic equations. On the next step, T (2 ), T F (2 ) and V (2 ) are computed and so forth. The boundary condition (5-12) requires instead all steps to be solved simultaneously, which is complicated, and the existing procedures for such problems are often unstable and require a good initial approximation. [min] V [M] [min] T [ C] V e V r [M/h] won by cooling
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92 For very slow countercurrent of the thermal fluid, the mixture is behaving adiabatically, and for very fast countercurrent, we will again approach the excess coolant limit, where the temperature of the thermal fluid is constant. A feature of the above figure is that, at the intermediate flow rate, F m F = 500 kg/h, the thermal fluid reaches the entrance hotter than at 250 kg/h or 2500 kg/h. The reason: a large amount of thermal fluid has a large heat capacity (which means that the heat of the reaction will produce smaller increase T F of the thermal fluid temperature); in addition, high flow rate means the thermal liquid is in contact with the hot zone for a shorter period of time. On the other hand, the 250 kg/h case corresponds to a small amount of the thermal fluid that equilibrates relatively quickly with the mixture the mixture at the entrance is cold, and this leads to a significant cooling of the thermal fluid. The cases c), constant temperature of the thermal fluid (excess coolant limit) , and d), no heat transfer (adiabatic limit) are obtained as low rate/high rate limits of both the co- flow and the counterflow cases. If F m F is set equal to zero in (5-11), it immediately follows that T F = T , and then the heat exchange term h ( T F T ) in the heat balance (5-10) of the mixture disappears to restore the adiabatic form of the balance. If F m F is set to infinity, from eq. (5-11) it follows that d T F /d = 0, i.e. the thermal fluid temperature is constant. This is valid for both co-current and countercurrent regimes: v F 0 medium rate exothermic reaction, co-current flow regime adiabatic mixture, as if no thermal fluid is present effective for cooling the mixture near the reaction rate peak, used for strongly exothermic reactions excess coolant limit, the temperature of the thermal liquid is constant exothermic reaction, countercurrent flow regime cools the reaction mixture after the reaction rate peak (good for reversible reactions as equilibrium conversion increases); delivers the heat of the reaction to the feed (good way to utilize the energy produced by the reaction) [min] T [ C] mixture thermal fluid 500 kg/h 250 kg/h 2500 kg/h
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93 Example 7-2. Consider the gas-phase irreversible endothermic reaction of cracking of acetone: CH 3 COCH 3 CH 2 =C=O + CH 4 , or for short, A B + C. This reaction produces the explosive ketene CH 2 =C=O, which is further used for the production of acetic anhydride. The reaction is 1 st order with respect to the acetone. Simulate four variants of this reaction in a PFR: a) with a co-flow heating/cooling; b) with a counterflow heating/cooling; c) with constant temperature of the cooling liquid (high flow rate v F ); d) adiabatic, as a limit of a). Plot the dependence of the composition, X , X e , T , T F and r down the length of the PFR reactor. It is desired to keep the conversion below X lim = 20%, due to danger of explosion. Shall the conditions specified by the following parameters lead to conversion below X lim ? Thermodynamic data : H (1035 K) = + 80.77 kJ/mol; c p A = 163 J/molK, c p B = 83 J/molK, c p C = 71 J/molK. Rate data : k = exp(34.34 34222/ T [K]) s -1 . Geometry : volume per tube 1 L, inner diameter 28.3 mm. Inflow : T 0 = 1035 K; F A0 = 135 kmol/h through 1000 tubes; p = 162 kPa (constant). Thermal fluid : T 0 F = 1250; c p F = 34.5 J/mol K; F F = 0.111 mol/s per tube; k h = 110 J/m 2 sK. Solution. The explicit equations we solve are once again the mole balance and the two heat balances. The mole equation follows from the balance d F A = r A d V ; using that F A = F A0 (1 X ( )), X being the conversion, and that r A = r , we can write: A0 d d X r V F = , where (5-13) [A] r k = , and ( ) ( ) 0 A 0 0 1 1 ( ) [A] 1 2 1 ( ) ( ) n X n p p X V p n RT n X n X RT X V RT V = = = + + . We used that n = n A + n B = n 0 (1 + X ), where n 0 is the initial number of moles of acetone. The other two equations we need are the heat balances for the mixture and for the thermal fluid, eqs. (5-5)&(5-8); however, we will use V as variable. The first one balances the heat to alter the temperature of the mixture, vc pV d T ( c pV heat capacity per unit volume), and the sum of the heat lost through the walls, k h ( T F T )d A , and the reaction heat − Hr d V . This leads to ( ) F d ( ) ( ) Δ d pV h T vc T V T V Hr V = , (5-14) where ( ) 0 0 0 A 0 0 0 0 0 Δ i i pi i pi pi p p n pv n pv nT p v c C v c c c c X n T n RT RT n RT = = = + , c p = c p B + c p C c p A = 9 J/molK is the heat capacity of the reaction. We used that d A /d V = 2/ R c , and that h = 2 k h / R c . Also, we used the ideal gas law for C i and v ( C i = p i / RT = n i p / nRT ; v / v 0 = nT / n 0 T 0 , where subscript 0 indicates the initial values at the entrance). Likewise, for the thermal fluid, the balance is between F F c p d T and k h ( T F T )d A , which gives ( ) F F F F d ( ) ( ) d p h T c F T V T V V = − . (5-15) Eqs. (5-13)-(5-15) are solved numerically for T ( V ), T F ( V ) and X ( V ) with Maple in the examples file. Let us now consider the four study cases.
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94 a) Co-flow double-tube heat exchange. The numerical solution is plotted for 3 values of the thermal fluid flow rate F F : The considered system is relatively simple: the heating fluid just delivers heat to the mixture, compensating for the endothermic process (which, in the absence of external heating, would soon freeze the reaction). The flow rate specified in the problem statement ( F F = 0.111 mol/s) is too high and results in conversion well above X lim . To avoid the danger of explosion, lower F F is required (0.02775 mol/s in the figure results in X only slightly higher than X lim ). In this case, however, a significant length of the reactor is not utilized at all little conversion is obtained for V from 0.6 to 1 L. b) Counterflow double-pipe heat exchange. The numerical solution is illustrated in the following figure: At the specified thermal fluid flow rate (0.111 mol/s), the heat of the fluid is mainly used to heat up the mixture at the end of the reactor. The reaction takes place mostly in the beginning and at the end of the reactor, as the mixture is too cool between V = 0.2 and 0.6 L. Nearby the rate peak, where the reaction heat is consumed, T F decreases significantly, even below the initial temperature of the mixture. Therefore, for this configuration, the thermal fluid acts as a coolant right at the entrance of the reactor (it delivers the positive reaction heat to the feed). This is an obvious nuisance we normally want to keep the feed temperature high for an endothermic reaction. The temperature profiles at F F of 0.444 mol/s are more reasonable; yet, for this particular problem, the counter-current heat transfer is less suitable than co-current, as it always delivers the positive reaction heat to the feed. V [L] T [K] mixture thermal fluid 0.111 mol/s 0.02775 mol/s 0.444 mol/s V [L] X V [L] T [K] mixture thermal fluid 0.111 mol/s 0.444 mol/s V [L] X
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95 The adiabatic case c) is obtained by the same code, by setting F F to 0 (or h to 0 no heat conductivity of the wall). The constant T F case d) is obtained by setting F F to ∞ (or directly by setting T F to its initial value). The two mixture temperature and conversion profiles are illustrated in the figures above. Note that the temperature and the conversion at the exit of the reactor is monotonous functions of F F , and the adiabatic / excess coolant cases set the lower and the upper limits of these. However, T and X near the entrance of the reactor are not monotonous with F F , due to the reaction heat being delivered to the feed. Let us summarize our findings for endothermic reactions in another table: v F 0 medium endothermic reaction, co-current flow regime adiabatic mixture, as if no thermal fluid is present ○ effective for heating up the mixture near the reaction rate peak excess coolant limit, the temperature of the thermal liquid is constant endothermic reaction, countercurrent flow regime ○ heats the reaction mixture after the reaction rate peak (good for reversible reactions as equilibrium conversion increases, but not for irreversible ones); ○ delivers the positive heat of the reaction to the feed, which is rarely desired. 5.3 Continuous stirred-tank reactor The heat balance of a CSTR is derived like that of a batch reactor. The heat delivered to the mixture for a small time d t includes the same 3 contributions: (1) the reaction taking place will produce heat − H d = − HVr d t , where d is the amount of reaction that took place for the period t t + d t . We used that r = V 1 d /d t by definition. (2) The heat d Q = J Q d t will be delivered to the mixture from the heat exchanger / electrical heating system / ambient medium. (3) If the mixture is stirred by a fan or another device, the shaft power J W consumed by the device is dissipated as heat by the viscous friction in the stirred mixture, and delivers additional J W d t joules to the reactor. However, in comparison with a batch reactor, the temperature of the CSTR is stationary. The sum of the contributions (1-3) will heat only the feed, from its initial temperature T 0 to the reactor operational temperature T . The heat required for this heating is c pi C i 0 ( T T 0 ) v d t . The respective heat balance is therefore: ( ) 0 0 Δ pi i Q W c C T T v V Hr J J = − + + . (5-16) This can be compared to the adiabatic heat balance (4-32). 5.4 Radiator coil heat exchanger The heat exchanger is, in first approximation, a long tube inside the batch/CST reactor, of walls of good heat conductivity, through which the coolant/the heating fluid flows. The thermal fluid enters the exchanger at a temperature of T 0 F and leaves it at T F . The heat balance for a small section of the exchanger is similar to that of a PFR, eq. (5-6), but without the reaction term:
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96 ( ) F F F F c d 2 π d p h T F c k T T R L = . Of course, in this case the reactor (of temperature T ) delivers heat to the thermal fluid, and not the opposite. We can easily solve this equation by separation of variables: F F 0 F F F c c F F F F F F F F F 0 2 π d d d ln T h h h p p p T R R L k A T T T T k L k T T F c T T F c T T F c = − ⎯⎯→ = − ⎯⎯→ = − . Here, A = 2 R c L is the contact area of the thermal fluid and the wall. Solving this equation for T F leads to the profile of the temperature of the thermal fluid along the length of the heat exchanger: ( ) F F 0 F F exp h p k A T T T T F c = + . Thus, the temperature drops exponentially with A , until the minimum possible value is reached ( T F = T , corresponding to thermal equilibrium). If the total area of the exchanger is A , then the temperature at the exit is: ( ) F F 0 F F exp h p k A T T T T F c = + . (5-17) For a CSTR , it is customary to specify the temperature T F of the thermal fluid at the exit instead of the flow rate F F of it. Е q. (5-17) is used accordingly to determine the flow rate needed to produce the required T F the solution for F F is: F F F 0 F ln h p k A F T T c T T = . (5-18) The most important characteristic of the exchanger is the power of the heat flux towards the reactor, as this is what appears in the heat balance (5-16). It can be computed as the difference of the molar enthalpy at the entrance and the exit of the exchanger, c p F ( T 0 F T F ), times the molar flux F F : ( ) F F F F F F 0 0 F 0 F ln Q p h T T J F c T T k A T T T T = = , form useful for CSTR. (5-19) For large flow rates / small contact areas, when k h A / F F c p F << 1, the exponent in eq. (5-17) can be expanded into series, which leads to ( ) ( ) F F F F 0 0 0 F F F F 1 h h p p k A k A T T T T T T T F c F c + = . Substitution of this into eq. (5-19) gives the simple linear formula ( ) ( ) F F F F F 0 0 Q p h J F c T T k A T T = = , high F F /low A limit. (5-20) For a batch reactor , where usually F F is kept constant but the reactor temperature changes, a more useful form is obtained by substituting (5-17) in the formula J Q = F F c p F ( T 0 F T F ): ( ) F F F 0 F F 1 exp h Q p p k A J F c T T F c = , form useful for batch reactor . (5-21) J W : it might depend on T as well, mainly through the viscosity; it might also be set to a fixed value (in which case the rpm vary with T ).
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97 Example 7-3. The main stage in the commercial production of propylene glycol is the hydrolysis of propylene oxide (following a S N 1 mechanism): O CH 3 O H 2 + CH 3 OH O H or for short, A + B C. This exothermic reaction takes place in a CSTR. The propylene oxide in methanol solution (15 °C) is mixed with water (15 °C) right before entering the reactor. The mixing enthalpy results in immediate increase in feed temperature to T 0 = 24 °C. The reactor temperature should not surpass the specified limiting value, T lim = 328 K, above which the propylene oxide is too volatile and is lost through the vent system. Find the temperature and the composition of the mixture in the reactor for (i) adiabatic operation, and (ii) radiator coil cooling. Assume that neither the mixing, nor the reaction, nor the temperature change the volume of the liquids. Thermodynamic data : H = 83.8 kJ/mol; c p A = 147 J/molK, c p B = 75 J/molK, c p C = 193 J/molK, c p ,MeOH = 82 J/molK. Rate data : the reaction follows a 1 st -order rate law r = k [A]; the Arrhenius parameters are k 0 = 16.96 10 12 h 1 , E A = 75.4 kJ/mol. Reactor volume : 1 m 3 . Feed temperature: 24 °C. Coolant enters at T 0 F = 18 °C (analyse also 0 and 36 °C). Inflow : v A = 1.3 m 3 /h, v B = 6.6 m 3 /h, v MeOH = 1.3 m 3 /h, F A0 = 18.6 kmol/h; F B0 = 365.4 kmol/h; F MeOH,0 = 32.1 kmol/h. Cooling device : radiator coil of area 0.26 m 2 and heat transfer coefficient k h = 2044 kJ/m 2 hK; assume the linear formula (5-20) is valid. Shaft work: J W = 15 MJ/h. Solution. The explicit equations we solve are the mole balances and the heat balance for the reactor. The mole balances are, according to eq. (1-72), A0 B0 [A] [B] = = − v F v F rV ; [C] v rV = . The rate is r = k [A]; therefore, from the 1 st equation we get 0 A0 [A] [A] 1 F k v kV = = + + , (5-22) and from the other two, B0 A0 [B] F F V k v v kV v = + ; A0 [C] F V k v kV v = + . Here, k is still undefined as the temperature of the reactor is not specified. The temperature is the solution of the heat balance (5-16), with J Q from eq. (5-20): ( ) ( ) F A0 0 0 0 Δ pi i h W F c F T T V Hk k A T T J v kV = − + + + . (5-23) We used the result (5-22) for [A] and the relation F i 0 = vC i 0 . In the above equations, according to the assumption v = v A + v B + v MeOH = 9.2 m 3 /h. The heat of the reaction is temperature- dependent, H = H + c p ( T T ), with heat capacity of the reaction equal to c p = c p C c p A c p B = -29 J/molK. The total heat capacity of the feed entering the mixture per unit time is c pi F i 0 = 32.8 MJ/hK. For the adiabatic case (1), the heat balance simplifies to ( ) A0 0 0 Δ pi i F c F T T V Hk v kV = − + . (5-24)
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98 Eqs (5-23)&(5-24) are non-linear equations for T , and as a rule, they have several solutions. Let us define the excess heating power as ( ) ( ) F A0 ,excess 0 0 0 Δ h h W pi i F J V Hk k A T T J c F T T v kV = − + + + , ( ) A0 ,excess 0 0 Δ h pi i F J V Hk c F T T v kV = − + in the adiabatic case . J h ,excess is an explicit function of the temperature, and is plotted in the figure below. When this quantity is positive, the reaction and the mixer produce more heat than the cold feed and the coolant consume. In such case, the excess heat leads to unsteady heating of the mixture ( T will increase with time, according to the non-stationary heat balance C p ,tot d T /d t = J h ,excess , where C p ,tot is the total heat capacity of the reactor + the mixture). When J h ,excess is negative, then the coolant plus the cold feed win, and there will be non-stationary cooling of the system ( T will decrease with time, C p ,tot d T /d t = J h ,excess < 0). Finally, when J h,excess = 0, the reactor is in steady state and the stationary state heat balance (5-23) or (5-24) is fulfilled 24 . Fig. 17. Excess heating power as function of temperature for adiabatic CSTR ( left ) and CSTR with heat exchange and shaft work ( right ) at three temperatures of the coolant. In the adiabatic case, if the temperature of the reactor is below 309 K, the heating power is positive, so T will increase with time. This will continue until the steady state at 309 K ( solution 1 ) is reached the reactor reaches stationary operation point there. If the initial temperature of the reactor is between 309 and 321 K, then J Q ,excess < 0 and the reactor will be cooling down with time, until the steady T = 309 K is reached again. Such a stationary state is stable ( attractor ); a small perturbation of the temperature of the reactor (e.g. to 308 or to 310 K) will be quickly compensated by the excess heating power and the temperature will decay back to 309 K. The third solution (329 K) is of the same kind. However, the second solution is unstable if the temperature is higher than 321 K by any small amount (+0.0001 K), the temperature of the reactor will be increasing with time until it runs away from the unstable steady state, 321 K, to the stable one, 329 K. If the temperature is by any small amount lower than 321 K, the reactor will relax to the 1 st solution, 309 K. Thus, for precisely the same variables (feed temperature and composition, cooling device etc.), the CSTR can operate in two different steady states. Which steady state will be actually reached depends mainly on the initial temperature (and the initial composition, see the footnote) of the reactor, and more precisely on whether the initial temperature is below or above the 24 This analysis is rigorously valid only in case that, at the temperature in question, the reaction is fast enough so that the steady state composition (5-22) is established much faster than the thermal equilibrium. Otherwise, one has to consider also the excess yield of the reaction. J Q ,excess [MJ/h] solution 3: 329 K, X = 66% solution 1: 309 K, X = 25% solution 2: 321 K, X = 50% T [K] J h ,excess [MJ/h] T 0 = 36 C 0 C 18 C F T [K] x x
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99 unstable steady state temperature 321 K (and whether the initial conversion is above or below 50%). Let us now consider case (2): CSTR with heat exchange and shaft work (Fig. 17- right ), at three different temperatures of the coolant, 0, 18 and 36 °C. The 18 °C coolant case is similar to the adiabatic case. The temperature of the reactor in the hotter steady state decreases (due to cooling), while the temperature of the colder stationary state increases (cooling ( T T 0 F ) is less efficient at lower temperature, and the shaft work term dominates). However, the other two cases, 0 and 36 °C, produce a qualitatively different picture only one steady state is possible at these operation points. Consider a case where the CSTR operated at the hotter steady state is gradually cooled down by decreasing the temperature of the coolant. As the temperature of the coolant is decreased from 36 to 18 °C, not much happens the temperature of the CSTR decreases a little bit from 330 K to 327 K. However, if the coolant is further cooled to 0 °C, the steady state operation of the CSTR will suddenly become impossible in the temperature range of around 325- 330 K. The reactor will “jump” to the second steady state at 308 K, with a completely different steady state composition. On the opposite, if the reactor is operated at the lower temperature and the temperature of the thermal fluid is gradually increased from 0 to 36 °C, the reactor will react little between 0 and 18°C, remaining at around 310 K, but once the 1 st steady state disappears, it will jump to 330 K. Multiple steady states are more common than many engineers imagine and are a source of much confusion. The need to “jump over” a useless steady state in order to reach the real operation point can be an issue for all continuous reactors (PFR, laminar, fluidized bed etc.), and has many names. An important example is the automotive catalytic converters. When you start your car, the converter is still cold and will operate at a low-temperature steady-state point for some time (up to 5 min). As the exhaust heats up, at a specific critical feed temperature, the transition to the high-temperature steady state suddenly appears, where the exothermic reactions (oxidation of CO and reduction of NO) produce heat that maintains an increased temperature of the catalyst. The auto engineers call this particular multi-steady state phenomenon converter light-off . It is not just that you produce poison for 5 min: the sudden increase in temperature damages the catalyst and reduces its “life expectancy” due to sintering (see ne xt section). Therefore, our chemical engineer community is under constant pressure to minimize it, both as time (an expensive converter can light-off after less than a minute) and as temperature jump upon light-off. Interstage cooling for reactors in series. Maps and trajectories. Optimal trajectory for exothermic reversible. Optimal rate vs. optimal selectivity. Problems with reading trajectories draw T(t) and C(t) for var. trajectories Optimal temperature progression as X increases from 0 to X for single irreversible and endothermic reversible reaction, optimal T is the highest (not the case for multiple) for reversible reaction, optimal T is the one that maximizes the rate. Locus of maximal rates (start at Tmax, then decrease it) Effect of the inerts. Effect of the gradients in r direction. Examples of consecutive reactors and strategies:
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100 Methanol from syngas, CO+2H2 MeOH, -25 kcal/mol 250 °C reversible and slow in practice, interstage cooling and cold feed injection Water-gas shift, CO + H2O CO2 + H2 two reactors, one at 800 and a second at 250 °C Read more Levenspiel ch. 9 [1]; Fogler’s ch. 12 [ 2]; Schmidt’s ch. 5 and 6 [14]. Supafastquiz Relate cooling device to reactor where it might be used: PFR cool feed gas injections batch reactor coil CSTR cooling jacket membrane tubular reactor electrical heating system catalytic Haber-Bosch a central tube with heating fluid Will this increase or decrease the heat/cooling duty J Q of the thermal system of a reactor: - decrease the area of a coil; - increase the thickness of the wall between the jacket and the PFR; - increase the temperature of the thermal fluid at the entrance of the jacket/coil; - change the thermal fluid to something of lower heat capacity; - increase the flow rate of the thermal fluid. Problems 1. Short and long exchangers Very often, eq. (5-21) is used in one of two limiting forms. a) In the first case, the engineer would like to extract as much heat as possible from the heating fluid. This is the long tube limit; the thermal fluid leaves at temperature equal to T . Derive the limits of eqs. (5-17)-(5-21) at A ∞. b) In the second case, the engineer tries to maximize the reactor volume and therefore keeps the exchanger as short as possible. Derive the limits of eqs. (5-17)-(5-21) at A 0 (use linear expansion of the exponents). 2. Heat transfer coefficient a) The overall heat transfer coefficient of a PFT reactor is h = 15 kJ/s m 3 . The diameter of the wall is 20-in; the length is 10 m; the thickness of the wall is 5 mm. What is the value of the specific coefficient k h ? How will h change if - the diameter is decreased to 15-in?
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101 - If the length is decreased to 5 m? - If the thickness of the wall is increased to 6 mm? b) To measure the heat transfer coefficient of a reactor, we pass thermal fluid at very high flow rate through the jacket (so that T F = const ); another thermal fluid (not the reactive mixture, but perhaps something resembling it e.g., just the solvent at the expected reaction temperature) is passed through the central tube. The temperature at the entrance is T 0 and is controlled; the one at the exit is T and is measured. - Solve the heat balance (5-5) to show that ( ) F F 0 ( ) exp( / ) h pV T T T T c   = + . - The fluid enters the reactor compartment at 330 and exits at 324.4 K. Find h and k h . The reactor is a cylinder 6 cm in radius and of 3.5 m length. The temperature of the coolant is 320 K. Heat capacity of the fluid in the reactor compartment: c pV = 2200 J/LK. Flow rate is 0.44 L/s. 3. Maple Endothermic liquid-phase A + B 2C in an isochoric catalytic batch reactor Simulate the evolution of the temperature, the conversion X = V /[A] 0 , and the composition [A], [B] & [C] inside a batch reactor where the simple endothermic reaction A + B 2C takes place. You have to solve the heat balance eqs. (5-1) together with the mole balance d V /d t = r using Maple’s dsolve(…, numeric, output=listprocedur e) . Ignore the shaft power J W . At what quenching time will the conversion be 95%? The reactor contains catalyst pellets of quite a significant volume V c and heat capacity; therefore, only a part V tot V c of the volume reactor is available for the reaction mixture. Thermodynamic data : f H A = +155 kJ/mol; f H B = 15.5 kJ/mol; f H C = + 250 kJ/mol; c p A = 15 J/molK; c p B = 35 J/molK; c p C = 25 J/molK. Rate data : k = 10 3 ×e 9260×(1/ T [K] 1/298) M 1 min 1 . Geometry : V tot = 100 L, but some is occupied by the catalyst. Catalyst : mass m c = 15 kg, specific heat capacity c c = 1150 J/kgK, density 0.9 kg/L. Initial state : T 0 = 298 K; [A] 0 = 5 M, [B] 0 = 6 M. Thermal fluid : constant T F = 650 K; coil coefficient k h A = 100 J/sK. 4. Maple Consider the liquid-phase elementary consecutive reactions taking place in PFR: 1 2 A B C ⎯⎯→ ⎯⎯→ . Simulate two variants of this reaction: (1) with constant temperature of the cooling liquid (double-pipe heat exchanger); (2) adiabatic. Plot the dependence of the composition, T , T F , r 1 and r 2 down the length of the PFR reactor. Find the conditions that maximize the yield of B. Thermodynamic data : H 1 = − kJ/mol; H 2 = + 60 kJ/mol; c p A = c p B = c p C = 40 J/molK. Rate data : k 1 = exp(40 28000/ T [K]) s -1 , k 2 = exp(35 23000/ T [K]) s -1 Geometry : diameter 25 mm. Inflow : T 0 = 580 K; [A] 0 = 9 M. Thermal fluid : constant T F = 690; k h = 150 J/m 2 sK. 5. Maple Consider the liquid-phase elementary parallel reactions in PFR and CSTR: 1 2 B A C ⎯⎯ ⎯⎯→ . Simulate these reactions taking place in: (1) adiabatic PFR; (2) PFR with constant temperature of the cooling liquid; (3) PFR with co-flow double-pipe heat exchanger; (4) PFR with counterflow double-pipe heat exchanger; (5) CSTR with coil radiator heat exchanger. Analyse the conditions in the CSTR as a function of the residence time . Thermodynamic data : H 1 = − kJ/mol; H 2 = 60 kJ/mol;
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102 heat capacity of the solution: c pV = 2000 J/LK. Rate data : k 1 = exp(110 40000/ T [K]) s -1 , k 2 = exp(35 15000/ T [K]) s -1 Geometry : PFR tube diameter 10 cm. Inflow PFR : T 0 = 340 K; [A] 0 = 1.5 M; v = 0.67 m 3 /s; = 20 min. Double-pipe heat exchange : T F = 340; c F pV = 3100 J/LK; k h = 66 J/m 2 sK; v F = 0.3 m 3 /s. Inflow CSTR : T 0 = 340 K; [A] 0 = 1.5 M; V = 100 L. Coil radiator heat exchange : k h = 66 J/m 2 sK; A = 1 m 2 ; T F = 330. 6. A B C in a CSTR A process that involves two simple consecutive reactions takes place in a CSTR: A B C. a) If [B] is the desirable product, find the optimal space-time opt of the reactor that maximizes X B and express opt as a function of temperature. b) The existing reactor in your company causes problems, as the mixture is very viscous at room temperature and good mixing is difficult. You propose to solve the problem by operating it at 360 K, where the viscosity is acceptable. A colleague of yours raises a concern that this will decrease the useful conversion. Is he right? Plot schematically the dependence of opt on the temperature. What is the optimal flow rate v opt of the CSTR at 298 and at 360 K? What is the conversion X B and the selectivity S BC under the optimal conditions at each temperature? c) The reactions are exothermic and the reactor currently has a radiator coil installed. What is the heat duty J Q of the coil that would keep the mixture at room temperature (if feed is at room temperature as well)? Find the area of the coil from the heat duty using the linear dependence between J Q and temperature difference between thermal fluid and reaction mixture. d) You are going to make changes anyway can you uninstall the coil? Under the assumption that the reactor is adiabatic, what should the temperature of the feed be in order the reactor temperature to be 360 K, in the absence of coil? Parameters: heat capacity per unit volume of the solution c p V = 1800 J·K -1 ·L -1 ; volume of the reactor V = 500 L; feed concentration [A] 0 = 1 M; reaction enthalpies 1 H = -90 kJ/mol and 2 H = -33 kJ/mol; rate constants 1 1 1 1 /[min ] 0.10 exp 450 /[K] 298 k T = ; 1 2 1 1 /[min ] 0.015 exp 550 /[K] 298 k T = ; cooling liquid enters the coil at T F = 12 °C; wall heat transfer coefficient k h = 100 J/m 2 sK. 7. Feed cooling Easily out of control
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103 6 Residence time distribution Your job is to: fundamentals operate with the statistical characteristics of reactors, say hi to laminar flow (microfluidic) reactors; skills use a distribution to predict averages, diagnose the illness of a bad reactor. 6.1 Brief introduction to probability The textbook chemical thermodynamics and chemical kinetics operate with quantities that have a well-defined unique value. In real-life physics and chemistry, such a thing as a “defined value” does not exist. Instead, the measured value of any physical variable is a random event . For example, we often say that that the temperature in the room is 21 °C (a fixed value). However, each time we measure it, it will be different (21.1, 21.3, 19.9, … °C), and only the average is 21 °C, with some variation about the mean ( deviation of, e.g., ±0.5 °C). This might be because of random draughts in the room, people passing by, or it could be instrument-related, or all of these simultaneously. Actually, as you might know from your thermodynamics course, even the most ideally thermostated ensemble of molecules has a fluctuating temperature: as Einstein 25 has shown, the fluctuation of the temperature (i.e. the mean deviation about the mean divided by the mean itself) is proportional to N 1/2 , where N is the number of molecule in the ensemble. This means that it is not only that you are measuring a quantity with an imperfect instrument under imperfect conditions, it is also that temperature is in principle a random quantity. A random variable x is completely defined by two characteristics: a probability distribution density x ( x ) and a domain of definition (all possible values of x , or the spectrum of x ). If one knows x and the domain of x , one knows everything that can be possibly known about the random quantity x , i.e. a random quantity is density + domain. There are two types of random variables: those with discontinuous spectrum and those with continuous one. Let x be a random variable of a discontinuous spectrum of possible values x 1 , x 2 , … Let P i be the probability for one of the possible events to take place (i.e. the probability for x = x i ). For example, if x is the outcome of throwing a die, then x 1 = 1, x 2 = 2, …, x 6 = 6, and P 1 = P 2 = … = 1/6. The rule of addition of probabilities (“or ≡ +” rule) states that the chance of x to have a value of either x i or x j is P i + P j . The random x surely ( P = 1) has a value among x i ; therefore, the probability for x to be either x 1 , or x 2 , or … is P i = 1. If P i = 1 indeed, we say that the probability distribution P i is normalized . Now let x be a random variable of a continuous spectrum in the range x min x max . The very small probability d P x for the event “ x has a value in the interval x x +d x ” is proportional to d x : d ( ) ( )d x x P x x x = ; (6-1) 25 /ˈaɪnʃtaɪn /
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104 this follows again from the rule of addition of probabilities (twice as wide interval produces twice as high probability). The proportionality coefficient x ( x ) = d P x /d x is called the density of the probability distribution , or, for short, the distribution density, or even shorter the density. The infinitely small probability d P x is called the elementary probability. Finally, the function P x that is given by the integral min ( ) ( )d X x x x P X x x = , (6-2) is called the cumulative distribution (or the cumulative, for short). P x ( X ) is the probability for x to have any value smaller than X . Question: if the unit of the random quantity x is [U], what is the unit of x ( x )? There is a probability addition rule also for random variables with continuous spectrum. It says that the probability for x to fall into the interval x 1 x 2 is the sum of the elementary probabilities d P x for x to fall into any of the infinitely small “stripes” of thickness d x that the interval x 1 x 2 comprises. Any sum of infinitely small quantities is an integral: 2 2 1 2 1 1 ... d d ( ) ( )d x x x x x x x x x P P P x x x = = = . (6-3) If x is defined in the domain x min x max , then the probability for x to have any value between x min and x max is 1. Using eq. (6-3), we can write this statement as max min max min ... ( )d 1 x x x x P x x = = . (6-4) This is called the normalization condition (the mathematical translation of the English “the probability for anything to happen is 100%”). Usually, this condition is used to determine the so-called normalizing coefficient c n of . If 0 ( x ) is a non-normalized distribution that does not integrate to 100%, the normalized distribution is equal to ( x ) = c n 0 ( x ), and from eq. (6-4) it follows that c n must be max min n 0 1/ ( )d x x c x x = . (6-5) Mean of a random quantity. All formulae below are given in two variants: for variables of discontinuous and of continuous spectrum. The mean value of x is given by i i i x x P = ; max min ( )d x x x x x x x = . This is clear for a die (3.5 = 1 1/6 + 2 1/6 + … + 6 1/6). The second formula is just the variant of the first for P i = d P x , in which the sum of infinitely small things is substituted with the respective integral. The mean x is often called the first moment of the distribution of x , and we often use the symbol x 1 for it. Every function f( x ) of the random x is also a random quantity. The average of f( x ) is defined as: f ( ) f ( ) i i i x x P = ; max min f ) ( ) f ( ) ( d x x x x x x x = . Here are some examples: max min ( l ) ) ( d n( ln ) x x x x x x x = , max min ln l ( n )d x x x x x x x = ;
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105 max min ( 1 d 1 ) x x x x x x x = , max min 1 1 ( )d x x x x x x x =  . Therefore, averaging Y means plugging Y inside the integral max min ( ) ... ... d x x x x x = . (6-6) Formally said, averaging of Y is applying the operator (6-6) to Y. The average of x n is called the n-th moment of the distribution, and is marked often as n x = x n . Another characteristic of the distribution is the most probable value x mp of the random variable x . It is either a maximum of x , or one of the boundary values x min and x max , whichever gives a higher x . Several random variables . For two independent random quantities x and y that have discontinuous spectrum, the probability P ij for the event “ x has value x i and y has y j ” is P ij = P x , i P y , j , where P x , i is the probability for x = x i and P y , j is that for y = y j . This is called the rule for multiplication of probabilities (“and ≡ ”). An example: two dice. The probability to throw 5 with the first dye ( x = 5) is P x =5 = 1/6. The probability to throw 5 with the second is P y =5 = 1/6. The probability for double five is, therefore, P 55 = P x =5 P y =5 = 1/36. Question: what is the probability to throw 1 and 3? For two random variables x and y with continuous spectrum, the elementary probability for them to fall simultaneously in the intervals x x +d x and y y +d y is proportional to the infinitely small area d x d y : d ( , ) ( , )d d xy xy P x y x y x y = , where xy is the compound distribution density of x and y . If x and y are independent events, then it is valid that d P xy = d P x d P y . Further, since d P x = x d x and d P y = y d y , we can write that d ( , ) d ( )d ( ) ( )d ( )d xy x y x y P x y P x P y x x y y = = . Comparing the two expressions for d P xy above, we see that the probability multiplication rule can be written as ( , ) ( ) ( ) xy x y x y x y = . The averaging for two variables works similarly to that for a single variable for example, the mean of a function f( x , y ) is f( , ) f( , ) i j i j j i j i x y x P x =  ; max max min min ( , )d f ( , ) f ( d , ) y x xy y x x y x y x y x y =   . Deviation from the mean value. Dispersion and fluctuation. The deviation x of a random quantity from its mean is a random quantity: x = x x . This random deviation is characterized by two averaged numbers the dispersion and the fluctuation ( question: why not just x ? ). The dispersion of x is defined as: ( ) 2 2 2 2 2 2 2 x disp x x x x xx x x x =  = = + = , (6-7) i.e. disp x = x 2 x 1 2 (using the moment notation). The dispersion is also called the second moment of x about x . This is the main characteristic of the absolute deviation of a random quantity away from its mean. Its square root is called the standard deviation of x : 2 2 2 x dev x x x = = . (6-8) The relative standard deviation is called the fluctuation of x , and is defined as
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106 2 / x fl x x = . An example: for a die, P i = 1/6. The average is x = (1+2+3+4+5+6)/6 = 3.5. The average square is x 2 = (1 2 +2 2 +3 2 +4 2 +5 2 +6 2 )/6 = 15.17. The dispersion is disp x = 2 x = 15.17 3.5 2 = 2.91, and the standard deviation is dev x = 2.91 1/2 = 1.71. The fluctuation of x is fl x = 1.71/3.5 = 0.49. It is common to write the results for the mean and the standard deviation as x = 3.5 ± 1.71, or for the men and the fluctuation as 3.5 ± 49%. Singular distributions . The Dirac 26 delta function (the peak function) is defined as , 0; δ( ) 0, 0, x x x = = δ( )d 1 x x − = . It is the distribution density of a certain event. If x has a spectrum of only one value, x i , its distribution is ( x x i ). The Heaviside step function is defined as: 0, 0; η( ) 1, 0. x x x = Several important properties of theirs: δ( )d η( ) x x x = ; d ( x )/d x = ( x ); (6-9) i i i f( ) δ( ) f( )δ( ) x x x x x x = ; (6-10) ( x ) = ( x ); ( x ) + ( x ) = 1; ( x ) ( x ) = sg( x ). Here, sg( x ) is the sign function. The rectangular pulse function which is 1 between a and b and 0 otherwise is also reducible to Heaviside: a , b = ( x a ) −  ( x b ). (6-11) These functions are widely used in physics and engineering, and some practice with them is required if you want to understand engineering literature (i.e. if you want to be good at what you do). These distributions are called singular because they either reach an infinite value (singularity) somewhere, as in the case of ( x ) at x = 0, or their derivatives have singularity, as in the case of ( x ) at x = 0. 6.2 The distribution of the residence time and how to measure it All reactors considered until now were assumed ideally mixed . This is a strong assumption that no real, dirty, rusty, greasy reactor could possibly fulfil. In an ideal PFR, all molecules are assumed to stay in the reactor for a fixed time . In the real PFR, the residence time of the material fed to the reactor varies some molecules stay longer than others. An ideal CSTR is another story the residence time varies even for an ideal CSTR, but in a well-defined way. In a real CSTR, residence time is pretty random. Consider the following real CSTR: 26 /dɪˈræk/
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107 (stolen from Fogler) Once the feed reaches the reactor volume, the turbulent flow patterns inside the reactor can send it anywhere. Some of it will reach the outlet almost immediately, without being able to undergo reaction at all a phenomenon called bypassing . Another part of the fluid will be thrown to the most remote corner of the reactor and will remain there for long time, degrading significantly and forming deposits this corner is known as dead zone . Thus, for both PFR and CSTR, the residence time is a random quantity , not just a fixed number. Question: what about the batch reactor? All properties of the mixture that are functions of are going to be random as well including conversion, composition, rate of heat production etc., and have to be treated as such. As a random variable, has a certain probability distribution density, ( ), which is an important characteristic of the reactor. Since d P = d is a dimensionless probability, has units of 1/s. The best way to obtain this distribution for a real reactor is experimentally; modelling is also an option, but modelling cannot detect “pathological” distributions . The usual way to measure is via a chemical called tracer . The tracer is ideally a molecule that (i) is easy to detect in small quantities, (ii) is stable and soluble under the conditions inside the reactor; (iii) is similar in properties to the reactants and the products of the real reaction (similar volatility, adsorption properties, association). Often used are radioactive tracers, dyes, inert gases of distinct spectra. The measurement of involves injection of the tracer in the feed of the reactor, and then measurement of its concentration at the outlet as a function of time. There are several ways to perform the injection. Fig. 18. Pulse injection in a PFR. The first way to inject the tracer is via pulse injection (very short intensive). Let an amount of n moles ( N molecules) of the tracer be injected in an extremely short period of time (at t = 0). This means that the initial time at which the tracer molecules are inserted is not random. If we inject a single tracer molecule in the precise moment t = 0, the probability with which it will exit in the period of times between t and t + d t is d P = ( t )d t , which we can schematically write as δ( 0) ( )d t t t 0 t t = V / v
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108 (1 molecule at the entrance, t = 0) ( elementary probability to detect it in t…t + d t at the exit). Here, the arrow means “passing through the reactor”. If a large number N of tracer molecules is injected in t = 0, then, in the time interval t ... t + d t , a small fraction d N = N d P will exit: δ( ) ( )d N t N t t (N molecules at the entrance, t = 0) ( d N molecules exiting in the period t…t + d t). The number of molecules exiting, d N = N d t , divided by the volume of fluid leaving for the same time interval, which is d V = v d t , is giving the concentration of the tracer in the moment t : C N ( t ) = d N /d V = N ( t )/ v , where C N is concentration in molecules per unit volume, m -3 . Expressing from the last equation, and passing to moles/m 3 , we obtain simply = vC ( t )/ n . (6-12) Thus, if one divides the measured concentration C ( t ) at the exit of the reactor by n / v , where n is the moles of tracer injected with the pulse injection, the distribution of is obtained. Fig. 19. Step injection in a PFR. Very often, instead of pulse injection, a step injection is utilized, i.e. a continuous injection that starts at t = 0 and continues until t = t end . Usually t end is large enough for stationary concentration of the tracer in the reactor to be established. In this case, the tracer molecules (of total number N ) are not injected simultaneously, but there is a period t between each two; the average value of this period is t = t end / N . If a molecule is injected in the moment t = t i , the probability it to exit between time t and t + d t is determined by the shifted distribution ( t t i ): δ( ) ( )d i i t t t t t . (1 molecule at the entrance, t = t i ) ( elementary probability to detect it in t…t + d t at the exit). The last equation reflects the fact that the residence time of the molecule that has been injected in the moment t i is t t i (and not just t ). Let us now have N molecules, each of which is injected in a different moment t i . The probability to detect any molecule between t and t + d t is, according to the rule “or = +”, equal to the sum of probabilities ( t t i )d t to detect each molecule in this range of time (the first OR the second OR … OR the last) : 1 1 δ( ) ( )d N N i i i i t t t t t = = . (6-13) (N molecule injected from 0 to t end at constant rate) (molecules exiting during t…t + d t). Note that in the second sum we should not count those molecules that have been injected after the moment t obviously, if t i > t , the molecule cannot be detected at the exit the residence time t t i is negative! Instead of complicated summation indexing, to simplify things, we will simply keep in mind that ( < 0) = 0 (there is zero chance to detect a molecule of negative residence time), so many of the terms under the sum in eq. (6-13) are zero. Now we assume that the tracer molecules are so many that we can pass from summation to integration. If the flow rate of molecules is constant, the rules for that operation are: end end 1 end 1 0 0 1 1 ... ...d ...d ...d ...d t t N N t N i i i t N i i t t t t t t = = = = , 0 t t = V / v C 0 ( t ) C ( t )
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109 where we used that i t = t i (injection time = number of the molecule times mean interval between two molecules entering) and that t = t end / N . Applying this rule to eq. (6-13), we obtain end end end end 0 0 δ( )d ( )d d t t i i i i N N t t t t t t t t t . (N molecule injected from 0 to t end at constant rate) (molecules exiting during t…t + d t). Next, we substitute N / t end with the feed flow rate F N 0 of the tracer, and we perform the integration: end end 0 end 0 0, 0 0 η( ) η( ) η ( )d d t N N t N i i F t t t F F t t t t = . (6-14) We used that the integral of is , eq. (6-9), and the definition (6-11) of rectangular step function a,b . The left side of the last equation just specifies the profile of the injection. Nearly always, the injection continues for a very long time (enough for steady state concentration profile of the tracer to be established inside the reactor). In such case, t end can be substituted with ∞: 0 0, 0 0 0 ( ) ( )d d N N N i i F F t F t t t t . (6-15) (flow in) (flow out). Finally, the integral on the left hand side can be transformed to the cumulative (6-2) of the distribution: ( ) 0 0 0 ( )d ( )d ( )d ( )d ( )d ( ) t t t i i i i t t t t t t t t t P t − − − = − = − = + = . (6-16) We first changed the integration variable to residence time, = t t i . Then we changed the limits of integration. In the last step, we used that ( < 0) = 0 (negative residence times are impossible). The combination of eqs. (6-15)&(6-16) tells us that if a step function-shaped injection of tracer is performed, the flow out of the reactor will be given by F N = F N 0 P ( t ), or after dividing by v and Avogadro’s number, C ( t ) = C 0 P ( t ). (6-17) We used that F N / vN A = C . Thus, the pulse injection produces concentration trajectory C ( t ) at the exit that is proportional to the residence time distribution density . The step-shaped injection produces concentration trajectory C ( t ) proportional to the cumulative P of the distribution. In the latter case, the distribution density is easily derived by differentiation: 0 d ( ) d ( ) ( ) d d P t C t t t t C = = . Both methods are widely used in practice. The pulse injection is better for expensive tracer that can be detected in very small concentrations; otherwise the step-shaped injection is preferred. 6.3 Ideal reactors An ideal batch reactor has fixed residence time, so = ( ) and P = ( ). A reason for non-ideality could be slow quenching process, in which part of the mixture remains unquenched longer than intended. However, the non-ideality of the batch reactors is usually dominated by other effects, such as non-homogeneous temperature and composition, which are
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110 characterized by respective statistical distributions T , concentration etc., which we are not going to consider. An ideally mixed PFR also has fixed residence time, and again = ( ) and P = ( ). In reality, the distribution of can be quite different from delta function, especially if the Reynolds number is not very high. In an ideally mixed CSTR , unlike the ideal PF and batch reactors, each part of the mixture stays in the reactor for a different amount of time and, therefore, has a distribution. We will now derive this distribution, by doing an imaginary tracer experiment. Let a tracer substance be pulse- injected into a perfectly mixed CSTR. “Perfectly mixed” means that at any moment of time, the concentration C ( t ) of the tracer in the tank is homogeneous. This concentration decreases with time, as the tracer is constantly leaving the reactor with the outflow. The mole balance for the tracer determines the evolution of C . The tracer that leaves for a short period of time d t is of amount vC d t ; this corresponds to a decrease in the total amount of tracer in the reactor by V d C = vC d t . This balance is an ODE for C ( t ): d d C V vC t = − , i.e. d d C C t = − . (6-18) We used that V / v = ; note that in the previous sections, we did not have to distinguish between the residence time (a random quantity with many possible values) and its average value (the space-time of the reactor). Let us remark here that, with respect to the tracer, the CSTR in our thought experiment is non-stationary so we cannot set the d C /d t term in eq. (6-18) to zero as in the steady-state CSTR equation (1-72); we used instead the general mole balance (1-54) (without reactions since the tracer is supposed to be inert, and with F 0 = 0 right after the injection).The above equation is integrated immediately to: 0 ( ) exp( / ) C t C t = . Recalling the relationship (6-12) between the tracer concentration and the residence time distribution, we obtain: 0 1 ( ) exp( / ) exp( / ) v C n = = . (6-19) We have used that the initial concentration of tracer in the reactor is C 0 = n / V , and that the space-time of the reactor is = V / v . Also, in this final result, instead of the experimental variable (time t after the pulse injection), we use the random residence time . The distribution is illustrated in Fig. 20. Let us now check if the obtained density is normalized: the domain of is 0…∞, and the probability P 0…∞ for to have any value has to be 1, / / / 0... 0 0 0 0 1 d e d e d de 0 1 1 P       = = = = − = − + = . Yes, it is normalized. Let us next check whether the average is indeed , as it should be: by parts / / / / 0 0 0 0 0 d e d de 0 e d de          = = − ⎯⎯⎯→ + = − = . (6-20) So this is also correct. Until now we learned nothing we did not know about the residence time. Finally, let us compute the average 2 (the second moment 2 of the residence time) and the dispersion of : by parts 2 2 2 / / 2 / 2 0 0 0 0 d de 0 e d 2 e d 2         = = − ⎯⎯⎯→ + = = . In the last step of the integration, we used eq. (6-20) as a ready formula. The dispersion is 2 2 2 disp = = .
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111 The standard deviation of is dev = ( disp ) 1/2 = , i.e. we can say that the residence time of a molecule in an ideal CSTR is ± . The fluctuation is ±100%! This means that almost every molecule going out of the reactor is either a newcomer or stayed in the reactor for more than twice the average residence time. Non-ideal CSTR modelled as ideal CSTR + PFR in series. In the real CSTR, the reaction fluid is led through a tortuous pathway (a sort of PFR, to which we refer as series sub-PFR) to the intensive mixing zone (which is effectively an ideal sub-CSTR within the real CSTR), and then led out from the mixing zone via another pathway (yet another PFR). This adds PFR to the average residence time, and modifies the distribution (6-19) to ( ) PFR CSTR / PFR CSTR 1 ( ) e , = . (6-21) This is perhaps the most widely used model for real CST reactors. Non-ideal CSTR modelled as ideal CSTR and ideal PFR in parallel. Another common situation occurs where the fluid fed to the real CST reactor can either reach directly the intensive mixing zone (the ideal sub-CSTR), or pass through a short-cut to the exit (a parallel sub-PFR). The distribution in this case is the sum of the distributions for the two pieces, weighted: CSTR / CSTR PFR PFR CSTR ( ) e δ( ) x x   = + . (6-22) Here, x CSTR and x PFR = 1 x CSTR are the fractions of the liquid that pass through the respective pathways. This is a common model for pathological residence time distribution of a reactor. Ideal laminar flow tubular reactor. Such reactors are used increasingly often in practice with the rise of microfluidics and lab-on-a-chip devices. The laminar flow through a tube is called Poiseuille-Hagen 27 flow and has a parabolic dependence of the velocity of the liquid on the distance from the centre of the tube (as you know from your course in fluid dynamics): ( ) 2 2 ,max c ( ) 1 / z z u r u r R = . (6-23) Here, u z ,max is the local fluid velocity in the centre of the tube; r is the distance from the centre, and R c is the radius of the cylindrical tube. The velocity at the wall (at r = R c ) is zero. Question: will this be valid for membrane laminar reactors? The total volumetric flow rate v through the cylinder is the sum of the flows through each ring section spanning from r to r +d r . In these ring sections u z is homogeneous, and the flow through each is d v = u z 2 r d r (2 r d r being the cross-section area of the ring). A sum of things so small is an integral: c c c 2 2 2 3 2 c c ,max ,max ,max c ,max 2 2 c c 0 0 0 1 π 1 2 π d d d 2 4 2 R R R z z z z R R r v u r r u r r r r u R u R R = = = = . We use this relationship to kick u z ,max out of the game: 2 ,max c 2 / π z u v R = . (6-24) 27 /pwazjˈoi - ˈhagən/ r d r d v = u z 2 r d r
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112 If the length of the tube is L c , and the flow is perfectly laminar, then the time during which a portion of fluid remains in the reactor is ( ) ( ) ( ) 2 c c c c 2 2 2 2 2 2 ,max c c c π ( ) 1 / 2 1 / 2 1 / z z L L R L t u r u r R v r R r R = = = = , or solved for r 2 2 c 1 2 r R t = . (6-25) We used eq. (6-24) to get rid of u z ,max ; R c 2 L c is the volume V of the reactor, and V / v is, of course, the average residence time . The elementary probability d P = d that a molecule has a residence time of is precisely equal to the probability this molecule to have passed through the reactor via the respective layer between r and r + d r for which u z = L c / , which is d P = d v / v = u z 2 r d r / v (amount of liquid flowing through the layer, d v = u z 2 r d r , divided by all fluid passing, v ). This can be written as: 2 ( )d 2 π d π d z z u u t t r r r v v = = ; ( ) 2 2 ,max 2 2 c 2 3 d ( ) π π d 2 2 z z u u r t R r v t v t t = = = . (6-26) We used eq. (6-23) for u z and eq. (6-25) for r 2 . Eq. (6-26) is the residence time distribution of an ideal laminar flow reactor. We missed one bit from the picture: what is the domain of definition of ? Ideally (i.e. in the absence of diffusion), the molecules at the wall of the reactor where the liquid is not moving will stay in it forever, so the upper bound is = ∞. The lower bound is, however, not 0; the fastest molecules move at velocity of u z ,max and will need time L c / u z ,max = R c 2 L c /2 v = /2 to reach the exit. Therefore, the sought residence time distribution of an ideal laminar flow reactor can be written as 2 3 ( ) / 2 , / 2 = . (6-27) Fig. 20. The dimensionless residence time distributions of ideal CST and LF reactors. Let us now test whether this distribution is normalized, and does it really give the correct average of ?  /
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113 ( ) 2 2 2 2 2 3 /2 /2 /2 ( )d d d 0 1 2 4 4 / 2 = = − = − + = ; ( ) 2 2 2 1 2 /2 /2 /2 ( )d d d 0 2 2 2 / 2  = = − = − + = . So far so good. And what is the second moment of the distribution, the dispersion, the deviation and the fluctuation of ? 2 2 2 2 /2 /2 /2 ( )d d dln 2 2   = = = − =  . As some of the molecules (those next to the wall) stay in the reactor forever, the dispersion of is infinite. This is a feature one often encounters with the higher moments of the random lifetimes/residence times of molecules in reactors. 6.4 Using the residence time distribution for diagnostics Real reactors suffer from various diseases accumulation of deposits; leakages; channelling in packed bed reactors; sticking of catalyst particles to one another. Were the chemical engineer a cardiologist, the residence time distribution curve would be a cardiogram. Ill PFRs. An ideal PFR has a ( 1 ) distribution, with 1 = V / v . One cannot expect a perfect peak and there always appear some dispersion, leading to a bell-shaped curve (Fig. 21a). As long as the dispersion is not high, the peak is in place (i.e. the average is indead V / v ) and its area is indeed 1, Fig. 21a is healthy-looking. A very wide peak suggests that the flow pattern is not that of a plug flow (the Reynolds number is too low?). V / v area = 1 a nice PFR (a) V / v peak comes early area < 1 long low tail (often hard to detect) there is stagnant zone (b) V / v area = 1 no long tail peak comes early dead volume (c)
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114 Fig. 21. PFR pathologies. Stagnant zone. In Fig. 21b we see too deviations: the peak comes early ( 1 < V / v ) and its area is less than 1. If the tracer experiment is sensitive, we might also detect a weak afterflow of tracer tracer slowly exits the reactor well after the main peak. This behaviour often appears with packed-bed reactors with small catalytic particles here and there, the particles stick to each other and the fluid passes very slowly if it is stuck to such a zone. The rest of the fluid passes more quickly, for time ( V V stagnant )/ v , where V stagnant is the total volume of the stagnant zones (in red in the cartoon in Fig. 21b), hence the shift of the main peak. Dead volume. If the PFR walls accumulate a deposit, the available volume of the reactor drops; the mean residence time drops from the expected value V / v to ( V V deposit )/ v . The curve is similar to the case of stagnant zone, and, in fact, an end-stage stagnant zone can behave as a dead volume (once it becomes impermeable to the reaction fluid). The difference is that the stagnant zone is still available for the liquid to pass (but slowly), while the dead volume is dead. The peak in case (c) is of area 1 (100% of the tracer goes out without afterflow). No tail is observed (but sometimes with stagnant zones the tail is also hard to detect). Internal circulation. If the tube of the PFR makes a U-turn, or if there is sharp angles somewhere, internal circulation might appear there will be a fraction of the volume that is occupied by a fluid that circulates. The fluid that enters this zone can make one round and then leave the zone, or stay in it and make another round etc. This results in characteristic peaks (a first for one round, a second for a second round etc.). Internal circulation can appear in catalytic reactors, if the particles make appropriate sockets. Deposits and surface defects can also produce circulation (Fig. 21d). Sometimes, only the first peak is easy to observe. Channelling is typical for packed-bed reactor. If the packing is not good, the liquid can find a shortcut way through the loose zones, resulting in an early peak; the rest of the fluid might leave the reactor in several portions coming out as one or several wide peaks in the residence time distribution curves (Fig. 21e). Late peak (Fig. 21e) nearly always signifies wrong tracer experiment. For example, a badly chosen tracer that adsorbs strongly on the catalyst particles might remain in the reactor for longer than the space-time V / v . Under construction, check webinars for the time being Ill CSTRs. An ideal CSRT has a 1 1 exp( 1 ) distribution, with 1 = V / v . The real reactors Fig. 22 a… area < 1 there is internal circulation main peak early additional peaks V / v (d) V / v peak comes late the tracer experiment is wrong (f)
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115 Fig. 22. CSTR pathologies. Long feed/outflow line. In Fig. 22b... Dead volume. deposits Bypassing flow. Internal circulation. Late curve… wrong tracer experiment. Read more Levenspiel’s Ch. 11 [ 1]. Fogler’s ch. 16&17 [ 2] but careful! Many mistakes! Problems 1. Derivations a) Let the tracer injection have a rectangular profile starting at t = 0 and ending at t = t end , as in eq. (6-14). Show that at the concentration profile at the exit of the reactor will correspond to 0 end ( ) / ( ) ( ) C t C P t P t t = . b) Derive the formula for the residence time distribution of an ideal CSRT via a thought step-injection tracer experiment: tracer of concentration C 0 is fed to a tank; C 0 v d t of it enters the tank for time d t , and C ( t ) v d t exits; the concentration C ( t ) in the tank increases from zero to C 0 . For the time d t the concentration of the tracer increases with d C . Write the mole balance for the tracer in the tank for the time d t , and solve it to obtain C ( t ). Use eq. (6-17) to find the cumulative and then the definition (6-1) to find the density of the distribution of . 2. Probability distributions a) Analyse the Gaussian distribution of the residence time in a non-ideal PFR, V / v a nice CSTR (a)
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116 ( ) 2 n 0 exp c   = , (6-28) where > 0 and 0 are parameters, and the domain of is ∞...∞. - Find the most probable ; - the average , 2 and ( 0 ) n (the moments of the distribution); - the dispersion, the standard deviation and the fluctuation of . - the average ln (the entropy of the distribution); - plot it for 0 = 1, and three values of (0.1, 1, 10). b) The Maxwell distribution of the absolute velocity v of a molecule in a gas reads ( ) 2 2 n B exp / 2 v c v mv k T = . Here, m is the mass [kg] of the molecule, T is the temperature and k B is Boltzmann’s constant. - Find the most probable v , the average v and v 2 , the dispersion, deviation, fluctuation of v ; - find the most probable kinetic energy = mv 2 /2; the average and 2 , the dispersion, deviation, fluctuation of ; - plot v for oxygen, nitrogen and helium at room temperature; - find the fraction of molecules in the atmosphere at room temperature that has supersonic velocities ( v s = 343 m/s). 3. Maple The following data was collected for pulse injection of tracer in a plug flow reactor: t [min] 15 17 18 19 20.5 22 C [mM] 0.1 2.2 8.8 9.0 2.5 0.2 a) Assume the residence time distribution is Gaussian, eq. (6-28), and determine its two parameters, and 0 . Find the average , 2 , the median, the dispersion, deviation and the fluctuation of the residence time. b) Assume now that the maximum of the Gaussian distribution is precisely at the space- time of the reactor, which has a known value: 0 = V / v = 18 min 25 s. This leaves a single unknown in the Gaussian distribution; determine it. Compare the standard deviation of the residuals for a) and b). 4. Maple The following data was collected for step injection of tracer in a CSTR: t [min] 6 12 24 36 60 90 120 180 C [mM] 4.2 7.4 11.8 14.5 18.2 21.2 22.85 24.55 The concentration of tracer at the entrance is 22 mM. The space-time of the reactor is = 49 min 36 s. The residence time distribution is expected to be biexponential: 1 1 1 1 2 2 1 exp exp x x = + . (6-29) a) Use the space-time of the reactor to constrain the value of x 1 (i.e. express x 1 through to obtain a formula with one fitting parameter less). Find P and the expected profile C ( t ). b) Fit the data to obtain 1 and 2 . c) Compare on a single plot the residence time distribution (6-29) and the distribution of an ideal CSTR of the same . 5. Specified residence time distribution For reactors of the given residence time distribution, find the normalization constant c n and compute 2 , , , and disp dev fl . Sketch or plot the distribution in its domain. a) ( ) 15 n c = , = 0…15 min.
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117 b) exp( ) n c k = , = 0…∞, k = 5 min -1 . (Use the integrals (7-24) if needed). 6. Pathologies of a LFR Match pictures and description
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118 7 Mixing models for nonideal reactors Your job is to: fundamentals understand text on more advanced concepts behind non-ideal reactors; skills predict the yield of completely segregated and completely mixed non-ideal reactor. The residence time distribution is an important characteristic of every reactor, but it is not sufficient to predict the outcome of the reactions taking place inside the reactor. Two reactors of similar can produce very different conversions if the mixing conditions are different. A complete statistical description of a reactor requires also a specification of the mixing conditions , via a certain mixing model. In this section, we will consider two limiting cases of mixing. The first case is complete non-mixing, known as the segregation model . This model corresponds to molecules inserted inside the reactor remaining together in their pathway through the reactor until the exit. Molecules of different age do not mix; each small volume of liquid behaves as a batch reactor. Two examples that are not too far away from this picture are: - a semi-batch reactor in which the liquid mixture is added very carefully during the reaction. In the absence of external mixing, at the point of quenching, the liquid at the top of the reactor will be still fresh, while that on the bottom will be converted to products. - A short laminar flow tubular reactor (see on the right). The liquid in the centre will exit quickly and will be of small conversion; the liquid near the walls is of infinite residence time and will, correspondingly, react completely. The other limiting case corresponds to a situation where as soon as new liquid enters in the reactor, it mixes completely with the mixture already present in the reactor. This is called the maximum mixedness model . In every small volume of the mixture, molecules of all ages will be present. This is typical for well-mixed reactors standard and membrane PFR where flow is of high Reynolds number, CSTR and semi-batch reactors equipped with powerful mixers etc. Real reactors behave as neither of these limits they are always partially mixed LFR more on the non-mixed side, CSTR more on the maximum mixedness side. The two limiting cases give the lower and the upper limit of conversion in the real reactor. As we shall see below, for first-order reactions, the two models predict the same conversion for the same residence time distribution, irrespective of the mixing pattern. For a single reaction of order smaller than one, given the , the maximum mixedness model will predict the highest conversion among all possible mixing models, and the segregation model the lowest one. The opposite is true for a single reaction of order higher than one: the segregation model predicts the highest conversion and the maximum mixedness the lowest. How large is the effect of the mixing mode depends also on the dispersion of the residence time: if the dispersion is small, i.e. is close to a ( 1 ), then mixing matters little. The wider the dispersion, the higher the effect from the mixing pattern. = 100 s = 50 s = 20 s = 15 s = 0…100 s
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119 7.1 Complete segregation model When the molecules of the same age group remain together during their pathway through the reactor until they exit from it, we speak of complete segregation (known also as the Danckwerts- Zwietering 28 model [8,9]). Every globule of liquid (i.e. every small homogeneous portion of fluid containing a macroscopic number of molecules) inserted in the reactor behaves as a separate batch reactor. A liquid made of such “impermeable” globules is often called a macrofluid (a misleading term that we will avoid). In this model, the reaction takes place in segregated globules (i.e. in zillions of small batch reactors). Only at the exit of the reactor and after the reaction has finished, this globules are mixed to form the homogeneous product we therefore often use the term conditions of late mixing for segregated reactors. Our aim now is to predict the composition of the outflow of a segregated reactor. The fluid behaves as an ensemble of globules, each of specific age. Let the reaction conversion inside one globule of age be X ( ), corresponding to composition C A ( ), C B ( ) etc. (the solution to the batch reactor problem). If the liquid globules are segregated, then the residence time distribution is also the probability distribution for taking a globule of certain age out of the reactor. Therefore, the mean composition of the product can be obtained directly by applying the averaging operator to X ( ), C A ( ) etc.: segr d X X X = = , d i i C C = , (7-1) where the integration is over the domain (all possible values) of . In this formula, X ( ) and C i ( ) under the integral are the batch reactor expressions for the considered reaction, and is the residence time distribution of the reactor of given volume and flow rate. There are many mistakes you can make with this formula. To begin with, (i) , under the integral is not the space-time of the reactor. Also, (ii) , might become a very different function if the flow rate is changed. If you want to predict the composition of the product of a real reactor using eq. (7-1) , you need to repeat the tracer experiment for a range of flow rates or reactor lengths to analyse the dependence of on these characteristics. Another pitfall is that, (iii) , eq. (7-1) is giving the composition at the exit of the reactor only, and is telling nothing about the time evolution of the composition (if we speak of batch and semi-batch reactors), or the profile of the composition along the length of a tubular reactor. Example 10-1. Using eq. (7-1), compute the conversion and the mixture composition for a first-order liquid-phase reaction A B (of rate constant k ) that takes place in a completely segregated (i) ideal PFR; (ii) ideal batch reactor; (iii) ideally mixed CSTR; (iv) ideal laminar flow reactor. Compare graphically the dependences of the respective conversions on the dimensionless space-time Da 1 = k , known as Damköhler ’s 29 number for a first-order reaction. Solution. First, let us write the solution for C i ( ) and X ( ) for A B in a batch reactor see sec. 1: A A0 e k C C = ; ( ) B A0 1 e k C C = ; 1 e k X = . (7-2) We now have to apply the averaging operator to each of these, eq. (7-1), using the residence time distribution for the respective reactor (i-iv). (i) For an ideal PFR, the residence time distribution is a Dirac delta function, ( ), see sec. 6.3. Eq. (7-1), together with the basic property (6-10) of , leads to 28 / ˈ dankverts- ˈ tsvi:terink/ 29 / ˈ d ɑːmkɔːlʌ/
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120 ( ) δ( )d ( ) i i i C C C = = , i.e. A A0 e k C C = and ( ) B A0 1 e k C C = ; ( ) δ( )d ( ) X X X = = , i.e. 1 e k X = . (7-3) That is, it is enough to substitute with the space-time in eqs. (7-2) to obtain the exact conversion and composition in a segregated PFR. Note that the content of a PFR can hardly be a segregated fluid, and the result (7-3) is correct by chance only: the globules travel together along the length of the reactor and exit in the same moment, so they have the same composition and it does not matter whether they mix or not. The segregated model will not produce correct results neither for non-ideal PFR, nor for membrane PFR. (ii) The ideal batch reactor has the same residence time distribution as a PFR and, therefore, it is again enough to substitute in eq. (7-2) with the quenching time . (iii) For an ideal CSTR, the residence time distribution follows the exponential formula (6-19). Substituting it together with eq. (7-2) into eq. (7-1), we obtain: ( ) 1 A0 A0 A 0 e d 1 k C C C k + = = + , and similarly, B A0 1 k C C k = + , 1 k X k = + . (7-4) As with the PFR, a CSTR is highly unlikely to follow the segregation model, due to the word “stirred” in its name. The result (7-4) is correct by pure chance the mixing pattern does not affect the outcome of a first-order reaction. However, the results from a Danckwerts-Zwietering averaging will be incorrect for any other order of the reaction. (iv) The mixture in a laminar-flow tubular reactor is far more likely to remain segregated until the exit in comparison with the previous three cases we considered. The residence time distribution is given by the 3 power law (6-27). Using it together with eqs (7-2), we can perform the averaging procedure: 2 2 2 by parts 3 2 /2 2 A0 A0 A A0 A0 /2 /2 /2 e d e d e e d 2 4 4 k k k k C C k C C C = = − ⎯⎯⎯→ = 2 2 2 by parts /2 1 /2 1 A0 A0 A0 A0 /2 /2 e e d 1 e e d . 4 2 4 k k k k k k k C C C C = + ⎯⎯⎯→ The last integral integrates to a function known as the integral exponent of the first order, 1 exp( k )d = E 1 ( k ), i.e. 2 2 2 2 /2 /2 A A0 A0 1 A0 A0 1 /2 1 e d E ( ) 1 e E 2 4 2 4 2 k k k k k k k C C C k C C = = + . We used that the integral exponent is zero at = ∞ when applying the integration limits. Next, the average C B and X can be computed as 2 2 /2 B A0 A A0 1 1 1 e E 2 4 2 k k k k C C C C = = ; 2 2 /2 A A0 1 1 / 1 1 e E 2 4 2 k k k k X C C = = . (7-5) This equation specifies the conversion of a first order reaction in a laminar flow reactor as function of the space-time of the reactor. It is a widely used to describe reactions taking place in microfluidic reactors.
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121 In summary, the four reactors will produce different conversion even though they have the same space-times (or the same V / v ). The three results (7-3),(7-4)&(7-5) are illustrated in the following figure, as functions of the dimensionless space-time Da 1 = k (Damköhler ’s number). 7.2 Complete mixedness Complete segregation is the extreme case of absolutely no mixing of the fresh mixture inserted in the reactor with the aged mixture that have been there already. The other extreme is the case of complete mixedness, where, as soon as the new mixture is inserted in the reactor, it is dispersed throughout the reactor ( early mixing ). In this situation, every drop of fluid in the reactor contains molecules of all ages, of the same age distribution. The “globules” of liquid are completely permeable, and therefore, indistinguishable. Such a mixture is often called a microfluid (again a somewhat misleading term which we will avoid). Semi-batch reactor derivation of the governing equations of the complete mixedness case. Let the mixture be injected in the semi-batch reactor continuously and non-stationary. The injection starts at t = 0 and ends at t = max (the quenching time). The inflow is specified by a flow rate function v ( t ), which may vary with time. Each portion of liquid d V = v ( t )d t injected into the reactor remains inside for a period from t to max , corresponding to residence time of = max t . If the total volume of mixture injected at quenching ( t = max ) is V max , then the elementary probability d P to find molecules of residence time between and + d is simply d V / V max , i.e. max max max max d d d d d V v t v v P V V V V = = = = , and therefore, d P /d = v ( t )/ V max . (7-6) Thus, v ( t ) = v ( max ) defines the density of the residence time distribution. Note the absolute values in the above derivation: the elementary probability d P is always a positive quantity; however, if d is defined as positive, then d t = d( max ) = d < 0. We fix this problem with the modulus. Integrating the first relation (7-6) from = 0 to = (corresponding to integration over t from max to max ), we obtain ( ) max max max max max m 0 ax max max 1 1 1 d d d ( ) 1 V v v t v t V V t P V V = − = = = . (7-7) Here, we used that the integral of v ( t ) gives the total volume V max V ( t ) of liquid that is inserted into the reactor from t = t (current moment) to max (quenching moment). Let us now write down the mole balance for the reactor. For a small period of time, t t +d t , the increase in moles of A in the reactor, d n A = d( VC A ), is due to (i) the reaction that produces Vr A d t moles of A and (ii) the inflow of A that brings in vC A0 d t moles, i.e. d VC A = Vr A d t + vC A0 d t . X Da 1 = k
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122 Since t = max , the residence time decreases as t increases, and d t = d . Dividing the above equation by V max d , we obtain: A A A0 max max max d 1 d VC V v r C V V V = − . Now we execute the differentiation of the product VC A : A A A A0 max max max max d 1 d d d C V V V v C r C V V V V + = − . Next, we use that d V /d = d V /d t = v = V max , and also that V / V max = 1 P (these are forms of eqs. (7-6)&(7-7) above). This simplifies the mole balance to the equation ( ) ( ) A A A A0 d 1 1 d C C P P r C + = − , or after rearrangements, ( ) A A A0 A d d 1 C r C C P = + . (7-8) Using that C A = C A0 (1 X ), we can write the same equation for the conversion: A A0 d d 1 r X X C P = + . (7-9) This is the mole balance equation for an infinitely well mixed reactor of known distribution of . We derived the equation using a semi-batch reactor, but it is equally valid for any completely mixed reactor. Using the rate law for an elementary reaction of the type A A …, ( ) A A ν ν 1 A A0 d ν 1 d 1 X kC X X P = − + . (7-10) The initial/boundary condition on eq. (7-8) is not intuitive. For the batch reactor problem we have just solved, t = 0 corresponds to C A = C A0 and = max . Therefore, the boundary condition reads C A ( = max ) = C A0 , or X ( = max ) = 0. (7-11) This is because the initial moment corresponds to the maximal possible residence time. Eqs. (7-8)&(7-11) specify a solution for the function C A ( ). The final composition of the reactor (at quenching) is calculated from the value of C A at t = max , which corresponds to = 0. Thus, the conversion produced in the reactor is A A0 1 ( 0) / ( 0) X C C X = = = = . (7-12) Again, while the formulae (7-11)&(7-12) were derived for semi-batch reactor, they are of general validity. The result (7-8) is easily generalized to many reactions: ( ) 0 d ν d 1 i ij j i i j C r C C P = + . (7-13) Example 10-2. The experimental residence time distribution of a reactor has been found to follow the dependence 0 max η( )η( ) = , i.e. 0 max 1, 0... . = = (7-14) a) Normalize this distribution. Compute the average 2 , the dispersion, the deviation of , and the cumulative P . Parameters : = 1 h. b) The first-order reaction A B takes place in this reactor ( k = 1 h -1 , [A] 0 = 1 M). Compute the conversion in case of complete segregation and complete mixedness.
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123 c) The same for the second-order reaction 2A B ( k = 1 h 1 ·M 1 , [A] 0 = 1 M). Solution. a) We use eq. (6-5) to compute the normalization coefficient: max max 1 1 n 0 max 0 0 1 d d c = = = , 1 max max η( )η( ) = . (7-15) Next, we compute the average and 2 : max max max 2 max 0 max max 0 0 1 1 1 d d 2 2    = = = = ; max max 2 2 3 2 max 0 max max 0 1 1 1 d 3 3 = = = . From the first of these equations, we find that max = 2 = 2 h. The dispersion and the standard deviation about the mean of are, from eqs. (6-7)&(6-8), 2 2 2 2 2 max max max 1 1 1 3 4 12 disp = = = ; max 1 12 dev = . Finally, the cumulative distribution function P follows from the definition (6-2): 1 max max 0 0 ( ) d d P = = = . b) For a first-order reaction in a batch reactor, we have eq. (7-2) holding true, batch 1 e k X = . If the real reactor that has the residence time distribution (7-15) is segregated , and every globule of fluid in it behaves as a batch reactor, then we can use eq. (7-1): max max max max max segr max max max max max 0 0 0 0 1 e 1 1 1 1 e d d e d 1 de 1 k k k k X k k = = = + = . (7-16) In the other limit, where the real reactor is completely mixed , we need to solve eq. (7-9). Using that (i) between = 0 and max we have = 1/ max and P = / max , and that r A = kC A = kC A0 (1 X ), we can write the explicit form of the equation: ( ) max d 1 1 d X k X X = − + . (7-17) This we solve using Maple; the general solution for X ( ) is ( ) 1 max 1 exp( ) 1 c k X k + = . Here, c 1 is the integration constant that is determined through the initial condition (7-11), which reads: ( ) max 1 max max 1 exp( ) ( ) 1 lim 0 c k X k + = = . For this to be fulfilled, it must hold true that 1 max 1 max 1 exp( ) 0, so that exp( ). c k c k + = = − Therefore, the solution to eq. (7-17) for X ( ) is ( ) ( ) max max 1 e 1 k X k = .
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124 Finally, the actual conversion in a completely mixed reactor is the value of this X at = 0, see eq. (7-12): max mixed max 1 e ( 0) 1 k X X k = = = . (7-18) Thus, a first-order reaction produces precisely the same conversion in the segregated and the mixed reactor of the same distribution time (7-15), compare eqs. (7-16)&(7-18). We can represent all conversions as functions of Damköhler ’s number Da 1 = k only: 1 batch 1 e Da X = ; max 1 2 2 segr mixed max 1 1 e 1 e 1 e 1 1 1 2 2 k Da k X X k k Da = = = = . c) For a second-order reaction 2A B in a batch reactor, A0 batch A0 2 2 1 kC X kC = + . The conversion in a segregated reactor of distribution density (7-15) is max max max A0 A0 segr batch max A0 max A0 0 0 0 2 2 1 1 d d d 2 1 1 2 1 1 kC kC X X kC kC = = = = + − + + ( ) max max max max A0 ma 0 x A A0 max A0 0 0 0 0 A d 1 1 d 1 d 1 1 1 2 1 2 1 2 1 1 2 1 2 kC C k kC k C kC = = = = + + + + ( ) ( ) max A0 A0 max 0 A0 max A0 max 1 1 1 ln 2 1 1 ln 2 1 2 2 kC kC kC kC = + = + . (7-19) For a completely mixed reactor, we need to solve eq. (7-9) again, but this time with r A = − kC A 2 = − kC A0 2 (1 X ) 2 : ( ) 2 A0 max d 1 2 1 d X kC X X = − + . (7-20) The initial condition is again X ( = max ) = 0. The solution is again possible to get with Maple only, with dsolve({de,ic}) , and it reads: ( ) ( ) ( ) 1 A0 max A0 max 0 A0 max 2 2 1 1 2 2 2 I kC X kC I kC = . (7-21) Here, I 1 ( x ) and I 0 ( x ) are called the Bessel I functions of the zeroth and the first kind, and they are similar to exp( x )/ x 1/2 (at x ∞) The conversion of the real mixed reactor is X ( = 0), i.e. ( ) ( ) 1 A0 max mixed A0 max 0 A0 max 2 2 1 1 2 2 2 I kC X kC I kC = . (7-22) We can represent all conversions as functions of the Damköhler number Da 2 = 2 kC A0 : 2 batch 2 1 Da X Da = + ; ( ) ( ) ( ) A0 max A0 2 segr A0 max A0 2 ln 2 1 ln 4 1 ln 2 1 1 1 1 2 4 2 kC kC Da X kC kC Da + + + = = = ; ( ) ( ) ( ) ( ) 1 A0 1 2 mixed A0 2 0 A0 0 2 2 4 2 2 1 1 1 1 4 2 2 4 2 2 I kC I Da X kC Da I kC I Da = = . (7-23)
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125 The mixing conditions do not matter in two cases: - for a first order reaction; - for a reactor of fixed residence time, i.e. = ( 1 ). In these cases, complete segregation and complete mixedness (and anything in-between) the same conversion. Read more Levenspiel ’s ch. 11, 15, and 16 [1]. Fogler’s ch. 18 [ 2]. Problems 1. Derive eq. (7-8) using a membrane PFR that is of length L . The mixture enters it at a rate F A0 , [mol/s]. The end of the PFR is closed. The mixture exits through the walls, with a known rate of profile j A ( L ), [mol/m 2 s]. Relate j A and . Write the mole balance for the reactor and simplify it to obtain eq. (7-8). 2. 2A B in segregated reactors Using eq. (7-1), compute the conversion and the mixture composition for a 2 nd order liquid- phase reaction 2A B (rate constant k ) taking place in a completely segregated (i) ideal PFR; (ii) ideal batch reactor; (iii) ideal CSTR; (iv) laminar flow reactor. Compare graphically the dependence of the conversion on k . 3. Zeroth-order reaction in a non-ideal reactor The reaction A 2B is of 0 th order (of constant rate r ), so in batch reactor it is valid that ( ) 0 0 0 0 0 [A] , [A] / ; [A] [A] η(1 /[A] ) 0, [A] / . rt t r rt rt t r = = Using this expression, compute the average composition and the conversion at the exit of a reactor under the assumption for complete segregation. The reactor has a distribution of: (i) ideal batch reactor; (ii) ideal CSTR; (iii) laminar flow reactor. Compare graphically the dependence of the conversion on the Damköhler number Da 0 = r /[A] 0 for the three reactors. 4. Experimental residence time distribution A segregated non-ideal laminar flow isothermal reactor has the experimental residence time distribution: n 3 1 c a = , where a = 0.001 min -4 and the range of is 0.6… a -1/4 min. a) Find the space-time of this reactor. b) The 2 nd order reaction 2A B takes place in this reactor, with k = 0.15 min -1 M -1 and [A] 0 = 0.5 M. Find the mean composition and conversion. Use the table of integrals from the first page. c) Find the specific rate of production of B (in M/h).
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126 5. A segregated tank reactor has the experimental residence time distribution: ( ) 2 2 n 1 / c a = , where a = 15 min and the range of is 0 a min. a) Find the space-time of this reactor, the dispersion and the standard deviation of . b) The 1 st order reaction A B takes place in this reactor, with k = 30 h -1 and [A] 0 = 0.5 M. Find the mean composition and conversion. Use the table of integrals from the first page. c) Find the value of the volume-specific rate of production of B (in M/h). 6. A B in segregated reactors Using eqs (7-1) and (1-48), compute the conversion and the mixture composition for a first-order reversible liquid-phase reaction A B taking place in (i) an ideal batch reactor; (ii) ideal PFR; (iii) ideal segregated CSTR; (iv) segregated laminar flow reactor. Use the list of integrals (7-24), unless you prefer Maple. If using Maple, compare graphically the conversion as function of the space-time in ideal PFR, ideal segregated CSTR, normal ideal CSTR (solution to a normal CSTR’s mole balance) and a laminar flow reactor, for [A] 0 = 1 M, K = 1 and k = 1 min -1 . 7. Autocatalytic reaction A + B 2B in segregated reactors Using eqs (7-1) and the result from problem 9 from sec. 1, compute and compare the conversion for the autocatalytic simple liquid-phase reaction A + B 2B taking place in (i) an ideal batch reactor or ideal PFR; (ii) ideal CSTR; (iii) segregated laminar flow reactor (numerical integration required!); (iv) non-ideal PFR (assumed to be segregated) with the experimental residence time distribution in the following figure: Is this normalized? All reactors have the same space-time as that for the non-ideal PFR (you need to calculate it). Parameters: [A] 0 = 1 M, [B] 0 = 10 -3 M, k = 0.9 s -1 M -1 . 8. A + B 2B in non-ideal reactor The simple autocatalytic reaction A + B 2B takes place in a non-ideal tank reactor that has the residence time distribution n max max 1 , 0... c = = . Find analytically the conversion if the mixture is completely segregated. Find numerically the conversion if it is mixed. Parameters: max = 15 min, [A] 0 =1 M, [B] 0 =10 3 M, k = 1 M -1 ·min -1 . How many equations are needed for the mixed case? [s] [s -1 ]
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127 Exam formulae List of formulae that will be available at the exam The Arrhenius equation for the rate constant vs. T normalized with respect to a standard temperature T °: 1 1 exp E k k R T T = , k the value of k at a standard temperature T ; E activation energy. Van ’t Hoff’s equation: Δ 1 1 exp H K K R T T = , where K is the equilibrium constant at temperature T °, and H is the heat of the reaction. Kirchhoff’s equation for K : Δ / Δ Δ 1 1 exp p c R p H c T T K K T R T T = , where c p is the heat capacity change for a mole of the reaction. General mole balance for a reactor: 0 d d d i i i i V n F F r V t = + (integral form), 1 i i i i C F C r t t V = − + (differential form). Here n i is the amount of component i in a volume V of the reactor, F i 0 is the inflow of i (mol/s), and F i is the outflow; r i is the production rate of i ; is the density of the mixture. Definition of selectivity, conversion and yield fraction: desirable key reagent desirable/undesirable undesirable key reagent Δ Δ n S n = ; desirable per mol key reagent desirable/undesirable undesirable per mol key reagent r s r = ; desirable key reagent desirable key reagent Δ Δ n Y n = ; desirable per mol key reagent desirable/undesirable key reagent r y r = . Definition of radical chain length: key reagent i r r = . Residence time distribution for an ideal PF or batch reactor: ( ) δ = . Residence time distribution for an ideal CSTR: 1 exp( / ) = . Residence time distribution for an ideal laminar flow reactor: 2 3 / 2 , / 2... = = . Several useful integrals:
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128 ( ) 1 1 d ln x a bx a bx b = + + ; 2 2 1 1 d ln 2 k x x k x k k x + = ; ( )( ) 1 1 d ln b x x a x b x a b a x + = + + ; 2 1 e d e kx kx kx x x k + = − ; 2 2 2 3 2 2 e d e kx kx kx k x x x k + + = − ; 2 2 3 3 3 4 6 6 3 e d e kx kx kx k x k x x x k + + + = − ; 2 3 1 2 1 e d e e E ( ) 2 2 2 kx kx kx k k x x kx x x = − + ; ( ) 2 2 3 2 ln 1 d 1 2 cx x x x x cx c c c + = + + ; 2 1 1 d ln 1 x cx x c cx x x + = + . (7-24) Mock exam Variant 1: Sec. 2, problem 12 Sec. 3, problem 8 Sec. 4, problem 7 Sec. 7, problem 3 Variant 2: Sec. 3, problem 10 Sec. 3, problem 9 Sec. 4, problem 6
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129 Sec. 7, problem 5
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130 Solutions to the mock exam problems Sec. 1. Introduction Sec. 2 Multiple reactions Problem 2-12 First note that the overall reactions are A 2B (which is equivalent to reaction 1) and 3A 4C (which is the sum of reaction 1 + 2 reaction 2), i.e. two parallel reactions. The sketch of composition vs. is therefore as for parallel reactions: a) The mole balances for CSTR are eq A : 0 A 1 2 1 2 [A] [A] [A] [A][B] r r r k k = = − = − ; eq B : B 1 2 1 2 [B] 2 2 [A] [A][B] r r r k k = = = ; eq C : C 2 2 [C] 2 2 [A][B] r r k = = = . These are 3 equations for 3 unknowns; we solve them backwards, first eq C for [C], then eq B for [B] and finally eq A for [A]: 2 [C] 2 [A][B] k = ; 1 2 2 [A] [B] 1 [A] k k = + ; ( ) ( ) ( ) ( ) ( ) 1 0 1 2 2 2 0 1 2 0 2 1 2 2 1 2 0 1 2 0 0 2 1 2 1 2 [A] [A] [A] [A] [A] 1 [A] [A] 1 [A] [A] 1 3 [A] 0 1 [A] 1 [A] 4[A] 1 3 4 [A] . 2 2 1 3 a b c k k k k k k k k k k k k k k b b ac c k k = − ⎯⎯→ + + + + + = ⎯⎯→ + + + + = = + When [A] 0 = 0, the last formula should give [A] = 0, which means that the correct solution is the one with +. b) For CSTR, there is no difference between overall and instantaneous selectivity. In view of the overall reactions, A 2B and 3A 4C, the selectivity and the yield coefficients are 1 CA B 1 2 1 BC BA C 2 2 [A] 2 4 / 3 2 1 2 2 2 3 2 3 k r r r r S r r r = = = = 2 [A] k 1 2 [B] . The yield ratios are B BA B B BA C CA BC / 1 / / 1 1/ r Y r r S = = + + ; C CA C B BA C CA BC / 1 / / 1 r Y r r S = = + + .
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131 As [B] increases monotonously with until it reaches its final constant value, S BC decreases monotonously, until it reaches a constant plateau value. Y C accordingly increases until a plateau, and Y B decreases until a plateau. The dependence on T is fixed by the ratio k 1 / k 2 = k 10 / k 20 exp[ ( E A1 E A2 )/ RT ]. If E A1 E A2 , S BC increases with temperature (together with Y B , and opposite to Y C ) and vice versa. Sec. 3. Reactive intermediates Problem 3-8. a) 1 is initiation, 2 & 4 are propagation, 3 is termination b) Start with the mass balances for the reactive intermediates in pseudo-steady approximation: 1 2 4 2 2 3 4 d[H ]/ d 2 0; d[HO ]/ d 2 0. t r r r t r r r = + = It is not necessary, but usually simpler to use instead of one of these equations the total radical production rate: ( ) 2 1 3 d [H ] [HO ] / d 2 2 0 t r r  + = . Using the last equation, we obtain [HO 2 ]: 2 1 1 2 3 2 2 2 3 [H ] [HO ] 0 [HO ] [H ] k I k I k k = ⎯⎯→  = , where I is the light intensity. The balance for [H ] then gives 3/2 1 1 2 2 2 4 2 2 1 2 4 2 2 2 3 1 2 [H ] [H ][O ] [HO ][H ] 0 [H ] 2 [H ] [H ] [O ] k I k I k k k I k k k + = ⎯⎯→  = + . We are now ready for the rates of formation of the stable molecules: 2 3/2 1 2 2 3 2 2 3 2 1 2 4 2 3 d[O ] [H ][O ] [HO ] [H ] [H ] d k I r r k k k I k t k = − + = − + = − ; we then use that r 4 = 2 r 3 + r 2 and r 1 = r 3 (as it follows from the pseudo-steady approximation above) 2 2 2 3 4 2 3 overall 2 2 1 4 3 4 d[H O ] d[O ] ; d d d[H ] d[O ] . d d r r r r r t t r r r r t t = + = = − = − = − = + As the overall reaction is H 2 + O 2 H 2 O 2 , its rate is d[H 2 O 2 ]/d t . The chain length is
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132 3/2 1 1 2 4 2 3 overall 2 2 2 2 i i 1 1 2 [H ] [H ] d[H O ] d[H O ]/ dt d d / d 2 2 [H ] k I k I k k r t r k I + = = = = . c) If the light intensity is low, the overall rate simplifies to overall 1 2 [H ] r k I = 3/2 1 4 2 3 [H ] k I k k + ; If the pressure increases by 1.5, then [H 2 ] increases by 1.5 and r overall increases by 1.5 1.5 . If the light intensity I increases by 2, the rate increases by 2 0.5 . d) As we are solving for [H 2 ], we start at d[H 2 ]/d t = - r overall , or 2 2 0 [H ] 3/2 1 1 1 2 2 2 4 2 4 4 3/2 3/2 3 2 3 2 3 [H ] d[H ] d[H ] d[H ] [H ] d d [H ] [H ] k I k I k I k k t k t t k k k = − ⎯⎯→ = − ⎯⎯→ = − ; 2 2 0 2 [H ] 1/2 1 1 2 4 4 2 1/2 1/2 1/2 2 2 0 3 2 0 3 [H ] [H ] 2 2 1 [H ] 1/ 2 [H ] [H ] [H ] 2 k I k I k k t t k k = − + = − ⎯⎯→ = + . Problem 3-9. a) Start with the mole balances of the reactive intermediates in pseudo-stationary state approximation: 1 2 1 2 1 2 3 [HClO][OH ] d[HClO]/ d [ClO ] [HClO][I ] 0; d[HIO]/ d [HClO][I ] [HIO][OH ] 0. t r r k k K t k k = = = We solve these for the concentrations of the reactive intermediates the first for [HClO] and then the second for the hypoiodous acid: 1 1 2 1 2 2 1 3 3 1 2 1 [ClO ] [HClO] ; [OH ] [I ] [I ] [I ] [ClO ] [HIO] [HClO] . [OH ] [OH ] [OH ] [I ] k k k K k k k k k k k K = + = = + The rate of formation of hypoiodite is 1 2 3 3 1 2 1 [I ][ClO ] d[IO ] [OH ][HIO] [OH ] d [I ] k k r k t k k K = = = + . b) At high pH (high [OH - ], k 2 [I - ] in the denominator negligible), the rate simplifies to 1 2 d[IO ] [I ][ClO ]/[OH ] d K k t = , which is 1 st order with respect to [I - ] At low pH, k 2 [I - ] dominates and 1 d[IO ] [ClO ] d k t = (0 th order with respect to [I - ]). The higher [OH - ], the slower the reaction, so NaOH stabilizes the mixture, while HCl destabilizes it.
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133 Problem 3-10. a) C A = C A0 V 1 ; C B = V 1 V 2 ; C C = V 2 . The total concentration is C A + C B + C C = C A0 . b) In terms of Vi for second order reversible reactions: ( ) ( ) ( ) 2 2 2 2 1 1 A B 1 1 A0 1 1 2 1 d / / d V V V V k C C K k C K t = = ; ( ) ( ) 2 2 2 2 2 2 B C 2 2 1 2 2 2 d / / d V V V V k C C K k K t = = . The initial conditions are V 1 (0) = V 2 (0) = 0. In terms of concentrations, ( ) ( ) ( ) ( ) 2 2 A 1 1 A B 1 2 2 2 2 B 1 2 1 A B 1 2 B C 2 2 2 C 2 2 B C 2 d / ; d d / / ; d d / . d C r k C C K t C r r k C C K k C C K t C r k C C K t = − = − = = = = The initial conditions are C A (0) = C A0 , C B (0) = C C (0) = 0. c) At equilibrium, d C i /d t = r 1 = r 2 = 0, so 2 2 2 2 Ae Be 1 Be Ce 2 / ; / , C C K C C K = = or after a square root, 1/2 1/2 Ae Be 1 Ce Be 2 / ; . C C K C C K = = Substituting these in the mole balance C Ae + C Be + C Ce = C A0 , we get an equation for C Be : 1/2 1/2 A0 Be 1 Be Be 2 A0 Be 1/2 1/2 1 2 / 1 C C K C C K C C K K + + = ⎯⎯→ = + + . The same result can be obtained in the usual way, by solving the equations r 1 = 0 and r 2 = 0 for V 1e and V 2e . Alternatively, since C Ae = C A0 V 1e and C Ce = V 2e , we find for the yields 1/2 1/2 1/2 Be 1 A0 2 A0 1e A0 Ae A0 A0 2e Ce Be 2 1/2 1/2 1/2 1/2 1/2 1 1 2 1 2 ; . 1 1 V V C K C K C C C C C C C K K K K K K = = = = = = + + + + The equilibrium overall selectivity and yield fractions are: 1/2 Be BCe 2 Ce C S K C = = ; Be Be 1/2 Be Ce 2 1 1 C Y C C K = = + + . The equilibrium ratios are 1/2 1/2 1/2 1/2 Be Ce Ce 1 2 1 2 Ae Be Ae ; ; . C C C K K K K C C C = = = (Note that K 1 is the equilibrium constant of 2A 2B rather than A B). d) If C is reactive intermediate, then d C C /d t = r 2 = 0. We look for C B ( t ), so we solve d C B /d t = r 1 r 2 = r 1 , or, using also C A C A0 , ( ) 2 2 B 1 A0 B 1 d / d C k C C K t = . This we solve as usual by separation of variables:
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134 B 1/2 1 A0 B B B 1 1 1 2 2 2 2 1/2 1/2 A0 B 1 A0 B 1 1 A0 1 A0 B 1 0 d d 1 d ln / / 2 C K C C C C k k t k t t C C K C C K K C K C C K + = ⎯⎯→ = ⎯⎯→ = . We used here the integrals from the 1 st page. Finally we solve for C B : 1/2 1 A0 1 1/2 1 A0 1 1/2 1 A0 1 2 / 1/2 2 / 1/2 1 A0 B B 1 A0 1/2 2 / 1 A0 B e 1 e e 1 k C t K k C t K k C t K K C C C K C K C C + = ⎯⎯→ = + . Sec. 4. Adiabatic processes Problem 4-6. a) The equilibrium yield follows from the equilibrium condition: ( ) ( ) 2 2 2 2 e e e 0 e 0 0 e e [B] /[A] / [A] 2 [A] 4 [A] 1 4 0 V V V V K K K K K = ⎯⎯→ = ⎯⎯→ + + = ; 2 0 0 e 4 [A] 1 8 [A] 1 4 2 8 V K K b b ac c K + + = = . When [A] 0 = 0, the yield should be zero, which means that the minus sign is the correct one. For the sketch: the reaction is exothermic, so V e decreases as T increases. At very high T , the equilibrium yield is 0; at very low T it is equal to V = [A] 0 /2. The equilibrium conversion is X e = V e / V , and it is 0.5 when 0 0 e 0 0 4 [A] 1 8 [A] 1 1/ 2 1/[A] 1/ 8 4 [A] K K X K K + − + = = ⎯⎯→ = = . Note this is easier to obtain directly from ( ) 2 e 0 e / [A] 2 V V K = , by substituting V e = V /2 = [A] 0 /4. The respective temperature follows from van ’t Hoff’s equation, 1 0 0 Δ 1 1 1 exp 1/[A] ln [A] 455 K Δ H R K T K R T T T H = ⎯⎯→ = + = . b) This one follows from the heat balance under adiabatic conditions: ( ) 0 0 Δ Δ . p V V p V H C T T V H T T C = − ⎯⎯→ = This is just a line, so the sketch should be The point where the line (the reaction path) crosses the equilibrium curve corresponds to equilibrium reached.
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135 c) At 125 °C, K is Δ 1 1 exp H K R T T = 0.47, and V e = 2.8 M. The conversion is 2 V e /[A] 0 = 69.6 %. The initial temperature follows from the adiabatic equation: ( ) 0 0 e Δ Δ 276 K p V V p V H C T T V H T T C = − ⎯⎯→ = + = . d) If conversion is 90% of the equilibrium, V = 0.9 V e , then the balance is ( ) 0 0 e Δ Δ 0.9 288 K p V V p V H C T T V H T T C = − ⎯⎯→ = + = . The integral follows from the mole balance: ( ) ( ) 2 2 0 d ( ) [A] [B]/ ( ) [A] 2 / d V V V k T K T k K t = = , so when V = 0.9 V e , ( ) e 0.9 2 0 0 d [A] 2 / V V V V t k K = , where 0 0 1 1 1 1 exp exp , Δ Δ 1 1 Δ 1 1 exp exp . Δ V p V p E E k k k V H R T T R T T C H H K K K V H R T T R T T C = = = = Problem 4-7. a) The mole balances for A and B read 2 0 A 2 B [A] [A] 2 2 [A] ; [B] 3 3 [A] . r r k r r k = = − = − = = + = + These are consecutively solved for [A] and [B]: ( ) 2 0 2 0 2 0 2 1 1 8 [A] 4 [A] [A] 2 [A] 0 [A] ; 2 4 3 1 1 8 [A] [B] 3 [A] . 16 k b b ac k c k k k k − + + + + = ⎯⎯→ = = − + + = + = The sketch is as for any simple reaction:
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136 b) The heat balance for an adiabatic CSTR reads ( ) ( ) 3 3 0 2 0 2 0 [J / kgK kg/m m / s K] Δ [J/mol mol/Ls L], 1 1 8 [A] Δ Δ Δ [A] . 16 p p p p c v T T HrV k HrV H H T T T k T c v c c k = − − + + = + = + = + For the sketch: at very small (large flow rate), the heat of the reaction is not enough to heat the feed so T 0 = T (the same result can be obtained by expanding in series T 0 at small ). At very large , the two 1s in the numerator can be neglected to produce feed temperature of ( ) 2 0 0 0,large 8 [A] [A] Δ Δ 16 2 p p k H H T T T c k c = + = + . For the reaction in question, H = 3 f H (B) −  f H (A) = +69 kJ/mol, i.e. this reaction is endothermic and the feed has to be heated to compensate for the reaction heat. T 0,large > T , and therefore, T 0 increases monotonously with from initial value T to final plateau at T 0,large . c) If the conversion is X = 1 [A]/[A] 0 = 0.83, then our formula for [A] specifies : ( ) ( ) 0 0 0 0 2 0 1 1 8 [A] 1 1 8 [A] 1 1 4 [A] , so 4 [A] 1.95 h. 1 2 [A] k X k X k k X X k − + + = ⎯⎯→ + = + = = We used k = 1.71 L/mol h (note it is given in m 3 in the statement) at 350 K. The respective feed flow rate is v = V / = 51 L/h. The composition of the reactor, according to the formulae derived above and the numbers given, is [A] = 0.73 M and [B] = 5.35 M. The initial temperature has to be 449 K. Sec. 5. Heat exchange Sec. 6. Residence time distribution Sec. 7. Mixing models Problem 7-3. First, have in mind that a 0 th order reaction has a finite time for completion once t > [A] 0 / r , the reaction is completed, [A] is zero and X is one. Inside a segregated reactor, you can have portions of liquid that are completely reacted and portions that are not.
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137 (i) The residence time distribution is a Dirac function, ( t ), so we just need to substitute t with : ( ) BR 0 0 [A] [A] η(1 /[A] ). r r = The respective conversion is X BR = 1 [A] BR /[A] 0 . (ii) For an ideal CSTR, the residence time distribution is = exp( t / )/ (where t is the random residence time and is the average residence time, i.e. the space-time of the CSTR). The average [A] is ( ) 0 [A] / 0 0 / / CSTR 0 0 0 0 0 [A] , [A] / 1 1 [A] [A] d e d [A] e d 0, [A] / r t t rt t r t t rt t t r = = = . This is calculated using the integrals from the first pages: ( ) 0 0 0 0 0 0 [A] / [A] / [A] / / / / / 0 CSTR 0 2 0 0 0 [A] / [A] / 1/ 0 0 0 0 0 0 [A] 1 / [A] e d e d [A] e e 1/ [A] e 1 e 1 [A] e 1 . [A] [A] r r r t t t t r r Da r r t t t t r r Da Da + = = + = = + + − + = + − The respective conversion is ( ) 0 1/ CSTR CSTR 0 0 [A] 1 1 e . [A] Da X Da = = (iii) For laminar flow reactor, 2 3 / 2 , / 2... t t = = . The respective average is ( ) 0 [A] / 2 2 0 0 0 0 3 LFR 3 /2 0 /2 0 [A] , [A] / [A] d , [A] / / 2; [A] d 2 0, [A] / 2 0, [A] / / 2. r rt t r rt t r t t t r t r = = In case that [A] 0 / r < /2, even the fastest portion of liquid (that flows through the centre of the tube) will remain in the reactor for time long enough to react completely, and therefore, once [A] 0 / r < /2, [A] = 0 and X = 1. We then compute the integral: ( ) 0 2 [A] / 2 2 1 0 0 0 0 /2 0 LFR 0 0 2 0 0 0 0 [A] [A] d [A] , ; [A] 1 , ; 2 2 1 2 2[A] 2 [A] [A] [A] 0, 0, 2 2 [A] 1 / 2 , 2; 0, 2. r t t r r r r r r Da Da Da = = = = The respective conversion: ( ) 2 0 0 LFR 0 1 1 / 2 , 2; 1, 2. Da Da X Da =
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138 Problem 7-5. a) First, normalize ; since 0 d 1 a = , for c n we get ( ) 2 2 n 0 1/ 1 / d 3/ 2 a c a a = = . The space-time of the reactor is the average residence time: ( ) 2 2 0 0 3 3 d 1 / d 2 8 a a a a a  = = = . The second moment, the dispersion and the standard deviation of are: ( ) 2 2 2 2 2 2 0 0 2 2 2 2 3 d 1 / d ; 2 5 19 / 320; 0.24 . a a a a a a a   = = = = = = b) For a 1 st order reaction A B, the batch reactor solution for the composition (of the equation d[A]/d t = k [A]) is [A] = [A] 0 exp( kt ), [B] = [A] 0 [A] and X = [B]/[A] 0 . Compute the mean [A] at the exit of the reactor: 2 2 2 0 0 2 2 3 0 0 0 0 2 2 2 2 0 0 0 2 2 2 2 0 3 3 e e 2 2 [A] [A] d [A] e e d [A] 2 2 3 1 2 [A] 2e 1 ; 2 3 1 2 [B] [A] [A] [A] [A] 2e 1 ; 2 [B]/[A] . a a a k k k k ka ka k k a a a k a k ka ka k a k a ka ka k a k a X + + = = = + = + = + + = = + = c) The volume-specific rate of production of B is 0 0 2 2 2 2 B 3 1 2 [A] [A] 2e 1 [B] [B] 2 4.3 M/h. 3 8 ka V ka v ka k a k a F a V + + = = = = We used a = 15 min = 0.25 h.
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139
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140 References 1. O. Levenspiel. Chemical reactor engineering, 3 rd ed. Wiley & Sons, 1999. 2. S. Fogler. Elements of chemical reaction engineering, 5 th ed. Prentice Hall, 2016 ( link ). 3. I. A. Semiokhin. A book of problems in chemical kinetics. Moscow, 2005. 4. O. Stern, M. Volmer, Phys. Ztschr. 20 (1919) 183. 5. L. Michaelis, M.L. Menten, Biochem. Z . 49 (1913) 333. 6. G. E. Briggs and J. B. S. Haldane, Biochem J. 19 (1925) 338. 7. F. A. Lindemann, Trans. Faraday Soc. 17 (1922) 598. 8. P.V. Danckwerts, Chem. Eng. Sci. 8 (1958) 93. 9. T.N. Zwietering, Chem. Eng. Sci. 11 (1959) 1. 10. CRC press, Handbook 11. J. Monod, Ann. Rev. Microbiology 3 (1949) 371 12. A. Novick, L. Szilard, Proc. N.A.S., Washington 36 (1950) 708 13. E. W. Thiele, Ind. Eng. Chem. 31 (1939) 916. 14. L.D. Schmidt. The engineering of chemical reactions. Oxford University Press, 1998. 15. I. Chorkendorff, J. W. Niemantsverdriet. Concepts of modern catalysis and kinetics, 3 rd ed. Wiley, 2017. 16. D. Y. Murzin, T. Salmi. Catalytic kinetics chemistry and engineering, 2 nd ed. Elsevier, 2016. 17. D. Y. Murzin, Engineering catalysis, 2 nd ed. De Gruyter, 2020. 18. J. M. Thomas, W. J. Thomas. Principles and practice of heterogeneous catalysis, 2 nd ed. Wiley, 2015. Bonus list:
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