4.

ISOTHERMAL REACTOR DESIGN

Professional Reference Shelf
R4.2 Recycle Reactors
Recycle reactors are used when the reaction is autocatalytic,
or when it is necessary to maintain nearly isothermal
operation of the reactor or to promote a certain selectivity
(see Section 5.6.6). They are also used extensively in
biochemical operations. To design recycle reactors, one
simply follows the procedure developed in this chapter and
then adds a little additional bookkeeping. A schematic
diagram of the recycle reactor is shown in Text Figure 4-15.

The recycled stream is drawn off at point Q and merged with

the fresh feed at Point P. We shall define the recycle
parameter R as the moles recycled per mole of product
removed at point Q.

Two Two conversions are usually associated with recycle

conversions: reactors: the overall conversion, X0, and the conversion per
Xsand X0 pass, Xs :

(CD4-88)
(CD4-89)

The only new twist in calculating reactor volumes or

conversions for a recycle reactor is a mole balance at the
stream intersections (points P and Q) to properly express

the species concentrations as a function of conversion.

Consider the gas-phase reaction

occuring in our reactor. Let X be the conversion of A in the

reactor per mole of A fed to the reactor. The design equation
is

Then:
Design equation:

Rate law:

with
Stoichiometry:
1. From the definition from the overall conversion, we can
define F A3 and F B3 leaving the system,
(CD4-90)
(CD4-91)

From the definition for conversion per pass, we can define

F A2 and F B3 leaving the reactor,
(CD4-92)
(CD4-93)

2. From the definition for the recycle parameter, R, we can

define F AR and F BR and the total molar flow rate in the
recycle stream, F tR
(CD4-94)

(CD4-95)

(CD4-96)
where

3. From the balance on the stream intersections, we have

(CD4-97)

(CD4-98)
(CD4-99)
(CD4-100)
Relating the molar
flow rates in the
various streams

(CD4-101)
(CD4-102)
(CD4-103)
(CD4-104)
(CD4-105)
(CD4-106)

The volumetric flow rate in the reactor, , is related to

the volumetric flow rate entering the reactor

by

(CD4-107)

where X is the number of moles of A reacted per

mole of A entering the reactor, and is defined by

(CD4-108)

The molar flow rate of A within the reactor is

(CD4-109)

4-110)

(CD

(CD4-111)

These equations for concentration are substituted into the

rate law, which is in turn substituted into the design
equation and integrated. For a first-order reaction in A and in
B,

(CD4-114)

Recycle
reactor
volume

(CD4-115)

where

The relationship between the overall conversion and the

conversion per pass can be found by equating F A2 from
Equations (CD4-107) and (CD4-106):

Then using Equation (CD4-97) and simplifying, we have

(CD4-116)