CONTINUOUS IDEAL

REACTORS

A. SARATH BABU
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Continuous Stirred Tank Reactor

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CSTR Contd. . . 3
CSTR Animation 4
• Also called as Mixed, Backmix, Ideal stirred tank reactor
• Open system, operates under steady state conditions
• Reactants are continuously introduced and products are
continuously withdrawn
• Perfect mixing – contents have uniform properties
– No spatial variations
• Conditions at the exit are same as inside the reactor
• Used for homogenous liquid phase reactions where
constant agitation is required
• Eg. Sulfonation, Polymerization, plastics, explosives,
synthetic rubber etc.
CSTR Contd. . . 5
Advantages:
• Cheap to construct
• Good temperature control
• Reactor has large heat capacity
• Easy access to interiors

Disadvantages:
• Conversion per unit volume of the reactor is
smallest compared to other flow reactors

CSTR Contd. . . 6
Fractional Conversion (xA):
FA0  FA
xA 
FA0
C A0  C A
xA  (for constant density)
C A0

Space time ():

Space time is the time required to process one
reactor volume of inlet material (feed) measured
at inlet conditions.  is the time required for a
volume of feed equal to the volume of the vessel
(V) to flow through the vessel.
 = V/v0 = sec
N.B. : Volume of vessel here means volume of Reaction Mixture. 7
Space Velocity (S):
Space velocity (S) is the reciprocal of space time,
the number of reactor volumes of feed, measured
at inlet conditions, processed per unit time.
Mean Residence time tm:
The residence time is the length of time species
spend in the reactor. All molecules that enter may
not spend the same time in the reactor.
The distribution of residence times – RTD
The average length of time that molecules spend in
the reactor – mean residence time (tm)
tm = V/vE
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 FA  FA0 (1  x A )
lit mol mol
v0  FA0 / C A0  
sec sec lit

For constant density:

FA FA0 (1  x A )
CA    C A0 (1  x A )
v v0

For variable density:

FA FA0 (1  x A ) (1  x A )
CA    C A0
v v0 (1   A x A ) (1   A x A )

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Stoichiometric Table – Flow Systems
aA + bB  rR + sS
Species Initial Change Final moles

AB FFA0B0 -F A0xA A0xA

-(b/a)F FFAB==FFA0A0(1-x )
(MBA-(b/a)xA)

R FR0 +(r/a)FA0xA FR= FA0(MR+(r/a)xA)

S FS0 +(s/a)FA0xA FS= FA0(MS+(s/a)xA)
I FI0 0 FI = FI0
Total FT0 FT = FT0 + NA0δxA

Where: MI = FI0/FA0
δ = Constant
For (r/a + s/a –density:
b/a – 1) C = C (1-x ) 10
A A0 A
11
 Design Equation
General Mass Balance Equation:

Rate of Input = rate of output + accumulation

+ rate of disappearance

FA0 = FA + 0 + (-rA) V
FA
FA0
CA
CA0
V
v0
FA0 - FA = (-rA) V
xA

FA0 xA = (-rA) V

V / FAo = xA / -rA
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General Design eqn. for a CSTR:
V / FAo = xA / -rA

V / (v0 CA0) = xA / -rA

 / CA0 = xA / -rA
Design eqn. for a CSTR under constant density:

 = (CA0 – CA) / -rA tm = V/vE

Note that the space time and the mean

residence time are equal only in the case of
constant density. 13
 DA =kCA0n-1 

Comparison of Different order

Reactions in a CSTR
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Plug Flow Reactor

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The necessary and sufficient
condition for plug flow is the
residence time in the reactor to
be the same for all elements of
the fluid.

PFR Animation 16
• PFR is also called as tubular reactor
• Residence time is same for all fluid elements
• Operated under steady state conditions
• Reactants are consumed as they flow down along the
length of the reactor
• Axial concentration gradients exist
• One long tube or a number of short tubes (see fig.)
• Choice of diameter depends on fabrication cost,
pumping cost and heat transfer needs
• Wide variety of applications in gas/liquid phase
• Eg.: Production of gasoline, cracking, synthesis of
ammonia, SO2 oxidation 17
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(1) The flow in the vessel is Plug flow.
(2)There is no axial mixing of fluid inside the
vessel (i.e., in the direction of flow).
(3)There is complete radial mixing of fluid inside
the vessel (i.e., in the plane perpendicular to
the direction of flow).
(4)Properties may change continuously in the
direction of flow
(5)In the axial direction, each portion of fluid,
acts as a closed system in motion, not
exchanging material with the portion ahead of
it or behind it.
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Advantages:
• Easily maintained as there are no moving parts
• High conversion per unit volume
• Unvarying product quality
• Good for studying rapid reactions

Disadvantages:
• Poor temperature control
• Hot spots may occur when used for exothermic
reactions

PFR Contd. . . 20
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Design Equation
General Mass Balance Equation:

Rate of Input = rate of output + accumulation

+ rate of disappearance

FA = FA + dFA + 0 + (-rA) dV
-dFA = (-rA) dV

FA0 dxA = (-rA) dV 24

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General Design eqn. for a PFR:
xA xA

V / FA0   dx A /  rA  / C A0   dx A /  rA
0 0

Design eqn. for a PFR (under constant density):

xA V

    dC A /  rA tm   dV / v
0 0

Note that the space time and the mean

residence time are equal only in the case of
constant density.
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CA/CA0

DA = kCA0n-1 

Comparison of Different order

Reactions in a PFR
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Item BR CSTR PFR

XA (NA0-NA)/NA0 (FA0-FA)/FA0

CA NA/V FA/v

-rA (NA0/V)dxA/dt FA0xA/V FA0dxA/dV

t NA0dxA/V(-rA)  = V/v0

Constant density

XA (CA0-CA)/CA0 (CA0-CA)/CA0

-rA -dCA/dt (CA0 -CA)/ -dCA/d

t -dCA/(-rA)  = V/v0

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Algorithm for Isothermal Reactor Design

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 CSTR PFR
xA

 / CA0 = xA / -rA  / C A0   dx A /  rA
0

 / CA0

 / CA0

1 /-rA

xA

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 CSTR PFR
x A

V / FA0 = xA / -rA V / FA0   dx A /  rA

0

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 CSTR xA PFR
 = (CA0 – CA) / -rA     dC A /  rA
0

 

1 /-rA 1 /-rA

CA0 CA CA0
CA

(Constant Density) 33
 CSTR (Constant Density) PFR


1 /-rA

1 /-rA
CA CA0

CVBR
CA CA0
t
1 /-rA

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CA CA0
 CSTR PFR
 / CA0
1 /-rA

 / CA0
xA

1 /-rA VVBR
t / CA0
1
 rA (1   A x A )
xA

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xA
 CSTR (Constant Density)
CA PFR
 = (CA0 – CA) / -rA     dC A /  rA
C A0
Zero Order
CA

 = (CA0 – CA) / k     dC A / k
CA0
k = CA0 – CA k = CA0 – CA
k = CA0 xA k = CA0 xA
Constant Density BR
kt = CA0 – CA
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 CSTR (Constant Density)
CA PFR
 = (CA0 – CA) / -rA     dC A /  rA
C A0
First Order
CA

 = (CA0 – CA) / kCA     dC A / kC A

C A0
C
k = (CA0 – CA)/CA  ln A
  ln(1  x A )  k
k = xA /(1-xA) C A0
Constant Density BR
CA
 ln  kt
C A0 37
 CSTR (Constant Density)
CA PFR
 = (CA0 – CA) / -rA     dC A /  rA
C A0
Second Order
CA

    dC A / kC A
2
 = (CA0 – CA) / kCA2
C A0
1 1
k = (CA0 – CA)/CA2   k
k CA0 = xA /(1-xA)2 C A C A0
Constant Density BR
1 1
  kt 38
C A C A0
Constant Density

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 For constant density:
• The performance of the Batch reactor is
similar to that of PFR for all orders
•The performance of all the three reactors is
the same in case of zero order reaction
•The performance of PFR is superior to that of
a CSTR for all orders > 0

For all reaction orders > 0

• The volume of a CSTR required for obtaining a
given conversion is larger than that of PFR
• For the same volumes of PFR & CSTR, the
conversion obtained is larger in the case of PFR
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 CSTR (Variable Density) PFR
xA

  C A0  dx A /  rA
CA 1  xA
 = CA0xA / -rA 
C A0 1   A x A
0
Zero Order
xA

 = CA0 xA / k   C A0  dx A / k
0
k = CA0 xA k = CA0xA

Variable Density BR:

C A0 ln(1   A x A )  k At 41
 CSTR (Variable Density) PFR
x
A
CA 1  xA
 = CA0xA / -rA 
C A0 1   A x A   C A0  dx A /  rA
0
First Order
xA

 = CA0 xA / kCA   C A0  dx A / kC A
0
k = CA0 xA/CA k  (1   A ) ln(1  x A )   A x A

Variable Density BR:

 ln(1  x A )  kt 42
 CSTR (Variable Density) PFR
xA

  C A0  dx A /  rA
CA 1  xA
 = CA0xA / -rA 
C A0 1   A x A
0
Second Order
xA

  C A0  dx A / kC A
2
 = CA0 xA / kC A
2

0
k = CA0 xA / CA2 C A0 k  2 A (1   A ) ln(1  x A )
  x  ( A  1) x A /(1  x A )
2
A A
2

Variable Density BR:

x A (1   A ) /(1  x A )   A ln(1  x A )  kC A0t 43
Variable Density

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 Relative performance of plug flow and
continuous-flow stirred tank reactors

Fraction unreacted is larger in CSTR for a given Da

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 Comparison of reactor volume required for a given
conversion for a first-order reaction in a PFR and a CSTR

• For small conversions VCSTR/VPFR = 1 (selection of reactor not

very critical).

• For large conversions, VCSTR/VPFR is very large (selection of

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reactor very critical).
 For Variable density:

• The performance of CSTR & PFR is similar in

case of zero order (irrespective of constant /
variable density)
• The performance of BR is different from the
performance of PFR (the performance was
similar in the case of constant density)
• The performance of PFR is superior to that of
a CSTR for all orders > 0 (same as constant
density)

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Comparison of possible advantages (+) and Disadvantages (-)
for Batch, CSTR and PFR Reactors

Criteria Batch CSTR PFR

Reactor size for given conversion + - +
Simplicity and Cost + + -
Continuous operation - + +
Large throughput - + +
Cleanout + + -
On-line analysis - + +
Product quality - + +

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 ANY CLARIFICATIONS ?

Abbey, Edward
That which today calls itself science gives us more and more information,
an indigestible glut of information, and less and less understanding.

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