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CSTR Applications v2
CSTR Applications v2
Senior TAC
Mettler-Toledo
1 Introduction to CSTR
2 Case 1: CSTR
5 Appendix
3
CSTRs vs. Flow Reactors
Advantages:
Good temperature control is easily maintained
Tank reactor behavior is well understood
Cheap to construct
Reactor has large heat capacity
Interior of reactor is easily accessed
Disadvantages:
Conversion of reactant to product per volume of reactor is
small compared to other flow reactors
Overall throughput typically lower
4
What is a CSTR?
CSTRs consist of:
- Tank (usually of constant volume)
- Stirring system to mix reactants (impeller or fast flowing introduction of reactants)
- Feed and exit pipes to introduce reactants and remove products
CSTRs are most commonly used in industrial processing, primarily in homogeneous
liquid-phase flow reactions, where constant agitation is required
CSTRs may be used by themselves, in series or in a battery
CSTRs are also used in the pharmaceutical industry as a loop reactor
CSTRs are often used in biological processes, such as cell cultures
- Fermenters are CSTRs used in biological processes in many industries such as brewing,
antibiotics and waste treatment, large molecules being broken down into smaller molecules
with alcohol as a by-product
5
How Can Mettler Toledo Help?
There are a variety of ways to set up CSTR systems
EasyMax is convenient since there are two well controlled independent reactors immediately
adjacent to each other
OptiMax and RX-10 can operate as single CSTR systems or coupled to other reactors and
controlled from same PC (up to four units connect to one PC)
Typically pumps are used to transfer liquids when running CSTR system for chemical
reactions – pumps can be syringe pumps, peristaltic and diaphragm pumps or even gravity
For crystallization systems, pumps transferring between CSTR's can physically change the
crystals so pressure difference (nitrogen and vacuum) can be used to transfer slurries through
larger diameter tubing
PAT is invaluable in keeping steady state monitored and well controlled
- ReactIR, FBRM, pH
6
Agenda 7
1 Introduction to CSTR
2 Case 1: CSTR
5 Appendix
Dosing
Pump
Gas Uptake Set
Liquid levels
stay constant
due to output
tube heights
8
BF3 catalyzed polymerization: Experimental Overview
Instrumentation:
- EasyMax 102 with Dosing Unit set up in a
continuous mode
- Universal Control Box connected to gas uptake
set
- 2 x Masterflex peristaltic pumps between
reactors and output from reactor 2
Chemistry:
- Monomer diluted in solvent in Reactor 1, Tr at 10°C
- Reactor 2 solvent only, Tr at 10°C
- Dilute monomer was added automatically by the EasyMax Dosing Unit, BF3 gas was gently
bubbled in with the EasyMax gas uptake set
- Reactor fill levels were held constant with a combination of adjusting peristaltic pump rates
and output tube height levels
1 Introduction to CSTR
2 Case 1: CSTR
5 Appendix
Other Feeds
N2 N2
Vacuum Vacuum
Liquid levels
stay constant
due to output
tube heights
11
Case 2: Continuous Crystallizer
12
Agenda 13
1 Introduction to CSTR
2 Case 1: CSTR
5 Appendix
14
Agenda 15
1 Introduction to CSTR
2 Case 1: CSTR
5 Appendix
16
Appendix
17