DESIGN AND FABRICTION OF COMPLEX

REACTOR COMBINATIONOF
(CSTR, PFR, TUBULAR &
ISOTHERMAL BATCH REACTOR)
A Major (or Minor) Project Report

Submitted in partial fulfilment of the requirements

For the award of the degree of Bachelor of Technology
In CHEMICAL ENGINEERING

SUBHA LAXMI BEHERA 110122058

CHITA RANJAN BAG 1221227004
NARAYAN SAHOO 1221227009
JIBAN RANJAN SAHOO 1221227008

DEPARTMENT OF CHEMICAL ENGINEERING

C.V. RAMAN COLLEGE OF ENGINEERING
BHUBANESWAR
OCTOBER 2014

C.V Raman College of Engineering

Bhubaneswar

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CERTIFICATE
We hereby certify that the work which is being presented in the B. Tech. Major (or
Minor) Project Report entitled “ DESIGN AND FABRICATION OF COMLEX
REACTOR COMBINATION OF (CSTR,PFR,TUBALAR AND BATCH
REACTOR)”, in partial fulfilment of the requirements for the award of the Bachelor
of Technology in Chemical Engineering and submitted to the Department of
Chemical Engineering of C.V. Raman College of Engineering, Bhubaneswar
(Odisha) is an authentic record of our own work carried out during a period from June
2013 to January 2014 under the supervision of Prof. Dr. R.R. Pradhan, Head,
Chemical Engineering Department.
.
Name Registration Number
SUVALAXMI SAHOO 1001227058

CHITA RANJAN BAG 1221227004

NARAYAN CHANDRA SAHOO 1221227009

JIBAN RANJAN SAHOO 1221227008

This is to certify that the above statement made by the candidates is correct to the best
of my knowledge.

Dr. Ranjita swain Prof. Dr. Ranjan R. Pradhan External

Project Guide Head Of The Department Examiner

ACKNOWLEDGEMENT

We would like to articulate our profound gratitude and indebtedness to our project
guide Rudra Narayan Mahapatra, who has always been a constant motivation and
guiding factor throughout the project time in and out as well. It has been a great

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 pleasure for us to get an opportunity to work under her and complete the project
successfully.
We wish to extend our sincere thanks to Prof. Dr. R. R. Pradhan, Head of our
Department, for approving our project work with great interest. I would like to mention Mr.
Rudra Narayan Mahapatra ,Mr. Gautam Ganesh and Rajib Ghosh for his cooperation
and constantly rendered assistance.
An undertaking of this nature could never been attempted with our reference to and
inspiration from the works of others whose details are mentioned in references section. I
acknowledge my indebtedness to all of them.
We take this opportunity to express my hearty thanks to all those who individually as well as
collectively helped us in the successful completion of this project
SUVALAXMI SAHOO 1001227058
CHITA RANJAN BAG 1221227004
NARAYAN CHANDRA SAHOO 1221227009
JIBAN RANJAN SAHOO 1221227008

ABSTRACT
In chemical industries application of reactors are vastly. It used to make various products at
different time. Many industries are using different types of reactor for different purpose. So
reactors are devices for containing and controlling chemical reactions. There are different
types of reactor considering the nature of the reactions and those are mainly categorised as
bio-reactor, chemical-reactor, fusion reactor and so many. But according to chemical
engineering concept these reactors are mainly classified as batch reactor, plug-flow reactor,
tubular-reactor, and CSTR reactor. Mainly batch reactor is a uniform mix reactor and the
composition is same everywhere in the reactor. This type of reactor is mainly used in
laboratory for studying the reaction rate in laboratory scale. Whereas PFR/tubular reactors
are continuous reactor where input of raw and output of product are continuously and PFR
/tubular reactors are used for the gold leaching from ore. CSTR is known as back mix
reactor, which is most common ideal reactor type in chemical engineering. It may be
continuous or batch type Reactor. CSTR used in biological processes in many industries for
making antibiotics, polyethene, etc. Chemical reactor design, optimization and scale up
provides up to data information: to help chemical and process engineers save time, money,
and materials. Dessions adding of different coverage of every aspects of selection, design
factors and parameters, optimization and scale up of reactors. And design a complex reactor
that is combination of CSTR, PFR, Tubular and Isothermal Batch Reactor.

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 LIST OF FIGURES

Sl. FIGURE NAME PAGE

No NO.
1 Fig 1.1 07

2 Fig 1.2 07

3 Fig 1.3 08

4 Fig 1.4 09

5 Fig 1.5 10

6 Fig 1.6 12

7 Fig 1.7 15

8 Fig 1.8 16

9 Fig 1.9 17

10 Fig 2.0 24

11 Fig 2.1 25

12 Fig 2.2 26

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 CONTENTS
Subjects Page No.
Introduction
1. a-> What is Reactor 6
1. b->Types of Reactor 6
1. c-> About Reactors 9
1. d->Analogy among the reactors 12
1. e->Advantages and Disadvantages of Reactors 13
1. f->Application of Reactors in Industry 14
1. g-> Performance equation of Reactors 17

Objective and Rationale 22

Theory and Method 22
4. A->Theory 22
4. B->Process Technology 23
4. C->Experiment Setup Diagram 26
4. D->Process Parameters 27
Conclusion 28

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 What is Reactor
Chemical reactors are vessels designed to contain chemical reaction.
Reactor is a device for containing and controlling a chemical reaction.
In chemical engineering, a device or process vessel, in which chemical reactions
(Catalyzed or non catalyzed) take place during a chemical conversion type of
Process. Reactors an apparatus or structure in which fissile material can be made to
Undergo a controlled, self-sustaining nuclear reaction with the consequent release of energy.

b->Types of Reactor
According to science-
Many types of Reactors are available, these are following types :-
Bioreactor: - any device or system that supports a biologically active
Environment.
Chemical reactor:- a device for containing and controlling a chemical
reaction .
Fusion reactor: - a device for containing and controlling a fusion power reaction.

Nuclear reactor:- a device for containing and controlling a nuclear reaction .

Reactor (Havoc):- a device for containing and controlling a nuclear reaction .

Reactor pattern: - design pattern used in concurrent programming .

But In Chemical Engineering
These are the following major reactor
Batch reactor
CSTR reactor

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PFR reactor
Tubular reactor

1.c About Reactors

Batch reactor:-

Fig 1.1

Batch reactor symbol

The Batch reactor is the generic term for a type of vessel widely used in the process
industries. Its name is something of a misnomer since vessels of this type are used for a
variety of process operations such as solids dissolution, product mixing, chemical reactions,
batch distillation, crystallization, liquid/liquid extraction and polymerization. In some cases,
they are not referred to as reactors but have a name which reflects the role they perform (such
as crystallizer, or bio reactor).

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Fig 1.2

A typical batch reactor consists of a tank with an agitator and integral heating/cooling
system. These vessels may vary in size from less than 1 litre to more than 15,000 litres. They
are usually fabricated in steel, stainless steel, glass lined steel, glass or exotic alloy. Liquids
and solids are usually charged via connections in the top cover of the reactor. Vapours and
gases also discharge through connections in the top. Liquids are usually discharged out of the
bottom.
The advantages of the batch reactor lie with its versatility. A single vessel can carry out a
sequence of different operations without the need to break containment. This is particularly
useful when processing toxic or highly potent compounds.

Continuous stirred-tank reactor:-

Fig 1.3

CSTR symbol
The Continuous flow Stirred-Tank Reactor (CSTR), also known as vat- or back mix
reactor, is a common ideal reactor type in chemical engineering. A CSTR often refers to a
model used to estimate the key unit operation variables when using a continuous [†] agitated-
tank reactor to reach a specified output. (See Chemical reactors.) The mathematical model
works for all fluids: liquids, gases, and slurries.
The behaviour of a CSTR is often approximated or modelled by that of a Continuous Ideally
Stirred-Tank Reactor (CISTR). All calculations performed with CISTRs assume perfect
mixing. In a perfectly mixed reactor, the output composition is identical to composition of
the material inside the reactor, which is a function of residence time and rate of reaction. If
the residence time is 5-10 times the mixing time, this approximation is valid for engineering
purposes. The CISTR model is often used to simplify engineering calculations and can be
used to describe research reactors. In practice it can only be approached, in particular in
industrial size reactors.
Assume:
Perfect or ideal mixing, as stated above
Integral mass balance on number of moles Ni of species i in a reactor of volume V.

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 [1]

Fig 1.4

Cross-sectional diagram of Continuous flow stirred-tank reactor

Where Fio is the molar flow rate inlet of species i, Fi the molar flow rate outlet, and
stoichiometric coefficient. The reaction rate, r, is generally dependent on the reactant
concentration and the rate constant (k). The rate constant can be determined by using a
known empirical reaction rates that is adjusted for temperature using the Arrhenius
temperature dependence. Generally, as the temperature increases so does the rate at which
the reaction occurs. Residence time, , is the average amount of time a discrete quantity of
reagent spends inside the tank.

Assume:

constant density (valid for most liquids; valid for gases only if there is no net change in the
number of moles or drastic temperature change)

isothermal conditions, or constant temperature (k is constant)

steady state

single, irreversible reaction (νA = -1)

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first-order reaction (r = kCA)

A → product

NA = CA V (where CA is the concentration of species A, V is the volume of the reactor, NA is

the number of moles of species A)

2.

The values of the variables, outlet concentration and residence time, in Equation 2 are major
design criteria.

To model systems that do not obey the assumptions of constant temperature and a single
reaction, additional dependent variables must be considered. If the system is considered to be
in unsteady-state, a differential equation or a system of coupled differential equations must
be solved.

CSTR's are known to be one of the systems which exhibit complex behaviour such as steady-
state multiplicity, limit cycles and chaos.

PFR (Plug Flow Reactor):-

Fig 1.5

Simple diagram illustrating plug flow reactor model

Main article: Plug flow reactor model

In a PFR, one or more fluid reagents are pumped through a pipe or tube. The chemical
reaction proceeds as the reagents travel through the PFR. In this type of reactor, the changing
reaction rate creates a gradient with respect to distance traversed; at the inlet to the PFR the
rate is very high, but as the concentrations of the reagents decrease and the concentration of
the product(s) increases the reaction rate slows. Some important aspects of the PFR:

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All calculations performed with PFRs assume no upstream or downstream mixing, as implied
by the term "plug flow".
Reagents may be introduced into the PFR at locations in the reactor other than the inlet. In
this way, a higher efficiency may be obtained, or the size and cost of the PFR may be
reduced.
A PFR typically has a higher efficiency than a CSTR of the same volume. That is, given the
same space-time (or residence time), a reaction will typically proceed to a higher percentage
completion in a PFR than in a CSTR. This is not always true for reversible reactions.
For most chemical reactions of industrial interest, it is impossible for the reaction to proceed
to 100% completion. The rate of reaction decreases as the reactants are consumed until the
point where the system reaches dynamic equilibrium (no net reaction, or change in chemical
species occurs). The equilibrium point for most systems is less than 100% complete. For this
reason a separation process, such as distillation, often follows a chemical reactor in order to
separate any remaining reagents or by-products from the desired product. These reagents
may sometimes be reused at the beginning of the process, such as in the Haber process. In
some cases, very large reactors would be necessary to approach equilibrium, and chemical
engineers may choose to separate the partially reacted mixture and recycle the leftover
reactants.

Tubular reactor or plug flow reactor:-

A tubular reactor is a vessel through which flow is continuous, usually at steady state, and
configured so that conversion of the chemicals and other dependent variables are functions of
position within the reactor rather than of time. In the ideal tubular reactor, the fluids flow as
if they were solid plugs or pistons, and reaction time is the same for all flowing material at
any given tube cross section. Tubular reactors resemble batch reactors in providing initially
high driving forces, which diminish as the reactions progress down the tubes.

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Fig 1.6
Flow in tubular reactors can be laminar, as with viscous fluids in small-diameter tubes, and
greatly deviate from ideal plug-flow behaviour, or turbulent, as with gases. Turbulent flow
generally is preferred to laminar flow, because mixing and heat transfer are improved. For
slow reactions and especially in small laboratory and pilot-plant reactors, establishing
turbulent flow can result in inconveniently long
Reactors or may require unacceptably high feed rates.

Analogy Among Reactors:-

Batch Reactor CSTR Reactor PFR Reactor

BATCH reactor is May continuous OR batch PFR is a Continuous type

non-continuous type. of reactor.
type.

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Uniform composition Composition is not varies , Composition varies along
everywhere, but with the length of the
composition change w.r.t. Its uniform everywhere. reactor
Time

Reactants will place in CSTR usually equipped PFR takes place

reactor & let them react & with an agitating devices perpendicular to the
after some time OR (Stirrer, Agitator) for direction of flow of
completion of reaction mixing purpose reactants & they don’t
take it out. have any agitating devices

All calculation will be Lateral mixing is allowed.

done on out-put Longitudinal mixing is not
composition allowed along the length.

Advantages of Reactors :-
Batch reactors :-

High conversion per unit volume for one pass

Flexibility of operation-same reactor can produce one product one time and a different
product the next

Easy to clean .

CSTR Reactors:-
CSTR's are known to be one of the systems which exhibit complex behaviour such as steady-
state multiplicity
It relatively cheap and simplicity to construct compare with other reactor such as batch
reactor and it also easy in controlling temperature in each stage since each operates in a
stationary state .
The heat transfer surface for this reactor also can be easily provided .

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PFR Reactors:-

High Conversion per Unit Volume

. Low operating (labor) cost

Continuous Operation

Good heat transfer

Disadvantages of Reactors:-
Batch Reactor:-
High operating cost
Product quality more variable than with continuous operation
CSTR Reactor :-
Temperature gradients
High maintenance cost

PFR Reactor:-

Undesired thermal gradients may exist

Poor temperature control

Shutdown and cleaning may be expensive

1.f->Application of Reactors in Industry:-

Batch Reactor:-
Batch reactors are used for most of the reactions carried out in a laboratory .
Batch reactors are usually used when a company wants to produce a range of products
involving different reactants and reactor conditions. They can then use the same equipment
for these reactions .
Examples of processes that use batch reactors include the manufacture of colorants and
margarine.

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 Fig 1.7
Figure Colorants being produced in a batch reactor. The top of the reactor is at floor level
and the rest of the reactor is suspended below it.

CSTR Reactor:-
CSTR are the most basic of the continuous reactors used in chemical processes.
CSTR used in biological processes in many industries, such as brewing, antibiotics,
polythene and waste treatment. In fomenters, large molecules are broken down into smaller
molecules, with alcohol produced as a by-product.

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 Fig 1.8
A CSTR reactor, used to make polyethene

PFR Reactors:-
PFR/Tubular Reactors are used for the gold leaching of ores flotation concentrates and
refractory ores that require accelerated or enhanced cyanidation reaction kinetics .
Tubular reactors operate at high pressure and temperature effecting gold cyanidation within
the volume of a pipe .

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 Fig 1.9
Tubular reactors are used, for example, in the steam cracking of ethane, propane and
butane and naphtha to produce alkenes.
Performance equation of Reactors :-

Batch Reactor:-

General Mole Balance Equation

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Assumptions

No inflow or out flow FA0 = FA = 0

2) Well mixed

Constant volume V = V0 (e.g. Liquid Phase or Gas Phase in a steel container)

CSTR Reactor:-
input of A - output of A = rate of disappearance of A due to reaction.

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Input (in kmol/hr, say) =FCA0,
output =FCA1,
rate of disappearance of A due to reaction =rAV,
so the mass balance is written as:

F(CA0-CA1)=rAV,

or

has units of time and is known as the mean residence time, and the symbol is used for
this residence time. Remember that for a CSTR, this is an average as particles have varying
residence times. The graphical representation of the performance equation is given below.

As for the batch reactor, the appropriate rate equation can now be used, and a particular
performance equation obtained. Some are listed below:
zero order:

first order:

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which can also be written as

Compare these with the batch reactor equations and note the similarity of the zero order.
Since the reaction in the CSTR takes place at the outlet concentration, the reaction rate for
many reactions (e.g. first order) is low, and this isn't an efficient utilisation of reactor volume.
For zero order reactions this doesn't apply.

A convenient way of achieving better efficiency is to use CSTRs in series, reducing the
volume of each. The output from the first CSTR is taken as the input to the second, etc, as
shown in the sketch.

Assuming first order kinetics and isothermal operation, for two equal sized reactors
(volume V2) we can write:

and similarly for a larger number of reactors. After N CSTRs (total volume Vtot, VN=V/N), the
ratio of initial to final concentrations is thus

and in the limit as this expression becomes

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This equation will be shown to be the performance equation of a plug flow reactor.

PFR Reactor:-

General Mole Balance Equation

IN - OUT + GENERATION = ACCUMULATION

At steady state-

Differentiating, that gives-

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For single reactions in terms of conversion-

The differential form of the PFR mole balance is-

The integral form is-

Objective and Rationale :-

The design of a chemical reactor deals with multiple aspects of chemical engineering.
Chemical engineers design reactors to maximize net present value for the given
reaction.
Minimizing the cost of the reactors.
Designers ensure that the reaction proceeds with the highest efficiency towards the
desired output product, producing the highest yield.

4THEORY and METHOD:-

4.a-THEORY:-
In manufactures o products for sale, the certainty of probability has usually to be satisfied for
the project to go forward.
Since no chemical reactor of itself can make a profit. The chemical reaction engineering has
to consider the effect of his reactor on the profitable of the project as whole.
There is the main aspect of the issue –

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a>-the cost of the reactor, that is both capital and both running cost
b>-The cost of the rest of the project of working of the product of the reactor to its final
soluble form.
c>-The effect of the project on the sources in which i is to be based has also to be considered.
On the one hand the choice o the entire project.
If certain chemical produce in rather small quantity, then they are made batch wise.
In bath wise operation the capital cost is less than for a corresponding continuous process
when the desire rate of production is less
Continuous processes are eventually adopted in almost all large scale, in chemical industry.
Diminished labour cost, any to the elementary of operation such as the repeated filling and
empty of batch vessel.
The facilities of automatic control. This also reduces labour cost, although it usually required
considerable capital only.

4.b->Process Technology:-
The reactors, in which chemicals are made in industry, vary in size from a few cm3 to the
vast structures that are often depicted in photographs of industrial plants. For example, kilns
that produce lime from limestone may be over 25 metres high and hold, at any one time, well
over 400 tonnes of materials.
The design of the reactor is determined by many factors but of particular importance are the
thermodynamics and kinetics of the chemical reactions being carried out.
The two main types of reactor are termed batch and continuous.

Batch wise reactors are used for most of the reactions carried out in a laboratory. The
reactants are placed in a test-tube, flask or beaker. They are mixed together, often heated for
the reaction to take place and are then cooled. The products are poured out and, if necessary,
purified.

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Figure 2.0
Illustrating a batch reactor.
Following reaction, the reactor is cleaned ready for another batch of reactants to be added.
Batch reactors are usually used when a company wants to produce a range of products
involving different reactants and reactor conditions. They can then use the same equipment
for these reactions.
Examples of processes that use batch reactors include the manufacture
of colorants and margarine .
Continuous reactors
An alternative to a batch process is to feed the reactants continuously into the reactor at one
point, allow the reaction to take place and withdraw the products at another point. There
must be an equal flow rate of reactants and products. While continuous reactors are rarely
used in the laboratory, a water-softener can be regarded as an example of a continuous
process. Hard water from the mains is passed through a tube containing an ion-exchange
resin. Reaction occurs down the tube and soft water pours out at the exit.

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Figure 2.1
Illustrating a continuous reactor.
Continuous reactors are normally installed when large quantities of a chemical are being
produced. It is important that the reactor can operate for several months without a shutdown.
The residence time in the reactor is controlled by the feed rate of reactants to the reactor. For
example, if a reactor has a volume of 20 m3 and the feed rate of reactants is 40 m3 h-1 the
residence time is 20 m3 /40 m3 h-1 = 0.5 h. It is simple to control accurately the flow rate of
reactants. The volume is fixed and therefore the residence time in the reactor is also well
controlled.
The product tends to be of a more consistent quality from a continuous reactor because the
reaction parameters (e.g. residence time, temperature and pressure) are better controlled than
in batch operations.
They also produce less waste and require much lower storage of both raw materials and
products resulting in a more efficient operation. Capital costs per tonne of product produced
are consequently lower. The main disadvantage is their lack of flexibility as once the reactor
has been built it is only in rare cases that it can be used to perform a different chemical
reaction .

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4.c->Experiment Setup Diagram:-

Fig 2.2
Diagram of Complex Reactor and combination of(Batch,CSTR,PFR and Tubular reactor) .
The above figure is a diagram of complex reactor and is a combination of Batch reactor,
CSTR reactor, PFR reactor and Tubular reactor. In this the reactors are connected parallel
and series simultaneously. But in once only, may parallel or series reaction are carried out.

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VIDUALISATION DIAGRAM OF COMBINE REACTOR (ISOTHERMAL BATCH
REACTOR,CSTR ,PFR and TUBULAR REACTOR ) Through PLC .
The above diagram is a visualisation of combined reactor that is controlling through
Programmable logical control. In which the raw materials are initially comes through two
mixable tank to Isothermal Batch reactor and then the product of the Batch Reactor again
comes to CSTR as a feed , and it is occurs simultaneously up to Tubular reactor . And all
the operation here controlled through PLC .

4.d->Process Parameters/Scale up:-

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 Industrial unit -

Reactor Technology -

Conclusion :-
Chemical reactor is a device or vessel in which chemical reactions take place during a
chemical conversion type of e process. Different types of reactors used in chemical
industry these are, Batch reactor are used for most of the reactions carried out in a
laboratory .PFR reactor used in gold industry for leaching of gold from its related ore
.CSTR reactor used in industry for the purpose of making polythene and also it use in bio
industry .Advantages and disadvantages of different types of rector . Future plan of
work, to design a complex and a combine reactor which is cost efficient , product quality

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is high, high yield percentages, low labour cost , less operation cost ,easy for processing
and handling .

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