Continuous flow reactors - Introduction

Plug flow reactor (PFR)

Continuous Stirred Tank Reactor (CSTR) or Mixed Flow Reactor (MFR)

In any reactor, for a small volume, the following holds true

(Rate of ) In + generation = Out + accumulation
Consider a PFR: It is a tubular reactor, typically long with a small cross sectional area.
We assume that
there is no back mixing
radially concentration
temperatures are uniform
Axially, concentration and temperature can vary (even in steady state conditions)
Obviously no slip conditions cannot confirm to this
In an ideal PFR, each element spends exactly same time in the reactor. This is given by V/Q,
which is easy to visualize if the volumetric flow rate is a constant. This is also called as mean
residence time.
Mass balance Development of Design Equation
dN A
dC
FA V + ( rA ) V V = FA V +V +
= FA V +V + A V
dt
dt
Under steady state conditions, we can write
FA V + ( rA ) V V = FA V +V
dFi
dFA
= rA and likewise
= ri
dV
dV

PFR under steady state conditions will yield an ordinary differential equation, ODE (may or may
not be linear), and in unsteady state conditions will yield a PDE, first order w.r.t. time and first
F
order w.r.t. volume. Note that the concentration can be written as C A = A In gas phase, we can
Q
further write PT Q = FT RT for the total and PAQ = FA RT for a species A. Q and T correspond to
the entire mixture and not to the individual species.

FAin FA
. The idea of conversion
FAin
may not apply if we have multiple reactions. It also doesnt apply in case of continuous reactors
under unsteady state conditions

In case of simple reactions, we can write conversion as x =

CSTR
Assume it is well mixed, uniform concentration and it spends, on the average, minutes in the
reactor. This is given by V/Q. This is also called as mean residence time.
The outlet concentration is the same as the concentration in the reactor. The mass balance
(design equation) is
FAin + ( rA ) V = FAout and likewise Fi in + ( ri ) V = Fi out
out

out

CSTR under steady state conditions will result in an algebraic equation (might be linear or
nonlinear). Unsteady state equation is an ODE , first order w.r.t. to time (may or may not be a
linear equation).

Consider the following examples. The reaction is A B

1. Zero order reaction, rate constant k = 0.05 mol/lit/min
2. First order reaction, rate constant k = 0.1 min-1
3. Second order reaction, rate constant k = 0.2 lit/mol/min
Feed contains 50 % A and 50% inert. The operation is at constant temperature and constant
pressure. If the molar flow rate is 100 mol/min and the volumetric flow rate is 100 lit/min,
determine the volume of reactor needed to get 20% conversion
Additional notes: Note that the idea of constant volume that we used in batch reactor cannot be
employed here. The volume of reactor is fixed here, but if there is an increase in number of
moles, then flow rate will increase. This will lead to dilution. We can have constant or variable
volumetric flow rate
Flow rate can change because there is change in number of moles, or temperature or pressure. A
species concentration can change because there is change in flow rate or because of reaction.
As long as we start from the original mass balance equation and simplify for a given condition,
we can handle all of these.
Solution:
dFA
dx
= FAin
= rA = k
dV
dV
dx
50
= 0.05
dV
50
V=
[0.2 0] = 200
0.05
Volume = 200 lit

1. (a)

(b) 50 kV = 40
V = 10
= 200
0.05
V = 200 lit. Both CSTR and PFR need the same volume for the zero order reaction
F (1 x )
F
2. (a) When we have constant volumetric flow rate C A = A = Ain
= C Ain (1 x )
Q
Q
dFA
dx
= FAin
= rA = kC A = kC Ain (1 x )
dV
dV
dx
k
1
0.1
= k C Ain
dV =
dV =
dV
1 x
FAin
Qin
100
V = 1000 ln ( 0.8 ) = 223.14

Volume = 223 lit

(b) The concentration at the inlet is CA = 0.5 mol/lit. At 20 % conversion, the
concentration of A at the outlet is 0.4 mol/lit. For a CSTR,
50 kC AV = 50 0.1 0.4 V = 50 0.04V = FA = 40
V=

10 1000
=
= 250
0.04
4

Volume = 250 lit.

Thus, for a first order reaction, UNDER ISOTHERMAL CONDITIONS, CSTR needs
more volume to achieve the same conversion.
3. (a) Second order reaction. PFR
dFA
dx
2
2
= FAin
= rA = kC A2 = kC Ain
(1 x )
dV
dV
0.2 0.52
dx
=
dV = 10 3 dV
2
50
(1 x )
0.2

1
1
=
1 = 0.25 = 103V
1 x 0
0.8
Volume = 250 lit
(b) Second order reaction , CSTR
FAin + ( rA ) out V = FAout
50 kC A2V = 40
50 0.2 0.42 V = 40
V=

10
= 312.5
0.2 0.42

Volume = 312.5 lit

Here again, CSTR needs higher volume than a PFR to yield the same conversion.

Additional notes:If the reaction order is negative, then CSTR is better. All these
conclusions are valid for simple reactions, isothermal conditions.

Usually liquid phase reaction is conducted in CSTR and gas phase in PFR. There are no
moving parts in PFR. It is harder to maintain temperature in PFR.