CL208 - 324 - Week1 Day 2

CL208/ CL324
CHEMICAL REACTION
ENGINEERING
Week 1
1
Contact Information
Prof. SONALI DAS
Email: [email protected]
Extn: 7265
Office hours: Thursday 2.00 – 3.00 pm
Room 122, Chemical Engineering

2
Contact Information
Teaching Assistants:
• Dr. Poulomi Sarkar: [email protected]
• Patel Vashishtha Baldevbhai: [email protected]
• Uttam Sharma: [email protected]
3
Attendance & Evaluation
Compulsory Class Attendance >80% - 20 out of 26 lectures
DX grade below 80% attendance
CL208 CL324
MID-SEM: 30% MID-SEM: 25%
END-SEM: 50% END-SEM: 45%
QUIZ: 15% QUIZ: 15%
Homework: 5% Homework: 5%
Project: 10%
4
Quiz Dates
• 22 January 2024 - Monday
• 10 February 2024 - Saturday
• 18 March 2024 - Monday
• 13 April 2024 - Saturday
Best 3 out of 4 quizzes will be considered for grading
5
Course Contents
• Introduction to Chemical Reaction Engineering.
• Kinetics of chemical reactions: Elementary and non-elementary reactions.
• Order and rate constant from experimental data.
• Design of batch reactors, ideal CSTR, PFR for systems without and with density
changes.
• Design of reactors with multiple reactions and for systems with temperature effects.
• Catalysis: Introduction, mechanisms, kinetics, reactor design.
• Catalyst deactivation: Kinetics and reactor design.
• Residence time distribution, Non-ideal reactors.
6
Learning Objectives
At the end of this course, you should be able to:
• Derive kinetic expressions from experimental data.
• Conduct mass & energy balance over ideal reactors and derive performance equation.
• Execute process design for ideal reactors for both non-catalytic and catalytic reactions
o Calculate the reaction time/ reactor volume required to meet desired product
composition
o For a given reaction time/ reactor volume, determine conversion.
• Determine the best reactor configuration to minimize reactor volume or to maximize

desired product selectivity for multiple reactions.
7
Learning Objectives
…contd.:
• For catalytic reactions, derive Langmuir-Hinshelwood kinetic expressions from given
reaction mechanism.
• Calculate global kinetics of heterogeneous catalytic/ non-catalytic reactions from

physical and chemical rate processes. Calculate effectiveness factor of catalysts.
• Design and diagnostics for non-ideal reactors.
8
Reference Books
1. Elements of Chemical Reaction Engineering, H.S.Fogler, 6th Edition, 2022, Pearson.
2. Chemical Reaction Engineering, O. Levenspiel, 3rd Edition, 1999, Wiley Eastern.
3. Chemical Engineering Kinetics, Joe Mauk Smith, 3rd Edition, 1981, McGraw-Hill, Chemical
Engineering Series.
4. Chemical Reactor Analysis and Design, Gilbert F. Froment, Kenneth B. Bischoff, Juray De
Wilde, 3rd Edition, 2011, John Wiley & Sons.
DISCUSSIONS IN CLASS WILL NOT BE PROVIDED AS NOTES.

PLEASE PAY ATTENTION IN CLASS!
Check Moodle for additional resources & announcements
9
Reactor Design
• What type/ configuration of equipment?
• What size of equipment to achieve required extent of reaction?

Process Design
• What operating conditions (temperature/ pressure/ flowrates)?
• What provisions needed for energy exchange?
• Decide pressure vessel size and shape
• Decide material of construction and pressure vessel flange class.
• Cost reactor shell as a pressure vessel.
• Design and add extra costs for mixers, internals, controls, etc.
10
Ideal Reactors
Ideal Batch Reactor Continuous Stirred Tank Reactor Plug Flow Reactor (PFR)
(CSTR)
Packed Bed Reactor (PBR)
• Continuous steady state • Continuous steady state operation

• No input/output stream
operation • Ideal “Plug Flow” –
during operation
• Perfect mixing NO Axial Mixing, infinite Radial
• Perfect mixing
• Composition of product is Mixing
• Unsteady state process
same as that within tank • Composition varies along axial
coordinate
11
Industrial Reactors
Butane/ Pentane/ Hexane Isomerization
1. Important for the production of branched hydrocarbons –

high Octane, raw materials for polymers
2. Liquid phase reaction on solid catalysts
3. Exothermicity is very mild (a few Kcal/mol) – cooling is

not required
Ideal Reactor Model?

13
Hydrogenation of Vegetable Oil/ Ghee
1. Increases shelf-life of unsaturated oils

2. Gas-Liquid-Solid reaction system
3. Exothermic
4. Mass transfer of H2 gas into the oil is often limiting
5. Good mixing is necessary to finely disperse gas bubbles and
increase gas-liquid interface
Ideal Reactor Model? 14

Catalytic Naphtha Reforming
-H2
RADIAL FLOW REACTOR Feed (naphtha)
• Endothermic Reversible Reaction

• Low pressure operation – pressure drop
across bed has to be low
• Multi-stages with interstage heating
conversion
15
Product
Temperature
Catalytic Naphtha Reforming
CATALYST DEACTIVATES BY COKE DEPOSITION –
HAS TO BE REGENERATED
Feed (naphtha)
Catalyst
Product N2 Ideal Reactor Model?

Fluidized Catalytic Cracking
• Endothermic reaction
• Reactor Temp ~ 500 oC
• Catalyst deactivates by coke
deposition with seconds!
• Continuous catalyst regeneration –
Catalyst bed is FLUIDIZED

17
Reaction engineering in nature
Modeling Digestion by Chem. Engg. Unit Operations
BIO-REACTOR
Enzyme
(catalyst)
Sucrose Glucose + Fructose
Ideal Reactor Model? NON-IDEAL FLOW PATTERNS

18
Reaction engineering in nature
Modeling Smog
Model CO ppm in air

spatially & temporally
19
Ideal Reactors
Continuous Stirred Tank Reactor Plug Flow Reactor (PFR)
(CSTR)
Piston Flow Reactor
Mixed Flow Reactor (MFR)
CA0
CAo CAf
CA0 > CA > CAf

CAf CAf
20

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CL208/ CL324

Office hours: Thursday 2.00 – 3.00 pm

Room 122, Chemical Engineering

• Dr. Poulomi Sarkar: [email protected]

• Patel Vashishtha Baldevbhai: [email protected]

• Uttam Sharma: [email protected]

END-SEM: 50% END-SEM: 45%

QUIZ: 15% QUIZ: 15%

Best 3 out of 4 quizzes will be considered for grading

• Derive kinetic expressions from experimental data.

o For a given reaction time/ reactor volume, determine conversion.

• Determine the best reactor configuration to minimize reactor volume or to maximize

• Calculate global kinetics of heterogeneous catalytic/ non-catalytic reactions from

• Design and diagnostics for non-ideal reactors.

2. Chemical Reaction Engineering, O. Levenspiel, 3rd Edition, 1999, Wiley Eastern.

DISCUSSIONS IN CLASS WILL NOT BE PROVIDED AS NOTES.

• What size of equipment to achieve required extent of reaction?

• What provisions needed for energy exchange?

• Decide pressure vessel size and shape

• Decide material of construction and pressure vessel flange class.

• Cost reactor shell as a pressure vessel.

Packed Bed Reactor (PBR)

• Continuous steady state • Continuous steady state operation

1. Important for the production of branched hydrocarbons –

2. Liquid phase reaction on solid catalysts

3. Exothermicity is very mild (a few Kcal/mol) – cooling is

Ideal Reactor Model?

1. Increases shelf-life of unsaturated oils

Ideal Reactor Model? 14

• Endothermic Reversible Reaction

Product N2 Ideal Reactor Model?

Ideal Reactor Model?

Ideal Reactor Model? NON-IDEAL FLOW PATTERNS

Model CO ppm in air

Ideal Reactor Model?

CA0 > CA > CAf

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