ADDIS ABABA UNIVERSITY

ADDIS ABABA INSTITIUTE OF TECHNOLOGY

SCHOOL OF CHEMICAL AND BIOENGINEERING

PROCESS ENGINEERING STREAM (PhD PROGRAME)

Course Title: - Catalysis (ChEg 8101)

Assignment III: - Non-isothermal and non-adiabatic Fixed Bed Reactor

By: - Daniel Tasew Desalegn GSR /6784/16

Fire Chewaka Tucho GSR /4205/16

Submitted to: - Professor Nurelegn Tefera (PhD)

January. 26/ 2023

Contents
1. Background on non-isothermal and non-adiabatic fixed bed reactor ................................................... 4
1.1. Background on Fixed bed reactor ................................................................................................. 4
Fig1. Fixed bed reactors ........................................................................................................................... 6
1.2. Non-isothermal and non-adiabatic fixed bed reactor .................................................................... 6
1.2.1. Non-Isothermal fixed bed reactor ......................................................................................... 6
1.2.2. Non-adiabatic fixed-bed reactor............................................................................................ 6
1.2.3. Examples of non-isothermal, non-adiabatic fixed-bed reactor ............................................. 8
1.2.4. Applications of non-isothermal, non-adiabatic fixed bed reactor processes ......................... 9
2. Design and modeling approaches ....................................................................................................... 12
2.1. Design Approaches in non-isothermal and non-adiabatic fixed-bed reactors............................. 12
2.2. Modeling Approaches in non-isothermal and non-adiabatic fixed-bed reactors ........................ 14
Reaction Kinetics: ................................................................................................................................... 14
2.3. Mass balance non-adiabatic fixed-bed reactor and non-isothermal fixed bed reactors .............. 15
2.3.1. Mass balance in a non-adiabatic fixed-bed reactor ............................................................. 15
2.3.2. Mass balance in non-isothermal fixed bed reactors ............................................................ 15
2.4. Energy balance for a non-adiabatic fixed-bed reactor ................................................................ 16
2.5. Energy balance equation for a non-isothermal fixed-bed reactor ............................................... 17
2.6. Computational Fluid Dynamics (CFD): ...................................................................................... 19
2.7. Validation and Verification:........................................................................................................ 19
3. BEST model and specific reaction process from the literature ........................................................... 20
3.1. Specific reaction process ............................................................................................................. 20
4. Mathematical model with the corresponding initial and boundary conditions (if any) ...................... 21
5. Draw backs of non-adiabatic non isothermal fixed bed reactor .......................................................... 24

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Non-isothermal and non-adiabatic Fixed Bed Reactor

(GII 2 students)

You are expected to:

1. Give background and application of such reactor type

2. Discuss design and modeling approaches
3. Choose best model and specific reaction process from the literature
4. Prepare the mathematical model with the corresponding initial and boundary
conditions (if any)
5. Choose or develop software for simulation of the specific reaction process selected
above (3)
6. Discuss your result

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1. Background on non-isothermal and non-adiabatic fixed bed reactor

1.1.Background on Fixed bed reactor

The discovery of solid catalysts and their application to chemical processes led to a breakthrough
of the chemical industry. The major part of the catalytic processes of today’s chemical and
petroleum refining industries is carried out in fixed bed reactors.

For economical production of large amounts of product, they are usually the first choice,
particularly for gas-phase reactions. Many catalyzed gaseous reactions are amenable to long
catalyst life (1-10 years); and as the time between catalyst change out increases, annualized
replacement costs decline dramatically, largely due to savings in shutdown costs .

In a fixed-bed reactor, the reactants flow through a stationary bed of solid catalyst. The reaction
takes place as the reactants pass through the catalyst bed.

It is not surprising, therefore, that fixed bed reactors now dominate the scene in large-scale
chemical product manufacture.

Basic chemical industry Petrochemical industry Petroleum refining

Seam reforming Ethylene oxide Catalytic reforming
Carbonmonoxide conversion ethylenedichloride Isomerization
Carbnmonxide methanation venylacetate Polymerization
Ammonia synehesis Malic anhydride Hydrodesulferization
Sulfuric acide synethesis Phtalic anhydride Hydro chraking
Methanol synesisis Cyclohexane
Oxo synethesis Styrene
Table 1.1. Basic fixed bed reaction processes

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 Table 1.2. Classifications of fixed bed reactors

Where ,

Cs - Catalyst surface concentration,

C -Gas bulk concentration,

Ts Surface temperature of the catalyst,

T - Bulk temperature of gas.

Pseudo-homogeneous models lump the gas and solid (catalyst) phases together in the reactor
modeling mass and energy balance equations.

When it is assumed that reactor temperature and composition only change in the axial direction
of the reactor and do not change in the radial direction, it is called a one-dimensional model.

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 Fig1. Fixed bed reactors

1.2.Non-isothermal and non-adiabatic fixed bed reactor

1.2.1. Non-Isothermal fixed bed reactor

Non-isothermal reactors are widely used in process plants. Reformers, catalytic reactors,
hydrocracking reactors are a few to be named. To achieve optimum rate of reaction,

Non-isothermal reactors are operated at various temperature conditions. Non-isothermal reactors

normally operate in adiabatic and non-adiabatic conditions. For non-isothermal reactor in
adiabatic operation, endothermic reactors require addition of heat to maintain the reactions;
while for exothermic reactors, it requires the removal of heat.

In a non-isothermal reactor, the temperature is not constant, and it can vary along the length of
the reactor or with time. This may be due to heat exchange with the surroundings, heat
generation or absorption during the reaction, or other external factors.

1.2.2. Non-adiabatic fixed-bed reactor

In a non-adiabatic reactor, there is heat exchange between the reactor and its surroundings. This
exchange can lead to temperature changes within the reactor.

Non-adiabatic reactors are common in industrial processes where heat management is crucial for
controlling reaction rates, selectivity, and overall process efficiency. The inclusion of heat
exchange mechanisms allows for better control of reaction temperatures, preventing issues such
as overheating or temperature fluctuations that could affect the reaction kinetics.

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In a non-adiabatic reactor, temperature control can be achieved by various means, such as using
a heat exchanger to remove or add heat to the reactor. This type of reactor is often employed
when precise temperature control is necessary, and the heat generated or absorbed during the
reaction needs to be managed to maintain optimal conditions.

In the context of a fixed-bed reactor:

Heat Effects in Reaction:

The chemical reaction occurring in the fixed-bed reactor may be exothermic (releases heat) or
endothermic (absorbs heat). In either case, the temperature inside the reactor will be influenced
by these heat effects.

Heat Exchange:

Heat exchange with the surroundings can occur through various means such as a jacket around
the reactor, external heat exchangers, or other cooling or heating mechanisms. This external heat
exchange helps in controlling the reactor temperature.

Temperature Profile:

Due to non-isothermal and non-adiabatic conditions, the reactor may exhibit a temperature
profile along its length or over time. Understanding and controlling this temperature profile is
crucial for optimizing the reaction kinetics and ensuring the stability and efficiency of the
process.

Thermal Management:

Efficient thermal management strategies are essential in non-isothermal and non-adiabatic fixed-
bed reactors. This may involve adjusting the flow rates of reactants, optimizing catalyst
properties, or using external heating or cooling methods to maintain the desired temperature
conditions.

When we discuss a non-isothermal and non-adiabatic fixed-bed reactor, it means that the reactor
is not operating under constant temperature conditions (non-isothermal) and is not perfectly
insulated from its surroundings (non-adiabatic).

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.

When considering a non-isothermal and non-adiabatic fixed-bed reactor, it means taking into
account the heat effects of the reaction and addressing temperature variations within the reactor.
This design is often applied when the reaction involved is exothermic or endothermic, and the
control of temperature is crucial for optimizing reaction rates, selectivity, and overall efficiency.

1.2.3. Examples of non-isothermal, non-adiabatic fixed-bed reactor

Here are a couple of examples of chemical reactions that might occur in a non-isothermal, non-
adiabatic fixed-bed reactor:

1. Hydrocracking of Heavy Oil Fractions:

This is a hydrocracking reaction commonly used in the petroleum industry to break down heavy
hydrocarbons into lighter fractions. The reaction is endothermic, requiring heat input.

2. Ammonia Synthesis:

The synthesis of ammonia from nitrogen and hydrogen is an important industrial process. It is
exothermic, releasing heat during the reaction

3. Dehydrogenation of Ethyl benzene to Styrene:

This reaction is used in the production of styrene monomer. It is endothermic, requiring heat.

4. Fischer-Tropsch Synthesis:

Fischer-Tropsch synthesis is used to produce hydrocarbons from synthesis gas (CO and H₂). The
reaction is exothermic.

These reactions are just examples, and the specific reactions in a non-isothermal, non-adiabatic
fixed-bed reactor would depend on the desired products and the feedstock used. The choice of
reactions also influences the reactor design and the control strategies needed for optimal

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performance. The kinetic expressions and thermodynamic properties of the reactions would need
to be considered in the modeling and simulation of the reactor system.

1.2.4. Applications of non-isothermal, non-adiabatic fixed bed reactor processes

Hydrocracking in Petroleum Refining:

Non-isothermal and non-adiabatic fixed-bed reactors are commonly used in the hydrocracking of
heavy petroleum fractions. Hydrocracking is an exothermic process where high-pressure
hydrogen gas is used to break down large hydrocarbons into smaller, more valuable products
such as diesel and gasoline. Efficient temperature control is essential to manage the heat released
during the exothermic reactions.

Catalytic Reforming:

Catalytic reforming is a process used to convert low-octane naphthas into high-octane gasoline
blending components. This process involves endothermic reactions, and a non-adiabatic reactor
design helps in maintaining the necessary temperature for the reaction by providing external
heat.

 Dehydrogenation:

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 Paraffins (saturated hydrocarbons) undergo dehydrogenation, losing hydrogen atoms
to form olefins (unsaturated hydrocarbons) and hydrogen. This step increases the
number of double bonds in the hydrocarbons.

 Isomerization:

Isomerization involves rearranging the hydrocarbon molecules to create branched

isomers. This increases the octane rating of the gasoline by enhancing its anti-knock
properties.
 Cyclization:

Cyclization reactions create rings in the hydrocarbon structure, leading to the

formation of naphthenes. These cyclic hydrocarbons contribute to the high octane of
the gasoline.
 Hydrogenation:

olefins formed during dehydrogenation are hydrogenated back to paraffins. This step
helps maintain the desired product composition

Ammonia Synthesis:

Ammonia synthesis is a crucial industrial process for producing ammonia from nitrogen and
hydrogen. The synthesis is exothermic, and a non-isothermal fixed-bed reactor is employed to
manage the heat released during the reaction and to maintain the optimal temperature for
ammonia production.

The reaction is reversible, meaning that it can proceed in both the forward and reverse directions.
Under typical industrial conditions, the reaction is carried out at high pressure (around 200 to
300 atmospheres) and elevated temperature (around 400 to 500 degrees Celsius) to favor the

formation of ammonia. Iron catalysts are also used to enhance the reaction rate.

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Methanol Synthesis:

Methanol synthesis is another example where a non-adiabatic fixed-bed reactor is used. The
synthesis of methanol from carbon monoxide and hydrogen is an exothermic reaction, and the
reactor design must consider effective heat removal to control the reaction temperature.

This industrial process is commonly carried out using a catalyst at elevated temperatures and
pressures. The primary reaction involved is:

The reaction is typically conducted over a copper-based catalyst, often supported on a zinc oxide
(ZnO) carrier, and sometimes including other metal oxides or promoters.

Dehydrogenation Reactions:

Dehydrogenation processes, such as the production of styrene from ethyl benzene, involve
endothermic reactions. Non-adiabatic reactors are employed to provide the necessary heat for the
reaction, ensuring optimal conversion rates.

This reaction is typically carried out at elevated temperatures in the presence of a catalyst. A
common catalyst for this process is iron oxide, sometimes promoted with potassium or other
materials.

Biomass Conversion:

Non-isothermal and non-adiabatic fixed-bed reactors are also applied in biomass conversion
processes, such as pyrolysis and gasification. These processes involve complex reactions with
varying heat effects, and effective temperature control is essential for the production of biofuels
and chemicals.

In summary, non-isothermal and non-adiabatic fixed-bed reactors find application in a variety of

chemical processes where precise temperature control is critical for achieving desired reaction

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outcomes, optimizing catalyst performance, and ensuring the overall efficiency of the process.
These reactors play a crucial role in industries ranging from petroleum refining to renewable
energy and bio-based chemical production.

2. Design and modeling approaches

Designing and modeling non-isothermal and non-adiabatic fixed-bed reactors is a complex task
that involves considering heat effects, temperature profiles, and reaction kinetics. Here are key
aspects to consider in the design and modeling of such reactors:

In the case of a non-adiabatic, non-isothermal fixed-bed reactor, the reaction kinetics would
consider factors such as heat transfer, temperature gradients, and their effects on the reaction
rate. This can be more complex than studying reactions under adiabatic or isothermal conditions
because it involves accounting for the thermal behavior of the system.

The temperature profile within the reactor may influence the reaction rates and selectivity of the
chemical processes occurring. Engineers and scientists use mathematical models, such as the
energy balance equation and reaction rate equations, to describe the behavior of non-adiabatic,
non-isothermal fixed-bed reactors. These models help in optimizing reactor design and operating
conditions to achieve the desired product yields and conversion efficiencies.

2.1.Design Approaches in non-isothermal and non-adiabatic fixed-bed reactors

Designing a non-adiabatic fixed-bed reactor involves considering various factors such as the
reaction kinetics, heat transfer, temperature profiles, and overall process optimization. Here are
some key steps and considerations in the design process:

Define Reaction Kinetics:

Understand the kinetics of the chemical reactions taking place in the reactor. This involves
knowing the rate expressions and mechanisms governing the reactions.

Material Selection:

Choose materials for the reactor construction that can withstand the operating conditions,
including temperature and pressure variations. Consider corrosion resistance and durability.

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Heat Transfer Analysis:

Perform a detailed heat transfer analysis to understand how heat is transferred within the reactor.
Consider conduction, convection, and radiation effects.

Energy Balance:

Develop an energy balance equation for the reactor to account for heat generation or
consumption due to the chemical reactions. This equation will help predict the temperature
profile within the reactor.

Temperature Control:

Implement temperature control mechanisms to maintain the desired temperature profile. This
may involve the use of external heat exchangers, coolers, or other thermal management systems.

Catalyst Selection:

Choose an appropriate catalyst for the reactions. The catalyst's activity and stability at the
operating temperature are crucial for achieving high conversion and selectivity.

Thermal Management:

Understanding the heat effects of the reaction is crucial. If the reaction is exothermic, efficient
cooling mechanisms need to be incorporated to avoid temperature runaway. If endothermic,
methods to supply external heat should be considered. This could involve the use of heat
exchangers, temperature control loops, or other thermal management systems.

Catalyst Selection and Packing:

The choice of catalyst and how it is packed in the reactor can significantly impact temperature
distribution. Optimizing the catalyst properties and bed structure can enhance heat transfer and
overall reactor performance.

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Reactant Feed Arrangement:

The arrangement of reactant feeds can influence temperature profiles. By strategically

introducing reactants along the reactor length, it's possible to control the temperature variations
and promote uniform reaction progress.

Instrumentation and Control Systems:

Implementing advanced process control systems is essential. Monitoring and controlling

variables such as temperature, pressure, and flow rates help in maintaining optimal reactor
conditions. Feedback control mechanisms can be employed to adjust operating parameters in
real-time.

Safety Measures:

Consideration of safety measures is critical in non-isothermal reactors, especially those with

exothermic reactions. This may involve incorporating safety relief systems, emergency shutdown
procedures, and other features to prevent and mitigate potential hazards.

2.2.Modeling Approaches in non-isothermal and non-adiabatic fixed-bed reactors

Reaction Kinetics:
Develop a detailed understanding of the reaction kinetics. This involves determining the rate
equations governing the reaction, identifying reaction intermediates, and estimating kinetic
parameters. Experimental data or kinetic models from literature can be used as a basis.

Heat Transfer Models:

Incorporate heat transfer models to account for temperature variations within the reactor. This
involves considering heat conduction, convection, and radiation within the catalyst bed and
between the bed and the reactor walls.

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2.3.Mass balance non-adiabatic fixed-bed reactor and non-isothermal fixed bed reactors

2.3.1. Mass balance in a non-adiabatic fixed-bed reactor

In a non-adiabatic fixed-bed reactor, a mass balance is applied to analyze and quantify the flow
of reactants and products within the system. The mass balance equation for a non-adiabatic
fixed-bed reactor can be expressed as:

Accumulation = Inflow – Outflow + Generation – Consumption

The mass balance equation, when simplified for a non-adiabatic fixed-bed reactor operating at
steady state, can be expressed as:

2.3.2. Mass balance in non-isothermal fixed bed reactors

The mass balance in a non-isothermal fixed bed reactor involves accounting for the changes in
the concentrations of reactants and products along the length of the reactor due to both chemical
reaction and temperature variations. The general form of the mass balance equation for a non-
isothermal fixed bed reactor can be expressed as:

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The term –α ⋅ ri represents the rate of consumption (negative for reactants) or production

(positive for products) of species i due to chemical reaction. The Thiele modulus (α) is a
dimensionless number that represents the ratio of the rate of reaction to the rate of diffusion,
providing insight into the importance of internal diffusion in comparison to the reaction rate.

2.4.Energy balance for a non-adiabatic fixed-bed reactor

The energy balance for a non-adiabatic fixed-bed reactor involves accounting for heat generation
or consumption due to chemical reactions, as well as heat transfer within the reactor. The general
form of the energy balance equation is as follows:

This equation represents the conservation of energy within the reactor. The left side accounts for
the rate of change of internal energy within the reactor, while the right side represents the heat
added or removed from the system due to chemical reactions, heat transfer, and any external heat
sources or sinks.

It's important to note that the specific form of the energy balance equation may vary based on the
assumptions made about the system, the complexity of the reactions, and the details of heat
transfer mechanisms. The equation may also be coupled with other equations describing mass
transfer, fluid flow, and reaction kinetics for a comprehensive model of the non-adiabatic fixed-
bed reactor.

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The energy balance for a non-adiabatic fixed-bed reactor involves accounting for heat generation
or consumption due to chemical reactions, as well as heat transfer within the reactor. The general
form of the energy balance equation is as follows:

2.5.Energy balance equation for a non-isothermal fixed-bed reactor

The energy balance equation for a non-isothermal fixed-bed reactor, taking into account heat
transfer and chemical reactions, can be expressed as:

This energy balance equation is a partial differential equation that describes the dynamic
behavior of temperature within the non-isothermal fixed-bed reactor, considering both chemical
reactions and heat transfer.

The coefficients (Aj, Uj ) are parameters that depend on the reactor design and the characteristics
of the heat transfer mechanisms involved. Solving this equation, often coupled with other
equations describing mass transfer and reaction kinetics, provides insights into the temperature
profile and overall behavior of the reactor.

For a non-isothermal and non-adiabatic reactor, additional terms related to the temperature
profile may be included in the mass balance equation if the temperature affects the reaction rates
or if there are heat effects associated with the reactions.

Keep in mind that the specific form of the mass balance equation may vary based on the reactor
configuration, the nature of the reactions, and any simplifying assumptions made during the
modeling process. Additionally, the mass balance equation is often part of a system of coupled

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partial differential equations that includes equations for energy balance, fluid flow, and reaction
kinetics in order to provide a comprehensive description of the reactor behavior.

The specific reaction kinetics in a non-isothermal, non-adiabatic fixed-bed reactor depends on

the chemical reactions occurring within the system. For a non-isothermal, non-adiabatic fixed-
bed reactor, the temperature T in the reaction rate expression may vary along the reactor bed due
to heat transfer and chemical reactions.

The energy balance equation, as mentioned before, is crucial in determining the temperature
profile within the reactor. This temperature profile influences the reaction rates and,
consequently, the species concentrations along the bed. The coupled set of mass balance, energy
balance, and reaction rate equations is solved numerically to predict the behavior of the reactor
under given operating conditions.

It's important to note that the specific reaction kinetics depend on the particular chemical
reactions occurring in the reactor. Reaction mechanisms and rate expressions vary for different
reactions, and a detailed understanding of the chemistry involved is essential for accurate
modeling and simulation.

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 2.6.Computational Fluid Dynamics (CFD):
CFD simulations can provide detailed insights into fluid flow, temperature distribution, and
concentration profiles within the reactor. This approach allows for a more realistic representation
of the reactor behavior under different conditions.

Dynamic Simulation:

Consider the dynamic behavior of the reactor by performing transient simulations. This helps in
understanding how the reactor responds to changes in operating conditions and aids in designing
effective control strategies.

Sensitivity Analysis:

Conduct sensitivity analyses to identify key parameters influencing reactor performance. This
helps in optimizing the design and operation of the reactor by focusing on critical variables.

2.7.Validation and Verification:

Validate and verify the model by comparing its predictions with experimental data. This step
ensures that the model accurately represents the real-world behavior of the non-isothermal and
non-adiabatic fixed-bed reactor.

By combining these designs and modeling approaches, engineers and researchers can develop
robust and reliable non-isothermal and non-adiabatic fixed-bed reactors for a wide range of
chemical processes. The iterative process of modeling, simulation, and experimentation is crucial
for refining the design and ensuring the reactor's optimal performance under varying conditions.

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3. BEST model and specific reaction process from the literature
Selecting the "best" model depends on the specific characteristics of the reaction and the
objectives of the study. Different models may be suitable for different types of reactions, and the
choice often depends on the complexity of the system, the available data, and the desired level of
detail. Here, I'll suggest a commonly used model for a specific reaction process.

For many catalytic fixed-bed reactor systems, a widely employed approach is to use a
combination of mass and energy balance equations along with reaction kinetics. This often
involves applying the one-dimensional heterogeneous model. The model considers the axial
(along the length of the reactor) and radial (across the reactor diameter) variations in temperature
and concentration. The key equations include the energy balance, mass balance, and rate
equations describing the reaction kinetics.

3.1.Specific reaction process

Steam methane reforming (SMR) reaction as specific reaction

Let's consider the steam methane reforming (SMR) reaction as an example. SMR is a crucial
industrial process for producing hydrogen, a key feedstock for various applications, including
ammonia synthesis and fuel cells. The reaction can be represented as follows:

Researchers were performing their experiments in temperatures between 400 °C and 450 °C,
using catalyst based on nickel with rare earth elements. Activation energy E act and constant A
for the Arrhenius equation in case of CO and CO2 creation were equal to respectively:

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Reasoning:

Complexity: The SMR process involves both endothermic and exothermic reactions, making it a
good test case for a non-isothermal reactor model.

Practical Importance: Hydrogen is a significant industrial product, and understanding the

dynamics of SMR reactors is crucial for optimizing hydrogen production.

Available Data: SMR is a well-studied reaction, and there is ample experimental and theoretical
data available for validation purposes.

Model Applicability: The complexity of the SMR reaction (involving heat exchange, multiple
reactions, and various species) makes it a suitable candidate for a one-dimensional
heterogeneous model.

Relevance: Given the global interest in clean energy and hydrogen production, understanding
and optimizing SMR reactors align with current research and development priorities.

Additional Consideration:

If computational efficiency is a concern and a simpler model is desired, a lumped-parameter

model or a pseudo-homogeneous model might be considered. However, these may sacrifice
some level of detail compared to a one-dimensional heterogeneous model.

Keep in mind that the "best" model also depends on the specific goals of your study, available
resources, and the level of detail required. Always check the latest literature for advancements in
modeling techniques and the most appropriate models for your particular application.

4. Mathematical model with the corresponding initial and boundary conditions (if any)
The mathematical models (for both external and internal reforming) were compared based on
available experimental data. In this analysis of mathematical models, particular attention was
paid to the causes of discrepancies between the mathematical models and the experimental data.
The steam reforming process is influenced by a number of different parameters such as:
temperature, ratio of the amount of water vapor to carbon contained in the fuel (steam to carbon
ratio), reaction time, presence of a catalyst, type of catalyst and many others. The models

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presented in this article were also compared in terms of taking into account various parameters
that may affect the process of steam reforming. An attempt was also made to assess the accuracy
of mathematical models. Unfortunately, for most of the equations considered in this article,
numerical values for inaccuracies are not given or described as acceptable or minor.

Reaction rate equations defined by the measurements could be described as:

Thus total reaction rate of methane steam reforming in analyzed conditions can be described as
follows:

For both low and high steam to carbon ratios, the reaction rate in analyzed conditions can be
described as:

Methane steam reforming with CO as product

Water gas shift reaction

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MSR with CO2 as product:

In this case, reaction rates for the formation of CO2 and CO and consumption of CH4 in steam
reforming process can be calculated as:

Energy balance

The total energy of the system is the sum of the products of specific energies, Ei, of the various
species in the system volume and the number of moles of that species:

In evaluating Esys , we shall neglect changes in the potential and kinetic energies, and substitute
for the internal energy U, in terms of the enthalpy Hi:

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Differentiating Equation the above equation gives:-

5. Draw backs of non-adiabatic non isothermal fixed bed reactor

Non-adiabatic, non-isothermal fixed bed reactors, while useful in certain applications, have
several drawbacks that need to be considered:

Temperature Gradients: In a non-adiabatic reactor, heat is not perfectly insulated, leading to

temperature variations along the reactor length. This can result in hotspots or uneven temperature
distribution, affecting reaction kinetics and selectivity.

Heat Management: Controlling the temperature becomes challenging, and the need for effective
heat management arises. This involves considerations for both removing excess heat and
providing heat when needed. Poor temperature control may lead to undesirable by-products or
incomplete reactions.

Thermal Runaway: If the heat generated by the exothermic reactions is not adequately
removed, it can lead to a situation called thermal runaway. This is a self-reinforcing process
where increasing temperature accelerates the reaction rate, leading to further temperature rise
and potentially catastrophic failure of the reactor.

Energy Efficiency: Non-isothermal reactors may have lower energy efficiency compared to
adiabatic ones. The need for external heating or cooling to maintain optimal reaction
temperatures can increase operational costs.

Complex Design: Designing and operating non-isothermal reactors require more sophisticated
engineering compared to adiabatic systems. Effective heat exchangers, temperature control
systems, and safety measures are essential components, making the overall system more complex
and potentially more expensive.

Catalyst Deactivation: Non-isothermal conditions can accelerate catalyst deactivation due to

factors such as thermal stress, sintering, or other temperature-related effects. This can reduce the
catalyst's effectiveness and increase the frequency of catalyst replacement.

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Safety Concerns: The potential for thermal runaway poses safety risks. Managing the heat
generated in exothermic reactions is critical to prevent accidents, and additional safety measures
are often necessary.

Scale-Up Challenges: Scaling up non-isothermal fixed bed reactors from laboratory to industrial
scales introduces additional challenges in terms of heat transfer, fluid dynamics, and overall
reactor performance. Achieving consistent and predictable results at larger scales can be
complex.

It's important to note that the drawbacks mentioned above depend on the specific conditions,
reactions, and catalysts involved. Engineers and scientists must carefully consider these factors
when choosing reactor types and designing processes to mitigate potential issues and enhance the

overall efficiency and safety of non-adiabatic, non-isothermal fixed bed reactors.

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References

1. Elements of chemical reaction engineering 4th edition

2. Wikipedia

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