Mass balance in a fixed bed reactor is similar to that of a plug-

flow reactor (eq. 1.1):

(2.1)
Recalling dW=
B
dV, then
0 A
A
F
r
dV
dX
=
(1.1)
0 A B
A
F
r
dW
dX

=
For a reaction:
A + bB cC + dD
Species Feed Rate Change within
Reactor
Effluent Rate
A F
A0
= F
A0
F
A0
X F
A
= F
A0
(1 X)
B F
B0
= O
B
F
A0
b F
A0
X F
B
= F
A0
(O
B
bX)
C F
C0
= O
C
F
A0
c F
A0
X F
C
= F
A0
(O
C
+ cX)
D F
D0
= O
D
F
A0
d F
A0
X F
D
= F
A0
(O
D
+ dX)
I F
I0
= O
I
F
A0
F
I
= F
I0
O
I
TOTAL
EFFLUENT
F
T
= F
T0
+ (d + c b 1) F
A0
X = F
T0
+ o F
A0
X
For the above reaction, (1 + b) mol of reactants give (c + d)
mol of product.
In flow systems where this type of reaction occurs, the
molar flow rate will be changing as the reaction progresses.
Because only equal numbers of moles occupy equal
volumes in the gas phase at the same temperature and
pressure, the volumetric flow rate will also change.
Assuming ideal gas behavior:
0 0 T
0 0
T
RT N
V P
RT N
PV
=
(2.2) 0
0 T
T
0
0
V
N
N
T
T
P
P
V
|
|
.
|

\
|
|
|
.
|

\
|
|
.
|

\
|
=
The above equation is further simplified by letting:
X y 1
N
X N N
N
N
0 A
0 T
0 A 0 T
0 T
T
o + =
o +
=
Recalling the last row in the previous table:
X N N N
0 A 0 T T
o + =
(2.3)
reactor the to fed moles of number total
conversion complete for moles of number total in change
= c
( )
0 A
0 T
0 A
y
N
N
1 b c d o = + = c
Equation (2.2) now becomes:
( )
0
0
0
V X 1
T
T
P
P
V c +
|
|
.
|

\
|
|
.
|

\
|
=
(2.4)
F
T
= F
T0
+ o F
A0
X
Kalau reaksinya berlangsung sempurna (X = 1):
( )
0 A 0 T 0 A 0 T T
N N X N N * N o + = o + =
Perubahan jumlah mol kalau reaksinya berlangsung
sempurna (X = 1):
( )
0 T 0 A 0 T 0 T T
N N N N * N o + = =
( )
0 A 0 A
N 1 b c d N + = o =
( )
0 A
0 T
0 A
y
N
N 1 b c d
o =
+
= c
To derive the concentrations of the species in terms of
conversion for a variable-volume flow system, we shall use
the relationships for the total concentration.
The total concentration at any point in the reactor is
RT
P
V
N
v
F
C
T T
T
= = =
At the entrance of the reactor:
0
0
0
0 T
0
0 T
0 T
RT
P
V
N
v
F
C = = =
(2.6)
(2.5)
Taking the ratio of eq. (2.6) to eq. (2.5), we have upon
rearrangement
0
0 T
T
0
0
v
F
F
T
T
P
P
v
|
|
.
|

\
|
|
|
.
|

\
|
|
.
|

\
|
=
From the above table:
X F F F
0 A 0 T T
o + =
(2.7)
Substituting eq. (2.8) in eq. (2.7):
(2.8)
|
|
.
|

\
|
o +
|
|
.
|

\
|
|
.
|

\
|
=
|
|
.
|

\
| o +
|
|
.
|

\
|
|
.
|

\
|
= X
F
F
1
T
T
P
P
v
F
X F F
T
T
P
P
v v
0 T
0 A
0
0
0
0 T
0 A 0 T
0
0
0
|
|
.
|

\
|
o +
|
|
.
|

\
|
|
.
|

\
|
= X
F
F
1
T
T
P
P
v v
0 T
0 A
0
0
0
( ) X y 1
T
T
P
P
v
0 A
0
0
0
o +
|
|
.
|

\
|
|
.
|

\
|
=
( ) X 1
T
T
P
P
v v
0
0
0
c +
|
|
.
|

\
|
|
.
|

\
|
=
(2.9)
We can now express the concentration of species j for a flow
system in terms of conversion:
|
.
|

\
|
|
|
.
|

\
|
|
.
|

\
|
|
|
.
|

\
|
=
|
.
|

\
|
= =
T
T
P
P
F
F
v
F
T
T
P
P
F
F
v
F
v
F
C
0
0 T
j
0
0 T
0
0
0 T
T
0
j j
j
|
.
|

\
|
|
|
.
|

\
|
|
.
|

\
|
=
T
T
P
P
F
F
C C
0
0 T
j
0 T j
(2.10)
Substituting F and F
T
in terms of conversion in eq. (2.10) yields
( )
|
.
|

\
|
|
|
.
|

\
|
o +
u + O
=
T
T
P
P
X F F
X F
C C
0
0 0 A 0 T
j j 0 A
0 T j
( )
( ) | |
|
.
|

\
|
|
|
.
|

\
|
o +
u + O
|
|
.
|

\
|
=
T
T
P
P
X F F 1
X
F
F
C
0
0 0 T 0 A
j j
0 T
0 A
0 T
|
.
|

\
|
|
|
.
|

\
|
o +
u + O
=
T
T
P
P
X y 1
X
y C
0
0 0 A
j j
0 A 0 T
|
.
|

\
|
|
|
.
|

\
|
c +
u + O
=
T
T
P
P
X 1
X
C C
0
0
j j
0 A j
(2.11)
Energy balance in a fixed bed reactor is similar to that of a
plug-flow reactor (eq. 1.56):
( ) ( ) ( ) | |
( )

O + A
A +
=
pi i p 0 A
Rx A a
C C X F
T H r T T Ua
dV
dT
(1.56)
( ) ( ) ( ) | |
( )

O + A
A +
=
pi i p 0 A B
Rx A a
C C X F
T H r T T Ua
dW
dT
Recalling dW=
B
dV, then
(2.12)
The majority of gas-phase reactions are catalyzed by
passing the reactant through a packed bed of catalyst
particles.
We now must determine the ratio P/P
0
as a function of
volume V or the catalyst weight, W, to account for
pressure drop.
We then can combine the concentration, rate law, and
design equation. However, whenever accounting for the
effects of pressure drop, the differential form of the mole
balance (design equation) must be used.
The equation used most to calculate pressure drop in a
packed porous bed is the Ergun equation:
( )
(

+
|
|
.
|

\
|
|
|

= G 75 . 1
D
1 150 1
D g
G
dz
dP
p
3
p c
Where
P : pressure, lb/ft
2
| : porosity (volume of void / total bed volume)
D
p
: diameter of particle in the bed, ft
: viscosity of gas passing through the bed, lb
m
/ft h
z : length down the packed bed of pipe, ft
u : superficial velocity = volumetric flow : cross sectional
area of pipe, ft/h
: gas density, lb/ft
3
G : u = superficial mass velocity, (g/cm
2
s) or (lbm/ft
2
h)
(2.13)
In calculating the pressure drop using the Ergun
equation, the only parameter that varies with pressure on
the right-hand side of eq. (2.13) is the gas density, .
We are now going to calculate the pressure drop through
the bed.
Because the reactor is operated at steady state, the mass
flow rate at any point down the reactor, (kg/s), is equal
to the entering mass flow rate, (i.e., equation of
continuity),
m
0
m
m m
0
=
v v
0 0
=
Recalling eq. (2.9), we have
|
.
|

\
|
c +
|
.
|

\
|
|
|
.
|

\
|
= =
X 1
1
T
T
P
P
v
v
0
0
0
0
0
(2.14)
Combining eqs. (2.13) and (2.14) gives:
( ) ( )
( ) X 1
T
T
P
P
G 75 . 1
D
1 150
D g
1 G
dz
dP
0
0
p
3
p c 0
c +
|
|
.
|

\
|
|
.
|

\
|
(

+
|
|
|
=
( ) X 1
T
T
P
P
v v
0
0
0
c +
|
|
.
|

\
|
|
.
|

\
|
=
(2.9)
Simplifying yields:
( ) X 1
T
T
P
P
dz
dP
0
0
0
c +
|
|
.
|

\
|
|
.
|

\
|
| =
( ) ( )
(

+
|
|
|
= | G 75 . 1
D
1 150
D g
1 G
p
3
p c 0
0
where:
(2.16)
(2.15)
For tubular packed-bed reactors we are more interested in
catalyst weight rather than the distance z down the reactor.
The catalyst weight up to a distance of z down the reactor is:
(

=
(

catalyst solid
of density
solids
of volume
catalyst
of weight
( )
C c
z A 1 W | =
where A
c
is the cross-sectional area.
The bulk density of the catalyst,
B
(mass of catalyst per
volume of reactor bed), is just the product of the solid
density,
C
, the fraction of solids, (1 |) :
( ) | = 1
C B
(2.17)
(2.18)
Using the relationship between z and W [eq. (2.17)] we can
change our equation (2.15) into:
( )
( ) X 1
T
T
P
P
1 A dW
dP
0
0
C c
0
c +
|
|
.
|

\
|
|
.
|

\
|
|
|
=
(2.19)
Further simplification yields:
where:
( ) X 1
T
T
P P
P
2 dW
dP
0 0
0
c +
|
|
.
|

\
|
|
|
.
|

\
| o
=
( )
0 C c
0
P 1 A
2
|
|
= o
(2.21)
(2.20)
( ) X 1
T
T
P
P
dz
dP
0
0
0
c +
|
|
.
|

\
|
|
.
|

\
|
| =
(2.15)
We note that:
when c is negative, the pressure drop AP will be less than
that for c = 0.
When c is positive, the pressure drop AP will be greater
than when c = 0.
(2.1)
0 A B
A
F
r
dW
dX

=
( ) ( ) ( ) | |
( )

O + A
A +
=
pi i p 0 A B
Rx A a
C C X F
T H r T T Ua
dW
dT
(2.12)
( ) X 1
T
T
P P
P
2 dW
dP
0 0
0
c +
|
|
.
|

\
|
|
|
.
|

\
| o
=
(2.20)
B
A
A
r
' r

=
Calculate the pressure drop in a 60 ft length of 1 1/2-in.
schedule 40 pipe packed with catalyst pellets 1/4-in. in
diameter when 104.4 lb/h of gas is passing through the bed.
The temperature is constant along the length of pipe at
260C. The void fraction is 45% and the properties of the gas
are similar those of air at this temperature. The entering
pressure is 10 atm.
EXAMPLE 2.1
SOLUTION
( ) X 1
T
T
P P
P
2 dW
dP
0 0
0
c +
|
|
.
|

\
|
|
|
.
|

\
| o
=
0
T T =
0 = c
P 2
P
P P
P
2 dW
dP
2
0
0
0
o
=
|
|
.
|

\
| o
=
dW dP
P
P 2
2
0
o =
} }
o =
W
0
P
P
2
0
dW PdP
P
2
0
W P
P
1 P
P
2
2
0
0
o =
|
|
.
|

\
|
( ) W P P
P
1
2
0
2
2
0
o =
|
|
.
|

\
|
W 1
P
P
2
0
2
o =
W 1
P
P
2
0
o =
|
|
.
|

\
|
( )
2 1
0
W 1
P
P
o =
( )
2 1
0
W 1
P
P
o =
( )
0 C c
0
P 1 A
2
|
|
= o
( )
C c
z A 1 W | =
( )
( )
C C
0 C c
0
z A 1
P 1 A
2
W |
|
|
= o
0
0
P
z 2
W
|
= o
2 1
0
0
0
P
z 2
1
P
P
|
|
.
|

\
| |
=
( )
0 C c
0
P 1 A
2
|
|
= o
( ) ( )
(

+
|
|
|
= | G 75 . 1
D
1 150
D g
1 G
p
3
p c 0
0
2
m
2
m
ft . h
lb
3 . 7383
ft 0141 . 0
h lb 4 . 104
G = =
For 1-in. schedule 40 pipe, A = 0.01414 ft
2
For air at 260C and 10 atm:
= 0.0673 lb
m
/ft.h

0
= 0.413 lb
m
/ft
3
D
p
= in = 0.0208 ft
2
f
m
8
c
h . lb
ft . lb
10 17 . 4 g =
( )
( ) ( )
( )( )
( )
(

= |
3 . 7383 75 . 1
0208 . 0
0673 . 0 45 . 0 1 150
45 . 0 0208 . 0 10 17 . 4 413 . 0
45 . 0 1 3 . 7383
3 8
0
2
f
2
2
3
f
in lb 7 . 14
atm 1
in 144
ft 1
ft
lb
1 . 164 =
m
kPa
8 . 25
ft
atm
0775 . 0 = =
( )( )
265 . 0
10
60 0775 . 0 2
1
P
z 2
1
P
P
2 1
2 1
0
0
0
=
(

=
|
|
.
|

\
| |
=
atm 65 . 2 P 265 . 0 P
0
= =
atm 35 . 7 P P P
0
= = A
Ethylene oxide is made by the vapor-phase catalytic oxidation of
ethylene with air:
O
C
2
H
4
+ O
2
CH
2
CH
2
We want to calculate the catalyst weight necessary to achieve 60%
conversion. Ethylene and oxygen are fed in stoichiometric
proportions to a packed-bed reactor operated isothermally at
260C. Ethylene is fed at a rate of 0.30 Ib mol/s at a pressure of 10
atm. It is proposed to use 10 banks of 1-in.-diameter schedule 40
tubes packed with catalyst with 100 tubes per bank.
Consequently, the molar flow rate to each tube is to be 3 10
4
Ib
mol/s. The properties of the reacting fluid are to be considered
identical to those of air at this temperature and pressure. The
density of the a -in.-catalyst particles is 120 lb/ft
3
and the bed
void fraction is 0.45
EXAMPLE 2.2
SOLUTION
The rate law is:
h . cat lb lbmol P P k r
3 2
B
3 1
A
'
A
=
C 260 at
h . cat lb . atm
mol lb
0141 . 0 k =
Mole balance:
0 A
'
A
F
r
dW
dX
=
Reaction: A + B C
Rate law :
( ) ( )
3 2
B
3 1
A
3 2
B
3 1
A
3 2
B
3 1
A
'
A
C kRTC RT C RT C k P P k r = = =
Stoichiometry: gas phase, isothermal
( )
|
.
|

\
|
c + =
P
P
X 1 v v
0
0
( ) X 1
T
T
P
P
v v
0
0
0
c +
|
|
.
|

\
|
|
.
|

\
|
=
(2.9)
|
.
|

\
|
|
|
.
|

\
|
c +
u + O
=
T
T
P
P
X 1
X
C C
0
0
j j
0 A j
(2.11)
For an isothermal gas phase reaction:
|
|
.
|

\
|
c +
u + O
=
0
j j
0 A j
P
P
X 1
X
C C
1
A
= O
5 . 0
F
F
0 A
0 B
B
= = O
Ethylene and air are fed to the reactor where ethylene and
oxygen are in stoichiometric proportions:
( )
88 . 1
F
F 21 79
F
F
0 A
0 B
0 A
0 I
I
= = = O
1
A
= u
5 . 0
B
= u
1
C
= u
( )
( )
148 . 0
5 . 0 21 / 79 5 . 0 1
1
1 5 . 0 1
N
N
y
0 T
0 A
0 A
=
+ +
= o = o = c
|
|
.
|

\
|
c +
u + O
=
0
j j
0 A j
P
P
X 1
X
C C
|
|
.
|

\
|
c +

=
|
|
.
|

\
|
c +
u + O
=
0
0 A
0
A A
0 A A
P
P
X 1
X 1
C
P
P
X 1
X
C C
|
|
.
|

\
|
c +

=
|
|
.
|

\
|
c +
u + O
=
0
0 A
0
B B
0 A B
P
P
X 1
X 5 . 0 5 . 0
C
P
P
X 1
X
C C
|
|
.
|

\
|
c +
=
|
|
.
|

\
|
c +
u + O
=
0
0 A
0
C C
0 A C
P
P
X 1
X
C
P
P
X 1
X
C C
3 2
B
3 1
A
'
A
C kRTC r =
( ) ( )
3 2
0
0 A
3 1
0
0 A
'
A
P
P
X 1
X 5 . 0 5 . 0 C
P
P
X 1
X 1 C
kRT r
(

|
|
.
|

\
|
c +

|
|
.
|

\
|
c +

=
( ) ( ) ( )
3 2 3 2 3 1
0
0 A
'
A
X 1 5 . 0 X 1
P
P
X 1
kRTC
r
|
|
.
|

\
|
c +
=
( ) X 1
P
P
X 1
kRTC
63 . 0 r
0
0 A
'
A

|
|
.
|

\
|
c +
=
( )
|
.
|

\
|
c +

o =
X 1
X 1
W 1 kRTC 63 . 0 r
2 1
0 A
'
A
( )
2 1 '
A
W 1
X 1
X 1
' k r o
|
.
|

\
|
c +

=
where k = 0.63 kRTC
A0
= 0.63 kP
A0
|
|
.
|

\
|
c +
u + O
=
0
j j
0 A j
P
P
X 1
X
C C
0 A
'
A
F
r
dW
dX
=
( )
2 1
0 A
W 1
X 1
X 1
' k
F
1
dW
dX
o
|
.
|

\
|
c +

=
( )
} }
o =
|
.
|

\
|

c +
W
0
2 1
X
0
0 A
dW W 1 dX
X 1
X 1
' k
F
( ) ( )
2 3
0 A
W 1 1
3
2
X
X 1
1
ln 1
' k
F
o
o
=
(

c +
( ) ( )
o
(

)
`

c
|
.
|

\
|

c + o
=
3 2
0 A
X
X 1
1
ln 1 ' k 2 F 3 1 1
W
(a)
( ) ( )
w
0
2 3
W
0
2 1
W 1
3
2
dW W 1 o
o
=
}
o
( ) ( )
2 3 2 3
0 1
3
2
W 1
3
2

o
+ o
o
=
( )
o
+ o
o
=
3
2
W 1
3
2
2 3
( )
2 3
W 1 1
3
2
o
o
=
Parameter evaluation per tube (i.e., divide feed rates by 1000):
Ethylene F
A0
= 3 10
-4
lbmol/s = 1.08 lbmol/h
Oxygen F
B0
= 1.5 10
-4
lbmol/s = 0.54 lbmol/h
Inert (N
2
)
= 5.64 10
-4
lbmol/s = 2.03 lbmol/h
Jumlah F
T0
= F
A0
+ F
B0
+ F
I
= 3.65 lbmol/h
2
2
4
I
O mol 21
N mol 79
s lbmol 10 5 . 1 F =

30 . 0
65 . 3
08 . 1
F
F
y
0 T
0 A
0 A
= = =
( )( ) 15 . 0 1 5 . 0 1 3 . 0 y
0 A
= = o = c
( )( ) atm 0 . 3 atm 10 3 . 0 P y P
0 0 A 0 A
= = =
atm 3
h . cat lb . atm
lbmol
0141 . 0 63 . 0 kP 63 . 0 ' k
0 A
= =
cat lb . h
lbmol
0266 . 0 =
For 60% conversion, eq. (a) becomes
( ) ( )
o
(

)
`

c
|
.
|

\
|

c + o
=
3 2
0 A
X
X 1
1
ln 1 ' k 2 F 3 1 1
W
( ) | |
o
o
=
3 2
0 A
' k F 303 . 1 1 1
W
h
lb
24 . 30
lbmol
lb
28
h
lbmol
08 . 1 m
0 A
= =
h
lb
28 . 17
lbmol
lb
32
h
lbmol
54 . 0 m
0 B
= =
h
lb
84 . 56
lbmol
lb
28
h
lbmol
03 . 2 m
0 I
= =
h
lb
4 . 104 m
0 T
=
2 2
c
0 T
ft . h
lb
3 . 7383
ft 01414 . 0
h lb 4 . 104
A
m
G = = =

( ) ( )
(

+
|
|
|
= | G 75 . 1
D
1 150
D g
1 G
p
3
p c 0
0
For air at 260C and 10 atm:
= 0.0673 lb
m
/ft.h

0
= 0.413 lb
m
/ft
3
D
p
= in = 0.0208 ft
2
f
m
8
c
h . lb
ft . lb
10 17 . 4 g =
( )
( )
( )( )( )( ) 10 45 . 0 1 120 01414 . 0
0775 . 0 2
P 1 A
2
0 C c
0

=
|
|
= o
2
f
2
2
3
f
in lb 7 . 14
atm 1
in 144
ft 1
ft
lb
1 . 164 =
ft
atm
0775 . 0 =
( )
( ) ( )
( )( )
( )
(

= |
3 . 7383 75 . 1
0208 . 0
0673 . 0 45 . 0 1 150
45 . 0 0208 . 0 10 17 . 4 413 . 0
45 . 0 1 3 . 7383
3 8
0
cat lb
0166 . 0
=
( ) | |
o
o
=
3 2
0 A
' k F 303 . 1 1 1
W
cat lb
0166 . 0
h . cat lb
lbmol
0266 . 0
h
lbmol
08 . 1
cat lb
0166 . 0
303 . 1
1 1
3 2
(
(
(
(

|
.
|

\
|
|
|
.
|

\
|

=
= 45.4 lb of catalyst per tube
= 45,400 lb of catalyst total
( )
2 1
0
W 1
P
P
o =
( ) 496 . 0 cat lb 4 . 45
cat lb
0166 . 0
1
2 1
=
(

|
|
.
|

\
|
=
P = 0.496 P0 = 4.96 atm
AP = P
0
P = 10 4.96 = 5.04 atm