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RESIDENCETIMEDISTRIBUTIONANDREACTORPERFORMANCE
Letusassumeforthemomentthatwecancalculatefromtheknowledgeoftheflow
patterntheRTDofthesystemorthatwecanreadilyobtainitexperimentallyonareactor
prototype.IsthereactorperformanceuniquelydeterminedbyitsRTD?Thisseemstobe
apertinentquestiontoask.
EXAMPLE1:
1a.
Q Q Q
PFR xA1 xA2
V/2 CSTR
V/2
1b.
Q Q Q
PFR
CSTR xA1' xA2'
V/2
V/2
FIGURE1:SchematicoftwosystemswiththesameRTD.
TheEfunctionforbothsystem1aand1bis:
1
2
3
4
5
6
where
7
8
9
t
10
istheHeaviside'sunitstepfunction.
2
_
t
exponentialdecay
E(t)
t
_t
2
FIGURE2:Impulseresponseofbothsystems1aand1b.
EXAMPLE2:
2a.
Q Q
2b.
Q aQ
a
(1)Q
aV
Q
a
(1)V
FIGURE3:SchematicoftwoflowsystemswiththeexponentialEcurve.
11
TheEcurveforbothsystems2aand2bis:
12
13
14
15
1_
t
E(t) exponential
FIGURE4:Impulseresponseforsystems2a)and2b).
IftheRTDofthereactordeterminesitsperformanceuniquely,thensystems1aand1b
shouldyieldthesameconversionforallreactionorders.Systems2aand2bshouldalso
behavealike.Wesuspectthatthiswillnotbethecasebecausewerecallthatreaction
ordershigherthanonewillgivehigherconversionsifmixingisdelayed,andhencewe
suspectthatsystem1awillperformbetterthan1bandsystem2bbetterthan2a.Fora
first order process conversion is entirely determined by the residence time of the
individualreactantelementsinthereactor,notbytheirsurroundingsinthereactor,and
hencewesuspectthatsystems1aand1bwillperformthesame,andsystems2aand2b
willperformalike.Forreactionorderslessthanonewesuspectthatthebehaviorwillbe
theoppositetothatfororderslargerthanone.
Let us consider first a 1st order irreversible reaction at constant temperature and of
constantdensityinsystems1aand1b.
SYSTEM1a:
16
17
18
SecondreactorCSTR:
19
20
21
Hence,
22
23
SYSTEM1b:
24
FirstreactorCSTR:
25
26
27
SecondreactorPFR:
28
29
30
31
32
33
JustasweexpectedtheperformanceofthesystemisentirelydeterminedbyitsRTDfora
firstorderreaction.Thiscanreadilybegeneralizedtoanarbitrarynetworkoffirstorder
processes.
Nowconsidera2ndorderirreversiblereactiontakingplaceinsystem1.
SYSTEM1a:
34
35
36
SecondreactorCSTR:
37
38
39
40
SYSTEM1b:
41
FirstreactorCSTR:
42
43
44
SecondreactorPFR:
45
46
47
48
49
50
NotethatbothexpressionsforconversionareafunctionoftheDamkohlernumberforthe
51
system,where .
52
53
54
55
56
57
58
ThetablebelowcomparestheresultsforvariousvaluesoftheDamkohlernumber.
59
60
61
62
You should plot now You will find that
63
.
64
When is this difference larger, at low or high values of
65
D
66
?
67
For a reaction of half order
68
69
weget
70
71
72
forsystem1a
73
74
75
forsystem1b
76
77
78
79
Youshouldchecktheaboveexpressionsanddrawyourownconclusions byplotting
80
81
and
82
83
.
Letusnowconsidersystem2andalstorderirreversiblereaction.
SYSTEM2a:
84
85
86
SYSTEM2b:
87
88
89
istheexitreactantconcentrationfromthe1stCSTR.
90
91
92
istheexitreactantconcentrationfromthe 2ndCSTR.
93
Thebalancearoundthemixingpointwherethetwostreamsjoinyields:
94
C
95
C
96
Hence,
97
98
99
Foranexercise considerSystem 2anda2ndorderreaction andthenazerothorder
reaction.Aretheconversionsnowdifferent?Why?
100
3.1 SEGREGATEDFLOWMODEL
TheaboveexamplesdemonstratethattheRTDofthereactordeterminesitsperformance
uniquelyincaseoffirstorderprocesses.Inafirstorderprocessconversionisdetermined
by the time spent by individual fluid reactant elements in the reactor, not by their
environmentinthereactor. Letusgeneralizethisconceptuallyinthefollowingway.
Assumethatalltheelementsoftheinflowcanbepackagedintolittleparcelsseparated
byinvisiblemembranesofnovolume.Mixingamongvariousparcelsisnotpermitted,
i.e noelementscancrossthemembranes(parcelwalls)exceptattheveryreactorexit
wherethemembranesvanishandthefluidismixedinstantaneouslyonmolecularlevel.
101
Consider the life expectation density function of the inflow
102
103
anddefineitas
104
105
106
=(fractionoftheelementsoftheinflowwithlifeexpectancybetween
107
108
) (54)
109
Clearly, due to steady state, if we look at the inflow at time
110
111
andifwecouldsubstituteamongwhitefluidaparcelofredfluidfortheelementsofthe
inflow of life expectancy,
112
113
, then
114
115
secondslatertheredparcelwouldappearattheoutletandwouldrepresenttheelements
116
117
. Hence, at steady
118
119
120
(55)
121
Hopefully,itiscleartoeveryonethatsincetheflowrateisconstant,andtherecanbeno
accumulation, the fraction of the fluid entering with life expectancy of
122
123
must equal the fraction of the fluid exiting with residence time
124
125
. Thismeansthatwecanconsiderthateachofourhypotheticalparcelsformedatthe
nletengulfsthefluidofthesamelifeexpectancy.Whenparcelsreachtheexit,eachparcel
illcontainfluidofthesameresidencetimespecifictothatparcel.Since,thereis
noexchangebetweenparcelsduringtheirstayinthereactor,eachcanbeconsideredab
tchreactor.Thereactantconcentrationattheoutflowisthenobtainedbymixingallthe
arcels of all residence times in
126
127
128
129
130
C
131
132
133
134
(56)
135
where
136
137
is obtained from the reactant mass
138
139
140
(57)
Nowfora1storderirreversiblereaction:
141
142
143
(58)
sothat
144
145
146
The above expression is nothing else but the Laplace transform of the
147
E
148
function evaluated at
149
150
,i.e,Laplacetransformvariabletakesthenumericalvalueoftherateconstant.
Conversioncanthenbecalculatedas:
151
152
Usingtheaboveformulaweget:
153
Forsystem1:
154
155
(59a)
156
Forsystem2:
157
158
(59b)
159
In terms of dimensionless quantities,
160
161
,andforafirstorderreactionwecanwrite:
162
163
Themodelthatwehavejustdevelopediscalledthe segregatedflow modelbecauseit
assumes that the fluid elements that enter together always stay together and are
surroundedatalltimesbythefluidelementsofthesameage,exceptattheoutletwhere
they finally mix intimately with elements of all ages in proportion dictated by the
164
residence time density function
165
166
.Afluidforwhichthismodelisapplicablebehavesasamacrofluidandhastheten
encyoftravellinginclumps.Aswehaveseenthesegregatedflowmodelgivestheexact
prediction of performance for 1st order reactions, but formula (56) is general and
redicts exit concentration for any reaction order for a macro fluid. However, for
167
nonlinear rate forms,
168
169
,aswehaveseenfromourexamples,reactorperformancedoesnotonlydependonthe
170
171
the exact performance but perhaps predicts a bound on the performanc
172
173
174
(60)
Wherefornthorderirreversiblekinetics
175
176
d
177
(61)
178
Forannthorderreactioneq.(60)giveseithertheupperorlowerboundonconversion
depending on the concavity (convexity) of the x A vs
179
180
curve.Wealwaysexpecttoobtainhigherconversioninasystemwherethereactionrate
ontheaverageishigher.Eq.(60)requiresthatmixingbetweenfluidelementsofvarious
agesoccursonlyattheexit.Letusconsideronlytwofluidelementsofequalvolumebut
differentage,andhencedifferentreactantconcentration,andletusexaminehowmixing
orlackofitaffectsthereactionrateforthesystemcomprisedofthesetwoelements.We
181
consider the rate obtainable if the elements are first intimately mixed,
182
183
, and the rate if they remain unmixed,
184
185
.Thesetworatesare:
186
187
188
(62)
r r r
r2 rm
rav
rm rav rav
r1 rm
189
FIGURE5: IllustrationoftheEffectofMixingorNomixingontherateforreaction
oforders
190
191
Rate vs reactant concentration is plotted for reaction orders of
192
193
in Figure 5. The two fluid elements have concentrations
194
195
respectively, and the corresponding rates are
196
197
Ifthefluidelementsdonotmix,butreacteachatitsownrate,theaverageratelieson
the chord connecting the points
198
199
and is
200
201
. Ifthetwofluidelementsaremixedfirst,theconcentrationinthemixedelementof
double volume is
202
203
, the rate at this new concentration is
204
205
and lies at the rate vs concentration curve evaluated at the abcissa of
206
207
. Clearly then, whenever the cord lies above the curve (the curve is concave up)
208
209
andlatemixing,orfluidsegregationbyage,leadstoincreasedrateandlargerconversion.
210
Whenthecordisalwaysbelowthecurve thenlatemixingorfluidsegregation
211
leadstoreducedratesandreducedconversion.Forfirstorderreactionsmicromixing,i.e.
Theabovediscussioncanbegeneralized(seeE.B.NaumanandB.A.Buffham,Mixingin
ContinuousFlowSystems,Wiley,1983)andaproofcanbegiventhatforallmonotonic
212
rate forms for which
213
214
thesegregatedflowmodelgivestheupperboundonconversion,whileforthemonotonic
rate forms for which
215
216
the segregated flow model gives the lower bound on conversion. For first order
processes
217
218
thesegregatedflowmodelgivestheexactprediction.
Intermsofourexamples,thesegregatedflowmodelpredictionfora2ndorderreaction
forScheme1is:
219
220
221
(63)
222
223
d
224
(64)
Sothatuponintegrationweget
225
226
227
(65)
Substitutingthisintotheaboveequation(63)yields:
228
229
230
(66)
Uponsubstitutioninthesecondintegralof
231
232
233
(67)
234
weget
235
236
237
(68)
238
Again it is instructive to plot
239
240
for segregated flow vs
241
D
242
andcompareittothetwomodelsbasedonidealreactorconceptsforsystem1aand1b.Y
u can find the values
Thesegregatedflowmodelrepresentsausefullimitingbehaviorofthesystemandgives
aboundonperformanceformonotonicrateforms.It'srequirementsare:i)thatthefluid
besegregatedbyage,andii)thatmixingbetweenelementsofvariousagesoccursatthe
latestpossibletime,i.e.onlyatthereactorexit.Thus,everypointinthesystemhasits
243
own age i.e. the point age density function in the system is a delta function
244
245
isthemeanageforthepointunderconsideration.
Considerthesketchbelowasarepresentationofthesegregatedflowmodel:
a a + Da
VI (a )Da VI (a + Da )Da
Q
QDa E (a)Da
Q
FIGURE6a: SchematicoftheSegregatedFlowModelforAlltheFluid.
246
An element of volume of the system occupied by fluid elements of age between
247
248
.Thus,thevolumescale,V,wherevolumeismeasuredfromthereactorentrance,and
theagescaleareproportionalandpointinthesamedirection.Wewantnowtomakea
249
balance on all fluid elements of age between
250
251
, i.e. in the differential volume,
252
253
assketchedinthefigure.
254
Wecanwrite:
255
256
257
258
259
260
261
262
where
263
264
.Nowwiththehelpofagedensityfunctionstheabovecanbewrittenas
265
266
267
(69)
Usingthemeanvaluetheoremweget:
268
269
270
Takingthelimitas
271
272
yields
V I(a + Da ) I(a )
lim = lim E(a) (69)
Q Da 0 Da D a O
dI
t = E (a ) (70)
da
a = I = 0 (70a)
273
Wehavederived,basedontheabove,thealreadywellknownrelationshipbetweentheI
and
274
E
275
function.
276
Now,basedontheabovemodelframework,wefocusonthereactantA(seeFigure6B).
Wemakeabalanceonthefluidelementsofreactantbetweenage
277
278
a
Q VI (a )CA (a )D a VI (a + Da )C A (a + Da )Da
VI (a )DarA Da
C Ao
QDa C A (a)E(a)Da
Q
C Aout
FIGURE6b: SchematicoftheSegregatedFlowModelforReactantA.
279
280
281
(Reactantelementsinthereactorofageabout
282
283
)
284
(Reactantelementsintheoutflowofageabout
285
286
collectedduring
287
288
)
289
(Reactantelementsinthereactorofageabout
290
291
thatreactintoproductduringtime interval
292
293
).
294
295
296
(71)
297
Here
298
299
is defined as positive for the rate of disappearance of reactant
300
301
. It is multiplied by
302
303
sincethisisthetimeduringwhichthereactiontakesplace.
304
Dividingby
305
306
andtakingthelimitas
307
weget:
308
309
310
311
312
313
314
(72)
315
316
t
317
(73)
318
Thisissatisfiedforall
319
320
onlyif
321
322
d
323
(74)
Reorganizingthisweget:
324
325
326
(75)
whichisthereactantmassbalanceinabatchsystem!
Theoutflowisnowrepresentedbysummingandaveragingthecompositionofallside
streamsthatformtheexitstream(seeFigure6).
327
328
329
(76)
whichisthesegregatedflowmodel.
ItwasZwietering(Chem.Eng.Sci.11,1(1959))whorealizedthatthesegregatedflow
modelrepresentsonelimitonmicromixingwithintheconstraintsimposedbytheRTDof
thesystem, i.erepresentssegregationbyageandmixingonmolecularscaleaslateas
possible, i.e.onlyattheexit.Thenecessaryconditionsforthesegregatedflowmodel
canthenbeexpressedbytherequirement that everypointinthesystemhasadelta
330
function age density function
331
332
sothatmixingofmoleculesofvariousagesispermittedonlyattheexit.
333
3.2 MaximumMixednessModel
Besidesclassifyingthefluidelementsaccordingtotheirage,onecanalsogroupthem
according totheirlife expectation, wherelifeexpectancy isthetime thatwillelapse
betweenthetimeofobservationofthesystemandthemomentwhenthefluidelement
leaves the system. In this manner each fluid element could be characterized by its
334
residence time
335
t
336
so that
337
338
Attheentrance,i.e.intheinfloweachfluidelementhasalifeexpectancyequalto
itsresidencetime.Thelifeexpectationdensityfunctionfortheelementsoftheinflow,as
339
seen before, equals the exit age density function
340
341
Eachfluidelementoftheoutflowhaszerolifeexpectationandanageequaltoitsresi
ncetime,andtheagedensityfunctionisthedensityfunctionofresidencetimes. The
342
fluid elements in the system are distributed in their age,
343
344
, and life expectancy,
345
346
. The number of elements in the system of life expectancy about
347
348
,mustequalthenumberofelementsofage,ifsteadystateatconstantvolumeistobe
aintained.Thus,thelifeexpectationdensityfunctionoftheelementsinthesystemequals
349
the internal age density function
350
351
Wecannowviewmicromixing,i.e.mixingprocessonsmallscaledowntomolecular
level,tobeatransitionofthefluidelementsfromsegregationbyagetosegregationby
lifeexpectation.Namely,atthereactorentranceallfluidelementsaresegregatedbyage
352
and have the same age of
353
354
and are distributed in life expectation with the density function
355
356
. Atthereactorexitallfluidelementsaresegregatedbylifeexpectationandhavelife
expectation
357
358
while they are distributed by age with the density function
359
360
.Thedetailsofthistransitionfromsegregationbyagetosegregationbylifeexpe
tationcouldonlybedescribedwiththecompleteknowledgeoftheflowpatternandturbulent
fields.However,justlikeitwaspossibletodescribeonelimitonmicromixing(the
latestpossiblemixing)bythesegregatedflowmodelbymaintainingsegregationbyage
ntilzerolifeexpectancywasreachedforeachelementofthesystem,itisalsopossiblet
describetheotherlimi tonm icromixing.Thisotherlimitoftheearliestpossible
ixing,orthemaximum mixedness model,isobtained byrequiringthatallelements o
variousagesareassembled(segregated)bytheirlifeexpectancy.Zwieteringsuggestedan
proved (Chem. Eng. Sci. ll,
361
a) Allfluidelementswithinanypointofthesystemhavethesamelifeexpectancy,
i.e. the point life expectancy density function is a delta function
362
363
,andallelementsofthepointexittogether.
364
b) All points with equal life expectation
365
366
areeithermixedoratleasthaveidenticalinternalagedistribution.
These conditions express the requirement that all the elements, which will leave the
systematthesametimeandhencewillbemixedattheoutflow,aremixedalreadyduring
allthetimethattheystayinthesystem. Thismeansthattheelementsofthelongest
residencetimearemetandmixedconstantlywithelementsoflesserresidencetimes,but
which have the same life expectancy and with which they will form the outflow.
Schematicallytheconceptualmaximummixednessmodelcanbedescribedassketched
below.
v l
l + Dl
l
VI (l + Dl )C A (l + Dl )Dl VI (l )C A (l )Dl
()
VI l Dl rA Dl
Q
C A (l = 0)
Q
()
QDl C Ao E l Dl
CAo
FIGURE7: SchematicoftheMaximumMixidnessModelforReactantA.
367
The life expectation scale runs opposite to the volume scale of the system which is
368
countedfromtheinlet. Thus representstheelementofreactorvolume
369
occupied by the fluid of life expectancy between
370
371
and
372
373
because at
374
375
and at
376
377
Themodelschematicallyshowsthatwehavedistributedtheinletflowaccordingtoits
lifeexpectationandaremixingitwiththefluidofotheragesbutwiththesamelife
expectation.
378
We can now write a balance on all fluid elements between life expectation
379
380
381
(Elementsofthesystemwithlifeexpectancyabout
382
383
)=
384
(Elementsofthesystemwithlifeexpectancyabout
385
386
+
387
388
)
389
(Elementsoftheinflowoflifeexpectancyabout
390
391
addedtothesystemduringtime
392
393
)
394
where
395
396
.
397
Then
398
399
(77)
400
Takingthelimitas
401
402
yields:
403
404
405
406
407
408
(78)
l I = 0 (78a)
409
Again we have derived the known relationship between the
410
I
411
and
412
E
413
function.
414
Letusmakenowa balanceonallfluidreactantelementsbetweenlifeexpectancy
415
416
(RefertoFigure7).
417
(Reactantelementsinthesystemoflifeexpectancyabout
418
419
)=
420
(Reactantelementsinthesystemoflifeexpectancyabout
421
422
+
423
424
)
425
(Reactantelementsoflifeexpectancyabout
426
427
addedtothesystemduringtime
428
429
)
430
(Reactantelementsoflifeexpectancyabout
431
432
thathavereactedduringtime
433
434
(79)
435
Takingthelimitas
436
437
438
439
440
441
d
442
(80)
or
443
444
445
(80a)
This is the governing differential equation for the maximum mixedness model. For
elementsofextremelylargelifeexpectationthechangeinreactantconcentrationissmall.
Therefore,theproperboundaryconditionis
446
447
448
(80b)
449
In practical applications of the maximum mixedness model one evaluates
450
451
byimplementingcondition(80b)intoeq.(80a)andsolving
452
453
454
(81)
455
Once
456
457
is obtained from eq (81), eq (80a) can be integrated backwards from
458
459
where the desired exit reactant concentration
460
461
isobtained.Fornumericalintegrationonecannotuseaninfiniteintegrationrange.Then
462
463
isoftenchosentorepresentinfinity bycheckingthatatsuchhigh
464
values of
465
466
is almost zero. Anothe
467
(a)
468
(82a
or
469
(b)
470
471
472
473
This still introduces a singularity at
474
475
andspecialprecautionhastobetakentointegrateeq(80a)properly.
476
ThemaximummixednessmodelofZwieteringgivenbyeqs.(80a)and(81)givesusthe
lower bound on conversion for monotonic rate forms with
477
478
and upper bound on conversion for monotonic rates with
479
480
.
ThesemodelscanbequiteusefulinassessingtheperformanceofaCSTRforwhichbya
tracertestitcanbeproventhattherearenostagnanciesandnobypassingandthattheE
curve is exponential. For water and liquid hydrocarbons the power input is usually
sufficienttogeneratesmalleddies. Kolmogoroff'sisotropicturbulencetheorypredicts
thatthemicroscaleofturbulence(i.ethesmallestsizeofturbulenteddiesbelowwhich
turbulentvelocityfluctuationsarehighlydampedbymolecularviscosity)isgivenby:
(83)
481
482
where is the
kinematicviscosityofthefluidand istheenergydissipatedperunitmass. Inwater
483
484
.Thecharacteristicdiffusiontimethenis
485
486
487
(84)
Waterandlowerchainhydrocarbonsarelikelytobehavelikeamicrofluid,andaCSTR
atsufficientenergydissipationwilloperateatmaximummixednessconditionexceptfor
veryfastreactionsandunpremixedfeeds, i.e.forreactionswithcharacteristicreaction
488
time
489
490
.
491
However in highly viscous polymer systems or larger and
492
493
. Then
494
495
and a CSTR with a premixed feed is likely to behave as in a segregated flow mo
e. Remembe
496
ForaCSTR
497
498
andeq(5a)leadstothecondition:
499
500
501
(85)
502
503
504
, eq (80a) is satisfied by eq (85) for all
505
506
. Therefore andisgivenbysolutionofeq(81)whichrepresentstheclassicalidea
reactordesignequationforaCSTRmixedonamolecularlevel.Naturally,thereacta
tconcentrationinaperfectlymixedCSTRinallfluidelementsisthesameandindepen
Thus,foraCSTR,thesegregatedflowmodelyields:
507
508
509
(86)
andthemaximummixednessmodelgives
510
511
512
. (87)
OntheotherhandforaPFR,thesegregatedflowmodelgives
513
514
515
(88)
516
MaximummixednessmodelforaPFR,uponreflection,showsthatcondition(81)isnot
valid, and must be replaced, due to the presence of a
517
518
ineq(80a),by
519
520
521
(89)
Theneq(80a)becomes
522
523
d
524
(90)
IfwesubstitutethemaximummixednessPFRequationbecomes
525
526
d
527
(91)
528
529
530
(92)
531
and the desired exit concentration is given by
532
533
whichisexactlytheexpressiongivenaboveforthesegregatedflowmodel.
BecausethePFRmodelanditsRTDprohibitmixingofelementsofdifferentages,there
isnodifferenceinthepredictionofthesegregatedfloworthe maximummixedness
model.Theybothyieldanidenticalresult.
ItremainsforthereadertoshowthatafirstorderreactioninasystemofanyRTD(not
thatofaCSTRorPFR)yieldsthesameresultaccordingtothesegregatedflowmodel
534
535
536
(93)
andthemaximummixednessmodel
537
538
539
(94)
540
541
542
(95)
543
Oneshouldnotethatthefunctionappearingintheaboveformulationofthemaximum
mixedness model, i.e.
544
545
hasspecialsignificance,iscalledtheintensityfunctionandisveryusefulinevaluationof
stagnancyorbypassingwithinthesystemasdescribedintheprevioussection.
L Fluidpassesthroughthevesselinaregularfashion.The
longerthefluidelementhasbeeninthevessel(thelarger
itsage)themoreprobablethatitwillexitinthenexttime
interval.
t
L Bypassing.Somefluidhasincreasedprobabilityof
leavingataveryyoungage.Restofthefluidbehaves
normally.
t
L Stagnancy.Aftermainflowleavestheprobabilityofthe
fluidcaughtindeadzonestoexitdecreasesuntilvery
largeagesarereachedatwhichpointallfluidmust
ultimatelyleave.
t
ForaCSTR ForaPFR
1 L
L
t
t
t t
3.3 OtherMicromixingModels
Attemptshavebeenmadetocharacterizetheintermediatelevelsofmicromixingbetween
theextremesofsegregatedflowandmaximummixednessbyappropriatemodels.Early
onDanckwerts(1951)andlaterZwietering(1952)introducedthedegreeofsegregation
asameasureofmicromixinginthesystemandproposedwaystoevaluatethismeasure
experimentallyortocalculateitfromthemodels.
KeyClassicalReferences:
546
1. Danckwerts,P.V.,Chem.Eng.Science,2,1(1953)
2. Danckwerts,P.V.,Chem.Eng.Science,8,93(1953)
3. Zwietering,T.W.,Chem.Eng.Science,77,1(1959)
547