Professional Documents
Culture Documents
2003)
Abstract
This paper proposes a mathematical model for the operation of a non- ideal plug
flow reactor in a saponification pilot plant of a typical process industry in Lagos,
Nigeria. The residence time distribution (RTD) analysis technique involving tracer
experiments was used. The model also gives a prediction of the number of ideal
continuous stirred tank reactors (CSTR) that could represent the non-ideal plug flow
reactor (PFR) in question. Simulated results reveals that 8.18 number of ideal stirred
tanks in series would represent the non-ideal plug flow reactor under study.
65
AU J.T. 7(2): 65-74 (Oct. 2003)
tracer experiment carried out on a non-ideal space time for ideal CSTR is the ratio of
plug flow reactor. The result was used to volume to volumetric flow rate, i.e. τ 1= τ 2= τ i.
determine the number of equal sized ideal Where the subscript 1,2 and i represents the
continuous stirred tank reactor (CSTR) first, second and ith tank respectively. Taking
arranged in series. The number of ideal stirred the material balance round tank 1 (Fig. 2)
tanks that will fit the RTD data of the non-ideal gives;
plug flow reactor simply means the number of dC
ideal CSTR in series that will be equivalent to vCo = vC1 + V 1 …………………5
dt
the non-ideal PFR. This one parameter model,
for specificity can be regarded as “tank in where Co is the inlet concentration to tank 1; C1
series model”. And, the only adjustable is the out let concentration from tank 1. For a
parameter to be extracted from the residence pulse tracer experiment, Co as a function of
time distribution (RTD), data is the number of time is zero. Therefore, equation 5 becomes;
tank n. dC1
In developing this model, let consider V1 = − vC1 ……………………...6
dt
three equal sized ideal CSTRs in series (Fig. 1). C1=Coe-vt/v1…………..…………….7
If a pulse tracer experiment is carried out on
these three tanks in series, then from RTD For ideal CSTR, the space time is given as;
function (Levenspiel 1972), the fraction of
tracer material leaving the last tank between τ =V/v or τ 1=V1/v …………………8
time t and t+∆t will be
C (t ) C1=Coe-t/τ1 ………………………...9
E (t ) = ∞ 3 ………………..….1
∫ 3
0
C (t ) dt The material balance on tracer around tank 2
where C3 is the concentration of tracer material will be;
exiting the system (3rd tank); E(t) is the RTD dC2
vC1 = vC2 + Vi ...……………10
function. The outlet concentration of tracer dt
material, C3(t) as a function of time, can be
Dividing through by Vi and then substituting
obtained by carrying out material balance
equation 7 and 8 into equation 10 gives a first
around each of the tanks. From the principle of
order ordinary differential equation;
conservation of mass;
dC2 C2 Co − t /τ
Input = Output + Disappearance + + = e ………………11 i
Accumulation ……………………………….2 dt τi τi
For a steady state system, there is no Using an integrating factor, e-t/τi along with the
accumulation, therefore; initial condition C2=0 ant t=0 gives;
Input = Output + Disappearance ...….3 Co t − t / τ
C2 = e ………..……………12
i
dt τ i τ i2
series, the volumetric flow rate v1 is constant
or
i.e. vin=vout for each of the tanks. The volume V
of each of the tanks is also identical i.e. Co t 2 − t / τ
C3 = e ..…….………………15
i
66
AU J.T. 7(2): 65-74 (Oct. 2003)
Co t 2 − t / τ ∞ n(nθ ) n −1 − nθ
e i
σ 2 θ = ∫0 θ 2 e dθ − 1 ……26a
2τ i2 (n − 1)!
E (t ) = .………………16a
∞ C t
2
∫0 2τ 2 e
o −t /τ
nn ∞
σ θ = ∫ θ n +1 e − nθ dθ − 1 .……26b
i
i
(n − 1)! 0
t 2 e −t /τ i
Integrating will give;
E (t ) = ∞ …………………16b
∫ t e dt n n (n + 1)!
2 −t /τ i
0
σ 2θ = − 1 ..……27a
By applying integration by part (Stroud 1995), (n − 1)! n n +2
equation 16b becomes; 1
σ 2θ = ..……………………….27b
t 2 −t /τ n
E (t ) = e ……………………17 i
n = 2 .…………………………..29
(n − 1)!τ i n
σ
The RTD function can be normalized by The number of tanks in series is given by n,
expressing in dimensionless time scale as where τ is the space-time in the combined tanks
(Levenspiel 1972; Coulson and Richardson in series, but it is equivalent to the mean
1994); residence time, tm, in the non-ideal plug flow
θ= t / τ ……………………………19 reactor.
67
AU J.T. 7(2): 65-74 (Oct. 2003)
68
AU J.T. 7(2): 65-74 (Oct. 2003)
3.2 Simulation Results concentration of stearic acid (A) and NaOH (B)
at different operating temperature conditions of
The simulated results are presented in 348 K, 363 K and 383K are presented in Tables
Tables 2-7. The variations in initial 2-5.
69
AU J.T. 7(2): 65-74 (Oct. 2003)
70
AU J.T. 7(2): 65-74 (Oct. 2003)
Comparative analysis of the results based simulated and practical conversions of A, and
on the absolute difference between the their percentage error is presented in Table 7.
Conversion of A (%)
S /No Absolute deviation, D Error (%)
Practical Simulated
1 51.00 56.82 5.82 11.41
2 18.04 19.06 1.02 5.65
3 68.00 71.57 3.57 5.25
4 18.20 19.69 1.49 8.19
5 75.00 80.93 5.93 7.91
6 18.43 19.85 1.42 7.71
A, increasing initial concentration of B leads to
The comparison of the simulated and increased conversion for the different operating
practical results shows that the experimental
outlet concentration and conversion of A were temperature. Increased operating temperature
lower than those of the simulated (Table 6). also, leads to increasing conversion (Fogler
This deviation was consistent. The percentage 1997). Fig. 4 gives the simulated result of the
error from Table 8 ranges from 5.25-11.41%. conversion of C17H35COOH at the three
The causes of the observed errors might be operating temperature of 348, 363, and 383 K
associated with the fact that the model did not while varying the concentration of
take into account the nature of the reactants, C17H35COOH. The result shows a decrease in
their concentration activeness, viscosity and other conversion of A (C17H35COOH) meaning that
parameters that have effects on the reaction. the reactant (A) is being used up. Conversion
From the tables of simulated result, it can was highest at 383 K and lowest at 348 K. Fig.
be seen that for a fixed initial concentration of 5 on the other hand shows the conversion of A
B, increasing initial concentration of A leads to with variation in concentration of NaOH. This
decreasing conversion for the different result shows an increase in conversion with
temperatures of operation. At increased increase in concentration of NaOH (Aweh
temperature however, the conversion increases. 2002; Nwokoro 2002). The observed results
Conversely, for a fixed initial concentration of might be connected with the fact that NaOH is
71
AU J.T. 7(2): 65-74 (Oct. 2003)
a strong base while C17H35COOH is a weak of India Private Ltd., New Delhi, pp.708-23,
acid. 759-65.
The model developed also gives a Himmelblau, D. M. 1996. Basic Principles and
prediction of the number of serially arranged Calculation in Chemical, 6th ed., Prentice-
ideal stirred tank reactors, n, that will have an Hall, Englewood Cliff, N.J., USA.
equivalent performance as a non-ideal plug Kreyszig, E. 1996. Advanced Engineering
flow reactor the size of which would be equal Mathematics, 5th ed. New Age Int’l. Ltd.,
to that of the combined tanks. Simulation of New Delhi, India.
equation 29 shows that the number of tanks in Levenspiel, O. 1972. Chemical Reaction
series would be 8.18. The significance of 8.18 Engineering. 2nd ed., pp.107-9, 253-99. John
tanks, means that this non-ideal plug flow Wiley, New York, N.Y., USA.
reactor under study could be represented by Luyben, W. L. 1990. Process Modeling,
nine ideal stirred tanks arranged in series with Simulation and Control for Chemical
the same flow rate of 0.098m3 / hr. The first Engineers, 2nd ed., pp15-38, 87-91.
eight tanks are of the same size (identical) and McGraw-Hill, Singapore.
the 9th tank is 0.18 of the 8th tank in size (Aweh Meyers, R. A. 1992. Encyclopedia of Physical
2002; Luyben 1990). The combined volume Science and Technology, Vol. 9, 2nd ed., pp.
(size) of the nine tanks must however, be equal 519-20. Academic Press, London.
to that of the plug flow reactor. From this Meyers, R.A. 1992. Encyclopedia of Physical
analysis it would be more economical to use a Science and Technology, Vol. 14, 2nd ed.,
single PFR than using about nine tanks of the pp. 347-9. Academic Press, London.
CSTR for the given reaction. Meyers, R.A. 1992. Encyclopedia of Physical
Science and Technology, Vol.15, 2nd ed.,
Academic Press, London.
4. Conclusion Nwokoro, U.T. 2002. Two parameter model
and computer simulation of a Continuous
The mathematical model for the operation stirred tank reactor. B.Eng. thesis, pp.1-73.
of a non-ideal plug flow reactor has been Federal University of Technology, Minna,
developed. The model was used to generate Nigeria.
simulated results for a non-ideal plug flow Paynes, J.A. 1982. Introduction to Simulation.
reactor of a saponification pilot plant. In the McGraw-Hill, New York, N.Y., U.S.A.
process of simulation, it was found out that Perry, R.H.; and Green, D.W. 1997. Perry’s
8.18 identically sized ideal stirred tanks Chemical Engineering Handbook, 7th ed.,
operating in series would have an equivalent pp.23(15-23). McGraw-Hill, New York,
performance with the non-ideal plug flow N.Y., U.S.A.
reactor. Richardson, J.F.; and Peacock, D. G. 1994.
Coulson & Richardson’s Chemical
rd
5. References Engineering”, Vol. 3, 3 ed., pp71-80, 102-
3. Pergamon, Great Britain.
Aweh, E.A. 2002. One parameter model and Smith, J.M.; Van Ness, H.C.; and Abbott, M.
computer simulation of a non-ideal plug M. 1996. Introduction to Chemical
flow reactor. B.Eng. thesis, Federal Engineering Thermodynamics, 5th ed., pp.
University of Technology, Minna, Nigeria. 64-5, 189-91, 604-8, 831-37, McGraw-Hill,
Fogler, H. S. 1997. Elements of Chemical Singapore.
Engineering Reaction, 2nd ed., Prentice-Hall Stroud, K. A. 1995. Engineering Mathematics,
4th ed., Macmillan, London.
72
AU J.T. 7(2): 65-74 (Oct. 2003)
90
80
70
Conversion (%)
60 348K
50
363K
40
30 383K
20
10
0
0.1
1.01
2.01
3.01
4.01
5.01
6
7
8
9
10
3
Concentration of C17H35COOH (kmol/m )
120
100
Conversion (%)
80 348K
60 363K
383K
40
20
0
0.1
1.01
2.01
3.01
4.01
5.01
6
7
8
9
10
3
Concentration of NaOH (kmol/m )
73
AU J.T. 7(2): 65-74 (Oct. 2003)
1 2 3
FAo, CAo
FA, CA
74
AU J.T. 7(2): 65-74 (Oct. 2003)
4
In (C B /C A )
348 K
3 363 K
383 K
2
0
0 20 40 60 80 100 120 140
Time (min.)
Fig. 3. Kinetic data showing time versus In (CB/CA) dependency obtained experimentally.
75