Chemical Reactor

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An advance model of chemical Reactor

#Chemical Reactor
Objective:
 A chemical reactor is an enclosed volume in which a chemical
reaction takes place. In chemical engineering, it is generally
understood to be a process vessel used to carry out a chemical
reaction, which is one of the classic unit operations in chemical process
analysis. The design of a chemical reactor deals with multiple aspects
of chemical engineering. Chemical engineers design reactors to
maximize net present value for the given reaction. Designers ensure
that the reaction proceeds with the highest efficiency towards the
desired output product, producing the highest yield of product while
requiring the least amount of money to purchase and operate.
Normal operating expenses include energy input, energy removal, raw
material costs, labour, etc. Energy changes can come in the form of
heating or cooling, pumping to increase pressure, frictional pressure loss
or agitation.
 Chemical reaction engineering is the branch of chemical engineering
which deals with chemical reactors and their design, especially by
application of chemical kinetics to industrial systems.
 The most common basic types of chemical reactors are tanks
(where the reactants mix in the whole volume) and pipes or tubes
(for laminar flow reactors and plug flow reactors)  Both types can be used as continuous reactors or batch reactors,
and either may accommodate one or more solids
(reagents, catalysts, or inert materials), but the reagents and
products are typically fluids (liquids or gases). Reactors
in continuous processes are typically run at steady-state, whereas
reactors in batch processes are necessarily operated in a transient
state. When a reactor is brought into operation, either for the first
time or after a shutdown, it is in a transient state, and key process
variables change with time.
 There are three idealised models used to estimate the most
important process variables of different chemical reactors:
 Batch reactor model,  Continuous stirred-tank reactor model (CSTR), and
 Plug flow reactor model (PFR).
Types:
1.Batch reactor
The simplest type of reactor is a batch reactor. Materials
are loaded into a batch reactor, and the reaction
proceeds with time. A batch reactor does not reach a
steady state, and control of temperature, pressure and
volume is often necessary. Many batch reactors therefore
have ports for sensors and material input and output.
Batch reactors are typically used in small-scale production
and reactions with biological materials, such as in brewing,
pulping, and production of enzymes. One example of a
batch reactor is a pressure reactor.
2.CSTR (continuous stirred-tank reactor)
In a CSTR, one or more fluid reagents are
introduced into a tank reactor which is typically stirred
with an impeller to ensure proper mixing of the
reagents while the reactor effluent is removed. Dividing
the volume of the tank by the average volumetric flow
rate through the tank gives the space time, or the time
required to process one reactor volume of fluid.
Using chemical kinetics, the reaction's
expected percent completion can be calculated.
3.PFR (plug flow reactor)
 In a PFR, sometimes called continuous tubular reactor (CTR),one or
more fluid reagents are pumped through a pipe or tube. The
chemical reaction proceeds as the reagents travel through the
PFR. In this type of reactor, the changing reaction rate creates
a gradient with respect to distance traversed; at the inlet to the
PFR the rate is very high, but as the concentrations of the reagents
decrease and the concentration of the product(s) increases the
reaction rate slows. Reactor design parameter
Reactor design basically means which type and size of reactor and method of
operation we should employ for a given conversation Parameters are-  1.Volume of reactor
 2.Flow rate
 3.Concentration of feed
 4.Reaction kinetic
 5.Temperature
 6.pressure
RAW MATERIALS
Chemical reactor materials selection is an important aspect in the design of
a chemical reactor. There are four main groups of chemical reactors -
CSTR, PFR, semi-batch, and catalytic - with variations on each. Depending on
the nature of the chemicals involved in the reaction, as well as the operating
conditions (e.g. temperature and pressure), certain materials will perform better
over others.
 Common building materials used for process plants include are :-  1. carbon steel.
 2. stainless steel.
 3. , steel alloys.
 4. graphite
 5. glass
 6. titanium
 7. , plastic
 8. Monel and etc.
Machines
For a chemical reactor ,various types of machines
have used. But for this reactor most common
machines are:-  1.Laser cutter machine.
 2.Glass cutting machine.
 3.Dankeen CNC cutting machine.
 4. Automatic Elastic Band & glass Joining Machine.
Design Description
Chemical reactors are the centre of the all chemical process industries, since they allow the
transformation of the raw materials to products with high added value. This equipment defines
the whole process, since the preparation process of raw materials depends on the reaction
conditions as well as the effluents of the reactor determine the separation strategy and the
difficulty to get the desired products with the adequate purity.  About all chemical reactor carry some major parts. There are:-  1.Reaction Area/Middle Tank.
 2.Tubular Grid.
 3.Hot water Inlet and Outlet pipe.
 4.Chemical Inlet &Outlet pipe.
 5.Trunk Cover.
 6.Reaction tube.
 7.Support base.
 8.nuts& bolts.
All prats with figure: Reaction Area/Middle Tank.
Chemical Inlet &Outlet pipe.
Trunk Cover.
Support base.
Hot water Inlet and Outlet
Tubular Grid.
Reaction tube.
nuts& bolts.
Chemical Reactor
Now the material of chemical reactor can be selected by two way
1. For simple chemical reaction.
2. For industry / when use for high temperature & pressure reaction.
Model 01
Model 02
Some Rendering photo
Result:
 The price of a chemical reactor depends on its size, quality ,performance
,material etc.
 However in this report, have focused two types of model.
 For model no 01 ,its price range $1,300 to $12,000 according to its size.
 But for model no 02, its price range $10,000 to $100,000 according to its size.
A chemical reactor is an enclosed volume in which a chemical reaction takes
place. chemical Designers ensure that the reaction proceeds with the
highest efficiency towards the desired output product, producing the highest
yield of Many real-world reactors can be modeled as a combination of these
basic types.
As there are less or ignoring frictionless its efficiency uptO 80%.
Pressure as well as temperature of a
chemical reactor only depends on its
materials .
Pressure Vessel Sizes: 50, 100, 300, 500, 1000, 2000, 4000, and 8000 ml
Pressure Rating: Up to 10,000 psi (689 Bar and 68.9 MPa) @
350°C
Pressure Vessel Material: 316 or 17-4-PH stainless steel on all wetted
parts
For model (02) when pressure vessel is
made by stainless steel.
For model (01) when pressure vessel is made
by double layer glass.
Double layer glass reactor capacity are 0.5L, 1L, 2L, 3L, 5L, 10L, 20L, 30L, 50L, 100L,
150L, 200L. High temperature is RT-300℃, low temperature is RT- -80℃. Heater, chiller,
vacuum pump and vacuum controller are optional for jacketed glass reactor.
Application of a chemical reactor
THANK YOU