Contents

Preface

About the Author

Chapter 1. Mole Balances

1.1 The Rate of Reaction, –rA

1.2 The General Mole Balance Equation

1.3 Batch Reactors (BRs)

1.4 Continuous-Flow Reactors

1.4.1 Continuous-Stirred Tank Reactor (CSTR)

1.4.2 Tubular Reactor

1.4.3 Packed-Bed Reactor (PBR)

1.5 Industrial Reactors

Chapter 2. Conversion and Reactor Sizing

2.1 Definition of Conversion

2.2 Batch Reactor Design Equations

2.3 Design Equations for Flow Reactors

2.3.1 CSTR (Also Known as a Backmix Reactor or a Vat)

2.3.2 Tubular Flow Reactor (PFR)

2.3.3 Packed-Bed Reactor (PBR)

2.4 Sizing Continuous-Flow Reactors

2.5 Reactors in Series

2.5.1 CSTRs in Series

2.5.2 PFRs in Series

2.5.3 Combinations of CSTRs and PFRs in Series

2.5.4 Comparing the CSTR and PFR Reactor Volumes and Reactor Sequencing

2.6 Some Further Definitions

2.6.1 Space Time

2.6.2 Space Velocity

Chapter 3. Rate Laws

3.1 Basic Definitions

3.1.1 Relative Rates of Reaction

3.2 The Reaction Order and the Rate Law

3.2.1 Power Law Models and Elementary Rate Laws

3.2.2 Nonelementary Rate Laws

3.2.3 Reversible Reactions

3.3 The Reaction Rate Constant

3.4 Present Status of Our Approach to Reactor Sizing and Design

Chapter 4. Stoichiometry

4.1 Batch Systems

4.1.1 Equations for Batch Concentrations

4.2 Flow Systems

4.2.1 Equations for Concentrations in Flow Systems

4.2.2 Liquid-Phase Concentrations

4.2.3 Gas Phase Concentrations

Chapter 5. Isothermal Reactor Design: Conversion

5.1 Design Structure for Isothermal Reactors

5.2 Batch Reactors (BRs)

5.2.1 Batch Reaction Times

5.3 Continuous Stirred Tank Reactors (CSTRs)

5.3.1 A Single CSTR

5.3.2 CSTRs in Series

5.4 Tubular Reactors

5.5 Pressure Drop in Reactors

5.5.1 Pressure Drop and the Rate Law

5.5.2 Flow Through a Packed Bed

5.5.3 Pressure Drop in Pipes

5.5.4 Analytical Solution for Reaction with Pressure Drop

5.6 Synthesizing the Design of a Chemical Plant

Chapter 6. Isothermal Reactor Design: Molar Flow Rates

6.1 The Molar Flow Rate Balance Algorithm

6.2 Mole Balances on CSTRs, PFRs, PBRs, and Batch Reactors

6.2.1 Liquid Phase

6.2.2 Gas Phase

6.3 Applications of the Molar Flow Rate Algorithm to Microreactors

6.4 Membrane Reactors

6.5 Unsteady-State Operation of Stirred Reactors

6.6 Semibatch Reactors

6.6.1 Motivation for Using a Semibatch Reactor

6.6.2 Semibatch Reactor Mole Balances

Chapter 7. Collection and Analysis of Rate Data

7.1 The Algorithm for Data Analysis

7.2 Determining the Reaction Order for Each of Two Reactants Using the Method of Excess

7.3 Integral Method

7.4 Differential Method of Analysis

7.4.1 Graphical Differentiation Method

7.4.2 Finding the Rate Law Parameters

7.5 Nonlinear Regression

7.6 Reaction Rate Data from Differential Reactors

7.7 Experimental Planning

Chapter 8. Multiple Reactions

8.1 Definitions

8.1.1 Types of Reactions

8.1.2 Selectivity

8.1.3 Yield

8.2 Algorithm for Multiple Reactions

8.2.1 Modifications to the Chapter 6 CRE Algorithm for Multiple Reactions

8.3 Parallel Reactions

8.3.1 Selectivity

8.3.2 Maximizing the Desired Product for One Reactant

8.3.3 Reactor Selection and Operating Conditions

8.4 Reactions in Series

8.5 Complex Reactions

8.5.1 Complex Reactions in a PBR

8.5.2 Multiple Reactions in a CSTR

8.6 Membrane Reactors to Improve Selectivity in Multiple Reactions

8.7 Sorting It All Out

8.8 The Fun Part

Chapter 9. Reaction Mechanisms, Pathways, Bioreactions, and Bioreactors

9.1 Active Intermediates and Nonelementary Rate Laws

9.1.1 Pseudo-Steady-State Hypothesis (PSSH)

9.1.2 Searching for a Mechanism

9.1.3 Chain Reactions

9.2 Enzymatic Reaction Fundamentals

9.2.1 Enzyme–Substrate Complex

9.2.2 Mechanisms

9.2.3 Michaelis–Menten Equation

9.2.4 Batch Reactor Calculations for Enzyme Reactions

9.3 Inhibition of Enzyme Reactions

9.3.1 Competitive Inhibition

9.3.2 Uncompetitive Inhibition

9.3.3 Noncompetitive Inhibition (Mixed Inhibition)

9.3.4 Substrate Inhibition

9.4 Bioreactors and Biosynthesis

9.4.1 Cell Growth

9.4.2 Rate Laws

9.4.3 Stoichiometry

9.4.4 Mass Balances

9.4.5 Chemostats

9.4.6 CSTR Bioreactor Operation

9.4.7 Wash-Out

Chapter 10. Catalysis and Catalytic Reactors

10.1 Catalysts

10.1.1 Definitions

10.1.2 Catalyst Properties

10.1.3 Catalytic Gas-Solid Interactions

10.1.4 Classification of Catalysts

10.2 Steps in a Catalytic Reaction

10.2.1 Step 1 Overview: Diffusion from the Bulk to the External Surface of the Catalyst

10.2.2 Step 2 Overview: Internal Diffusion

10.2.3 Adsorption Isotherms

10.2.4 Surface Reaction

10.2.5 Desorption

10.2.6 The Rate-Limiting Step

10.3 Synthesizing a Rate Law, Mechanism, and Rate-Limiting Step

10.3.1 Is the Adsorption of Cumene Rate-Limiting?

10.3.2 Is the Surface Reaction Rate-Limiting?

10.3.3 Is the Desorption of Benzene Rate-Limiting?

10.3.4 Summary of the Cumene Decomposition

10.3.5 Reforming Catalysts

10.3.6 Rate Laws Derived from the Pseudo-Steady-State Hypothesis (PSSH)

10.3.7 Temperature Dependence of the Rate Law

10.4 Heterogeneous Data Analysis for Reactor Design

10.4.1 Deducing a Rate Law from the Experimental Data

10.4.2 Finding a Mechanism Consistent with Experimental Observations

10.4.3 Evaluation of the Rate Law Parameters

10.4.4 Reactor Design

10.5 Reaction Engineering in Microelectronic Fabrication

10.5.1 Overview

10.5.2 Chemical Vapor Deposition

10.6 Model Discrimination

Chapter 11. Nonisothermal Reactor Design–The Steady State Energy Balance and Adiabatic PFR Applications

11.1 Rationale

11.2 The Energy Balance

11.2.1 First Law of Thermodynamics

11.2.2 Evaluating the Work Term

11.2.3 Overview of Energy Balances

11.3 The User Friendly Energy Balance Equations

11.3.1 Dissecting the Steady-State Molar Flow Rates to Obtain the Heat of Reaction

11.3.2 Dissecting the Enthalpies

11.3.3 Relating ΔHRx(T), image, and ΔCP

11.4 Adiabatic Operation

11.4.1 Adiabatic Energy Balance

11.4.2 Adiabatic Tubular Reactor

11.5 Adiabatic Equilibrium Conversion and Reactor Staging

11.5.1 Equilibrium Conversion

11.5.2 Reactor Staging

11.6 Optimum Feed Temperature

Chapter 12. Steady-State Nonisothermal Reactor Design—Flow Reactors with Heat Exchange

12.1 Steady-State Tubular Reactor with Heat Exchange

12.1.1 Deriving the Energy Balance for a PFR

12.2 Balance on the Heat Transfer Fluid

12.2.1 Co-Current Flow

12.2.2 Counter Current Flow

12.3 Algorithm for PFR/PBR Design with Heat Effects

12.3.1 Applying the Algorithm to an Exothermic Reaction

12.3.2 Applying the Algorithm to an Endothermic Reaction

12.4 CSTR with Heat Effects

12.4.1 Heat Added to the Reactor, image

12.5 Multiple Steady States (MSS)

12.5.1 Heat-Removed Term, R(T)

12.5.2 Heat-Generated Term, G(T)

12.5.3 Ignition-Extinction Curve

12.6 Nonisothermal Multiple Chemical Reactions

12.6.1 Energy Balance for Multiple Reactions in Plug-Flow Reactors

12.6.2 Parallel Reactions in a PFR

12.6.3 Energy Balance for Multiple Reactions in a CSTR

12.6.4 Series Reactions in a CSTR

12.6.5 Complex Reactions in a PFR

12.7 Safety

Chapter 13. Unsteady-State Nonisothermal Reactor Design

13.1 The Unsteady-State Energy Balance

13.2 Energy Balance on Batch Reactors

13.2.1 Adiabatic Operation of a Batch Reactor

13.2.2 Case History of a Batch Reactor with Interrupted Isothermal Operation Causing a Runaway Reaction

13.3 Semibatch Reactors with a Heat Exchanger

13.4 Unsteady Operation of a CSTR

13.4.1 Startup

13.5 Nonisothermal Multiple Reactions

Appendix A. Numerical Techniques

Appendix B. Ideal Gas Constant and Conversion Factors

Appendix C. Thermodynamic Relationships Involving the Equilibrium Constant

Appendix D. Nomenclature

Appendix E. Software Packages

E.1 Polymath

E.1.A About Polymath

E.1.B Polymath Tutorials

E.2 AspenTech

E.3 COMSOL

E.4 Software Packages

Appendix F. Rate Law Data

Appendix G. Open-Ended Problems

G.1 Design of Reaction Engineering Experiment

G.2 Effective Lubricant Design

G.3 Peach Bottom Nuclear Reactor

G.4 Underground Wet Oxidation

G.5 Hydrodesulfurization Reactor Design

G.6 Continuous Bioprocessing

G.7 Methanol Synthesis

G.8 Alcohol Metabolism

G.9 Methanol Poisoning

G.10 Cajun Seafood Gumbo

Appendix H. How to Use the DVD-ROM

H.1 DVD-ROM Components

H.2 How the DVD-ROM/Web Can Help Learning Styles

H.2.1 Global vs. Sequential Learners

H.2.2 Active vs. Reflective Learners

H.2.3 Sensing vs. Intuitive Learners

H.2.4 Visual vs. Verbal Learners

H.3 Navigation

Index

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