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Catalytic Reactors
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Solid catalyst gas phase reaction
Fixed bed/Packed bed reactors Fluidized bed reactor
Catalytic reactors
Packed bed reactor
It may not be possible to use this
reactor for removing/adding heat.
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Multi-tube fixed bed reactor
If heat of reaction is large, each catalyst
tube must be small to prevent excessive
temperature within the reaction mixture.
It can be used for high exothermic reaction.
Multi bed reactor
This arrangement reduces the
temperature variation.
All these reactors use relatively large size catalyst (granular, pellet, cylindrical or spherical)
for low pressure drop.
Catalyst is stationary.
Catalytic reactors (Cont.,)
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Catalytic reactors (Cont.,)
Fluidized bed reactors:
Suitable, when frequent catalyst regeneration is required (or) for reaction with a very high heat
effects.
Containing fine catalyst particles (50 250 m).
The reactant gas is introduced through the bottom of the reactor at a rate such that catalyst
particles are suspended in a gas stream without being carried out .Under these conditions, the
entire bed of particles behave like a boiling liquid. This action tends to make composition of
reaction mixture and temperature uniform throughout the bed.
FBR for a stable catalyst which does not
require regeneration continuously.
FBR for deactivating catalyst that requires
removal & regeneration continuously.
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FIXED BED REACTOR FLUIDIZED BED REACTOR
Catalyst particles are stationary and
gas flows through it.
Catalyst regeneration is a serious
problem.
Operation is not practically isothermal.
No carryover of catalyst particles. So, it
does not require recovery units.
Cannot use very small size catalyst
particles due to plugging and high
pressure drop. Uses relatively large size
particles for low pressure drop.
Gas approximates plug flow.
Small diameter multi tubular units.
Catalyst particles are suspended in the
gas stream. They move about depending
upon the gas stream velocity.
Catalyst regeneration is very easy.
Practically isothermal operation.
Carry over of catalyst particles. So,
requires recovery units.
Uses fine size catalyst particles (which
provides large area of contact).
Gas flow is far from plug flow with
considerable by passing.
Large diameter vessels.
Catalytic reactors (Cont.,)
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Multi phase reactors:
Three phases Gas, Liquid phases that contact a solid
Slurry & Trickle bed reactor
Catalytic reactors (Cont.,)
Slurry reactor
Catalyst (~100m) is suspended in the liquid and gas
is bubbled through the liquid.
It may be operated in either a semi-batch (or)
continuous mode.
Only little movement between particles and fluid.
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Main advantage
Temperature control and heat recovery are easily achieved.
Constant overall catalytic activity can be maintained by the addition of small amount of
catalyst.
Adv. over fixed bed reactor is similar to FBR.
Catalytic reactors (Cont.,)
When to use
When there are both volatile and non-volatile reactants, or when a liquid solvent is
necessary with all gaseous reactants, three phase reactor is needed.
Most disadvantage of slurry reactor
Difficulty in retaining the catalyst in the vessel (screens and other devices placed in the
outlet lines tend to clog or otherwise be unreliable)
Slurry reactors:
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Slurry reactor Fluidized bed reactor
Catalyst suspended in a liquid Suspending fluid is the reacting
gas itself.
Catalytic reactors (Cont.,)
Ex: Hydrogenation of fatty
acid over a supported
nickel catalyst.
Ex: Polymerization of ethylene
(or) propylene.
(liquid: Cyclohexane)
H
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H
2
Solid catalyst
Gas bubble
Liquid
G
L
G L
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Trickle bed reactor:
Gas and liquid flow concurrently downward over fixed bed of
catalyst particles contained in a tubular reactor.
Since the catalyst particle sizes in these reactors are
relatively large, intraparticle resistances will be more
significant than for slurry reactor.
No difficulty in retaining the large particles in the bed.
Catalytic reactors (Cont.,)
Three phase fluidized bed reactor
L
G
Gas
Solid

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