L17-1 Review: Unsteady State Nonisothermal Reactor Design Q Goal: develop EB for unsteady state reactor An open system (for example, CSTR) Fin Fout Hin Hout W dEsys dt Q Rate of rate of heat accumulation flow from = of energy in surroundings system to system dEsys dt W n FE i i i1 in Rate of work Rate of energy done by added to + system on system by surroundings mass flow in 0 steady state dEsys dt n FE i i i1 out Rate of energy leaving system by mass flow out 0 unsteady state Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-2 Review: Simplified EB for Well-Mixed Reactors n n Q WS FH i i i1 n FH i i in i1 out dHi n dNi d Ni Hi PV dt dt dt i1 i1 Total Energy Balance for unsteady state Constant PV variation Made following dNi substitutions & dHi Cpi dT d Fi0 F i irA V PV 0 dt dt solved for dT/dt: dt dt n Energy balance for unsteady state reactor with phase change: Q WS Fi0 Hi Hi0 H RX T rA V i1 n NiCpi dT dt i1 n Q WS Fi0Cpi T Ti0 H RX T rA V Energy balance for dT i1 unsteady state reactor n dt NiCpi without phase change: i1 Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Review: Unsteady State EB, Liquid-Phase Reactions L17-3 n Q WS Fi0Cpi T Ti0 H RX T rA V i1 n NiCpi dT dt i1 For liquid-phase reactions, often Cp = SiCpi is so small it can be neglected When Cp can be neglected, then: n NiCpi NA0Cps where Cps SiCpi is the heat capacity of the solution i1 If the feed is well-mixed, it is convenient to use: SFi0Cpi FA0Cps Plug these equations & Ti0 = T0 into the EB: Q WS FA 0 Cps T Ti0 H RX T rA V dT NA0 Cps dt This equation for the EB is simultaneously solved with the mass balance (design eq) for unsteady state, nonisothermal reactor design Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Review: Nonisothermal Batch Reactor Design L17-4 n Q WS Fi0Cpi T Ti0 H RX T rA V i1 0 n NiCpi dT dt i1 No flow, so: Q WS H RX T rA V n NiCpi i1 Put the energy balance N N X where Ni0 & C C i A0 i i A i i pi P NA 0 in terms of conversion: Q WS H RX T rA V n NA0 iCpi Cp X A i1 dT dt Solve with the batch reactor design dX A N equation using an ODE solver (Polymath): A0 dt rA V Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Review: Adiabatic Nonisothermal Batch Reactor Design L17-5 0 0 For negligible Q WS H RX T rA V dT Substitute: iCpi Cps stirring work: n dt Rearrange NA0 iCpi Cp XA i1 XA T dX A dT X 0 CpS Cp X A T H RX TR Cp T TR A0 0 CpS T T0 CpS T T0 Integrate & X XA A solve for XA: HRX T H RX TR Cp T TR Solve for T: H RX T0 X A H RX T0 X A T T0 T T0 n Cps X A Cp iCpi X A Cp Solve with the batch reactor design equation using an ODE solver (Polymath) i1 XA dX A 0 rA V t NA0 Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17 Basic Catalysis & Reaction Mechanisms L17-6 • Though we have discussed the use of catalyst in a PBR, we have not discussed the process of catalysis itself • An understanding of catalysis, the mechanisms, and catalytic reactor design are the subject of the next few lectures • Catalyst properties • Steps involved in a catalytic reaction • Development of a rate law using steps in catalytic reaction • Different types of catalyst mechanisms • Design of catalytic reactors Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-7 Catalysts & Catalysis • ~1/3 of the GNP of materials produced in the US involve a catalytic process • A Catalyst is a substance that speeds up the rate of reaction but is not changed by the reaction • A catalyst lowers the energy barrier by promoting a different molecular pathway (mechanism) for the reaction • Homogeneous catalysis: catalyst is in solution with at least 1 reactant • Heterogeneous catalysis: more than 1 phase, usually solid and fluid or solid and gas is present. Reaction occurs at solid/liquid or gas interface. Many catalyst are porous (high surface area) catalyst Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Steps in a Heterogeneous Catalytic Reaction 7. Diffusion of B from external surface to the bulk fluid (external diffusion) 1. Mass transfer of A to surface 2. Diffusion of A from pore mouth to internal catalytic surface L17-8 3. Adsorption of A onto catalytic surface 6. Diffusion of B from pellet interior to pore mouth 5. Desorption of product B from surface 4. Reaction on surface Ch 10 assumes steps 1,2,6 & 7 are fast, so only steps 3, 4, and 5 need to be considered Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-9 Adsorption Step The adsorption of A (gas phase) on an active site S is represented by: A A A(g) + S ⇌ A·S I -S-S-S-S-S-SS: open (vacant) surface site A·S: A bound to a surface site Rate of adsorption = rate of attachment – rate of detachment rAD k APACv k ACAS Conc of sites occupied by A partial pressure of A Molar conc of vacant sites on surface • Rate is proportional to # of collisions with surface, which is a function of PA • Rate is proportional to # of vacant (active) sites, Cv, on the surface • Active site: site on surface that can form a strong bond with adsorbed species k In terms of the adsorption equilibrium constant KA where K A A kA kA r k P C C rAD k APACv k ACAS AD A A v A S k A C rAD k A PA Cv A S KA Equation I Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-10 Site Balance Ct: Total number of active sites per unit mass of catalyst divided by Avogadro’s # (mol/g cat) Cv: Number of vacant sites per unit mass of catalyst divided by Avogadro’s # Vacant active site Active site occupied by A A Active site occupied by B B Surface Cv is not measurable, but the total number of sites Ct can be measured In the absence of catalyst deactivation, assume the total number of active sites remains constant: Site balance: Ct = Cv + CA·S + CB·S We will use the site balance equation to put Cv in terms of measurable species Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-11 Langmuir Isotherm Adsorption Adsorption of carbon monoxide onto a surface: CO + S ⇌ CO·S CCOS kA r k P C KA AD A CO v rAD k APCOCv k ACCOS K kA A Determine the concentration of CO adsorbed on the surface at equilibrium At equilibrium, rAD = 0: Rearrange & solve for CCO·S C rAD 0 k A PCOCv COS KA CCOS PCOCv KA CCOS K APCOCv Put Cv in terms of Ct using the site balance; only CO can absorb on the surface: Ct Cv CCOS Ct CCOS Cv Insert into eq for CCO·S from rxn rate CCOS K APCOCv CCOS K APCO Ct CCOS Solve for CCO·S CCOS K APCOCt K APCOCCOS CCOS K APCOCCOS K APCOCt K P C CCOS A CO t Concentration of CO adsorbed on 1 K APCO surface vs PCO→ Langmuir Isotherm Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-12 Surface Reaction Step After the molecule is adsorbed onto the surface, it can react by a few different mechanisms 1. Singe site mechanism: Only the site to which the reactant is absorbed is involved in the reaction kS CBS A B where K r k C A·S ⇌ B·S S S S A S k S K I I S ⇌ -S-SEquation IIa 2. Dual site mechanism: Adsorbed reactant interacts with another vacant site to form the product A·S + S ⇌ S + B·S A B CBSCv rS k S CASCv I I Equation IIb ⇌ K S -S-S-S -S-S-S3. Eley-Rideal mechanism: reaction between adsorbed reactant and a molecule in the gas phase A·S + B(g) ⇌ C·S B C A CCS r k C P I S S A S B Equation IIc I ⇌ K S -S-S-S-S-S-S Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-13 Desorption Step Products are desorbed into the gas phase C·S ⇌ C + S C C I ⇌ -S-S-S-S-S-S- PCCv rD,C kD CCS K D,C Equation III where KD,C kD k D Note that the desorption of C is the reverse of the adsorption of C rD,C rAD,C Also the desorption equilibrium constant KD,C is the reciprocal of the adsorption equilibrium constant KC 1 KD,C KC Substituting 1/KC for KD,C in the rate equation for product desorption gives: rD,C kD CCS KCPCCv Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-14 Derive a Rate Law for Catalytic Rxn • Postulate catalytic mechanism, and then derive the rate law for that mechanism • Assume pseudo-steady state hypothesis (rate of adsorption = rate of surface reaction = rate of desorption) • No accumulation of species on the surface or near interface • Each species adsorbed on the surface is a reactive intermediate • Net rate of formation of species i adsorbed on the surface is 0, ri·S=0 • One step is usually rate-limiting • If the rate-limiting step could be sped up, the entire rxn would be faster • Although reactions involve all 7 steps, (for chapter 10) only adsorption, surface reaction, or desorption will be rate limiting • The surface reaction step is rate limiting ~70% of the time! • Steps to derive the rate law • Select among types of adsorption, surface reaction, and desorption • Write rate laws for each individual step, assuming all are reversible • Postulate which step is rate limiting • Use non-rate-limiting steps to eliminate the surface concentration terms that cannot be measured Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Consider A ⇌ B and assume the following mechanism is correct: CAS 1. Adsorption: A(g) + S ⇌ A·S rAD k A PA Cv K A L17-15 CBSCv r k C C 2. Surface reaction: A·S + S ⇌ S + B·S S S A S v K S PBCv 3. Desorption: B·S ⇌ B + S rD kD CBS K D We need to select one of these 3 reactions as the rate limiting step, then derive the corresponding rate equation, and see if this rate eq matches experimental data. Which step is the most logical to start with? a) Adsorption b) Surface reaction c) Desorption d) None of the above e) Any of these would be “logical” - they all have equal probability of being the rate limiting step The surface reaction step as is rate limiting ~70% of the time Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Consider A ⇌ B and assume the following mechanism is correct: CAS 1. Adsorption: A(g) + S ⇌ A·S rAD k A PA Cv K A L17-16 CBSCv r k C C 2. Surface reaction: A·S + S ⇌ S + B·S S S A S v K S PBCv 3. Desorption: B·S ⇌ B + S rD kD CBS K D Derive the rate equation for when the surface reaction is rate limiting (true ~70% of the time) C C r 'A rS k S CASCv BS v KS 1. CA·S, Cv, and CB·S need to be expressed in terms of measurable quantities • For surface reaction-limited mechanisms, kS is small and kA and kD are relatively large • Therefore rAD/kA and rD/kD are very small, and can be approximated as equal to zero 2. Use this relationship to eliminate CA·S and CB·S from their respective rate equations and the site balance to eliminate CV Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Consider A ⇌ B and assume the following mechanism is correct: 3. Desorption 1. Adsorption 2. Surface reaction C rAD k A PA Cv AS KA CBSCv rS k S CASCv K S Derive the rate equation for when the surface reaction is rate limiting L17-17 PC rD kD CBS B v KD CBSCv r 'A rS k S CASCv K S Use rAD/kA =0 and rD/kD =0 to eliminate CA·S and CB·S from their respective rate equations and the site balance to eliminate CV Use rAD/kA =0 & rAD equation to solve for CA·S: CAS rAD 0 PA Cv kA KA Use rD/kD =0 & rD equation to solve for CB·S: r PC D 0 CBS B v kD KD CAS rAD k A PA Cv K D CAS PA Cv KA CAS K APACv PC rD kD CBS B v KD PC B v CBS KD Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Consider A ⇌ B and assume the following mechanism is correct: 3. Desorption 1. Adsorption 2. Surface reaction L17-18 C PC C C rAD k A PA Cv AS rS k S CASCv BS v rD kD CBS B v KA KD KS Derive the rate equation for when the surface reaction is rate limiting CBSCv r 'A rS k S CASCv K S PBCv CBS rAD/kA =0 & rD/kD =0 CAS K APACv KD Use site balance to solve for CV: Ct Cv CAS CBS Cv Ct CAS CBS Make substitutions for CA·S & CB·S, solve for Cv PC PC Cv Ct K APA Cv B v Cv K APA Cv B v Ct KD KD PB Cv 1 K APA Ct KD Cv Ct 1 K APA PB KD Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Consider A ⇌ B and assume the following mechanism is correct: 3. Desorption 1. Adsorption 2. Surface reaction C rAD k A PA Cv AS KA CBSCv rS k S CASCv K S L17-19 PC rD kD CBS B v KD Derive the rate equation for when the surface reaction is rate limiting Ct PBCv CBS Cv CAS K APACv KD 1 K APA PB KD CBSCv r 'A rS k S CASCv Substitute in CA·S, CB·S, &Cv KS 2 2 Ct Ct PB r 'A rS k S K APA 1 K APA PB KD K SKD 1 K APA PB KD 2 Ct PB r 'A rS k S K P A A K K 1 K P P K A A B D S D This is the rate equation in terms of measurable species and rate constants for the mechanism given in the problem statement Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Evaluating a Catalytic Reaction Mechanism L17-20 • Collect experimental data from test reactor • See if rate law is consistent with data • If not, then try other surface mechanism (i.e., dual-site adsorption or Eley-Rideal) or choose a different rate-limiting step (adsorption or desorption) Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Consider A ⇌ B and assume the following mechanism is correct: 3. Desorption 1. Adsorption 2. Surface reaction C rAD k A PA Cv AS KA CBSCv rS k S CASCv K S L17-21 PC rD kD CBS B v KD C Now derive the rate equation for r ' A rAD k A PA Cv AS when adsorption is rate limiting: KA Conc of vacant and occupied sites must be eliminated from the rate equation If adsorption is rate limiting, kS>>kAD, so rS/kS can be approximated as 0. Then: CBS Cv rS k S CASCv K S CBS Cv CAS Cv KS rS C C 0 CAS Cv BS v kS KS CBS CAS KS Need to put CB·S in measureable terms If adsorption is rate limiting, kD>>kAD, so rD/kD can be approximated as 0. Then: P C rD kD CBS B v KD rD P C 0 CBS B v kD KD PB Cv CBS KD Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Consider A ⇌ B and assume the following mechanism is correct: 3. Desorption 1. Adsorption 2. Surface reaction L17-22 C rAD k A PA Cv AS KA PBCv CBSCv r k C rS k S CASCv D D BS K K D S C Now derive the rate equation for r ' A rAD k A PA Cv A S when adsorption is rate limiting: KA Conc of vacant and occupied sites must be eliminated from the rate eq CBS CAS KS PB Cv CBS Solve for Cv using the site balance equation KD Make substitutions C C CBS PB Cv Ct Cv CAS CBS t v KS KD for CA·S & CB·S Ct PB PB PB Cv PB Cv Cv Ct Cv 1 Ct Cv PB PB K K K K SK D KD 1 S D D K SKD KD Substitute PB Ct PB Ct Substitute Cv into the CBS CAS PB PB CB·S into PB PB expression KD 1 K SK D 1 CA·S: K K K for CB·S: K K K S D D S D D Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. Consider A ⇌ B and assume the following mechanism is correct: 3. Desorption 1. Adsorption 2. Surface reaction L17-23 C PC C C rAD k A PA Cv AS rS k S CASCv BS v rD kD CBS B v KA KD KS Now derive the rate equation for C A S r ' r k P C A AD A A v when adsorption is rate limiting: K A PB Ct PB Ct Ct CAS CBS Cv P P P P P P K SKD 1 B B KD 1 B B 1 B B K SKD KD K SKD KD K SKD KD Use these eqs P C P C A t B t r k to replace CA·S AD A PB PB PB PB 1 & Cv in rAD: K A K SK D 1 K K K K K K S D D S D D k P P Factor r k C A B AD A t PB PB out Ct: PB PB 1 K A K SKD 1 K K K K K K S D D S D D Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-24 The gas phase hydromethylation of toluene: C6H5CH3 + H2 → C6H6 + CH4 is to be carried out in a PBR. Plot the conversion and the partial pressures of toluene, hydrogen and benzene as a function of catalyst weight. FA0 = 50 mol toluene/min, P0 = 40 atm, T= 913K, a= 9.8 x 10-5 kg-1, Feed is 30% toluene (species tol), 45% hydrogen (species H) and 25% inerts (I) Rate law:rT' kPHPtol k= 0.00087 mol/atm2·kg cat·min 1 K tolPtol KBPB KB = 1.39 atm-1 Ktol= 1.038 atm-1 ' kPHPtol dXtol rtol ' r Rate law: T Mole balance: 1 K tolPtol KBPB dW FA0 1 Xtol P 1 Xtol P T0 Stoichiometry:Ctol Ctol,0 CT CT0 1 X P tol 0 1 Xtol P0 T 1 Need concentrations in terms of pressure Ptol,0 Ptol P C RT Ctol Ctol,0 Ptol Vtol ntolRT tol tol RT RT Total P Ptol Ptol,0 1 Xtol P 1 Xtol P P Ptol,0 y where y= RT RT 1 Xtol P0 Total P tol 1 Xtol P0 at inlet Ftol,0 0.3 0.3 0.3 0 0 y tol,0 1 1 1 1 0 y Tol,0 FT0 1 Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-25 The gas phase hydromethylation of toluene: C6H5CH3 + H2 → C6H6 + CH4 is to be carried out in a PBR. Plot the conversion and the partial pressures of toluene, hydrogen and benzene as a function of catalyst weight. FA0 = 50 mol toluene/min, P0 = 40 atm, T= 913K, a= 9.8 x 10-5 kg-1, Feed is 30% toluene (species tol), 45% hydrogen (species H) and 25% inerts (I) Rate law:rT' 2·kg cat·min kPHPtol k= 0.00087 mol/atm 1 K tolPtol KBPB KB = 1.39 atm-1 Ktol= 1.038 atm-1 ' dXtol rtol kPHPtol Rate law:rT' Mole balance: dW FA0 1 K tolPtol KBPB Stoichiometry: Ptol,0 y tol,0P0 P Ptol Ptol,0 1 Xtol y where y= P0 Ptol,0 0.3 40atm 12atm 0 y tol,0 0.3 0 Use the Ergun equation to evaluate y: Isothermal rxn & =0, so: y 1 a W 1 2 Ptol Ptol,0 1 Xtol 1 a W 12 Need an equation for PB & PH PB Ptol,0 Xtol y PH2 Ptol,0 H2 Xtol y H2 FH2 Ftol 0.45 1.5 0.3 Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-26 The gas phase hydromethylation of toluene: C6H5CH3 + H2 → C6H6 + CH4 is to be carried out in a PBR. Plot the conversion and the partial pressures of toluene, hydrogen and benzene as a function of catalyst weight. FA0 = 50 mol toluene/min, P0 = 40 atm, T= 913K, a= 9.8 x 10-5 kg-1, Feed is 30% toluene (species tol), 45% hydrogen (species H) and 25% inerts (I) k= 0.00087 mol/atm2·kg cat·min kPHPtol Rate -1 K = 1.038 atm-1 K = 1.39 atm B tol 1 K tolPtol KBPB ' 0 dXtol rtol kPHPtol ' y tol,0 0.3 Rate law:rT Mole balance: dW FA0 1 K tolPtol KBPB 0 law:rT' Stoichiometry: Ptol Ptol,0 1 Xtol 1 a W 12 PB Ptol,0 Xtol y Ptol,0 12atm PH2 Ptol,0 1.5 Xtol y y 1 a W 12 Finally, calculate the kg P 1atm 12 5 1 1 9.8 10 kg W 1 a W cat where P0 = 1atm: 40atm P0 0.000625 1 9.8 10 5 kg1W 12 Wfinal 10197.7kg Plug equation in boxes into Polymath to solve Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-27 Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-28 Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign. L17-29 Slides courtesy of Prof M L Kraft, Chemical & Biomolecular Engr Dept, University of Illinois, Urbana-Champaign.