2019

NAME:
AFFILIATION:
1/1/2019
Table of Contents
Abstract ......................................................................................................................................................... 2
Keywords ...................................................................................................................................................... 2
Introduction ................................................................................................................................................... 2
Applications of MAN ............................................................................................................................... 3
Global Utilization of Maleic Anhydride ................................................................................................... 4
Characteristic Properties of MAN............................................................................................................. 4
Materials and Methodology .......................................................................................................................... 5
Available & feasible process routes to MAN production ......................................................................... 5
Production Route Comparison .................................................................................................................. 6
Process Flow Diagram .................................................................................................................................. 7
Material & Methodology .............................................................................................................................. 8
Reactant Material ...................................................................................................................................... 8
Calculations............................................................................................................................................... 9
Material Balance of the Reactor.............................................................................................................. 10
Basis ........................................................................................................................................................ 10
Reactions ................................................................................................................................................. 10
Energy Balance of the Reactor................................................................................................................ 15
Design of a Reactor................................................................................................................................. 20
Choice of a Reactor................................................................................................................................. 20
Fluidized Bed Reactor............................................................................................................................. 22
Assumptions of the Model .................................................................................................................. 22
Chemical Reaction .............................................................................................................................. 23
Reaction Kinetics ................................................................................................................................ 23
Reaction Parameters............................................................................................................................ 23
Design Steps........................................................................................................................................ 24
Design Equation .................................................................................................................................. 24
Results & Discussions................................................................................................................................. 27
SPECIFICATION SHEET...................................................................................................................... 27
Conclusion .................................................................................................................................................. 28
References ................................................................................................................................................... 29

1
Abstract

A reactor is a vessel utilized for the response of the constituents of feed as reactants to give the yield as
product items. The primary working guideline of the reactor is that it gives the reasonable responding
medium to the reactants to give items. This report characterizes the plan of a Fluidized Bed reactor with its
geometry and working conditions as mass and vitality balance relations. The oxy-acetylation process jumps
out at proselyte n-butane to Maleic Anhydride inside the reactor. The goal of this examination is to structure
the reactor, characterize the response energy and to study and manage every single procedure parameter
engaged with the reactor plan completely.

Keywords

Maleic Anhydride, Reactor, Reaction, Oxygen, MAN.

Introduction

2
Maleic anhydride (MAN) (butene dioic anhydride, toxilic anhydride, 2,5-dioxofuran), an organic
compound with the formula C2H2(CO)2O is the acid anhydride of maleic acid.

Figure 1: Chemical Formula of MAN

In its pure state it is a colorless or white solid with an acrid odor. Maleic anhydride is a solid at room
temperature. Above 52.9 °C it becomes a clear, colorless, low viscosity liquid. Maleic anhydride is soluble
in water forming maleic acid. In the United States, one plant uses only n-butane and another uses n-butane
for 20 %of its feedstock, but the primary raw material used in the production of Maleic Anhydride is
benzene. The Maleic Anhydride industry is converting old benzene plants and building new plants to use
n-butane. Maleic Anhydride also is a by-product of the production of phthalic anhydride. It is a solid at
room temperature but is a liquid or gas during production. It is a strong irritant to skin, eyes, and mucous
membranes of the upper respiratory system. Table further explains some physical and chemical properties
of industrial maleic anhydride.

Applications of MAN
Maleic anhydride is truly a remarkable molecule in that it possesses two types of chemical functionality
making it uniquely useful in chemical synthesis and applications. Maleic anhydride itself has few
consumers uses but in derivative form, it is extremely versatile in the consumer uses in which it is found.

▪ The majority of the maleic anhydride produced is used in unsaturated polyester resin. Unsaturated
polyester resin is then used in both glass-reinforced applications and in unreinforced applications.
▪ Another significant use of maleic anhydride is in the manufacture of alkyd resins, which are in turn
used in paints and coatings.
▪ Other applications where maleic anhydride is used include the production of agricultural chemicals,
maleic acid, copolymers, fumaric acid, lubricant additives, surfactants and plasticizers.

3
▪ It is also used as a co-monomer for unsaturated polyester resins, an ingredient in bonding agents
used to manufacture plywood, a corrosion inhibitor, and a preservative in oils and fats.
▪ Fumaric acid and maleic acid are produced from maleic anhydride. The primary use for fumaric
acid is in the manufacture of paper sizing products. Fumaric acid is also used as a food acidulate
and the Maleic acid is a particularly desirable acidulate in certain beverage selections.
▪ Maleic anhydride is used in a multitude of applications in which a vinyl copolymer is produced by
the copolymerization of maleic anhydride with other molecules having a vinyl functionality.

Global Utilization of Maleic Anhydride

Unsaturated Polyester Resins 51 %

Others (Intermediates) 27 %

1,4 Butanediol 13 %

Fumaric Acid 4%

Lube Oil Additives 3%

Agricultural Chemicals 1.8 %

Characteristic Properties of MAN

Chemical Name Maleic Anhydride

Molecular Weight 98.06 g/mol Chemical Formula C4H2O3

Colorless crystalline needle

Color flakes or white solid at room Odor Acrid
temperature

Melting Point 52.85 oC Boiling Point 202 oC

Flash Point 102 oC Density 1.48 g/cm3

Heat capacity
0.1199 kJ/mol.K Heat capacity (Liquid) 0.164 kJ/mol.K
(Solid)

4
Toxic to inhale, ingest
Solubility 3700 mg/L at room temp. Toxicity
and touch

Materials and Methodology

Available & feasible process routes to MAN production
Generally, there are 3 routes that can be considered for the commercial production of man. The 3 routes are
given below together with their chemical reactions.

1. Benzene Partial Oxidation to MAN:

Vaporized benzene and air are mixed and heated before entering the tubular reactor. Inside the reactor, the
benzene/air mixture is reacted in the presence of a catalyst that contains approximately 70 percent vanadium
pentoxide (v2O5), with usually 25-30% molybdenum trioxide (MoO3), forming a vapor of ma, water, and
carbon dioxide.

2. N-BUTANE Partial Oxidation to MAN:

5
Butane and compressed air are mixed and fed adiabatic reactor, where butane reacts with oxygen to form
maleic anhydride. The reaction is exothermic, therefore either a fluidized bed reactor or a packed bed reactor
with heat removal to stay close to isothermal.

3. Phthalic Anhydride Recovery Process to MAN:

C8H10 + 7.5O2 → C4H2O3 + 4H2O + 4CO2

The process technology involved in this process route includes LURGI - BASF Phthalic Anhydride Process
and Techno bell Limited Process. Hot air and vaporized o-xylene are mixed and sent to a packed bed reactor.
Most of the oxylene reacts to form phthalic anhydride, but some complete combustion of o-xylene occurs
and some maleic anhydride is formed as a by-product.

Production Route Comparison

Manufacturing
Process Description
Schemes Main Reactions

Partial oxidation of n-butane to

desired product with small amount
From n – Butane C4H10 + 3.5O2 ---------> C4H2O3 + of formic acid and acrylic acid as by
4H2O products. Being economical, super
attractive for industrial production.

Oxidation of benzene in the vapor

phase with undesired side reactions
giving sufficient amount of carbon
From Benzene oxides. Relative High cost and
C6H6 + 4O2 -----> C4H2O3 + 2CO2 + 2H2O hazards of benzene makes this
process obsolescent and less
attractive.

Manufacturing Processes From n – Butane From Benzene

Total conversion 82.2 % 85-95 %

6
Temperature Range 380 - 410°C 400 - 450°C

Vanadium and Molybdenum

Catalyst Vanadium Phosphorus Oxide
Oxides

Economics less cost route relatively expensive

Environmental Impact Greener route Hazardous effects

On the basis of the above-mentioned comparison the process we have selected for our project is “Production
of MAN from n-Butane”.

Process Flow Diagram

7
R-101 Rector

C-101 Compressor

T-101 Absorption Tower

E-101,102 Heat Exchanger

V-101 Flashing Vessel

R-102 Reactor

T-102 Distillation Column

Material & Methodology

Reactant Material

n-Butane and compressed air is mixed and then fed to the adiabatic reactor where butane reacted with
oxygen to give maleic anhydride. The reaction is exothermic, therefore either a fluidized bed reactor or a
packed bed reactor with heat removal to stay close to isothermal. The reactor effluent is cooled and sent to
packed bed absorber, where it is contacted with water to remove the light gases and all of the maleic
anhydride reacts to form maleic acid. The vapor effluent, which consists of non-condensable must be sent
to an after-burner to remove any carbon monoxide prior to venting to the atmosphere. The liquid effluent
is then cooled and flashed at 101 kPa and 120°C. The vapor effluent after flashed is sent to waste treatment
where else the liquid effluent, is sent to another reactor where maleic acid is broken down to maleic
anhydride and water. The reactor effluent is then sent to distillation column where maleic anhydride and
water are separated. The distillate from the distillation column is sent to waste treatment.

8
Calculations

Molecular Weights
Components Molecular Formula
(kg/kmol)
Maleic Anhydride C4H2O3 98.06
Maleic Acid C4H4O4 116.072
Water H2O 18.015
Acrylic Acid C3H4O2 72.06
Formic Acid CH2O2 46.025
n – Butane C4H10 58.12
Oxygen O2 31.998
Nitrogen N2 28.013
Carbon dioxide CO2 44.01
Carbon monoxide CO 28.01

9
Material Balance of the Reactor

Basis
1500 kg/hr of Maleic Anhydride producing per day.
By preliminary assumed balance we have:
6244.52182 kg/hr. of Maleic Anhydride produced by = 5800 kg/hr. of Butane entered
1 kg/hr. of Maleic Anhydride produced by = 5800/6244.52182 = 0.9288141137
1500 kg/hr of Maleic Anhydride produced by = 0.9288141137 × 1500 = 1393.221171 kg/hr of Butane.

Reactions
Main Reaction
The total conversion of butane is 82.2 %.
C4H10 + 3.5O2 → C4H2O3 + 4H2O (Maleic Anhydride)
Side Reactions
C4H10 + 5.5O2 → 2CO + 2CO2 + 5H2O
C4H10 + 3.5O2 → C3H4O2 + CO2 + 3H2O (Acrylic Acid)
C4H10 + 6O2 → CH2O2 + 3CO2 + 4H2O (Formic Acid)

10
Selectivities
• C4H2O3 70.0 %
• CO2 1.0 %
• C3H4O2 1.0 %
• CH2O2 1.0 %

Reaction 1:

C4H10 + 3.5O2 → C4H2O3 + 4H2O

Assuming 100% conversion,

O2 used:

58 kg/hr. of Butane require = 112 kg/hr. of O2

1kh/hr. of Butane needs = 112/58 of O2

1393.221171 kg/hr of Butane needs = 112/58 × 1393.221171 = 2690.358123 kg/hr of O2

Generally, we use 200-250 % excess air for this reaction.

So,

O2 provided:

= 2.5 × 2690.358123

= 6725.895 kg/hr of O2

We know that:

Mass of O2 in Air = total mass of Air × Mass fraction of O2 (0.21)

Total mass of Air entering = 6725.895 /0.21 = 32028.073 kg/hr.

Mass of N2 in Air = Mass of Air – Mass of O2 = 32028.073 – 6725.895 = 25302.18 kg/hr.

Now,

𝑆𝑖𝑛𝑔𝑙𝑒 𝑃𝑎𝑠𝑠 𝑌𝑖𝑒𝑙𝑑

𝑆𝑒𝑙𝑒𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
𝑇𝑜𝑡𝑎𝑙 𝐶𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛

11
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐷𝑒𝑠𝑖𝑟𝑒𝑑 𝑃𝑟𝑜𝑑𝑢𝑐𝑡
𝑆𝑖𝑛𝑔𝑙𝑒 𝑃𝑎𝑠𝑠 𝑌𝑖𝑒𝑙𝑑 =
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑓𝑒𝑑

&

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑟𝑒𝑎𝑐𝑡𝑒𝑑

𝑇𝑜𝑡𝑎𝑙 𝐶𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛 =
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑓𝑒𝑑

Now, the selectivity becomes:

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐷𝑒𝑠𝑖𝑟𝑒𝑑 𝑃𝑟𝑜𝑑𝑢𝑐𝑡

𝑆= × 100
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡𝑠 𝑟𝑒𝑎𝑐𝑡𝑒𝑑

Moles of desired product produce = Stoichiometric co-efficient of the product × reactant moles (R)

𝐶𝑜 − 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡(𝑈)

𝑆𝑡𝑜𝑖𝑐ℎ𝑖𝑜𝑚𝑒𝑡𝑟𝑖𝑐 𝐶𝑜 − 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 =
Co − efficient of the reactant(V)

&

the required selectivity eq. is as follows:

𝑈 𝑅
𝑆=( × ) × 100
𝑉 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑟𝑒𝑎𝑐𝑡𝑒𝑑

(formula used for moles so we convert masses to moles in accordance with it)

Reaction 1:

C4H2O3:

S = 70 %

70 = [(1/1) × R1/1] × 100

R1 = 0.7 moles of Butane used.

Reaction 2:

R1 + R2 + R3 + R4 = Total Conversion

R2 = 0.822 – (R1 + R2 + R3)

Reaction 3:

12
S = 1.0 %

1.0 = [(1/1) × R3/1] × 100

R3 = 0.01 mole of Butane used.

Reaction 4:

S = 1.0 %

1.0 = [(1/1) × R4/100] × 100

R4 = 0.01 mole of Butane used.

Now,

R2 = 0.822 – (0.7 + 0.01 + 0.01)

R2 = 0.102 moles of Butane used.

Total Moles produced:

Reaction 1:

O2 consumed = (32/58) × 1393.2212 × 0.7 × 3.5 = 1883.25069 kg/hr.

C4H10 consumed = 1393.2212 × 0.7 = 975.254819 kg/hr.

Reaction 2:

O2 consumed = (32/58) × 1393.2212 × 0.102 × 5.5 = 431.225973 kg/hr.

C4H10 consumed = 1393.2212 × 0.102 = 142.108559 kg/hr.

Reaction 3:

O2 consumed = (32/58) × 1393.2212 × 0.01 × 3.5 = 26.9035812 kg/hr.

C4H10 consumed = 1393.2212 × 0.01 = 13.9322117 kg/hr.

Reaction 4:

O2 consumed = (32/58) × 1393.2212 × 0.01 × 6 = 46.120425 kg/hr.

13
C4H10 consumed = 1393.2212 × 0.01 = 13.9322117 kg/hr.

Total O2 consumed in the reactor = 1883.25069 + 431.225973 + 26.9035812 + 46.120425

Total O2 consumed in the reactor = 2387.500669 kg/hr.

Total C4H10 consumed in the Reactor = 975.254819 + 142.108559 + 13.9322117 + 13.9322117

Total C4H10 consumed in the Reactor = 1145.227801 kg/hr.

Unreacted C4H10 = 1393.2212 – 1145.227801 = 247.993399 kg/hr.

Components Inlet (kg/hr) Outlet (kg/hr)

C4H10 1393.221 247.993

O2 6725.895 4338.394
N2 25302.18 25302.177

C4H2O3 --- 1647.844

CO2 --- 257.890

CO --- 137.208

C3H4O2 --- 17.295

CH2O2 --- 11.049

H2O --- 1461.440

TOTAL 33421.29 33421.29

14
Energy Balance of the Reactor

Liquid-Phase Heat Capacity: Cp = A + BT + CT2 + DT3 + ET4

Liquid-Phase Heat Capacity (J/kmol. K)

Components
A B C D
Water 92.053 -3.9953e-2 -2.1103e-4 5.3469e-7
Maleic
-3.123 0.08323 -5.217X10-5 1.156X10-7
anhydride
n-butane 3.96 37.15X10-2 -18.34X10-5 35X10-9
Oxygen 25.48 1.520X10-2 -0.7155X10-5 1.312X10-9
Cp
Nitrogen 28.90 -0.1571X10-2 0.8081X10-5 -2.873X10-9
Carbon dioxide 22.26 5.981X10-2 -3.501X10-5 7.469X10-9
Carbon
28.16 0.1675X10-2 0.5372X10-5 -2.222X10-9
monoxide

acrylic acid = 2050 J/kmol.K

Cp formic acid = 101.3 J/kmol.K

394 394

Ĥi Oxygen = ∫ Cp dT = ∫ A + BT + CT2 + DT3 dT

298 298

298.15 298.1
5 15
= AT + BT2/2 + CT3/3 + DT4/4

= 25.48(394-298) + (1/2) (1.52X10-2) (3942-2982) + (1/3) (-0.7155X10-5)

(3943-2983)+ (1/4) (1.312X10-9) (3944-2984)

= 2873.52 J/kmol.K
394 394

Ĥi Nitrogen ∫ Cp DT = ∫ A + BT + CT2 + DT3 DT

=298
298

298.15
= AT + BT2/2 + CT 3
/3 + DT4/4 298.1
5
=28.90(394-298) + (1/2) (-0.1571X10-2) (3942-2982) + (1/3) (0.8081X10-5)

(3943-2983)+ (1/4) (-2.873X10-9) (3944-2984)

= 2804.05 J/kmol.K
394 394

Ĥi Water = ∫ Cp dT = ∫ A + BT + CT2 + DT3 dT

298 298

298.15
= AT + BT2/2 + CT 3
/3 + DT4/4 298.1
5
=92.053 (394-298) + (1/2) (-3.9953e-2) (3942-2982) + (1/3) (-2.1103e-4)

(3943-2983)+ (1/4) (5.3469e-7) (3944-2984)

= 19302287.84 J/kmol.K
394 394

Ĥi n-butane = 298
∫ Cp DT =∫ A + BT + CT2 + DT3 DT
298

298.15
= AT + BT2/2 + CT 3
/3 + DT4/4 298.1
5
=3.96 (394-298) + (1/2) (37.15X10-2) (3942-2982) + (1/3) (-18.34X10-5)

(3943-2983)+ (1/4) (35X10-9) (3944-2984)

= 10740.43 J/kmol.K

16
Molar flow rate, N Enthalpy, Ĥi
Components
(kmol/h) (kJ/kmol. K)
Nitrogen gas 37.65205 2.804
Oxygen gas 8.757676 2.874
n-butane 1.000877 10.74

Nnitrogen Ĥinitrogen = 105.57

NOxygen ĤiOxygen = 25.169

Nn-butane Ĥin-butane = 10.749

∑Ĥ4 = 141.50
683 683

Ĥo Oxygen = 298
∫ Cp.dT =∫ A + BT + CT2 + DT3 dT
298

298.15
= AT + BT2/2 + CT 3
/3 + DT4/4 298.1
5
= 25.48(683-298) + (1/2) (1.52X10-2) (6832-2982) + (1/3) (-0.7155X10-5)

(6833-2983) + (1/4) (1.312X10-9) (6834-2984)

= 12052.23 J/kmol.K
683 683
Ĥo Nitrogen =∫ Cp.dT =∫ A + BT + CT2 + DT3 dT
298 298

298.15
= AT + BT2/2 + CT 3
/3 + DT4/4 298.1
5
= 28.90 (683-298) + (1/2) (-0.1571X10-2) (68322982)

+(1/3) (0.8081X10-5) (6833-2983) + (1/4) (-2.873X10-9) (6834-2984)

= 11466.33 J/kmol.K
683 683
Ĥo water =∫ Cp.dT = ∫ A + BT + CT2 + DT3 dT
298 298

= AT + BT2/2 + CT
2 3/3 + DT4/4 298.1
9 5
8
.
1 17
5
= 92.053(683-298) + (1/2) (-3.9953e-2) (6832-2982) + (1/3) (-2.1103e-4) (6833-2983) + (1/4)

(5.3469e-7) (6834-2984)

= 251811.59 J/kmol.K
683 683
Ĥo n-butane = ∫ Cp.dT = ∫ A + BT + CT2 + DT3 dT
298 298

298.15
= AT + BT2/2 + CT 3
/3 + DT4/4 298.1
5
= 3.96 (683-298) + (1/2) (37.15X10-2) (6832-2982) + (1/3) (-18.34X10-5) (6833-2983) + (1/4)

(35X10-9) (6834-2984)

= 55654.68 J/kmol.K
683 683
Ĥo carbon monoxide = ∫ Cp.dT =∫ A + BT + CT2 + DT3 dT
298 298

298.15
= AT + BT2/2 + CT 3
/3 + DT4/4 298.1
5
= 28.16(683-298) + (1/2) (0.1675X10-2) (6832-2982) + (1/3) (0.5372X10-5) (6833-2983) + (1/4)

(-2.222X10-9) (6834-2984)

= 11564.55 J/kmol.K
683
683
Ĥo carbon dionoxide = ∫ Cp.dT = ∫ A + BT + CT2 + DT3 dT
298 298
298.15
= AT + BT2/2 + CT 3
/3 + DT4/4 298.1
5
= 22.26 (683-298) +(1/2) (5.98110-2) (6832-2982) + (1/3) (-3.501X10-5) (6833-2983) + (1/4)

(7.469X10-9) (6834-2984)

= 16847.01 J/kmol. K
683
683
Ĥo maleic anhydride = ∫ Cp.dT = ∫ A + BT + CT2 + DT3 dT
298 298

298.15
= AT + BT2/2 + CT 3
/3 + DT4/4 298.1
5
= -3.123 (683-298) + (1/2) (0.08323) (6832-2982) + (1/3) (-5.217X10-5) (6833-2983) + (1/4)

18
(1.156X10-7) (6834-2984)

= 15495.6 J/kmol.K
683 683
Ĥo formic acid =∫ Cp. dT =∫ 101.3 dT
298 298

= 39000.5 298.15
J/kmol.K 298.1
5
683 683

Ĥo acrylic acid =∫ Cp. dT =∫ 2050 dT

298 298

298.15
= 789250 J/kmol.K 298.1
5

Enthalpy, Ĥo
Components Molar flow rate, N
(kJ/kmol.K)
Nitrogen gas 37.65205 11.47
Carbon monoxide 0.204 11.56
Oxygen 5.648 12.05
Carbon dioxide 0.2442 16.85
n-butane 0.178156 55.65
Water 3.3829 251.81
Formic acid 0.001 39.00
Acrylic acid 0.001 789.25
Maleic anhydride 0.7 15.5

Nnitrogen Ĥonitrogen = 431.869

NCarbon monoxide ĤoCarbon monoxide = 2.35824

Noxygen Ĥooxygen = 68.0584

NCarbon dioxide Ĥocarbon dioxide = 4.11477
Nn-butane Ĥon-butane = 9.914381
Nwater Ĥowater = 851.848
Nformic acid Ĥoformic acid = 0.039

19
NAcrylic acid Ĥo Acrylic acid = 0.78925
NMaleic anhydride Ĥo Maleic anhydride = 10.85
∑H5 = 1379.841

Q = Ĥout-Ĥin
Q = 1379.841 - 141.50
≈ - 1238.341 kJ/hour (Exothermic Reaction)

Therefore, the reactor needs to release -1238.341 kJ/hour of heat in order for the process to occur.

Design of a Reactor

Reactant gas can be made to contact solid catalyst in many ways, and each has its specific advantages and
disadvantages. There are two broad types of Reactors.

1. Fluidized Bed Reactor

2. Packed Bed Reactor

Choice of a Reactor

Reactors

Homogeneous Heterogeneous

PLUG Fluidized
C.S.T.R Fixed bed
FLOW bed

The temperature of the reactor is around 4100C due to the highly exothermic reaction involved. At this
temperature the components are in gas phase. Temperature control in the reactor is important and is the key
to the reactor type selection.

20
Fluidized Bed Reactor Fixed Bed Reactor
• Useful when solid particles which are involved • Has the ability to process large volumes of
in reactions must be removed frequently fluid
(online regeneration) • Effective temperature control of larger fixed
• Temperature control is easy as the rate of heat beds is difficult
transfer is relatively higher in fluidized beds • In exothermic reactions hot spots are formed
• Excellent solid gas contact which are bad for catalyst life
• Temperature uniformity • Pressure drop is high
• Low residence time which is more feasible for • Offline regeneration
exothermic reactions
• Vulnerability to large-scale catalyst releases
from explosion venting
• Back mixing

The fluidized bed reactor (FBR) is chosen over the packed bed reactor (PBR) due to several reasons. As
shown in the Tables above, both reactors can be used for multiphase reactions but the FBR have an
advantage of good control of the temperature uniformity, control of the hot spots and online catalyst
regeneration. Fluidized-bed catalytic reactors have been characterized as the workhorses of process
industries. For economical production of large amounts of product, they are usually the first choice,
particularly for gas-phase reactions. Many catalyzed gaseous reactions are amenable to long catalyst life
(1-10 years); and as the time between catalyst changes outs increases, annualized replacement costs decline
dramatically, largely due to savings in shutdown costs. It is not surprising, therefore, that fluidized-bed
reactors now dominate the scene in large scale chemical product manufacture.

We used the Kunii-Levenspiel bubbling bed model to describe reactions in fluidized beds. In this model,
the reactant gas enters the bottom of the bed and flows up the reactor in the form of bubbles. As the bubbles
rise, mass transfer of the reactant gases takes place as they flow (diffuse) in and out of the bubble to contact
the solid particles where the reaction product is formed.

The product then flows back into a bubble and finally exits the bed when the bubble reaches the top of the
bed. The rate at which the reactants and products transfer in and out of the bubble affects the conversion,
as does the time it takes for the bubble to pass through the bed. Consequently, we need to describe the
velocity at which the bubbles move through the column and the rate of transport of gases in and out of the

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bubbles. To calculate these parameters, we need to determine a number of fluid mechanics parameters
associated with the fluidization process.

Fluidized Bed Reactor

It has the ability to:

▪ Process large volumes of fluid.

▪ Deals with heterogeneous (gas-solids) system.
▪ Useful when solid particles which are involved in reactions must be removed frequently.
▪ Temperature control is easy as the rate of heat transfer is relatively higher in fluidized beds.

Assumptions of the Model

▪ All particles are of the same size
▪ Emulsion phase exists at minimum fluidization velocity
▪ Gas void fraction is equal to void fraction at minimum fluidization velocity
▪ Concentration of solids present in emulsion phase is equal to that in the wakes
▪ Order of reaction Is 1

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▪ Rate of change of concentration (w.r.t position) in cloud and emulsion phase is very small

Chemical Reaction
C4H10(g) +3.5 O2(g) → C4H2O3(g)

∆H = -244 kJ at 25°C & 1 atm.

The Catalyst used is the mixed oxides of vanadium and phosphorous.

NAME n-Butane Vanadium phosphorus oxides Nitrogen Oxygen

FORMULA C4H10 V1P1.2OX N2 O2

Reaction Kinetics

• kcat = 8.1048 x 106 exp(-15649/T)

• Oder of reaction: pseudo first order reaction

• Reaction rate = k.CA

Reaction Parameters

1. Umf =minimum fluidization velocity

2. Ut = terminal velocity

3. Εmf = porosity at minimum fluidization

4. U0 = superficial velocity

5. Ub = bubble velocity

6. Db = dimeter of column

7. Kbc = mass transfer coefficient b/w bubble and cloud phase

8. Kce = mass transfer coefficient b/w emulsion and cloud phase

9. H= height of column

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10. W= weight of column

11. Kbc = mass transfer coefficient b/w bubble and cloud phase

12. Kce = mass transfer coefficient b/w emulsion and cloud phase

13. KR = The overall transport coefficient

Design Steps

1. Specify Flow rates, conversion particle size & operating conditions

2. Calculate minimum fluidization and terminal velocity

3. Specify superficial velocity

4. Calculate area and diameter

5. Calculate initial & max bubble diameter

6. Guess height and Calculate bubble diameter

7. Calculate bubble velocity

8. Calculate mass transfer coefficients

9. Calculate KR

10. Calculate height

11. Calculate weight of bed

Design Equation

For Superficial Velocity:

(ψdp)2 [𝑔𝜌𝑐−𝜌𝑔] 3
Umf = 150µ η
(ε mf/1−εmf)

εmf = 0.586ψ−0.72 (µ2/ρgηdp3)0.029(ρg/ρc)0.021

εmf = 0.633

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Umf =0.124 cm/s

Ut = (1.78×10−2η2/ρgµ)1/3(dp)

Ut= 826 cm/s

UT < U0 < Umf

Bubble Velocity & Bubble Diameter:

Ubr= (0.71)gdb1/2

Ubr=136.7

Ub=Ubr+(U0−Umf)

Ub= 145.6

db = dbm − (dbm−dbo )e−0.3h/Dt

db =38.91cm

dbm =0.652[As (U0−Umf )]0.4

dbm =91.53 cm

db0=0.00376(U0−Umf )2

db0 = 0.179 cm

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For Mass Transfer Co-efficient:

Kbc=4.5(umf/db)+5.85(DAB1/2g1/4 /db5/4 )

Kbc=6.91 s-1

Kce=6.77[εmf DABUb /db3 ]1/2

Kce=4.92 s-1

1
KR=𝛾𝑏 + 𝐾𝑐𝑎𝑡 1
+ 1
𝐾𝑏𝑐 𝛾𝑐+ 1 𝐾𝑐𝑎𝑡
+
𝛾𝑒 𝐾𝑐𝑒

KR= 8.64

For Height & Weight of the Column:

h = (Ub /kcatKR )ln(1/1−X)

h = 2.73128 m

W = ρcAch(1−εmf )(1−δ)

W = 13.417 ton

A=Q/ U0

3.357 m2

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Results & Discussions

SPECIFICATION SHEET
Identification

Item Reactor
Item number R-101
Type Fluidized bed reactor

Function

Conversion of Butane to Maleic Anhydride

Reaction Specification

Nature of Reaction Exothermic

Type of Operation Steady State

Type of Process Adiabatic Process

Specified Conversion 70 %

Nature of Catalyst Solid Particles

Design Specification

Operating temperature 410 °C

Operating pressure 275kPa

Design temperature 430 °C

Design pressure 285 kPa

Diameter 1.23 m

Reactor height 2.76 m

weight of catalyst bed 13.417 ton

Area of reactor 3.357 m2

Space Time 683 seconds

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Conclusion

The fundamental point of this report is to assess the ideal structure computations and design plan parameters
of the Fluidized Bed Reactor. This technique enables us to assess the ideal structure geometry and working
states of the reactor framework. The above-mentioned design was optimally enhanced inside the
impediments of the reactor utilized and is displayed above as the most ideal situation as the material and
vitality balance computations. The results are adequate to work the reactor at about 410 degree Celsius and
3 bars approximately with the feed material of butane and air mixture to give Maleic Anhydride as a
noteworthy item. The diameter of the reactor vessel is around 4 feet while the height of the vessel is around
9 feet. The contextual analysis has appeared extensive potential of the vital parameters of the reactor
utilized. The essential point of this report is to assess the ideal design plan estimations and structure
parameters of the Fluidized Bed Reactor. This technique enables us to evaluate the ideal structure geometry
and working states of the reactor framework. The last structure was executional and advanced inside the
impediments of the reactor utilized and is introduced on as the most ideal situation as the material and
energy balance of the reactor. The contextual analysis has appeared extensive potential energy utilizations
of the reactor used.

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References

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