Process Technology Equipment Chapter 16 Reactors
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CHAPTER 16 Reactors
Table of Contents
Contents
Page
Chapter Overview
2
Class Preparation Checklist
2
Chapter Objectives
2
Agenda
3
Lesson Plan
4
16.1 Types of Reactors
6
16.2 Components of Reactors
8
16.3 Auxiliary Equipment Associated with Reactors
16.4 Operating Principles
16.5 Potential Problems
16.6 Safety and Environmental Hazards
16.7 Process Technician’s Role
9
9
10
12
12
Summary and Wrap-Up
13
Suggested Student Activities
14
End of Chapter Review Questions
14
Clicker Questions
Appendix
23
26
Process Technology Equipment Chapter 16 Reactors
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CHAPTER 16 Reactors
Chapter Overview
Reactors are vessels in which chemical reactions are initiated and sustained. Within a
reactor, raw materials are combined at various flow rates, pressures, and temperatures,
and then reacted to form a product. These reactions can be batch reactions or
continuous.
In the process industries, reactors come in many shapes and sizes. The most common
types of reactors, however, are stirred tank, fixed bed, fluidized bed, tubular, and
reaction furnace. The factors that determine which type of reactor will be used are the
type of catalyst and the properties of the reactants.
Class Preparation Checklist
1.
Familiarize yourself with the chapter content.
2.
Bring cutaways or other hands-on teaching aids if available.
3.
Copy and distribute any fill-in-the-blank handouts for today’s content.
4.
Safety Minute prepared or assigned
5.
Review the PowerPoint slides associated with this chapter (if used) and
make sure that your computer is correctly set up to navigate the slide deck
smoothly.
6.
Request the appropriate A/V equipment (if needed) and make sure that
your computer is correctly synched with the projector to avoid any delays in
the classroom.
Chapter Objectives
16.1 Identify the purpose, common types, and applications of reactors (NAPTA
Reactors).
16.2 Identify the components of reactors and the purpose of each (NAPTA
Reactors).
16.3 Identify auxiliary equipment associated with reactors (NAPTA Reactors).
16.4 Explain the operating principles of reactors (NAPTA Reactors).
16.5 Identify potential problems associated with reactors (NAPTA Reactors).
16.6 Describe safety and environmental hazards associated with reactors
(NAPTA Reactors).
16.7 Describe the process technician’s role in reactor operation and
maintenance. (NAPTA Reactors).
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Class Agenda
Activity
Minutes
PPTs
Handouts
(title, if any)
1. Welcome to Class
1
2. Introduction and Agenda
2
3. Safety Minute
3
4. Objectives
4
5. Objectives (cont.)
5
6. Terms
6
7. Terms (cont.)
7
8. Types of Reactors
8
9. Stirred Tank Reactor
9
10. Tubular Reactor
10
11. Fixed Bed Reactor
11
12. Fluidized Bed Reactor
12
13. Nuclear Reactor
13
14. Components of Reactors
14
15. Reactor Systems
15
16. Auxiliary Equipment
16
17. Auxiliary Equipment (cont.)
17
18. Operating Principles
18
19. Potential Problems
19
20. Potential Problems (cont.)
20
21. Safety and Environmental Hazards
21
22. Process Technician’s Role
22
23. Process Technician’s Role (cont.)
23
24. Summary and Wrap-Up
24
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Chapter 16 Lesson Plan
Welcome Everyone to Class
Time: 1 minute
Resources: Slide 1
Introduction and Agenda
Time: 1 minute
Resources: Slide 2
Student Safety Minute
Time: 1 minute
Resources: Slide 3
Objectives
Time: 1 minute
Resources: Slide 4
well.
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Objectives (cont.)
Time: 1 minute
Resources: Slide 5
Terms
Time: 2 minutes
Resources: Slide 6
Terms (cont.)
Time: 2 minutes
Resources: Slide 7
Sample Instructor Script:
Process Technology Equipment Chapter 16 Reactors
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• Sparger
• Stirred tank reactor
• Temperature control system
• Tubular reactor
• Vessel heads
16.1 Types of Reactors
Time: 2 minutes
Resources: Slide 8
16.1.1 Stirred Tank Reactors
Time: 2 minutes
Resources: Slide 9
16.1.2 Tubular Reactor
Time: 2 minutes
Resources: Slide 10
Sample Instructor Script:
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A tubular reactor is composed of one or more pipes or tubes in which reactants flow and
a chemical reaction takes place. Tubular reactors may be required if the reaction must
occur quickly.
16.1.3 Fixed Bed Reactor
Time: 2 minutes
Resources: Slide 11
16.1.4 Fluidized Bed Reactor
Time: 2 minutes
Resources: Slide 12
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16.1.5 Nuclear Reactor
Time: 2 minutes
Resources: Slide 13
Sample Instructor Script:
Nuclear reactors are high-temperature and high-pressure reactors used to generate the
steam necessary to produce electricity. Instead of a chemical reaction (such as burning
coal), a nuclear reaction (splitting uranium atoms through fission) is used to produce
heat. The reactor, its components, and the water pumped through the reactor control
the nuclear chain reaction and carry away the heat generated.
Commercial nuclear reactors in the United States can be divided into two groups:
boiling water reactors and pressurized water reactors. The classification of the reactor
depends on whether the reactor coolant is used directly or indirectly.
The fuel rods in a nuclear reactor typically last from 18 to 24 months. After that, about
one-third of the fuel rods are replaced with fresh fuel rods, and the remaining rods are
rearranged so that they are consumed more evenly. The spent nuclear fuel is very
radioactive, so it must be shielded at all times.
16.2 Components of Reactors
Time: 3 minutes
Resources: Slide 14
Sample Instructor Script:
While different reactor types consist of various components, some of the main
components include a shell, vessel heads, an agitator, baffles, a tank, a mixing system,
a heating and cooling system, and a relief system.
The shell is the outer surface, casing, or external covering of a vessel, consisting of side
walls, vessel heads, and a discharge area.
The side walls of a reactor vessel contain the pressure inside the reactor. The vessel
heads are the components at the top and bottom of the shell that enclose it. Nozzles
welded onto the shell and heads are used for a variety of purposes, such as attaching
piping for flow into and out of the reactor, providing a location for instrumentation
connections, and connecting auxiliary equipment.
16.2.1 Reactor Systems
Time: 2 minutes
Resources: Slide 15
Other systems associated with reactor systems are as follows:
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16.3 Auxiliary Equipment
Time: 3 minutes
Resources: Slide 16
16.3.1 Auxiliary Equipment (cont.)
Time: 2 minutes
Resources: Slide 17
16.4 Operating Principles
Time: 2 minutes
Resources: Slide 18
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16.5 Potential Problems
Time: 3 minutes
Resources: Slide 19
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16.5.1 Potential Problems (cont.)
Time: 3 minutes
Resources: Slide 20
Sample Instructor Script:
Other potential problems include:
• Loss of mixing system: Loss of a mixing system component will have a
negative effect on reactor product quality and yield.
• Instrumentation failure: The consequences associated with instrumentation
failure can have a significant impact on both the quality and quantity of the
product, as well as equipment reliability and plant operating costs.
Process Technology Equipment Chapter 16 Reactors
16.6 Safety and Environmental Hazards
Time: 3 minutes
Resources: Slide 21
Sample Instructor Script:
In addition, personal protective equipment (PPE) should be worn during normal and
abnormal reactor operations. In addition to basic PPE (gloves, safety shoes and
glasses, hard hat, hearing protection, and flame-resistant clothing), additional PPE may
be required, including the following:
16.7 Process Technician’s Role
Time: 3 minutes
Resources: Slide 22
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16.7.1 Process Technician’s Role (cont.)
Time: 2 minutes
Resources: Slide 23
Sample Instructor Script:
Process technicians must always listen for any abnormal noises.
Process technicians must always check for the following:
• Excessive equipment vibration
• Excessive heat on motorized equipment
• Leaks of any kind
• Reactor products
Summary and Wrap–Up
Time: 3 minutes
Resources: Slide 24
Sample Instructor Script:
Let’s summarize today’s lesson and consider what we will be doing in the next class.
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Suggested Student Activities
End of Chapter Review Questions
(Note to Instructor: If you have time, you can use these questions to test your
students’ knowledge of the content presented in this chapter.)
1. What type of reactor can be used for both batch and continuous reaction
processes?
A. Tubular reactor
B. Fixed bed reactor
C. Stirred tank reactor
D. Fluidized bed reactor
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2. What type of reactor is widely used in the chemical industry to produce
materials like polyester and ammonia?
A. Tubular reactor
B. Fixed bed reactor
C. Stirred tank reactor
D. Fluidized bed reactor
3. What type of reactor has a stationary catalyst bed?
A. Tubular reactor
B. Fixed bed reactor
C. Stirred tank reactor
D. Fluidized bed reactor
4. What type of reactor contains one or more mixers or agitators mounted on a
shaft inside the tank?
A. Tubular reactor
B. Fixed bed reactor
C. Stirred tank reactor
D. Fluidized bed reactor
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5. Which of the following is an example of a fluidized bed reactor?
A. Hyrdotreating reactor
B. Fluid catalytic cracking reactor
C. Steam methane reformer reactor
D. Sulfuric acid alkylation reactor
6. Which of the following is an example of a stirred tank reactor?
A. Hydrotreating reactor
B. Fluid catalytic cracking reactor
C. Steam methane reformer reactor
D. Sulfuric acid alkylation reactor
7. What happens to the reaction rate when the temperature increases?
A. Reaction rate increases