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Product Description
By: Matthew Grisewood
A plug flow reactor is a type chemical reactor which is a tank that has
a pipe-shape, walls coated with a catalyst, and an inlet flow of pure
reactant.
Figure 1: A simple schematic of a plug flow reactor. A reactant is inserted into the tank via the inlet flow.
The reactant is converted to product in the reactor, and the product flows out of the reactor by the
outlet flow.
Reactors are used in the chemical industry for millions of
processes, from the production of high-fructose corn
syrup (HFCS) to the formation of polyester and
everywhere in between. There are many different types of
reactors due to the numerous different factors that can
control the formation of product during the reaction. It is
the responsibility of chemical engineers to run these
reactions so that the amount of product can be
maximized while the cost is minimized.
Figure 2: An interior view of a plug flow reactor. The above diagram approximates what a plug
flow diagram would look like if it were to be sliced in half. The large rectangles show the inner and
outer surfaces of the reactor. The reactants come in through the inlet flow (represented by
squares) and react to form the product (represented by triangles) which is eliminated from the
reactor through the outlet flow. The reaction occurs with the use of a catalyst (represented by
circles), which are attached to the interior wall of the PFR. The actual reactions that are taking
place are represented by double arrows in the reactor. Note that the reactant molecules must
combine with the catalyst molecules at the interior wall of the reactor since the catalyst is not
allowed to move from the wall.
Figure 3: An illustration of mass transfer limitation. In reactor 1 (top), the reactor is not
mass transfer limited because the concentration of the substrate (represented by triangles)
is constant throughout the reactor. However in reactor 2 (bottom), the substrate
concentration is much higher in the bulk than at the surface of the enzyme. The substrate
does not move quickly enough in the reactor, and the reactor is therefore mass transfer
limited.
PFR
Figure 4: Graphical representation of situation when a plug flow reactor is advantageous. Before the substrate
reaches either reactor, the concentration is the same. In a CSTR (thin line), the concentration of the substrate is
immediately diluted to a constant value upon entering the reactor. However, in a PFR (thick line), the concentration
of the substrate goes down slowly. The shaded region shows that a PFR is advantageous because of the period of
time in the reactor when the concentration is higher than the concentration in the CSTR. This value in the shaded
region will exceed the value where the concentration of substrate is lower for a PFR because of the higher values
for the concentration in the reaction rate equation. Therefore, a plug flow reactor is the most advantageous reactor
for most kinetically limited scenarios.