The General Designing Specs of Packed Bed Reactor. The Presentation Highlights 50 TPD H2SO4 Sulpur Converter i presented during Graduation. Aspen hysys is Also used to check pressure drop in a reactor

1. Designing of a Packed Bed
Reactor For So2 to So3
Conversion for H2SO4
Manufacturing
NAME : RIZWAN YASEEN
ROLL NO : RP15-CE - #31
I.C.E.T PUNJAB UNIVERSITY

2. Table of Contents
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 Introduction .
 Case Study (Akbari Chemicals ).
 Chemical Kinetics of Reaction .
 Rate Equation .
 Material Balance over Reactor .
 Designing of SO2 converter .
 Rate of Reaction for specific Conversion .
 Weight of catalyst .
 Hight and Dia of Reactor and Bed Hight.
 Pressure Drop in Reactor .
 Rating of a Packed Bed Reactor for Optimal Conditions.

3. Capacity : 50 ton/day
Manufacturing Process : Contact Process
Raw material : Elemental Sulphur
Reactor : Packed Bed
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4. 4
Chemical Kinetics of Reaction
 Oxidation of sulfur dioxide to sulfur trioxide over supported vanadia catalysts Joseph P.
Dunn, Prashanth R. Koppula, Harvey G. Stenger, Israel E. Wachs*
 Study showed that only one site is required for So2 Oxidation
 Activation Energy is approximately 20.18kj/kmole for Vanadia Catalyst.
 The oxidation of SO2 is an exothermic reaction with fast reaction kinetics and high reaction
enthalpy (-99 kJ/mol).
 kinetics are generally limited by heat and mass transfers, it is thus imperative to take into
account the parameter temperature.

5. Rate Limiting Step
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The simultaneous External and internal Diffusion was
investigated by laboratory of Engineering Process and
Industrial System (LR GPSI), National School of
Engineers of Gabes (ENIG), University of Gabes (UG),
 Th external film Mass resistance
is investigated with respect to
observe rate and it was negligible
i.e. 0.15
 The Concentration of So2 on
surface is 6.2610-5 so Surface
reaction is also not limited no
pore internal diffusion limited
 Study Shows that desorption step
of intrinsic kinetics is rate
limiting step

6. Rate Equation :
 The Rate Equation Suits best for Oxidation of So2 is

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 Where Pi is the Partial pressure of Species k and Kp are rate and
Equilibrium Constants

7.  Material Balance Over Reactor
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Reactants Products
Nso2 = 21.90 Kmole
No2 = 43.819 kmole
NN2 = 247.81 kmole

8. Operating Conditions :
Pressure Inside Reactor = 2 atm
Temperature (isothermal) = 600◦C
KP = 7.86 atm1/2
kc = 7.53 × 10-5
Rate = 0.000516
Designing of PFR
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




9.  Weight of catalyst = 230 lbs
Volume of Catalyst= 4259 ft3
Volume of catalyst Bed = 7744 ft3
Assume Bed Porosity = 0.45
Diameter Bed = 15.35 ft
Height of Bed= 38.07 ft
Designing of PFR
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Height Reactor= 43.7 ft

10. Volume of Reactor = 7722 ft 3
Volume per tube = 0.843 ft3
No of Tubes = 5052 tubes
Cross Sectional Area= 2210 ft2
Designing of PFR

11. Pressure Drop Across Reactor
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Po = 2 atm Pfinal = 1.78 atm
Pressure Drop = 0.22 atm or 3.236PSI
The values used here are in British Engineering System

12. Rating of a PFR
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13. Ratings of PFR
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14.  Tube Dimensions
and Bed
Porosity(Optimal)
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15.  Attempt to Reduce Void
age for greater Solid gas
Contact
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16. Performance of Reactor
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17. Thank You
 Questions/Answers ?
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