Front Matter
Preface to the First Edition
Preface to Second Edition
Table of Contents
1. Reactor Design - General Principles
1.1 Basic Objectives in Design of a Reactor
1.2 Classification of Reactors and Choice of Reactor Type
1.2.1 Homogeneous and Heterogeneous Reactors
1.2.2 Batch Reactors and Continuous Reactors
1.2.3 Variations in Contacting Pattern - Semi-Batch Operation
1.2.4 Influence of Heat of Reaction on Reactor Type
1.2.4.1 Adiabatic Reactors
1.2.4.2 Reactors with Heat Transfer
1.2.4.3 Autothermal Reactor Operation
1.3 Choice of Process Conditions
1.3.1 Chemical Equilibria and Chemical Kinetics
1.3.2 Calculation of Equilibrium Conversion
1.3.3 Ultimate Choice of Reactor Conditions
1.4 Chemical Kinetics and Rate Equations
1.4.1 Definition of Reaction Rate, Order of Reaction and Rate Constant
1.4.2 Influence of Temperature. Activation Energy
1.4.3 Rate Equations and Reaction Mechanism
1.4.4 Reversible Reactions
1.4.5 Rate Equations for Constant-Volume Batch Reactors
1.4.6 Experimental Determination of Kinetic Constants
1.5 General Material and Thermal Balances
1.6 Batch Reactors
1.6.1 Calculation of Reaction Time; Basic Design Equation
1.6.2 Reaction Time - Isothermal Operation
1.6.3 Maximum Production Rate
1.6.4 Reaction Time - Non-Isothermal Operation
1.6.5 Adiabatic Operation
1.7 Tubular-Flow Reactors
1.7.1 Basic Design Equations for a Tubular Reactor
1.7.2 Tubular Reactors - Non-Isothermal Operation
1.7.3 Pressure Drop in Tubular Reactors
1.7.4 Kinetic Data from Tubular Reactors
1.8 Continuous Stirred-Tank Reactors
1.8.1 Assumption of Ideal Mixing. Residence Time
1.8.2 Design Equations for Continuous Stirred-Tank Reactors
1.8.3 Graphical Methods
1.8.4 Autothermal Operation
1.8.5 Kinetic Data from Continuous Stirred-Tank Reactors
1.9 Comparison of Batch, Tubular and Stirred-Tank Reactors for a Single Reaction. Reactor Output
1.9.1 Batch Reactor and Tubular Plug-Flow Reactor
1.9.2 Continuous Stirred-Tank Reactor
1.9.3 Comparison of Reactors
1.10 Comparison of Batch, Tubular and Stirred-Tank Reactors for Multiple Reactions. Reactor Yield
1.10.1 Types of Multiple Reactions
1.10.2 Yield and Selectivity
1.10.3 Reactor Type and Backmixing
1.10.4 Reactions in Parallel
1.10.5 Reactions in Parallel - Two Reactants
1.10.6 Reactions in Series
1.10.6.1 Batch Reactor or Tubular Plug-Flow Reactor
1.10.6.2 Continuous Stirred-Tank Reactor - One Tank
1.10.6.3 Reactor Comparison and Conclusions
1.10.7 Reactions in Series - Two Reactants
References
Nomenclature
2. Flow Characteristics of Reactors - Flow Modelling
2.1 Non-Ideal Flow and Mixing in Chemical Reactors
2.1.1 Types of Non-Ideal Flow Patterns
2.1.2 Experimental Tracer Methods
2.1.3 Age Distribution of a Stream Leaving a Vessel - E-Curves
2.1.4 Application of Tracer Information to Reactors
2.1.4.1 Direct Application of Exit Age Distribution
2.1.4.2 Macromixing and Micromixing
2.1.4.3 Significance of Linear and Non-Linear Processes
2.1.4.4 Occurrence of Micromixing in Flow Reactors
2.2 Tanks-in-Series Model
2.3 Dispersed Plug-Flow Model
2.3.1 Axial Dispersion and Model Development
2.3.2 Basic Differential Equation
2.3.3 Response to an Ideal Pulse Input of Tracer
2.3.4 Experimental Determination of Dispersion Coefficient from a Pulse Input
2.3.5 Further Development of Tracer Injection Theory
2.3.6 Values of Dispersion Coefficients from Theory and Experiment
2.3.7 Dispersed Plug-Flow Model with First-Order Chemical Reaction
2.3.8 Applications and Limitations of the Dispersed Plug-Flow Model
2.4 Models Involving Combinations of the Basic Flow Elements
References
Nomenclature
3. Gas-Solid Reactions and Reactors
3.3.6 Catalyst De-Activation and Poisoning
3.4 Mass Transfer from a Fluid Stream to a Solid Surface
3.5 Chemical Kinetics of Heterogeneous Catalytic Reactions
3.5.1 Adsorption of a Reactant as the Rate Determining Step
3.5.2 Surface Reaction as the Rate Determining Step
3.5.3 Desorption of a Product as the Rate Determining Step
3.5.4 Rate Determining Steps for other Mechanisms
3.5.5 Examples of Rate Equations for Industrially Important Reactions
3.6 Design Calculations
3.6.1.2 Dispersion in Packed Bed Reactors
3.6.2 Thermal Characteristics of Packed Reactors
3.6.2.1 Sensitivity of Countercurrent Cooled Reactors
3.6.2.2 The Autothermal Region
3.6.2.3 Stability of Packed-Bed Tubular Reactors
3.6.3 Fluidised Bed Reactors
3.7 Gas-Solid Non-Catalytic Reactors
3.7.1 Modelling and Design of Gas-Solid Reactors
3.7.2 Single Particle Unreacted Core Models
3.7.3 Types of Equipment and Contacting Patterns
References
Nomenclature
4. Gas-Liquid and Gas-Liquid-Solid Reactors
4.1 Gas-Liquid Reactors
4.1.1 Gas-Liquid Reactions
4.1.2 Types of Reactors
4.1.3 Equations for Mass Transfer with Chemical Reaction
4.1.4 Choice of a Suitable Reactor
4.1.5 Information Required for Gas-Liquid Reactor Design
4.1.6 Examples of Gas-Liquid Reactors
4.1.6.1 Packed Column Reactors
4.1.6.2 Agitated Tank Reactors: Flow Patterns of Gas and Liquid
4.1.6.3 Well-Mixed Bubble Column Reactors: Gas-Liquid Flow Patterns and Mass Transfer
4.1.7 High Aspect-Ratio Bubble Columns and Muitiple-lmpeller Agitated Tanks
4.1.8 Axial Dispersion in Bubble Columns
4.1.9 Laboratory Reactors for Investigating the Kinetics of Gas-Liquid Reactions
4.1.9.1 Types of Laboratory Gas-Liquid Reactors
4.1.9.2 Laboratory Reactors with Controlled Gas-Liquid Mass Transfer Characteristics
4.1.9.3 Reactors Eliminating Gas-Liquid Mass Transfer Resistance
4.2 Gas-Liquid-Solid Reactors
4.2.1 Gas-Liquid-Solid Reactions
4.2.2 Mass Transfer and Reaction Steps
4.2.3 Gas-Liquid-Solid Reactor Types: Choosing a Reactor
4.2.4 Combination of Mass Transfer and Reaction Steps
4.2.4.1 Suspended-Bed Reactor
4.2.4.2 Three-Phase Fluidised Suspended-Bed Reactor - Combination of Mass Transfer and Reaction Steps
4.2.4.3 Trickle-Bed Reactor - Combination of Mass Transfer and Reaction Steps
4.2.4.4 Trickle-Bed Reactor - Simplified Steady State Treatment
4.2.4.5 Calculation Using Simplified Steady State Treatment
References
5. Biochemical Reaction Engineering
5.4.5 The Significance of Kinetic Constants
5.4.6 The Haldane Relationship
5.4.7 Transformations of the Michaelis-Menten Equation
5.4.8 Enzyme Inhibition
5.4.9 The Kinetics of Two-Substrate Reactions
5.4.9.1 Single Displacement Reactions
5.4.9.2 Double Displacement Reactions
5.4.9.3 Kinetic Constant Determination
5.4.9.4 The Alberty Equation
5.4.10 The Effects of Temperature and pH on Enzyme Kinetics and Enzyme De-Activation
5.4.11 Enzyme De-Activation
5.5 Metabolism
5.5.1 The Roles of Metabolism
5.5.1.1 The Synthesis of Materials for Cell Structure
5.5.1.2 The Generation of Energy for Growth, and for Chemical and Mechanical Work
5.5.2 Types of Reactions in Metabolism
5.5.2.1 Catabolic Metabolism
5.5.2.2 Anabolic Metabolism
5.5.2.3 Intermediary Metabolism
5.5.2.4 Primary and Secondary Metabolism
5.5.3 Energetic Aspects of Biological Processes
5.5.4 Energy Generation
5.5.5 Substrate Level Phosphorylation
5.5.6 Aerobic Respiration and Oxidative Phosphorylation
5.5.6.1 Carbon Flow and the Generation of Reducing Power in Oxidative Phosphorylation
5.5.6.2 The Respiratory Chain
5.5.6.3 Electron Transport Processes Linked to Phosphorylation
5.5.6.4 Energy Efficiency of Aerobic Respiration Oxidative Phosphorylation
5.5.6.5 Energy Capture and Electron Transport Processes
5.5.7 Photosynthesis
5.6 Strain Improvement Methods
5.6.1 Mutation and Mutagenesis
5.6.2 Genetic Recombination in Bacteria
5.6.3 Genetic Engineering
5.6.4 Recombinant DNA Technology
5.6.5 Genetically Engineered Products
5.7 Cellular Control Mechanisms and Their Manipulation
5.7.1 The Control of Enzyme Activity
5.7.2 The Control of Metabolic Pathways
5.7.2.1 Regulatory Enzymes
5.7.2.2 Allosteric Enzymes and the Regulation of Biosynthetic Pathways
5.7.2.3 Kinetics of Allosteric Enzymes
5.7.2.4 Covalent Modulated Enzymes
5.7.2.5 Iso-Enzymes
5.7.3 The Control of Protein Synthesis
5.8 Stoichiometric Aspects of Biological Processes
5.9 Microbial Growth
5.10 Immobilised Biocatalysts
5.10.2 Effect of Internal Diffusion Limitation
5.11 Reactor Configurations
5.12 Estimation of Kinetic Parameters
5.13 Non-Steady State Microbial Systems
5.14 Further Design Considerations
5.15 Appendices
Appendix 5.1 Proteins
Appendix 5.2 Nucleic Acids
Appendix 5.3 Derivation of the Michaelis-Menten Equation Using the Rapid Equilibrium Assumption
Appendix 5.4 The Haldane Relationship
Appendix 5.5 Enzyme Inhibition
Appendix 5.6 Information Storage and Retrieval in the Cell
References
Nomenclature
6. Sensors for Measurement and Control
6.3.5 Vacuum Sensing Devices
6.4 The Measurement of Temperature
6.5 The Measurement of Level
6.5.1 Simple Float Systems
6.5.2 Techniques Using Hydrostatic Head
6.5.3 Capacitive Sensing Elements
6.5.4 Radioactive Methods Nucleonic Level Sensing
6.5.5 Other Methods of Level Measurement
6.6 The Measurement of Density Specific Gravity
6.7 The Measurement of Viscosity
6.7.1.3 Measurement of the Torque Exerted on a Stationary Surface by an Adjacent Moving Surface
6.7.1.4 By the Reaction of a Vibrating Element Immersed in the Liquid
6.7.2 Continuous On-Line Measurement of Viscosity
6.8 The Measurement of Composition
6.8.1 Photometric Analysers
6.8.2 Electrometric Analysers
6.8.2.1 Conductivity Cells
6.8.2.2 pH Measurement and other Ion Selective Electrodes
6.8.2.3 ORP Redox Sensors
6.8.2.4 Polarographic Sensors
6.8.2.5 High Temperature Ceramic Sensors Zirconia Cells
6.8.3 The Chromatograph as an On-Line Process Analyser
6.8.4 The Mass Spectrometer
6.8.5 Thermal Conductivity Sensors for Gases
6.8.6 The Detection of Water
6.8.7 Other Methods of Gas Composition Measurement
6.9 Process Sampling Systems
6.10 The Static Characteristics of Sensors
6.10.1 Definitions
6.10.1.1 Range
6.10.1.2 Span
6.10.1.3 Turndown
6.10.1.4 Sensitivity
6.10.1.5 Resolution
6.10.1.6 Repeatability
6.10.1.7 Accuracy Precision, Bias and Measurement Error
6.10.1.8 Threshold
6.10.1.9 Dead Band, Dead Space, Dead Zone
6.10.1.10 Scale Readability
6.10.1.11 Zero Shift Zero Error
6.11 Signal Conditioning
6.11.1 Bridge Circuits
6.11.2 Amplifiers
6.11.3 Signals and Noise
6.11.4 Filters
6.11.5 Converters
6.11.5.2 Digital to Analog D/A Conversion
6.11.6 Loading Effects
6.12 Signal Transmission Telemetry
6.12.1 Multiplexers Time Division Multiplexing
6.12.2 Serial Digital Signals
6.12.3 The Transmission of Analog Signals
6.12.4 Non-Electrical Signal Transmission
6.12.5 Smart Transmitters and Associated Protocols - Intelligent Hardware
References
Nomenclature
7. Process Control
7.1 Introduction
7.2 Feedback Control
7.3 Qualitative Approaches to Simple Feedback Control System Design
7.4 The Transfer Function
7.4.1 Linear Systems and the Principle of Superposition
7.4.2 Block Diagram Algebra
7.4.3 The Poles and Zeros of a Transfer Function
7.5 Transfer Functions of Capacity Systems
7.5.1 Order of a System
7.5.2 First-Order Systems
7.5.3 First-Order Systems in Series
7.5.4 Second-Order Systems
7.6 Distance-Velocity Lag Dead Time
7.7 Transfer Functions of Fixed Parameter Controllers
7.8 Response of Control Loop Components to Forcing Functions
7.8.1 Common Types of Forcing Function
7.8.1.1 The Step Function
7.8.1.2 The Sinusoidal Function
7.8.1.3 The Pulse Function
7.8.2 Response to Step Function
7.8.3 Initial and Final Value Theorems
7.8.4 Response to Sinusoidal Function
7.8.4.2 The Substitution Rule
7.8.4.3 Second-Order Systems
7.8.4.4 Distance-Velocity Lag
7.8.5 Response to Pulse Function
7.8.6 Response of More Complex Systems to Forcing Functions
7.9 Transfer Functions of Feedback Control Systems
7.9.1 Closed-Loop Transfer Function between C and R
7.9.2 Closed-Loop Transfer Function between C and U
7.9.3 Calculation of Offset from the Closed-Loop Transfer Function
7.9.4 The Equivalent Unity Feedback System
7.9.4.1 Conversion to Unity Feedback When the Transfer Function in the Feedback Part of the Loop is Represented by a Steady-State Gain K
7.9.4.2 Conversion to Unity Feedback When the Dynamics of the Feedback Part of the Loop are Significant
7.10 System Stability and the Characteristic Equation
7.10.1 The Characteristic Equation
7.10.2 The Routh-Hurwitz Criterion
7.10.3 Destabilising a Stable Process with a Feedback Loop
7.10.4 The Bode Stability Criterion
7.10.5 The Nyquist Stability Criterion
7.10.6 The Log Modulus Nichols Plot
7.11 Common Procedures for Setting Feedback Controller Parameters
7.11.1 Frequency Response Methods
7.11.2 Process Reaction Curve Methods
7.11.3 Direct Search Methods
7.12 System Compensation
7.12.2 Series Compensation
7.12.2.1 Lead Compensation
7.12.2.2 Lag Compensation
7.12.2.3 Lag-Lead Compensation
7.13 Cascade Control
7.14 Feed-Forward and Ratio Control
7.15 MIMO Systems - Interaction and Decoupling
7.15.1 Interaction between Control Loops
7.15.2 Decouplers and Their Design
7.15.3 Estimating the Degree of Interaction between Control Loops
7.16 Non-Linear Systems
7.17 Discrete Time Control Systems
7.17.1 Sampled Data Discrete Time Systems
7.17.2 Block Diagram Algebra for Sampled Data Systems
7.17.3 Sampled Data Feedback Control Systems
7.17.4 Hold Elements Filters
7.17.5 The Stability of Sampled Data Systems
7.17.6 Discrete Time Digital Fixed Parameter Feedback Controllers
7.17.7 Tuning Discrete Time Controllers
7.17.8 Response Specification Algorithms
7.18 Adaptive Control
7.18.1 Scheduled Programmed Adaptive Control
7.18.2 Model Reference Adaptive Control MRAC
7.18.3 The Self-Tuning Regulator STR
7.19 Computer Control of a Simple Plant - The Operator Interface
7.19.1 Direct Digital Control DDC and Supervisory Control
7.19.2 Real Time Computer Control
7.19.2.1 Clock Based Operations
7.19.2.2 Sensor Based Operations
7.19.2.3 Interactive Systems
7.19.3 System Interrupts
7.19.4 The Operator/ Controller Interface
7.20 Distributed Computer Control Systems DCCS
7.20.1 Hierarchical Systems
7.20.2 Design of Distributed Computer Control Systems
7.20.3 DCCS Hierarchy
7.20.3.1 Level One
7.20.3.2 Level Two
7.20.3.3 Level Three
7.20.3.4 Level Four
7.20.3.5 Level Five
7.20.4 Data Highway DH Configurations
7.20.5 The DCCS Operator Station
7.20.6 System Integrity and Security
7.20.7 SCADA Supervisory Control and Data Acquisition
7.21 The Programmable Controller
7.22 Regulators and Actuators Controllers and Control Valves
7.22.1 Electronic Controllers
7.22.2 Pneumatic Controllers
7.22.3 The Control Valve
7.22.3.1 The Actuator
7.22.3.2 The Valve Positioner
7.22.3.3 Valve Body and Valve Trim
7.22.3.4 Control Valve Characteristics
7.22.4 Intelligent Control Valves
Appendices
References
Nomenclature
Conversion Factors for Some Common SI Units
Prefaces
Problems
Index
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z