Instructor: Dr. Michael .F. Cunningham

Course Outline

1. Introduction to concepts of scaleup and course objectives.

2. Selection of reactor types

                        - based on vessel type / flow streams

                        - based on phases present in reactor (number and type of each phase)

3. Goals in reactor selection

4. Flow patterns and residence time distributions (RTDs) in chemical reactors

                        - overview

                        - functions used to characterize RTDs

                        - coupling of reaction kinetics with RTDs; evaluation and integration

                        - effects of micromixing/macromixing

                        - closed and open systems

                        - measuring RTDs

                        - analytical distribution functions (single reactors, tanks in series)

                        - laminar flow models

- axial dispersion models (coupling of reactions kinetics and fluid mechanics/momentum transfer)

                        -  summary of scaleup considerations

5. Mixing in chemical reactors

- characterizing “goodness” of mixing (scale of segregation, intensity of segregation)

                        - more on macromixing versus micromixing

                        - coupled effects of diffusion (mixing) and chemical reaction

6. Scaling up mixing processes

                        - concepts of geometric, kinematic, dynamic similarity

- selection and use of dimensionless numbers to quantify important mixing parameters and characteristics

                        - different types of agitation and agitators

                        - overview and guidelines for approaching scaleup of mixing proceses

7. Fermentation processes

8. Environmental concerns in the scaleup of laboratory chemical processes

There are two assignments and a major project.

 Assignment 1 gives you the opportunity to work with a pilot scale reactor (2 gallon) that is very similar in design to larger vessels. You will learn how to experimentally determine a heat transfer coefficient under various mixing conditions. This will give you insight into the effects of coupled heat transfer and mass transfer.

Assignment 2 gives you experience in measuring residence time distributions for two types of continuous reactors (stirred tank, tubular) under different mixing and flow rate conditions respectively. You will learn how to interpret the response curves, and translate them into the appropriate type of residence time distribution function. This exercise provides insight into the effects of coupled momentum transfer and mass transfer.

The major project involves design and comparative assessment of different reactor types (batch and continuous). You will simulate complex reaction kinetics, accounting for heat effects and residence time distributions. The project has been designed to provide experience in developing the skills and knowledge to treat the coupling of chemical reactions with transport phenomena (mass transfer (mixing, diffusion), momentum transfer (fluid mechanics, as characterized by the residence time distribution) and heat transfer).