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Principles of Chemical Reactor Analysis and Design: New Tools for Industrial Chemical Reactor Operations, 2nd Edition

Principles of Chemical Reactor Analysis and Design: New Tools for Industrial Chemical Reactor Operations, 2nd Edition

Uzi Mann

ISBN: 978-0-470-38581-4

Mar 2009

460 pages



An innovative approach that helps students move from the classroom to professional practice

This text offers a comprehensive, unified methodology to analyze and design chemical reactors, using a reaction-based design formulation rather than the common species-based design formulation. The book's acclaimed approach addresses the weaknesses of current pedagogy by giving readers the knowledge and tools needed to address the technical challenges they will face in practice.

Principles of Chemical Reactor Analysis and Design prepares readers to design and operate real chemical reactors and to troubleshoot any technical problems that may arise. The text's unified methodology is applicable to both single and multiple chemical reactions, to all reactor configurations, and to all forms of rate expression. This text also . . .

  • Describes reactor operations in terms of dimensionless design equations, generating dimensionless operating curves that depict the progress of individual chemical reactions, the composition of species, and the temperature.
  • Combines all parameters that affect heat transfer into a single dimensionless number that can be estimated a priori.

  • Accounts for all variations in the heat capacity of the reacting fluid.

  • Develops a complete framework for economic-based optimization of reactor operations.

Problems at the end of each chapter are categorized by their level of difficulty from one to four, giving readers the opportunity to test and develop their skills.

Graduate and advanced undergraduate chemical engineering students will find that this text's unified approach better prepares them for professional practice by teaching them the actual skills needed to design and analyze chemical reactors.



Chapter 1: Overview of Chemical Reaction Engineering.

1.1 Classification of Chemical Reactions.

1.2 Classification of Chemical Reactors.

1.3 Phenomena and Concepts.

1.4 Common Practices.

1.5 Industrial Reactors.

1.6 Summary.


Chapter 2: Stoichiometry.

2.1 The Four Contexts of "Chemical Reactions".

2.2 Chemical Formula and Stoichiometic Relations.

2.3 Reaction Extent.

2.4 Independent and Dependent Chemical Reactions.

2.5 Characterization of Reactor Feed.

2.6 Characterization of Reactor Performance.

2.7 Dimensionless Extents.

2.8 Independent Species Specifications.

2.9 Summary.



Chapter 3: Chemical Kinetics.

3.1 Species Formation Rates.

3.2 Rates of Chemical Reactions.

3.3 Rate Expressions of Reaction Rates.

3.4 Effects of Transport Limitations.

3.5 Characteristic Reaction Time.

3.6 Summary.



Chapter 4: Species Balances and Design Equations.

4.1 Macroscopic Species Balances - General Species-based Design Equations.

4.2 Species-based Design Equations of Ideal Reactors.

4.3 Reaction-based Design Equations.

4.4 Dimensionless Design Equations.

4.5 Summary.



Chapter 5: Energy Balances.

5.1 Review of Thermodynamic Relations.

5.2 Energy Balances.

5.3 Summary.



Chapter 6: Ideal Batch Reactor.

6.1 Design Equations and Auxiliary Relations.

6.2 Isothermal Operations with Single Reactions.

6.3 Isothermal Operations with Multiple Reactions.

6.4 Non-Isothermal Operations.

6.5 Summary.


Chapter 7: Plug Flow Reactor.

7.1 Design Equations and Auxiliary Relations.

7.2 Isothermal Operations with Single Reactions.

7.3 Isothermal Operations with Multiple Reactions.

7.4 Non-Isothermal Operations.

7.5 Effects of Pressure Drop.

7.6 Summary.


Chapter 8: Continuous Stirred Tank Reactor (CSTR).

8.1 Design Equations and Auxiliary Relations.

8.2 Isothermal Operations with Single Reactions.

8.3 Isothermal Operations with Multiple Reactions.

8.4 Non-Isothermal Operations.

8.5 Summary.


Chapter 9: Other Reactor Configurations.

9.1 Semi-Batch Reactors.

9.2 Plug-Flow Reactor with Distributed Feed.

9.3 Distillation Reactor.

9.4 Recycle Reactor.

9.5 Summary.


Chapter 10: Economic-Based Optimization of Reactor Operations.

10.1 Economic Objective Functions.

10.2 Batch and Semi-Batch Reactors.

10.3 Flow Reactors.

10.4 Summary.



Appendix A: Summary of Key Relationships.

Appendix B: Microscopic Species Balances - Continuity Equations.

Appendix C: Summary of Numerical Methods.


  • A unified, systematic, generic approach to design chemical reactors with multiple reactions.
  • Capability to formulate the design of any reactor configuration with any number of chemical reactions having any stoichiometry and any form of rate expression.
  • Reactor operations are described by dimensionless variables (in most cases, between -1 and 1) and dimensionless design equations.
  • The design is formulated in terms of the smallest number of design equations and the least number of terms in each equation; hence, the most robust formulation.
  • Solutions of the design equations provide dimensionless operating curves (a new concept in CRE).
  • These curves provide complete information on the progress of the chemical reactions, the formation (or depletion) of all individual species, and changes in temperature (see example on next page). Reactor sizing represents a "point" on these curves (similar to the way a "point" on dimensionless friction factor versus Reynolds number charts is used).
  • New design capabilities for reactor configurations whose design equations are not available in the literature (semi-batch reactor, filling reactor, plug-flow reactor with distributed feed, distillation reactor, etc.).
  • A framework for new economic-based optimization tools for chemical reactor operations, and for analyzing integrated chemical processes.