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  • Sunday, 29 June 2025

    Design of a Mixed Flow Reactor / Continuous Stirred Tank Reactor

    Hello All, Hope everyone doing good ....!!!

    Welcome back to PharmaCalculations.com! After our detailed discussion on Plug Flow Reactor (PFR) design, let’s now explore the design of another commonly used reactor type in pharmaceutical and chemical process industries — the Mixed Flow Reactor (MFR), also known as Continuous Stirred Tank Reactor (CSTR).

    This post will walk you through the step-by-step design of an MFR using the same kinetic data and feed conditions used in our previous PFR design post.

    If you haven't gone through the post of designing a PFR, please do it now: https://www.pharmacalculations.com/2025/05/design-of-plug-flow-reactor-pfr.html

    Objective

    To design a Mixed Flow Reactor (MFR) based on available kinetic data, rate constants, and conversion targets, assuming the reaction follows first-order kinetics.

    Given Data (Same as PFR Post)

    Parameter                                                    Value
    Type of reaction                                                    A → Products
    Order of reaction                                                            First-order
    Rate constant, k                                                    0.0616 min⁻¹
    Initial concentration, Cₐ₀                                                        1.5 mol/L
    Desired conversion, X                                                        70% or 0.70
    Volumetric flow rate, v₀                                                            100 L/min


    Step-by-Step MFR Design

    Step 1: Performance Equation of MFR

    For a Mixed Flow Reactor, the performance equation is:

    V=v0XrAV = \frac{v_0 \cdot X}{-r_A}

    Where:

    • VV = Volume of reactor (L)

    • v0v_0 = Volumetric flow rate (L/min)

    • XX = Fractional conversion

    • rAr_A = Rate of reaction at outlet conditions (mol/L·min)


    Step 2: Calculate Outlet Concentration

    CA=CA0(1X)=1.5(10.70)=0.45 mol/LC_A = C_{A0} \cdot (1 - X) = 1.5 \cdot (1 - 0.70) = 0.45 \text{ mol/L}


    Step 3: Rate of Reaction at Outlet

    For a first-order reaction,

    rA=kCA=0.06160.45=0.02772 mol/L.min-r_A = k \cdot C_A = 0.0616 \cdot 0.45 = 0.02772 \text{ mol/L·min}

    Step 4: Calculate Reactor Volume

    V=v0XrA=1000.700.02772=2525.27 LV = \frac{v_0 \cdot X}{-r_A} = \frac{100 \cdot 0.70}{0.02772} = 2525.27 \text{ L}

    So, the required MFR volume is approximately 2525 L.


    Step 5: Reactor Dimensions (Assume Vertical Cylindrical Tank)

    Assume Height-to-Diameter (H/D) ratio = 2:1 (common for stirred reactors)

    Let:

    V=π(D2)2HV=π(D2)22D=π2D3D=(2Vπ)1/3V = \pi \cdot \left(\frac{D}{2}\right)^2 \cdot H \Rightarrow V = \pi \cdot \left(\frac{D}{2}\right)^2 \cdot 2D = \frac{\pi}{2} D^3 \Rightarrow D = \left(\frac{2V}{\pi}\right)^{1/3}
    D=(225253.1416)1/3=(1607.5)1/311.8 inches0.3 mD = \left(\frac{2 \cdot 2525}{3.1416}\right)^{1/3} = \left(1607.5\right)^{1/3} \approx 11.8\ \text{inches} \approx 0.3\ \text{m}

    Diameter = 0.3 m, Height = 0.6 m


    Step 6: Agitator Power Estimation

    Use the Power number (Nₚ) method:

    P=NpρN3D5P = N_p \cdot \rho \cdot N^3 \cdot D^5

    Assume:

    • Np=5N_p = 5 (for Rushton turbine)

    • ρ=1000\rho = 1000 kg/m³ (approx. for liquid)

    • D=0.2D = 0.2 m (agitator diameter, 2/3 of tank diameter)

    • N=2N = 2 rev/s (120 RPM)

    P=51000230.25=5100080.00032=12.8 WP = 5 \cdot 1000 \cdot 2^3 \cdot 0.2^5 = 5 \cdot 1000 \cdot 8 \cdot 0.00032 = 12.8\ \text{W}

    Required agitator power = ~13 W


    Hope you understood the post well.

    If any queries, pl free to write us at pharmacalc823@gmail.com

    Comments are most appreciated .......!!

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