Plug flow, or tubular, reactors consist of a hollow pipe or tube through which reactants flow. Pictured below is a plug flow reactor in the form of a tube wrapped around an acrylic mold which is encased in a tank. Water at a controlled temperature is circulated through the tank to maintain constant reactant temperature.
Plug flow reactors, also known as tubular reactors, consist of a cylindrical pipe with openings on each end for reactants and products to flow through.
Plug flow reactors are usually operated at steady-state. Reactants are continually consumed as they flow down the length of the reactor.
The movie below shows the operation of a plug flow reactor. Plugs of reactants are continuously fed into the reactor from the left. As the plug flows down the reactor the reaction takes place, resulting in an axial concentration gradient. Products and unreacted reactants flow out of the reactor continuously.
Plug flow reactors may be configured as one long tube or a number of shorter tubes. They range in diameter from a few centimeters to several meters. The choice of diameter is based on construction cost, pumping cost, the desired residence time, and heat transfer needs. Typically, long small diameter tubes are used with high reaction rates and larger diameter tubes are used with slow reaction rates.
The picture below shows a disassembled tubular reactor.
Plug flow reactors have a wide variety of applications in either gas or liquid phase systems. Common industrial uses of tubular reactors are in gasoline production, oil cracking, synthesis of ammonia from its elements, and the oxidation of sulfur dioxide to sulfur trioxide. Pictured below is a tubular reactor used in research on the oxidation of nitrogen compounds. It reaches temperatures of 800 - 1100°C.
Tubular reactors can also be used as bioreactors or for small scale production. The tubular bioreactor shown below is used for the production of algae. The algae is then compressed and dried and can be used as feed for a biodiesel reactor.
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