A microreactor similar to the one shown in Figure P4-19 from the MIT group is
used to produce phosgene in the gas phase.
$$\begin{array}{c}
\mathrm{CO}+\mathrm{Cl}_{2} \rightarrow \mathrm{COCl}_{2} \\
\mathrm{A}+\mathrm{B} \rightarrow \mathrm{C}
\end{array}$$
The microreactor is \(20 \mathrm{mm}\) long. \(500 \mu \mathrm{m}\) in diameter,
and packed with catalyst particles \(35 \mu \mathrm{m}\) in diameter. The
entering pressure is \(830 \mathrm{kPa}(8.2 \mathrm{atm})\) and the entering
flow to each microreactor is equimolar. The molar flow rate of \(\mathrm{CO}\)
is \(2 \times 10^{-5} \mathrm{mol} / \mathrm{s}\) and the volumetric flow is
\(2.83 \times 10^{-7} \mathrm{m}^{3} / \mathrm{s}\). The weight of catalyst in
one microreactor: \(W=3.5 \times 10^{-6} \mathrm{kg}\). The reactor is kept
isothermal at \(120^{\circ} \mathrm{C}\). Because the catalyst is also slightly
different than the one in Figure \(\mathrm{P} 4-19,\) the rate law is different
as well:
$$-r_{A}^{\prime}=k_{A} C_{A} C_{B}$$
(a) Plot the molar flow rates \(F_{\mathrm{A}}, F_{\mathrm{B}}\), and
\(F_{\mathrm{C}},\) the conversion \(X\), and pressure ratio \(y\) along the length
of the reactor.
(b) Calculate the number of microreactors in parallel to produce 10.000
kg/year phosgene.
(c) Repeat part (a) for the case when the catalyst weight remains the same but
the particle diameter is cut in half. If possible compare your answer with
part (a) and describe what you find. noting anything unusual.
(d) How would your answers to part (a) change if the reaction were reversible
with \(K_{\mathrm{C}}=0.4 \mathrm{dm}^{3} / \mathrm{mol} ?\) Describe what you
find.
(e) What are the advantages and disadvantages of using an array of mi reactors
over using one conventional packed bed reactor that provides same yield and
conversion?
(f) Write a question that involves critical thinking. and explain wh involves
critical thinking.
(g) Discuss what you learned from this problem and what you believe th the
point of the problem. Additional information:
\(\alpha=3.55 \times 10^{5} / \mathrm{kg}\) catalyst (based on properties of air
and \(\phi=0.4\) ) \(k=0.004 \mathrm{m}^{6} / \mathrm{mol} \cdot \mathrm{s} \cdot
\mathrm{kg}\) catalyst at \(120^{\circ} \mathrm{C}\)
\(v_{0}=2.83 \cdot 10^{-7} \mathrm{m}^{3} / \mathrm{s}, \rho=7 \mathrm{kg} /
\mathrm{m}^{3}, \mu=1.94 \cdot 10^{-5} \mathrm{kg} / \mathrm{m} \cdot
\mathrm{s}\)
\(A_{c}=1.96 \cdot 10^{-7} \mathrm{m}^{2}, G=10.1 \mathrm{kg} / \mathrm{m}^{2}
\cdot \mathrm{s}\)