Flow Reactor Types
The two main types of flow reactors are plug flow reactors and mixed flow reactors. Plug flow reactors are also called piston flow reactors, while mixed flow reactors are also referred to as vat reactors or back-mix reactors. A mixed flow reactor contains a rapidly rotating basket or other container that holds the catalyst, or the chemical that will cause the reactor in the tank.
Mixed Flow Reactor
A mixed flow reactor is a continuous stirred-tank reactor. The flow of chemicals, called reactants, and their products, are continuously added and removed. A mechanical or hydraulic agitator, such as a mixing arm or pump, is used in the tank of the mixed flow reactor to maintain uniform composition and temperature. The chemicals are added to the tank at the inlet and are completely and instantly mixed into the bulk of the reactor by the mixing arm or pump. The reactor tank and outlet fluid always have an identical, homogeneous composition. In other words, because the flow of the reactants and products runs at a steady rate of continuous flow, the feed creates a uniform composition in the reactor tank. This means that the exit stream has the same composition as the tank.
Main Advantages
Since the reactant chemical mixtures that leave the tank reactor are from the reactor itself and not from an outside source, the driving forces or the chemical reactant concentrations are low in volume. The low amount of reactants means that the mixed flow reactor can handle rapid exothermic and endothermic reactions, or it has a quick heating and cooling time.
Other Advantages
The rapid mixing of a continuous stirred-tank or a mixed flow reactor allows for continuous, day-to-day operation because it can control the temperature of the mixture in the reactor. This also results in a low operating cost, as people don't need to work so hard to keep it running.