Laboratory reactors and their limitations

TLDR

Choosing the appropriate laboratory reactor for kinetic studies is critical, as a wrong choice can cause costly delays and erroneous scale‑up, and no single reactor is ideal for complex industrial systems. The authors propose a systematic method for selecting reactors that are most likely to yield reliable kinetic data. The method evaluates potential reactors to identify those best suited to provide the desired data. The paper discusses pitfalls and limitations of various laboratory reactors in complex industrial reaction systems.

Abstract

Abstract Choosing the type of laboratory reactor for evaluating process kinetics may be the most crucial step in an industrial process development program. Not only would a wrong choice result in expensive delays, but data may be obtained which would scale‐up erroneously, leading to a disastrous commercial design. Some of the pitfalls and limitations of various laboratory reactors are discussed for some typically complex industrial reaction systems. A modus operandi is suggested for choosing from among the potential reactors those that have the best chance of supplying the desired data. As is typical of many complex industrial reaction systems, no one reactor turns out to be ideal and many times the building of two or more types is advantageous.