CSTR vs Plug Flow Reactor Volume & Conversion Calculator
Calculate required reactor volume, residence time (τ), and Damköhler number ($Da$) for first and second order reactions in CSTR and PFR systems.
Kinetic Parameters & Operating Conditions
Reactor Sizing & Volume Comparison
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Continuous Reactor Sizing & Levenspiel Plots
For reactions with positive reaction orders ($n > 0$), the reaction rate is highest at high reactant concentrations and decreases as conversion proceeds. In a Continuous Stirred-Tank Reactor (CSTR), the entire vessel operates at the final exit concentration ($C_{A,exit}$), meaning the rate of reaction is at its absolute minimum throughout the entire tank volume.
Plug Flow Reactor (PFR) Superiority at High Conversion
In a Plug Flow Reactor, concentration drops progressively along the reactor length, keeping the average reaction rate much higher than in a CSTR. As target conversion approaches $90\%$ or $99\%$, the ratio $V_{CSTR} / V_{PFR}$ escalates exponentially, often requiring a CSTR to be $5\times$ to $20\times$ larger than an equivalent tubular PFR.