ABSTRACT
This chapter outlines the steps that are taken to do design, rating and performance calculations with reference to the reactions in the production of hydrogen, ammonia and methanol. There are a number of steps in the design of a catalytic reactor once the catalyst kinetics and the catalyst performance with time have been established. As the design life of the catalyst is increased the design volume and the cost of the vessel are also increased, but the total cost of catalyst and its reduction over the life of the plant will be smaller. Reactors are normally designed for a catalyst activity or active catalyst volume which is less than when the catalyst is new, with the result that when the catalyst is new and is operated at the design operating temperature, the exit composition may be very close to the equilibrium value. Well-designed catalysts only sinter very slowly at normal operating temperatures.
