Since its introduction into chemical engineering by Danckwerts(1953), the concept of a residence-time distribution has become an important tool in the analysis of chemical reactors. It is discussed prominently in most textbooks on chemical reactor design, and my previous works discuss its implications and uses. My own work on reaction engineering and process control includes some key ideas from my involvement with residence-time distributions. But there are some basic problems in applying this concept directly to heterogeneous catalytic reactors, which are the mainstream industrial reactors in the petrochemical and oil industries. Residence-time distributions do not apply to catalytic reactors in a conventional sense, so it is time to re-evaluate how we use them in teaching students about reactor design. Following I will review the development of these concepts and the lessons they teach us about chemical reactor design. This unconventional review is influenced by the development of my own ideas on the subject Therefore, I will supply an outline for those readers interested in different aspects of the subject 97 Brought to you by | Purdue University Libraries In Section II are some basic concepts and underlying assumptions needed for discussion. A detailed review of the conventional use of residence-time distribution appears in Shinnar (1987). Here Section II explains why the concepts fail to apply to catalytic reactors. Section ΠΙ discusses intensity function and how to perform useful tracer experiments in catalytic reactors despite the nonapplicability of residence-time distributions. Section IV deals with first-order reactions in homogeneous reactors (readers familiar with this section can skip it). Section V extends some results of first-order reactions to nonlinear reactions and defines the concepts of averageable and nonaverageable reactions, which are useful in defining the minimum information needed for reliable scale-up in nonlinear reactions. Section VI deals with Zwietering's concept of bonding and extends it to reactor design. Section VI also discusses model uncertainty and the minimum information required for design. Section VII reviews theory of tracer experiments in heterogeneous systems. Section VIII reviews the use of these results to define a modified residence-time distribution for packed-bed reactors and use of tracer experiments to diagnose different packed-bed reactors. Section IX extends this to nonlinear reactors in packed beds. Section X reviews and presents design concepts for fluid-bed reactors, a subject that strongly requires a revised outlook. While neither residence-time nor contact-time distributions lead to straightforward algorithmic design methods, derived lessons prove useful in the design of fluid-bed catalytic reactors. In Section X, the concept of contact-time distribution is shown to suffer from problems similar to residence-time distributions and surrounding misconceptions. Section XI uses these results to discuss the design of circulating fluid-bed and riser reactors. Ren...