Enhancing the Thermal Performance of Slender Packed Beds through Internal Heat Fins

Rational design of a methanation reactor by neutron imaging

The reaction conditions in industrial scale chemical reactors can differ markedly from the ones in a small laboratory scale reactor. The differences are both conceptual and practical, and can at best be analysed by studying a full reactor, which requires an analytical method capable of quantifying the distribution of reactants and products in a running reactor. For this, we introduce non-destructive operando neutron imaging in combination with modelling. As a representative reaction, we studied the hydrogenation of carbon dioxide to methane selected due to the large neutron cross-section of hydrogen and hydrogen-containing species. The integration of the measurement setup/reactor into the neutron beamline enables the temporally resolved measurement of the distribution of adsorbed water on the catalyst under operating conditions (p, T). The resulting quantitatively determined partial pressure of the water thus indirectly enables the spatial and temporal conversion of the processes. The knowledge gained from this experimental approach, combined with modelling, allows the design of reactor dimensions under optimized reaction conditions. The good agreement between simulation and experimental neutron imaging warrants the method as a reliable instrument for reactor characterization and design, with the prospect of its application on reactors on the industrial scale.

Process Intensification in Chemical Reaction Engineering

Process Intensification (PI) is a modern trend in Chemical Reaction Engineering (CRE) science [...]

Particle-Resolved Computational Fluid Dynamics as the Basis for Thermal Process Intensification of Fixed-Bed Reactors on Multiple Scales

Process intensification of catalytic fixed-bed reactors is of vital interest and can be conducted on different length scales, ranging from the molecular scale to the pellet scale to the plant scale. Particle-resolved computational fluid dynamics (CFD) is used to characterize different reactor designs regarding optimized heat transport characteristics on the pellet scale. Packings of cylinders, Raschig rings, four-hole cylinders, and spheres were investigated regarding their impact on bed morphology, fluid dynamics, and heat transport, whereby for the latter particle shape, the influence of macroscopic wall structures on the radial heat transport was also studied. Key performance indicators such as the global heat transfer coefficient and the specific pressure drop were evaluated to compare the thermal performance of the different designs. For plant-scale intensification, effective transport parameters that are needed for simplified pseudo-homogeneous two-dimensional plug flow models were determined from the CFD results, and the accuracy of the simplified modeling approach was judged.