Optimal design of a structured fixed-bed reactor using geometry optimization and Stratoconception printing process

Abstract

The aim of this paper is to determine the shape of a xed-bed reactor which maximizes the conversion rate under the constraints of process model equations (i.e. continuity, Navier-Stokes, and mass balance equations), energy dissipation, iso-volume, and manufacturing. Incompressible uid, laminar ow regime and steady-state conditions in the reactor are the main assumptions taken into account. The optimization method developed is based on the adjoint system method and OpenFOAM framework is used as CFD solver to compute the state vector and its adjoint variables introduced by the optimization approach. The algorithm developed is then tested on two dierent cases, a reactor where a rst order homogeneous reaction takes place and another one involving a surface reaction. The optimization results show a signicant improvement of the conversion rate by 2.7% in the rst case, and by 16% in the second one. Finally, initial and optimal shapes are manufactured using a 3D printing technique.

Production of Customized Reactors by 3D Printing for Corrosive and Exothermic Reactions

“…Only then, the full topology optimization will be implemented. 38 With existing tools, such an approach is computationally expensive and is so far limited to small reactors.…”

“…A more advanced optimization would link directly the shape optimization with tools that allow a simultaneous prediction of the heat exchange and the hydrodynamics of the system. Only then, the full topology optimization will be implemented . With existing tools, such an approach is computationally expensive and is so far limited to small reactors.…”

CFD-based geometrical shape optimization of a packed-bed reactor combining multi-objective and adjoint system methods

“…The two (conflicting) objectives considered are the energy dissipation due to viscous fluid friction J 1 and the average reactant concentration at the outlet boundary J 2 . They are expressed by the following relations Courtais et al (2021b):…”

“…They allow large and sufficient modifications of the shape (in contrast to parametric methods) and therefore considerably improve the performance of the object while avoiding high CPU consumption. Finally, they guarantee the manufacturability of the final object (Courtais et al, 2021b) since its topology is chosen by the user (unlike topological methods).…”

“…Furthermore, in most process engineering studies, the investigated problem is formulated as a single-objective minimization or maximization problem (e.g. the reactant concentration at the reactor outlet (Courtais et al, 2021b) or the average outlet fluid temperature (Feppon et al, 2021)) under constraints imposed by the optimized process. However, the constant improvement of the industrial sector frequently requires to consider and optimize simultaneously multiple conflicting objectives (e.g.…”