Structure-Resolved CFD Simulations of Different Catalytic Structures in a Packed Bed

Abstract

Structure-resolved simulations of fluid flow, heat transfer, and chemical reactions were performed to understand the effect of different catalytic structures on reactor performance using methane steam reforming reactions. For this purpose, 7-hole pellets, monolith, and foam structure with the same geometric surface area and volume were considered for a rational comparison. The monolith offered the lowest ΔP, whereas the foam gave the highest CH4 conversion. However, the monolith gave the best CH4 conversion to ΔP ratio. The effect of different catalytic structures on catalyst deactivation was investigated using propane dehydrogenation reactions. The monolith gave the highest propane conversion and also the lowest propene yield because of faster catalyst deactivation compared to the other catalytic structures. On the other hand, the propane conversion and propene yield were slightly lower for the foam compared to that for the 7-hole pellets. The present work provides a quantitative comparison between the catalytic structure and the overall reactor performance.

Robust Self‐Catalytic Reactor for CO2 Methanation Fabricated by Metal 3D Printing and Selective Electrochemical Dissolution

“…[ 41 ] This effect is particularly prominent in monolith reactors, which exhibit low‐pressure drops with the laminar flow within their large straight channels. [ 42–44 ] As shown in Figure 4e, the CO 2 conversion rate and CH 4 selectivity at a flow rate of 20 mL min −1 were 80.9% and greater than 99.8%, respectively. With increasing flow rate, the conversion rate decreased slightly but remained greater than 76.2% even at 80 mL min −1 and the CH 4 selectivity remained greater than 99.8%.…”

Telescoped Two-Step Continuous-Flow Synthesis of Vanillin

“…The main concern in the flow reactor is the pressure drop (ΔP) across the packedbed reactor when the feeding flow rate is considerably increased. 45 The pressure loss across the catalyst bed would not only impede the stable operation of the reactor but also lead to a decrease in catalytic efficiency and cause significant catalyst degradation. Therefore, it is necessary to design a catalyst that can maximize the catalytic efficiency and catalyst durability while minimizing ΔP.…”

Centralized and distributed hydrogen production using steam reforming: challenges and perspectives

“…Three different catalyst structures, namely, seven-hole pellets, monoliths, and foams, have been proposed to enhance the surface area within a compact space, and their effect on SMR performance has been explored with CFD. 90 The monolithic structure exhibited the lowest pressure drop and the highest methane conversion per pressure drop because the monolith has a lower velocity owing to the streamlined flow guided by the channel walls.…”