Topology optimization of a packed bed microreactor involving pressure driven non-Newtonian fluids

Abstract

Multivariable optimization is an important task for a microreactor to operate with better control and efficacy. The bed porosity in a packed bed microreactor is one of the key parameters to regulate the reaction rate. In this study, we offer a topology optimization technique for augmenting the reaction conversion by attaining an optimal catalyst bed porosity for non-Newtonian reactants that follow power-law behaviors. Considering a tubular microreactor and pressure gradient driven flow, we have analyzed a first-order exothermic reaction system, and have elaborated the sensitivity of power-law parameters on the average bed porosity, reaction conversion, and temperature distribution in the reactor. Our results indicate that with increasing flow consistency and behavior indices, the average bed porosity needs to increase for the optimum reactor performance that encompasses an enhanced reaction rate and uniform temperature distribution inside the reactor. We herein suggest a simple approach to optimize a microreactor to improve its efficiency without altering the physicochemical properties of the catalyst.