Performance analysis, statistical modeling, and multiple response optimization of a novel fixed-bed quartz reactor packed with Ba-Pt@γ-AL2O3 using response surface methodology

In the present study, a novel fixed-bed continuous reactor with a preheating chamber was designed to be utilized for the practical application of removal studies of dangerous pollutants, especially NO_X removal by NO_X Storage Reduction (NSR) catalysts on a laboratory scale. The reactor's design and operational parameters, including outer wall temperature (50-600 °C), volumetric flow rate (0.3-3 L/min), wall temperature time (0.16-10 min), and granule surface area inside the preheating chamber (0-270 cm²), were statistically modeled and optimized using Response Surface Methodology (RSM). For more logical and effective parameter optimization, the ratio of gas and catalyst temperatures and pressure drop to the reactor outer wall temperature (GT/ROWT, CT/ROWT, and PD/ROWT) were also included in the optimization process. Experimental results showed that gas temperature, catalyst temperature, and pressure drop ranged from 31 to 177 °C, 51-585 °C, and 7-153 Pa, respectively. Optimal conditions were determined to be an outer wall temperature of 230 °C, a volumetric flow rate of 3 L/min, a wall temperature time of 0.16 min, and a granule surface area of 67.3 cm². The results demonstrated that outer wall temperature, flow rate, time, and surface area of granules have significant and interaction effects on the responses and should be considered when researchers assess the removal efficiency of thermal catalysts.