A platinum-coated staggered reactor to intensify lean hydrogen/air combustion: A large eddy simulation study

• LES modelling of turbulent catalytic hydrogen/air combustion. • Intensification of the turbulent catalytic process in non-planar reactor. • Enhanced catalytic activity with staggered cylinders in a non-planar reactor. • Convective mass and heat transfer influence catalytic activity. • Achieved 62.5 % catalyst saving with non-planar reactor design. Catalytic-aided combustion has been proven effective for premixed hydrogen/air mixtures, particularly under lean to ultra-lean conditions. However, minimising the required catalyst sets a significant challenge because noble metals with high catalytic activity are rare and expensive. Therefore, this study aims to intensify the catalytic combustion process by investigating a non-planar reactor comprising an array of platinum-coated half- and full-cylinders through large eddy simulation. A premixed mixture with a fuel-lean equivalence ratio of 0.15 and an incoming Reynolds number of 3500 based on hydraulic diameter is used. For comparison, a planar reactor without cylinders is also studied under the same operating conditions and with the same amount of platinum-coated surface area. The simulation employs the turbulent kinetic energy sub-grid model and the eddy dissipation concept to model the turbulent catalytic reacting flow. The discrete ordinate model is used to account for radiation heat transfer in the catalytic process. Numerical simulations are validated against experimental results prior to analysis. The findings indicate that the placement of cylinders along the reactor length enhances convective mass transfer and intensifies catalytic combustion, resulting in effective combustion over a smaller catalytic surface. Compared to planar models, non-planar reactors demonstrate a much better H 2 conversion efficiency throughout the reactor length, saving nearly 62.5 % of the catalyst.