Topology optimization and numerical validation for heat transfer improvement in a packed-bed reactor with monolithic catalyst

This study focuses on optimizing heat transfer in packed-bed reactors by simplifying the problem to a two-dimensional steady-state heat conduction scenario. The objective is to efficiently arrange a limited volume of high-conductivity material to transport heat from the source to the low-conductivity heat-absorbing materials, representing the reacting fluid phase. The topology optimization problem is tackled using a density-based method that relies on a gradient-based algorithm. The optimized design is extruded and compared to a honeycomb internal structure using high-fidelity simulations for steam methane reforming. Results show a 6.04% improvement in CH 4 conversion for the optimized structure, highlighting the potential of this method to enhance monolithic catalysts, particularly in cases where heat transfer critically influences the reaction. • Optimized heat transfer in packed-bed reactors using topology optimization. • Simplified problem to 2D steady-state heat conduction for efficient and effective design process. • Achieved higher CH₄ conversion in 3D steam methane reforming simulations compared to honeycomb. • Method improves monolithic catalysts where heat transfer is critical.