Two-phase flow effect on methane conversion in pyrolysis reactors embedding molten salts or metals

In this work, we numerically investigate the impact of flowrate, sparger and reactor geometry on methane conversion in lab-scale cylindrical pyrolysis reactors embedding molten salts or metals. A multiscale approach is enforced, where a diffusion-reaction model yielding the conversion vs time within a single rising bubble is combined with the average residence time of gas bubbles obtained through the two-phase turbulent bubbly flow model. We find that the relative size of the sparger and the height-to-diameter ratio of the molten medium are key parameters for controlling the average residence time of the bubbles, which always results lower than that predicted by the terminal velocity of a single bubble rising in an overall static melt. The highest relative discrepancy (order 300%) between the single-bubble estimate and the CFD-based residence time is found in the case of molten salts in low-aspect ratio reactors fed by small spargers. The physical mechanism underpinning the influence of geometric parameters on the overall conversion is addressed in detail, together with the impact of two-phase flow effects on the estimation of bubble size in laboratory scale bubble reactors. • Multiscale approach developed for conversion vs. height in molten media pyrolysis reactors. • Effect of gas flow rate and reactor geometric characteristics on residence time assessed. • Turbulent motion of liquid causes decrease in residence time compared to stagnant liquid. • Proposed approach allows indirect measurement of bubble diameter from experimental conversion.