Heat transfer in intensified synthesis reactors

AbstractThis study investigates the heat transfer characteristics of various geometries—including diamond cells, TPMS (Triply Periodic Minimal Surface), and monolith structures—within a packed bed reactor. The literature review presents an overview of catalytic methanol production via CO₂ hydrogenation, emphasizing the role of structured metallic designs, such as honeycomb monoliths, foams, and Periodic Open Cellular Structures (POCS), in enhancing reactor performance. By focusing on process intensification within catalytic reactors, this study evaluates the effect of structured packed bed characteristics on heat transfer. During the experimental phase, several POCS lattice structures, primarily diamond cells and multiple TPMS geometries, were fabricated and dedicated heat transfer tests in a non-reactive setup were performed. Heat transfer was evaluated using a one-dimensional model to assess the influence of lattice structure, cell size, porosity, and wall contact on the air-side heat transfer coefficient. This study demonstrates that TPMS structures, particularly the diamond matrix, offer superior heat transfer performance compared to POCS structures and other TPMS geometries, such as the gyroid matrix. Smaller cell sizes within these structures further enhance heat transfer efficiency, making them ideal for optimizing thermal management in small-scale, distributed chemical production systems