Design and Experimental Validation of a Gas-Flow-Optimised Reactor for the Hydrogen Reduction of Tellurium Oxide

This study presents the development and evaluation of a novel solid–gas reactor designed to enhance the hydrogen reduction kinetics of tellurium oxide (TeO2) under atmospheric pressure. Such gas–solid reactions can be processed in several types of reactors, including but not limited to fixed-bed reactors, moving-bed reactors, and fluidised-bed reactors. A combination of computational fluid dynamics (CFD) and experimental validation was employed to design and optimise a reactor’s geometry and gas-flow distribution. Single-phase CFD simulations were performed using the k–ω SST turbulence model to examine gas-flow behaviour, temperature uniformity, and gas-flow dead zones for two lance designs. The modified lance produced a stable swirling flow that improved gas distribution and eliminated stagnation regions. Experimental trials confirmed the simulation outcome in optimised gas-flow: the redesigned reactor achieved up to 65% conversion after 1 h and 70% after 2 h, a marked improvement over the rotary kiln, which required 5–6 h to reach similar levels. However, excessive gas flow led to cooling effects that reduced conversion efficiency. These results demonstrate the effectiveness of integrated CFD-guided reactor design for accelerating hydrogen-based oxide reduction and advancing sustainable metallurgical processes.