Design of a new FM01-LC reactor in parallel plate configuration using numerical simulation and experimental validation with residence time distribution (RTD)

• New geometry distributor designs for FM01-LC were developed.
• High and low velocity zones inside the electro-active area were minimized.
• A fully developed flow within the electro-active area was achieved.
• The liquid flow pattern behavior of the new FM01-LC is nearly to plug flow.
• CFD simulation results were in good agreement with the RTD experimental.

The goal of this work was to develop new geometry design of inlet and outlet distributors of the FM01-LC in parallel plate configuration using Computational Fluid Dynamics (CFD). The new distributor geometry was experimentally evaluated with RTD experimental curves using the stimulus-response technique and approximated with axial dispersion model (ADM), plug dispersion exchange model (PDEM) and by solving the hydrodynamic (Reynolds average Navier–Stokes equation for low Reynolds number, RANS-LRN) and mass transport (convection–diffusion equation in transient and turbulent regimen) equations using computational fluid dynamics (F-tracer RTD method). Two sets of RTD experiments (common and new inlet and outlet distributors) in FM01-LC reactors with channel thickness of 0.011 m were carried out. The volumetric flows (Q) employed were from 0.5 to 3.5 L min−1 (U0 = 0.02-0.15 m s−1). The new FM01-LC reactor had a more homogeneous velocity field in the entire reaction zone, as shown by axial dispersion values lower than those obtained with the common FM01-LC, at different Reynolds numbers. The RTD curves obtained with Comsol Multiphysics 4.3a are in agreement with RTD experimental curves, but deviations are observed at Reynolds numbers greater than “5991”.