Computational Fluid Dynamics in chemical reactor analysis and design: Application to the ZoneFlow™ reactor for methane steam reforming

The ZoneFlow reactor (Tribute Creations, LLC) is a tubular reactor with two types of internals: a core type and adjacent to the wall, a casing type, both covered with a thin layer of catalyst. It aims for higher energy efficiency and lower steam-to-carbon ratios in methane steam reforming by a judicious design of the relative position of the internals and their geometrical characteristics and a higher catalyst effectiveness.The performance of this novel structured catalytic reactor for synthesis gas production by methane steam reforming was simulated using a reactor model accounting in detail for the flow pattern by means of Computational Fluid Dynamics (CFD). A Reynolds Averaged Navier Stokes (RANS) approach was taken. Turbulence, heat transfer by convection and radiation, detailed reaction kinetics including coking, intra-particle diffusion limitations, and the compressibility of the gas phase were accounted for. Simulations were carried out to investigate the ZoneFlow reactor performance under typical commercial operating conditions and compare it with a conventional packed bed reactor using the same Ni catalyst.

► ZoneFlow reactors are a novel type of tubular, structured catalytic reactors. ► ZoneFlow optimizes heat transfer, the flow pattern and the catalyst efficiency. ► CFD simulations including detailed reaction kinetics of methane steam reforming. ► Comparison of the ZoneFlow reactor and packed bed reactor performances. ► Simulations at typical commercial operating conditions and low S/C-ratio.