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”.