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Chemical Engineering Communications, Vol.190, No.4, 540-559, 2003
Strategies for size reduction of microreactors by heat transfer enhancement effects
One of the likely aims of reactor miniaturization in the field of chemical production and energy generation is to increase the conversion to the desired product and the selectivity of the process through better control of heat and mass transfer. In addition to the effects related to miniaturization, a further increase of the transfer coefficients is achieved by applying microstructuring techniques. In this context, three different approaches for heat transfer enhancement in miniaturized reaction systems are presented. The ideas put forward rely on entrance flow effects, inertial flows in meandering channels, and suppression of axial heat conduction. Among these ideas the entrance flow effect, realized by an arrangement of microfins with a typical dimension of a few hundred micrometers, provides the most efficient heat transfer. It is found that a heat transfer enhancement of at least one order of magnitude can be achieved compared to unstructured channels. On this basis, a miniaturized heat-exchanger reaction system is investigated, where a kinetic model of an endothermic, heterogeneously catalyzed gas-phase reaction is used. The miniaturized heat-exchanger reactor, both with and without heat transfer enhancement; is subsequently benchmarked against conventional fixed-bed technology. It is shown that, for the reaction system under study, a substantial reduction of the required amount of catalyst can be achieved in microsystems.