Computational fluid dynamics‐based optimization of dimpled steam cracking reactors for reduced CO₂ emissions

Abstract

Spherical dimples in cylindrical tubes enhance heat transfer and lead to a more uniform radial temperature profile. To combine these positive properties with a low pressure drop, a single dimple was optimized through a genetic algorithm. Multiple design parameters such as width, height, and curvature of the dimple were investigated. Heart‐shaped dimples outperformed spherical dimples. Three‐dimensional reactive simulations of a Millisecond propane steam cracking reactor showed that both the spherically dimpled and the heart‐shaped dimpled coil positively affect the light olefin selectivity, mainly through an increase in propylene selectivity. The optimized dimples could reduce the high pressure drop penalty by 21%. Run length simulations proved that the optimized dimple shape results in an additional run length extension of 18%. Next to this, the fuel rate consumption can be decreased by 6% compared to a bare coil, which could theoretically result in 4% less CO2 emissions.

Wall‐resolved large eddy simulation of turbulent flows in helically ribbed steam cracker reactors

“…geometry in future work. This would be similar to the work performed by Dedeyne et al, who combined the Dakota toolkit with OpenFOAM to optimize multiple design parameters for a dimpled reactor 50. …”

Geometry Optimization for Multi-Inlet Vortex Photoreactor for CO2 Reduction

“…On other hand, Computational Fluid Dynamics (CFD) is a well-established tool for numerous areas of science and engineering [34][35][36]. CFD uses numerical methods and empirical approximations to solve the Navier-Stokes equations, and due to the development of numerical methods and advances in computational technology, there exists a growing confidence in the results of these computational methods.…”

A comprehensive sensitivity analysis on the performance of pseudo‐steady propane thermal cracking process

“…By these techniques, different effective key parameters, such as tube shapes, sizes, configurations, furnace dimension, burner styles, and their arrangements, fuel composition, distinct combustion, turbulence, and radiation models have been investigated 13–18 . Dedeyne et al, 19 have proposed spherical dimples inside the reactor tube in order to increase radial heat flux profile uniformity for propane thermal cracking and investigated it using CFD simulation. They have found an optimized heart‐shaped dimple, which has led to reduce pressure drop, increase propylene selectivity, and a drop in fuel consumption.…”