Production of Customized Reactors by 3D Printing for Corrosive and Exothermic Reactions

Abstract

This work presents a continuous reactor designed to be produced by 3D printing with the ultimate objective of performing fast, exothermic, and corrosive reactions. The dilution of sulfuric acid with water was used as a model for reactor design. A good mixing inside the reactor will promote the dilution and at the same time increase the heat transfer. Fast heat transfer is important to avoid vaporization of reactants/products and to control corrosion inside the reactor. The reactor was designed using a genetic algorithm to maximize the surface area of a prespecified reactor volume while ensuring a good mixing of the reactants. We have experimentally demonstrated that dilution of sulfuric acid can be done continuously in a Hartridge–Roughton mixer with lattices for enhanced heat transfer. Selected designs with internal and external lattices for enhanced heat exchange were manufactured by 3D printing using the Ti64 alloy. Different printing services were used to compare the quality of reactors that can be achieved by new industrial players that do not possess a 3D printer. One important item that should be considered when 3D printing is used for corrosive reactions is cross-contamination with other metals, since that can significantly affect the life and safety conditions of the reactors.

Predicting the Flow Behavior and Residence Time Distribution in Chemical Reactors: A Simplified and Fast Approach Using Smoothed Particle Hydrodynamics

“…[ 41 ] Recently, these mixers were used for performing strongly exothermic reactions continuously. [ 42 ] Although previous works reported shape optimization of H‐R mixers, [ 43 ] the optimal shape for integrating reaction and heat transfer remains a challenge. We have also performed SPH simulations of a H‐R mixer for different particle sizes and compared the results using detailed CFD simulations.…”

Recent Advances in the Development of Highly Conductive Structured Supports for the Intensification of Non-adiabatic Gas-Solid Catalytic Processes: The Methane Steam Reforming Case Study

“…This may be due partly to the lack of confidence of major industrial players towards these technologies and to the still limited possibilities in terms of size that can be allowed by 3D printing. Instead, for small scale systems, 3D printing is starting to offer interesting potential as an enabling technology, as recently presented by Grande and coworkers (Grande and Didriksen, 2021).…”

In Search of an Effective Workability Zone during the 3D Printing of Polymeric Periodic Open Cellular Structures Potentially Useful as Microreactors

“…Grande. This has allowed him and his team to establish improvements in the catalytic properties of some systems through the creation and control of the shape of POCS-type reactors [35][36][37].…”