Innovative Autothermal Reactor Design via Additive Manufacturing: Optimization of Catalytic Exothermic Reactions Using Porous Media for Heat Management

Designing autothermal reactors demands meticulous heat management throughout their structure. In cases where reaction heat is sourced from catalytic exothermic reactions, the distribution of this heat becomes critical. This paper explores the utilization of additive manufacturing techniques to fabricate reactors in a single, seamless process. This innovative approach allows for the precise mixing of fuel and oxidant, facilitating reactions in accordance with predefined patterns. Specifically, the study investigates the incorporation of a porous medium, acting as a diffusive medium for the oxidant (e.g. air). The reaction heat is generated at the catalyst sites when the fuel (e.g. methane) reacts with the oxidant. To benchmark this innovative design, a laser-cut distributor with air holes in series is used as a point of comparison. Employing additive manufacturing techniques, these reactors are crafted from high-temperature stainless steel Crofer 22 APU using laser-based powder bed fusion (PBF-LB/M). The solid and porous components are produced with parameters individually optimized for each part. Notably, flow uniformity, temperature profile along the reactor and concentration distribution of oxygen, derived from simulation outcomes, emerge as pivotal factors in effectively coupling exothermic and endothermic reactions within the system. ... mehrIt leads printing flexible and complex designs in only one step.