Temperature control strategy for safer and heat-efficient operations in a catalytic flow reactor

[Display omitted] •Temperature control strategy was established using a new dimensionless number.•Validity of the proposed dimensionless number was confirmed through simulations.•Given the reaction properties, a temperature controllable reactor can be designed.•A reactor can be maximized within an allowable temperature by proposed method. A new temperature control strategy for a packed-bed tubular reactor was proposed. Case studies of a highly exothermic 1st-order reaction and an actual 2nd-order reaction were conducted using the computational fluid dynamics software COMSOL Multiphysics® 4.4. Through the simulation, the important factors for reactor temperature control were confirmed, which were the parameters related to heat transfer. Based on the ratio of the heat generation rate to the heat transfer rate, a new dimensionless number was proposed for controlling the temperature increase within an acceptable range in a reactor. Through case studies, the validity of the proposed dimensionless number was confirmed, and an important value of a proportionality constant was derived from the results. Using the proposed dimensionless number, a reactor size can be maximized within an acceptable temperature increase. The results obtained in this study are expected to provide important guidelines for temperature control and maximization of production using flow reactors.