Numerical Simulation of Airflow Distribution and Structural Optimization of a VOCs Catalytic Combustion Reactor
This study presents a numerical simulation of the internal flow field in a volatile organic compounds (VOCs) catalytic combustion reactor used in an enameled wire enterprise. Using ANSYS Fluent, the effects of inlet expansion section length, inlet expansion section angle, and catalyst bed spacing on the velocity field were systematically investigated. Additionally, the influence of heating tube configuration on the temperature field was analyzed. The results indicate that an expansion section length of 250 mm is optimal, balancing spatial constraints and the avoidance of recirculation zones. A zero-degree expansion angle yields the most uniform velocity distribution, though practical considerations necessitate case-specific angle selection. A catalyst bed spacing of 0.05 m satisfies the engineering requirement of maintaining pressure drop across a single catalyst layer below 200 Pa while significantly improving gas distribution within the bed. Alternating heating tubes on both sides of the reactor enhance temperature uniformity and elevate the overall catalyst bed temperature, thereby promoting efficient VOCs catalytic combustion. These findings provide quantitative guidance for reactor design optimization, contributing to improved catalytic performance and extended catalyst lifespan.