Modeling and optimization of flow distribution in multistage pipe distributors

Abstract

AbstractMultistage pipe distributors are generally used in industrial‐scale reactors to generate uniform fluid distribution and reduce dead zones at reactor bottom. This study aims to develop an accurate and easy‐to‐use model for design and optimization of these distributors, integrating the advantages of analytical models and computational fluid dynamics (CFD) simulation. For analytical models, the empirical correlations of pressure recovery coefficient and discharge coefficient were systematically evaluated. CFD simulations of single‐stage distributors reveal the mechanisms behind flow maldistribution, that is, the relationship between vortex evolution at branch corner and discharge coefficient. A three‐phase characteristic for discharge coefficient along flow direction is found with increasing the ratio of branch length to diameter. A generalized discharge coefficient was then proposed to represent an intrinsic approach to optimize flow uniformity. Finally, the analytical model was extended to multistage distributors by a double‐convergence solution strategy, and provides guidelines of design and optimization of these complex distributors for process industry.