Multi-objective structure optimization and performance analysis of catalytic micro-reactor channel designed by an improved topology optimization model

Abstract

Previous micro-reactor channel studies mainly focus on the limited design space or structure layout, rarely exploits design forms in which the procedural topology structure evolves freely. Therefore, a multi-objective topology optimization model are proposed for the inverse free evolution of micro-reactor channels, which can synergistically balance the effects among three objectives of reaction rate, flow loss and heat transfer to achieve optimal comprehensive performance. The topology optimization problem is formulated based on the material density-based design variable. The fluid dynamics response of design variables at each optimization iteration is updated by solving multi-physics governing equations, objective functions and variable constraints. Adjoint-based sensitivity analysis and GCMMA algorithm are used to obtain the gradient information of objective functions and update design variables, respectively. Additionally, the strict volume constraints and proposed pseudo-design-domain concept are introduced into the multi-objective function. In numerical examples, the influence of different Re conditions and different multi-objective weight-ratios on optimal designs is investigated, and their regular evolution mechanisms and the trade-off between performance optimization and structure evolution are analyzed. Then, the optimization principles for topology structure and performance parameters under the control of multi-objective functions are revealed. Finally, the comprehensive performance of micro-reactors under topology optimization method is compared with that of traditional micro-reactors to demonstrate the effectiveness of the improved method and reveal the physical mechanisms of multi-objective performance enhancement. The comparison results show that topology optimization designs can achieve 86.1% growth in reaction rate and 47.1% reduction in flow loss, and comprehensive performance coefficients have also been significantly optimized.