Parametric study of methane catalytic combustion in a micro-channel reactor: Effects of porous washcoat properties

Abstract

A washcoat resolved numerical model of catalytic micro combustor fueled by methane is developed. Detailed gas phase mechanism and alumina dioxide supported Pt-based surface mechanism are adopted. This model proves to capture flow, temperature and species fields precisely including impermeable flow and products accumulation in porous washcoat layer. The novelty and superiority of this research compared to traditional modeling method in which instantaneous diffusion onto catalytic wall is assumed lies in that: it is possible to investigate effects of porous washcoat properties with this full-scale numerical model. Computational results show that homogeneous reactions (HR) are impaired and heterogeneous reactions (HTR) are strengthened as channel confinement increases. Da number analysis reveals that the micro combustor works under a mixed controlled mode in which catalytic reaction rate and internal mass diffusion rate are comparable. When washcoat layer thickness increases from 15 μm to 75 μm, overall catalyst usage roughly decreases from 0.34 to 0.05. It is concluded washcoat thickness can’t be too thin in order to maintain HTR intensity and too thick since catalyst usage is extremely low. Porous washcoat properties impact combustion characteristics in a similar mechanism: modifying effective mass diffusion coefficient. In general, increasing porosity, average pore diameter and decreasing tortuosity will enhance HTR and impair HR. In real application, these parameters can be utilized to modify combustion temperature, emission performance and stability operation map.