An innovative “hybrid-scale” numerical simulation method was proposed to address the low-velocity filtration combustion within double-layer pellet-packed beds. This approach integrates the volume averaging method in the preheating and post-flame zones while direct pore-level simulation in the reaction zone. Based on the hybrid-scale simulation results, a comprehensive analysis was conducted on the theoretical rigor and errors arising from the application of the volume averaging method. The results suggest that in the strictest sense, the volume-averaging method is not suitable for the reaction zone, as the flame thickness is typically smaller than the characteristic length of a representative element volume (REV). However, when the characteristic length is comparable to the pellet diameter, the spatial deviation values of temperature and component concentration in the majority (>80 %) of the reaction zone are smaller than their intrinsic average values. The error introduced by the volume-averaged reaction rate model primarily originates from the spatial heterogeneity of the component concentration field within the REV. The existing volume-averaged reaction rate model tends to underestimate the actual reaction rate by up to 20 %. The recommended mesh size when using volume averaging method should be comparable to the equivalent diameter of the pellet to improve the calculation accuracy
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