Packed bed reactors (PBRs) are extensively used in chemical process industries to perform solid-catalyzed gas–liquid reactions. Their performance is significantly influenced by liquid distribution which is a strong function of particle shape and size. In the present work, we simulated the steady-state local liquid distribution, pressure drop (ΔP/L), and overall liquid holdup (〈εL〉) for the beds packed with spherical and cylindrical particles using a three-dimensional (3D) Eulerian multifluid model and validated the predictions using corresponding high-speed imaging measurements performed in pseudo-2D packed beds. We showed that the Eulerian model with existing closures significantly underpredicts the liquid distribution for the bed randomly packed with cylindrical particles. To address this, we proposed a modification in existing mechanical dispersion force (F→D) model as a function of average particle orientation angle (θ). The modification significantly improved agreement between the predictions and the corresponding measurements. Using the modified model, we showed that the increased magnitude of F→D in the lateral direction leads to higher lateral liquid spreading for cylindrical particles as compared to that for the spherical particles. Importantly, the modified model also predicted the local liquid distribution and ΔP/L for beds packed manually with cylindrical particles oriented at different θ in a satisfactory agreement with the corresponding measurements. On increasing θ, the F→D in lateral direction (i.e., perpendicular to flow) as well as liquid–solid interaction force (F→LS) in axial direction (i.e., parallel to flow) found to increase significantly. As a result, the lateral liquid spreading as well as ΔP/L decrease substantially on increasing θ.
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