Simulative Investigations of Non-Idealities in a Laboratory Scale Differential Recycle Reactor

This study optimizes Differential Recycle Reactors (DRR) for efficient kinetic data acquisition in heterogeneously catalyzed reactions, ensuring fluid dynamics comparable to production-scale fixed-bed reactors through fully recycled batch-mode operation. A model-based sensitivity analysis identifies key parameters—reactor shape, superficial velocity, reaction rate, and wall flow—revealing that short, wide designs with high fluid velocity minimize differential conversion and maldistribution while maximizing data quality. Operation maps and a reactor performance number guide optimal regimes, validated against ideal batch kinetics, enabling reliable scale-up, catalyst screening, and process design.