Hierarchical numbering-up of modular reactors: A multi-objective optimization approach

Proper upscaling of modular reactors for renewable energy transformation, storage and power-to-fuels/ chemicals, including fuel cells, redox flow cells and micro catalytic/electrocatalytic reactors, is crucial for enabling an economically feasible net-zero-emission future. In this work, we eatablish a multi-objective optimization model for hierarchical numbering-up of modular reactors considering flow uniformity, flow resistance and total device volume as the optimization objectives; the hierarchical topology of reaction channel networks and the geometry of reaction channels and multi-level distributors serve as the decision variables. An evolutionary optimization algorithm is developed to solve the formulated mixed integer non-linear programming problem cost-effectively. Appropriate sizing of primary reaction channels for equipment integration is found to be application-specific. Hierarchical channel layouts are shown to be essential for large-scale applications. Increasing the number of plates per reactor-stack and incorporating reactor-stacks into arrays prove to be superior to the common practice of enlarging individual plates. The proposed approach and the revelation of optimal numbering-up modes under different representative scenarios will enlighten development of systematic design methodologies for a variety of modular devices.

Automated summary

In this study, a multi-objective optimization model was established for hierarchical numbering-up of modular reactors, considering flow uniformity, flow resistance, and device volume as optimization objectives. Through an evolutionary optimization algorithm, it was found that appropriate adjustment of reaction channel sizes and hierarchical channel layouts are crucial for achieving large-scale applications.