Intensified silicon carbide heat-exchanger reactor for exothermic catalytic reactions

This project studies how to design and test a silicon‑carbide (SiC) heat‑exchanger reactor that can handle very exothermic catalytic reactions. The epoxidation of cyclohexene with an organic peroxide is used as a model reaction. First, a batch stirred reactor is used to screen possible catalyst materials and to measure the reaction kinetics under controlled conditions. Next, a continuous milli‑fixed‑bed reactor is built inside a high‑thermal‑conductivity SiC heat exchanger. This design aims to keep the reaction safe and at a constant temperature. The reactor’s performance is examined with detailed multiphysics simulations. The models calculate how conversion, epoxide yield, and temperature change along the catalytic bed. Because SiC conducts heat very well,

the approach helps prevent hot spots and thermal runaway in highly exothermic processes. The simulation‑driven design method can guide scale‑up and optimization of continuous‑flow catalytic systems, showing that structured SiC heat‑exchanger reactors are a practical way to intensify chemical processes.

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