Numerical Methods for Thermo-Structural Analysis in Tubular Heat Exchanger Reactors for Synthetic Fuel Production

The transition to sustainable energy sources has intensified interest in synthetic fuel production, offering an alternative to fossil fuels. Tubular heat exchanger reactors play a critical role in this process, enabling efficient thermal exchange and chemical reactions under extreme operating conditions. However, these reactors face significant challenges related to thermal gradients, structural stresses, and long-term material degradation, requiring advanced numerical tools for accurate analyses. This study presents the development and application of numerical methods for the thermo-structural analysis of tubular heat exchanger reactors. A comprehensive approach was adopted to assess the thermal and mechanical behaviour of reactor components, incorporating material properties such as creep characteristics. Thermal simulations revealed significant temperature gradients across the reactor walls. Thermo-structural analyses were performed comparing two different materials, considering the effects of tensile loads, internal pressure, and creep phenomena. Special attention was given to the structural influence of the catalyst mass housed within the tubes. Additionally, different mounting strategies were evaluated. This work highlights the crucial role of advanced numerical modelling techniques in the design of efficient and durable tubular reactors, supporting the development of enhanced synthetic fuel production processes. Future work will focus on the detailed analysis of the manifold system and structural connections.