Advances in design of internals: Applications in conventional and process intensification units

Internals within reactors play an important role in the chemical industry, and numerous studies focus on their investigation and development. This review discusses the application of internals in both conventional and Process Intensification (PI) units, including stirred tanks, fluidized beds, bubble columns, tubular vessels, trickle beds, spinning disks, rotating packed beds, rotating fluidized beds, and microreactors. It emphasizes enhancing mass and heat transfer through internals such as baffles, packing, heat exchange elements, and wall modifications. Recurring themes include phase distribution, interfacial area, slip velocities, heat transfer, and pressure drop. While internals offer benefits, challenges such as fouling and catalyst attrition are acknowledged, yet often under -quantified. Practical aspects, including manufacturing and safety, are often overlooked. The review highlights the urgent need for comprehensive evaluations, incorporating detailed Computational Fluid Dynamics (CFD) simulations and experimental studies. Based on previous research, this work aims to provide insights into innovative reactor designs that ultimately lead to optimal efficiency and energy balance in chemical processes.