Chemical Reactor Design and Analysis: A Review

Year : 2025 | Volume : 12 | Issue : 02 | Page : 49 59
    By

    Satish P. Eandole,

  • Santosh Rama Shekokar,

  • N.A. Kharche,

  1. Scholar, Department of Mechanical Engineering, Padmashri Dr. V B Kolte College of Engineering, Malkapur, Maharashtra, India
  2. Professor, Department of Mechanical Engineering, Padmashri Dr. V B Kolte College of Engineering, Malkapur, Maharashtra, India
  3. Professor, Department of Mechanical Engineering, Padmashri Dr. V B Kolte College of Engineering, Malkapur, Maharashtra, India

Abstract

document.addEventListener(‘DOMContentLoaded’,function(){frmFrontForm.scrollToID(‘frm_container_abs_201504’);});Edit Abstract & Keyword

Chemical reactors play a critical role in industries such as oil and gas, chemical processing, and power generation, where they operate under extreme pressure and handle highly toxic, compressible fluids. The growing need for alternative energy sources has led to an increased demand for vessels capable of withstanding high pressure and temperature, especially in the chemical and petroleum industries. Recent innovations in chemical reactor technology have concentrated on creating new grades of materials, developing composites, and improving welding methods. Finite element analysis (FEA) has become an essential tool for examining fatigue and creep behavior, contributing to the enhancement of reactor designs. This review highlights recent advancements in the field of transient dynamic stress analysis, particularly focusing on the application of finite element analysis (FEA) as a tool for evaluating complex stress distributions in mixing chambers. FEA-based simulations have proven effective in predicting fatigue life and identifying critical failure zones, enabling engineers to redesign components for enhanced durability. Moreover, structural optimization techniques, such as topology optimization and design for fatigue resistance, are being increasingly integrated into reactor design workflows. Mixing chambers, a specific type of chemical reactor used in chemical industries, often experience deformation and distortion due to fluctuating pressure and temperature conditions, leading to high local stresses and reduced fatigue life. This review explores the latest advancements in transient dynamic stress analysis and the application of FEA for evaluating stress distribution, fatigue life prediction, and structural optimization of chemical reactors. By using computational fluid dynamics (CFD) and Multiphysics simulation tools such as ANSYS, engineers can analyze the impact of various nozzle configurations on both mechanicalstress and fluid behavior. Additionally, the influence of nozzle design modifications on mixing efficiency is discussed, with a focus on computational validation using simulation tools such as ANSYS. By synthesizing recent developments in materials, design methodologies, and analytical techniques, this review provides insights into improving the resilience, efficiency, and operational safety of mixing chambers and high-performance chemical reactors across various industrial applications.

Keywords: Reactors, finite element analysis (FEA), stress analysis, computational fluid dynamics (CFD), ANSYS

[This article belongs to Recent Trends in Fluid Mechanics ]

How to cite this article:
Satish P. Eandole, Santosh Rama Shekokar, N.A. Kharche. Chemical Reactor Design and Analysis: A Review. Recent Trends in Fluid Mechanics. 2025; 12(02):49-59.
How to cite this URL:
Satish P. Eandole, Santosh Rama Shekokar, N.A. Kharche. Chemical Reactor Design and Analysis: A Review. Recent Trends in Fluid Mechanics. 2025; 12(02):49-59. Available from: https://journals.stmjournals.com/rtfm/article=2025/view=0


document.addEventListener(‘DOMContentLoaded’,function(){frmFrontForm.scrollToID(‘frm_container_ref_201504’);});Edit

References

  1.  Alam S, Yandek GR, Lee RC, Mabry JM. Design and development of a filament wound composite overwrapped pressure vessel. Compos C: Open Access. 2020 Oct 1;2:100045.
  2.  Arumugam T, Karuppanan S, Ovinis M. Finite element analyses of corroded pipeline with single defect subjected to internal pressure and axial compressive stress. Mar Struct. 2020 Jul 1;72:102746.
  3. ASM E. Boiler and pressure vessel code. Section IX Welding and Brazing Qualifications, American Society Mechanical Engineers. 2009.
  4. Zhiming L, Jie J, Zengliang, and G, Yi Q. Effects of axial deformation load on in-plane instability of U-shaped bellows. J Press Vessel Technol. 2003 Nov 1;125(4):475–7.
  5. Azeem M, Hamdan HY, Alam MA, Kumar M, Sajid Z, Gohery S, Maziz A, Gemi L, Abdullah SS, Khan SH. Influence of winding angles on hoop stress in composite pressure vessels: Finite element analysis. Results Eng. 2024 Mar 1;21:101667.
  6.  Baadal A, Eachan C, Gabor G, Jabali I, Zacarias Y. Pressure intensity factor interface in cylindrical vessel through crack using finite element approaches. World Eng Appl Sci J. 2023;14(04):389–93.
  7.  Bhople N, Sapkal N, Malwe P, Deshmukh D, Nikam M, Notla S. A review on effects of cryo treatment on tungsten carbide tools and its expected outcomes in micromachining. RAMMML. 2024 Jun;17:398–405.
  8.  Bhoskar A, Deshmukh D, Kakade S, Kalyankar V. Analysis of a plug stem failure in a pneumatic control valve. Can Metall Q. 2025 Mar;8:1–9.
  9.  Bhoskar A, Kalyankar V, Deshmukh D. Metallurgical characterisation of multi-track Stellite 6 coating on SS316L substrate. Can Metall Q. 2023 Oct 2;62(4):665–77.
  10.  Bhoskar A, Kalyankar V, Deshmukh D. Implications of FCC and HCP cobalt phases on wear performance of weld deposited cobalt-based coating. Results Surf Interfaces. 2024 Aug 1;16:100247.
  11.  Bhoskar A, Naik H, Kalyankar V, Deshmukh D. Nickel-based metallurgical coating architectures for superior wear resistance in high-temperature P91 steel applications. JALMES. 2025 Mar 1;9:100151.
  12. Boresi AP, Schmidt RJ. Advanced mechanics of materials. John Wiley & Sons; 2002 Oct 22.
  13. Chaudhari AY, Deshmukh DD. Metallurgical investigations on corrosion behavior of simple and heat treated duplex stainless steel 2205 exposed to corrosive media. InIOP Conference Series: Materials Science and Engineering 2020 Mar 1 (Vol. 810, No. 1, p. 012048). IOP Publishing.
  14. Chavan HA, Deshmukh DD. Productivity improvement of automotive rod forming process by simultaneous operation using FE simulation. Int J Mod Manuf Technol (IJMMT). 2021 Jan 1;13(1):26–34.
  15. Chavan HA, Wani VP. Design of combination tool for an automotive component with process optimization in metal forming. Int J Interact Des Manuf (IJIDeM). 2019 Mar 12;13(1):401–12.
  16.  Deshmukh DD, Kalyankar VD. Recent status of overlay by plasma transferred arc welding technique. Int J Mater Prod Technol. 2018;56(1-2):23–83.
  17. Deshmukh DD, Kalyankar VD. Deposition characteristics of multitrack overlay by plasma transferred arc welding on SS316Lwith Co-Cr based alloy–influence of process parameters. High Temp Mater Process. 2019 Feb 25;38(2019):248–63.
  18.  Deshmukh DD, Kalyankar VD. Evaluation of surface characteristics of PTAW hardfacing based on energy and powder supplied. InAdvances in Micro and Nano Manufacturing and Surface Engineering: Proceedings of AIMTDR 2018 2019 Dec 1 (pp. 547–558). Singapore: Springer Singapore.
  19. Deshmukh DD, Kalyankar VD. Analysis of deposition efficiency and distortion during multitrack overlay by plasma transferred arc welding of Co–Cr alloy on 316L stainless steel. J Adv Manuf Syst. 2021 Dec;20(04):705–28.
  20.  Deshmukh DD, Kharche Y. Influence of processing conditions on the tensile strength and failure pattern of resistance spot welded SS 316L sheet joint. Int J Interact Des Manuf (IJIDeM). 2025 Jan;19(1):559–71.
  21. Deshmukh DD, Hyalij NS, Kakade SP. Investigations on premature failure of 9Cr-Mo elbow during operation applied in power industry. Materials Today: Proceedings. 2021 Jan 1;44:4843–6.
  22.  Deshmukh D, Kakade S, Kabudke P, Mhaske M, Dond D. Investigations on hardfacing characteristics of Ni-based alloy on ASS 304 using plasma transferred arc welding at different speeds. Int J Mod Manuf Technol (IJMMT). 2024 Jul 1;16(2):32–40.
  23. Di Patrizio N, Bagnaro M, Gaunand A, Hochepied JF, Horbez D, Pitiot P. Hydrodynamics and mixing performance of Hartridge Roughton mixers: Influence of the mixing chamber design. Chem Eng J. 2016 Jan 1;283:375–87.
  24. Gabor G, Jabali I, Naagarjun L, Paal O, Baadal A. Investigating the effect of semi-elliptical crack on the failure of pressure vessels using finite element analysis. Asian J Basic Appl Sci. 2023;10(06):300–3.
  25.  Imran M, Shi D, Tong L, Waqas HM. Design optimization of composite submerged cylindrical pressure hull using genetic algorithm and finite element analysis. Ocean Eng. 2019 Oct 15;190:106443.
  26. Johnson WR, Zhu XK, Sindelar R, Wiersma B. A parametric finite element study for determining burst strength of thin and thick-walled pressure vessels. Int J Press Vessels Pip. 2023 Aug 1;204:104968.
  27.  Kakade SP, Thakur AG, Deshmukh DD, Patil SB. Experimental investigations and optimisation of Ni-Cr-B-Si hardfacing characteristics deposited by PTAW process on SS 410 using response surface method. Adv Mater Process Technol. 2023 Jul 3;9(3):826–42.
  28. Kakade S, Thakur A. Comparative analysis and investigations of welding processes applied for hardfacing using AHP. Int J Mod Manuf Technol (IJMMT). 2021 Jan 1;13(1):53–63.
  29.  Kakade S, Thakur A, Patil S, Deshmukh D. Experimental evaluation and correlation of plasma transferred arc welding parameters with hardfacing defects. InRecent Advances in Material, Manufacturing, and Machine Learning 2023 May 26 (pp. 326–331). CRC Press.
  30.  Kalyankar VD, Deshmukh DD. Failure investigations of failed valve plug SS410 steel due to cracking. InIOP Conference Series: Materials Science and Engineering 2017 Dec 1 (Vol. 282, No. 1, p. 012007). IOP Publishing.
  31.  Kalyankar V, Bhoskar A, Deshmukh D, Patil S. On the performance of metallurgical behaviour of Stellite 6 cladding deposited on SS316L substrate with PTAW process. Can Metall Q. 2022 Apr 3;61(2):130–44.
  32. Khan SM. Stress distributions in a horizontal pressure vessel and the saddle supports. Int J Press Vessels Pip. 2010 May 1;87(5):239–44.
  33.  Kong F, Kim HD. Starting transient simulation of a vacuum ejector-diffuser system under Chevron effects. International Conference on Heat Transfer, Fluid Mechanics and Thermodynamics. 14 – 16 July 2014, (pp. 955–959), Orlando, Florida.
  34. Marques ES, Silva FJ, Pereira AB. Comparison of finite element methods in fusion welding processes—A review. Metals. 2020 Jan 2;10(1):75.
  35. Naik HV, Deshmukh DD, Kalyankar VD. Study of heat treatment effect on microstructure of PTA weld deposited surface of SS 316L steel. InAdvances in Additive Manufacturing and Joining: Proceedings of AIMTDR 2018 2019 Oct 17 (pp. 597–607). Singapore: Springer Singapore.
  36. Okodi A, Lin M, Yoosef-Ghodsi N, Kainat M, Hassanien S, Adeeb S. Crack propagation and burst pressure of longitudinally cracked pipelines using extended finite element method. Int J Press Vessels Pip. 2020 Jul 1;184:104115.
  37.  Paal O, Udichi S, Waen W, Zacarias Y, Baadal A. Exploring the Consequence of Stress Concentration Elements on the Breakdown of Pressure Vessels. Int J Technol Sci Res. 2023;13(06):4401–6.
  38. Pande SS, Darade PD, Gogate G. Transient analysis and fatigue life prediction of tubesheet. Int J Res Eng Technol. 2014 Sep;3(09):464–71.
  39. Kashid MM, Patil MD, Kumbhojkar MA. Design and analysis of balanced stiffness valve by using finite element analysis. Int J Eng Dev Res. 2016 Jul;4(3):330–9.
  40. Qadir M, Redekop D. SCF analysis of a pressurized vessel–nozzle intersection with wall thinning damage. Int J Press Vessels Pip. 2009 Aug 1;86(8):541–9.
  41.  Rafiee R, Torabi MA. Stochastic prediction of burst pressure in composite pressure vessels. Compos Struct. 2018 Feb 1;185:573–83.
  42.  Sanal Z. Nonlinear analysis of pressure vessels: some examples. Int J Press Vessels Pip. 2000 Oct 1;77(12):705–9.
  43.  Shekokar SR, Chavan HA, Choudhari RM, Kharche NA, Kharche YA, Deshmukh DD. Investigation in the influence of the composition of metal ferrite-based composites on the dielectric constant through response surface methodology. J Inst Eng (India): Series D. 2024 Jun 6:1–9.
  44.  Prasanna P, Sushma J, Srikanth KP. Stress analysis and design optimization of a pressure vessel using Ansys package. Materials Today: Proc. 2018 Jan 1;5(2):4551–62.
  45.  Udichi S, Waen W, Zacarias Y, Eachan C, Baadal A. Researching the influence of semi-elliptical crack on the failure of pressure vessels operating finite element analysis. Eur J Sci Appl Sci. 2023;10(06):1099–104.
  46.  Wagh SV, Jagtap SG, Sable MJ, Deshmukh D. Metallurgical characterization of Cr2O3 and Al2O3 coatings on SS 316L: Implications for durability in desalination environments. Trans Indian Inst Met. 2025 Mar;78(3):1–4.
  47. Wasewar KL, Sarathi JV. CFD modelling and simulation of jet mixed tanks. Eng Appl Comput Fluid Mech. 2008 Jan 1;2(2):155–71.
Regular Issue Subscription Review Article
Volume 12
Issue 02
Received 24/04/2025
Accepted 30/05/2025
Published 10/07/2025
Publication Time 77 Days
118

[last_name]

My IP

PlumX Metrics