Bionic butterfly wing double-gradient gradually-changed aperture methane dry reforming porous foam reactor and optimization method thereof
By employing a butterfly-wing dual-gradient pore size design in a methane dry reforming reactor and optimizing the pore size distribution using a genetic algorithm, the problem of uneven temperature distribution was solved, resulting in a more efficient thermochemical reaction.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-24
- Publication Date
- 2026-03-10
AI Technical Summary
The uneven temperature distribution in solar-driven methane dry reforming reactors affects the stability and reliability of the system.
A biomimetic butterfly-wing dual-gradient pore size methane dry reforming porous foam reactor was developed. The butterfly wing Gyroid structure was used as the unit lattice, and the pore size distribution was optimized by genetic algorithm. The pore size was designed to be gradually varied in both the axial and radial directions. The reactor was then fabricated using 3D printing technology.
It significantly improves temperature uniformity and thermochemical reaction performance, enhances the volumetric absorption capacity of solar energy, expands the chemical reaction zone, and improves reaction efficiency and stability.
Smart Images
Figure CN121623710A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to a methane dry reforming porous foam reactor and an optimization method thereof, in particular to a bionic butterfly wing double-gradient gradient pore size methane dry reforming porous foam reactor and an optimization method thereof. BACKGROUND
[0002] Solar-driven methane dry reforming (DRM) reaction can not only convert two major greenhouse gases, methane and carbon dioxide, but also convert solar energy into chemical energy in products, thus realizing efficient utilization of solar energy. However, the Gaussian distribution of light intensity generated by the solar light concentration system leads to uneven heating of the receiving surface, and the one-sided heating in the photo-thermal driven reaction system further exacerbates the temperature gradient problem inside the reaction system. The porous foam reactor has great potential in the field of solar-driven thermochemical reactions due to its unique light transmission and absorption characteristics, excellent heat conduction and excellent mechanical strength. However, this type of reactor still faces the problem of uneven temperature distribution, which seriously affects the stability and reliability of the system. SUMMARY
[0003] The first object of the present application is to provide a bionic butterfly wing double-gradient gradient pore size methane dry reforming porous foam reactor capable of enhancing the penetration of sunlight, fluid-solid heat exchange capacity, and axial and radial temperature uniformity. The second object of the present application is to provide an optimization method for the bionic butterfly wing double-gradient gradient pore size methane dry reforming porous foam reactor.
[0004] Technical solution: The bionic butterfly wing double-gradient gradient pore size methane dry reforming porous foam reactor of the present application takes the butterfly wing Gyroid structure as a unit lattice, and the pore size of the reactor gradually changes along the axial direction and gradually changes along the radial direction.
[0005] Further, the pore size ranges from 1 to 5 mm.
[0006] The optimization method for the bionic butterfly wing double-gradient gradient pore size methane dry reforming porous foam reactor of the present application comprises:
[0007] S1: Test the concentrated solar radiation energy flow distribution and fit it into a Gaussian distribution curve;
[0008] S2: Take the butterfly wing Gyroid structure as a unit lattice, and use nTopology software to establish a cylindrical uniform foam model;
[0009] S3: Import the Gaussian distribution curve data and the uniform foam model into COMSOL software, establish a multi-physical field model coupling chemical reaction, porous medium flow, fluid-solid heat transfer, solar radiation transmission and absorption, and simulate the reaction process in the porous foam reactor; take solar-fuel efficiency as the optimization target, and configure the pore size And the aperture range, which is optimized using a genetic algorithm to obtain the optimal coefficients. , , ,in Radial position, This refers to the axial position.
[0010] Furthermore, in step S1, the fitted Gaussian distribution curve is: ,in Represents radiative energy flux density. ; , , All are constants.
[0011] Furthermore, in step S3, the genetic algorithm is a single-objective optimization algorithm from the MATLAB toolbox.
[0012] Furthermore, the input-output and variable control between the CFD model and the genetic algorithm are controlled using COMSOL Multiphysics 5.6 with MATLAB, where the variables are... , , The optimization is controlled by a genetic algorithm. First, the variable to be optimized is initialized or updated. Then, the values of other variables related to the optimized variable in the control equation are updated according to the value of the variable to be optimized. The updated variables are input into the COMSOL solver to solve the CFD model, update the pore size and related boundary conditions and empirical formulas, and further obtain new simulation results. The performance of the current foam reactor is evaluated to determine whether the optimization results have converged. The optimization ends when the set conditions are met.
[0013] Furthermore, the setting condition is that the average change in fitness value is less than 1. Or the number of iterations reaches 100.
[0014] Furthermore, in step S3, the aperture The values at the four vertices of the 2D axisymmetric model are restricted to 0.01~14.00 mm; the 2D axisymmetric model is formed by the radius and generatrix of the cylinder.
[0015] Furthermore, the optimization method for the biomimetic butterfly-wing dual-gradient pore size methane dry reforming porous foam reactor also includes:
[0016] S4: Based on the optimal coefficients , , The determined optimal gradient pore size distribution, combined with the butterfly wing Gyroid structure, was used to establish a dual-gradient gradient pore structure model using nTopology software. The biomimetic butterfly wing dual-gradient gradient pore size methane dry reforming porous foam reactor was then fabricated using 3D printing.
[0017] Furthermore, in step S2, the uniformly porous foam model is formed by periodically filling a cubic lattice type; in step S4, when establishing the dual-gradient gradual pore structure model, the axial pore size is achieved by changing the size of the cubic lattice; and the radial pore size is achieved by changing the radial wall thickness of the unit lattice.
[0018] Beneficial effects: Compared with the prior art, the present invention has the following significant advantages:
[0019] The unit structure is inspired by the unique Gyroid structure found on butterfly wings, which possesses high connectivity and excellent specific surface area characteristics, thereby increasing the heat transfer area for thermochemical reactions. Furthermore, by introducing an axial and radial dual-gradient pore structure and optimizing the pore size distribution using a genetic algorithm, a gradient pore size design is achieved. This design enables volumetric solar energy absorption, significantly improving temperature uniformity and thus effectively enhancing thermochemical reaction performance. Compared to traditional uniform-pore-size foam reactors, the TPMS (Tri-Periodic Minimal Surface, a special type of surface that exhibits periodic repetition along three independent directions in three-dimensional space with zero average curvature, possessing advantages such as high specific surface area and low pressure loss) biomimetic continuous gradient pore structure enables gradual heating of the gas, effectively increasing the chemical reaction area and significantly enhancing the efficiency of methane dry reforming reactions. The TPMS biomimetic continuous gradient pore structure of this invention exhibits unique advantages in temperature distribution, better adapting to the needs of methane dry reforming reactions and ensuring the reaction proceeds over a wider area. Meanwhile, the large pores on the surface allow radiation to penetrate the foam structure, enhancing radiation absorption; the small pores at the bottom effectively reduce the fluid-solid temperature difference, achieving uniform heating of the foam interior, thereby improving the overall reaction efficiency. Attached Figure Description
[0020] Figure 1 This is a schematic diagram of the structure of the solar-driven methane dry reforming reactor in an embodiment of the present invention;
[0021] Figure 2 These are scanning electron microscope images of the gyroid structure of a butterfly wing in an embodiment of the present invention;
[0022] Figure 3 These are the COMSOL model verification results in the embodiments of this invention;
[0023] Figure 4 This is a dual-gradient foam pore size distribution designed according to the Gyroid structure in this embodiment of the invention;
[0024] Figure 5 This is a comparison of the foam temperature distribution before and after optimization using COMSOL coupled with MATLAB in this embodiment of the invention;
[0025] Figure 6 These are the infrared thermal imaging results of uniformly porous foam and dual-gradient foam in the embodiments of the present invention;
[0026] Figure 7 These are the stability test results of the simulated sunlight-driven methane dry reforming foam reactor in the embodiments of the present invention;
[0027] Figure 8 This is the average gas reaction rate of a simulated solar-driven methane dry reforming foam reactor in this embodiment of the invention. Detailed Implementation
[0028] This invention combines experiments and simulations, genetic algorithm optimization, and foam structure design to optimize and validate a solar-driven methane dry reforming reactor. The solar-driven methane dry reforming porous foam reactor is shown below. Figure 1 As shown, a solar simulator powered by a xenon lamp simulates sunlight collected by a concentrating system, and the flux on the reactor surface exhibits a Gaussian distribution. Concentrated radiation drives a catalyst loaded on a foam reactor to convert reactant gases (methane and carbon dioxide) into high-value-added syngas (hydrogen and carbon monoxide).
[0029] The present invention will be further described below with reference to the accompanying drawings.
[0030] Example 1: Example 1 provides a biomimetic butterfly wing dual-gradient pore size methane dry reforming porous foam reactor, which uses a butterfly wing Gyroid structure as the unit lattice, and the reactor pore size is gradually changed along the axial direction and also along the radial direction.
[0031] like Figure 2 As shown, after removing the reticulated surface of the green ventral scales on the dorsal surface of the wings of the Green Gray butterfly (Callophrys rubi), SEM images revealed that the scale structure contains crystalline regions several micrometers in size, forming a gyroscopic structure with high connectivity and a large specific surface area. This structure endows the butterfly wings with unique optical properties, as its multiple refractions and reflections effectively improve light utilization.
[0032] Example 2: Example 2 provides an optimization method for the biomimetic butterfly-wing dual-gradient pore size methane dry reforming porous foam reactor described in Example 1, including:
[0033] S1: The distribution of concentrated solar radiation energy flow was tested using a heat flow testing system and fitted to a Gaussian distribution curve.
[0034] This embodiment uses a typical Gaussian radiation maximum energy flux density of 422. The average energy flux density is 188 The total power is 140.5. The Gaussian distribution curve is fitted as follows: , Represents radiative energy flux density. ; =318128.79, =15887.09, =102422.43.
[0035] S2: Using the butterfly wing Gyroid structure as the unit lattice, a cylindrical uniformly porous foam model was established using nTopology software.
[0036] Using the implicit modeling technology provided by nTopology software, a cylinder with a diameter of 30 mm and a height of 30 mm was created as the initial implicit structure of the foam. The Gyroid structure observed on butterfly wings was extracted as the unit lattice, and a cubic lattice type was selected to periodically fill the lattice to form a uniformly porous foam model. By adjusting relevant parameters, precise control was achieved over key features such as the shape, size, and porosity of the foam structure, with a pore size of 1 mm and a porosity of 0.8.
[0037] The method for testing a uniform-pore foam reactor is as follows:
[0038] a. Before testing, measure the energy flow distribution and total energy flow of the system, and control the simulated total solar power to be 140.5. ;
[0039] b. A mixture of methane, carbon dioxide, and nitrogen is introduced for purging and washing. The total flow rate of the mixture is 1000 ml / min, and the volume ratio of methane, carbon dioxide, and nitrogen is 41.5%:38.5%:20.0%. The flow rate is precisely controlled by a mass flow meter.
[0040] c. After the gas washing is completed, turn on the simulated concentrated solar xenon lamp, adjust the position of the reactor so that the radiation shines directly on the foam surface through the viewing window, forming a 30mm concentrated light spot; the catalyst deposited on the surface of the porous foam reactor absorbs light energy and converts it into heat energy, and the photothermal coupling drives the gas reaction; during the test, the reaction gas is continuously introduced, and the generated gas is tested by chromatography.
[0041] Through calculation, this uniform small hole ( The average solar-fuel efficiency of the 1mm foam reactor is 26.65%. and The reaction rates were 38.91 and 45.12, respectively. .
[0042] S3: Import Gaussian distribution curve data and uniform-pore foam model into COMSOL software to establish a multiphysics model coupling chemical reaction, porous media flow, fluid-solid heat transfer, solar radiation transfer and absorption to simulate the reaction process in the porous foam reactor; use solar-fuel efficiency as the optimization objective to configure pore size. And the aperture range, which is optimized using a genetic algorithm to obtain the optimal coefficients. , , ,in Radial position, This refers to the axial position.
[0043] Specifically, a COMSOL simulation optimization model was established based on the experimental results of a uniform-pore foam reactor. The model was verified by comparing the experimental results, and the results are as follows: Figure 3 As shown, the model error is within 5%.
[0044] The optimal aperture distribution was optimized using COMSOL Multiphysics 5.6 with MATLAB. The input-output and variable control between the CFD model and the genetic algorithm were implemented, with the variables being... , , The genetic algorithm used is a single-objective optimization algorithm from the MATLAB toolbox. Aperture The values at the four vertices of the 2D axisymmetric model are restricted to 0.01~14.00mm. The 2D axisymmetric model is formed by the radius and generatrix of the cylinder (the cylinder model can be decomposed into several 2D axisymmetric models along the circumference. The 2D axisymmetric model is used to simplify the calculation).
[0045] The optimization is controlled by a genetic algorithm. First, the variable to be optimized is initialized or updated. Then, other variables related to the optimized variable within the control equation are updated according to the desired value. The updated variables are input into the COMSOL solver to solve the CFD model, updating the pore size, related boundary conditions, and empirical formulas. After obtaining new simulation results, the software is paused. The results are output to the genetic algorithm program to evaluate the current performance of the foam reactor. The performance results are then output to the optimization program, which determines whether the optimization has converged. Optimization ends when a set condition is met: the average change in fitness value is less than 1. Or, the number of iterations reaches 100. The optimal pore size distribution is obtained as follows: Figure 4 As shown, =-0.00378、 =0.13279、 =0.00101, the minimum and maximum apertures are 1.01 mm and 4.995 mm respectively (the present invention selects a 1~5 mm gradient).
[0046] S4: Based on the optimal coefficients , , The determined optimal gradient pore size distribution is combined with the butterfly wing Gyroid structure. A dual gradient pore structure model is established using nTopology software (the specific steps are similar to those of the uniform pore foam model). Then, through field-driven design, the gradient lattice design is achieved by changing the size of the cubic lattice, thus realizing the axial gradient of the pore size; and the radial gradient of the pore size is achieved by changing the radial wall thickness of the unit lattice.
[0047] A biomimetic butterfly-wing-inspired, dual-gradient pore size porous foam reactor for dry reforming of methane was fabricated using high-temperature nickel-based materials via 3D printing for catalyst deposition. The catalyst is... .
[0048] A biomimetic butterfly-wing-inspired, dual-gradient pore size methane dry reforming porous foam reactor was tested using the same method as described above. Calculations showed that this dual-gradient pore size foam reactor achieved an average solar-fuel efficiency of 40.46%. and The reaction rates were 38.91 and 45.12, respectively. .
[0049] This invention, by introducing a dual-gradient gradient pore size structure and integrating a genetic algorithm for fine-tuning the pore size distribution, not only significantly enhances the volumetric absorption capacity of solar energy but also substantially improves the temperature uniformity within the reactor, thereby powerfully driving a leap forward in the performance of solar-driven methane dry reforming reactions. Compared to conventional uniform-pore-size foam reactors, the TPMS biomimetic continuous gradient pore structure employed in this invention effectively expands the chemical reaction zone through gradual gas heating, greatly promoting the efficiency improvement of methane dry reforming reactions.
[0050] like Figure 5 As shown, the biomimetic continuous gradient pore structure of this invention exhibits unique advantages in temperature distribution. Its carefully designed temperature gradient perfectly matches the requirements of the methane dry reforming reaction, ensuring that the reaction can proceed stably and efficiently over a wider range. Furthermore, as... Figure 6 As shown, the large pore design on the surface of this structure allows solar radiation to penetrate deeply into the foam structure, thereby enhancing the radiation absorption efficiency; while the small pore design at the bottom effectively reduces the temperature difference between the fluid and the solid, achieving uniform heating of the internal region of the foam, further improving the overall reaction efficiency and stability (e.g., Figure 7(As shown in Figure 8). This invention demonstrates greater competitiveness and broader application value in the field of solar-driven methane dry reforming. It not only injects new vitality into the development of clean energy technology, but also shows broad prospects for industrial applications.
Claims
1. A biomimetic butterfly wing dual-gradient graded-aperture methane dry-reforming porous foam reactor, characterized in that, The butterfly wing Gyroid structure is taken as a unit lattice, and the reactor aperture is gradually changed along the axial direction and gradually changed along the radial direction.
2. The biomimetic butterfly wing dual-gradient continuously varying aperture methane dry-reforming porous foam reactor according to claim 1, wherein, The aperture ranges from 1 to 5 mm.
3. An optimized method of biomimetic butterfly wing dual-gradient tapered pore methane dry-reforming porous foam reactor as claimed in claim 1 or 2, wherein, It comprises: S1: test the concentrated solar radiation energy flow distribution and fit it into a Gaussian distribution curve; S2: taking the butterfly wing Gyroid structure as a unit lattice, a cylindrical uniform pore foam model is established by using nTopology software; S3: Import the Gaussian distribution curve data and the uniform pore foam model into COMSOL software, establish a multi-physical field model coupling chemical reaction, porous medium flow, fluid-solid heat transfer, solar radiation transmission and absorption, to simulate the reaction process in the porous foam reactor; take the solar-fuel efficiency as the optimization target, configure the pore diameter and pore diameter range, and optimize by genetic algorithm to obtain the optimal coefficient 、 、 , is the radial position, is the axial position.
4. The optimization method of biomimetic butterfly wing dual- gradient metamaterial aperture methane dry-reforming porous foam reactor according to claim 3, characterized in that, In step S1, the fitted Gaussian distribution curve is: wherein represents the radiant energy flow density, ; , , are constants.
5. The optimization method of biomimetic butterfly wing dual- gradient ramped apertures methane dry-reforming porous foam reactor according to claim 3, characterized in that, In step S3, the genetic algorithm selects a single-target optimization algorithm in the MATLAB toolbox.
6. The optimization method of biomimetic butterfly wing dual- gradient ramped apertures methane dry-reforming porous foam reactor according to claim 5, characterized in that, The input and output and variable control between the CFD model and the genetic algorithm are controlled by COMSOL Multiphysics 5.6 with MATLAB, and the variables are , , ; the optimization is controlled by the genetic algorithm, first, the variables to be optimized are initialized or updated, then the values of other variables related to the optimization variables in the control equation are updated according to the values of the variables to be optimized, the updated variables are input into the COMSOL solver to solve the CFD model, the aperture and related boundary conditions and empirical formula are updated, further new simulation results are obtained, the performance of the current foam reactor is evaluated to determine whether the optimization result converges; when the set condition is met, the optimization is ended.
7. The optimization method of biomimetic butterfly wing dual- gradient ramped apertures methane dry-reforming porous foam reactor according to claim 6, characterized in that, The set condition is that the average change in fitness value is less than 1 Or the number of iterations reaches 100.
8. The optimization method of biomimetic butterfly wing dual- gradient ramped apertures methane dry-reforming porous foam reactor according to claim 3, characterized in that, In step S3, the pore size The values on the 4 vertices of the 2D axisymmetric model are limited within 0.01-14.00 mm; the 2D axisymmetric model is formed by the radius and the generatrix of the cylinder.
9. The optimization method of biomimetic butterfly wing dual- gradient ramped apertures methane dry-reforming porous foam reactor according to claim 3, characterized in that, It also comprises: S4: the optimal coefficient is determined according to the optimal coefficient 、 、 The determined optimal gradient pore size distribution is combined with the butterfly wing Gyroid structure, a double gradient gradient pore structure model is established by using nTopology software, and the biomimetic butterfly wing double gradient gradient pore methane dry reforming porous foam reactor is made by 3D printing.
10. The optimization method of biomimetic butterfly wing dual- gradient ramped apertures methane dry-reforming porous foam reactor according to claim 9, characterized in that, In step S2, the uniform pore foam model is formed by selecting a cubic lattice type periodic filling; in step S4, when establishing a double-gradient pore structure model, the aperture is gradually changed along the axial direction by changing the size of the cubic lattice, and the aperture is gradually changed along the radial direction by changing the radial wall thickness of the unit lattice.