This project focuses on developing parallel milli-reactor systems for the selective oxidation of n-butane to maleic anhydride. The core of the work involves reactor design and flow optimization using computational fluid dynamics (CFD), with special emphasis on internal geometric features (baffles, inserts and guiding structures) to intensify mixing, heat management and reaction-zone uniformity.

A detailed gas-phase oxidation kinetic mechanism was incorporated into the CFD model, and the reaction kinetics were validated against Müller (2024) experimental data to ensure high fidelity. After validation, systematic CFD studies were performed to optimize GHSV, reaction temperature, n-butane feed concentration, oxygen ratio and residence time distribution to meet industrial performance targets for conversion, selectivity and maleic anhydride yield.

The study also evaluates industrial operability, including hotspot suppression, pressure drop, scale-out feasibility, and impact of channel parallelization for refinery-scale deployment. The CFD-established optimal conditions will serve as the basis for subsequent prototype fabrication and pilot testing in Phase-II of the project.

Funding agency:  Bharat Petroleum Corporation Limited (BPCL) R&D

Team: Dr. V. M. Rajesh (Principal Investigator), Dr. Sanjeev Yadav (Co-PI), Prof. R. P. Chhabra (Co-PI), Dr. Karan Gupta (Co-PI), Mr. Varun Kumar (PhD Scholar) from the Department of Chemical Engineering