Numerical investigation of heat transfer and temperature distribution in a Microwave-Heated Heli-Flow reactor and experimental validation

Microwave-heated flow systems (MWFSs), offering improved process control, enhanced product yields, and the potential for scalable and sustainable manufacturing routes, have gained significant popularity in continuously manufacturing nanomaterials and their hybrids. Temperature control in a microwave zone can maintain fine control over the manufactured materials' properties; however, the current state-of-the-art designs lack monitoring of the temperature distribution throughout the flow reactor. Herein, a unique model of numerical estimations of temperature distribution in a microwave-heated system featuring a helical flow milli-reactor, HeliFlow, is described and validated by experimentally acquired temperature profiles. The proposed numerical model accurately predicts the temperature profile along the Heli-Flow and the steady-state outlet temperature at the MW cavity's exit. The helical design of the reactor promotes homogeneous heating and eliminates orientation-related discrepancies. The maximum outlet temperatures achieved at different microwave powers and FRs align well with expected trends. The modeled temperatures closely match the experimental and analytical measurements, indicating the effectiveness of the simulation approach. This research contributes to understanding temperature distribution in MWFSs and offers insights for optimizing nanomaterial synthesis and other applications.