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Advanced fluidized bed reactor performance: Optimizing residence time distribution through helical screw induced rotation (HSIR).

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Title: Advanced fluidized bed reactor performance: Optimizing residence time distribution through helical screw induced rotation (HSIR).
Authors: Javanmard, Arash1,2 (AUTHOR) arash.javanmard2020@gmail.com, Zuki, Fathiah Mohamed1,2 (AUTHOR) fathiahmz@um.edu.my, Daud, Wan Mohd Ashri Wan1,2 (AUTHOR), Patah, Muhamad Fazly Abdul1,2 (AUTHOR)
Source: Canadian Journal of Chemical Engineering. Apr2026, Vol. 104 Issue 4, p2104-2120. 17p.
Subjects: Multi-objective optimization, Continuous flow reactors, Fluidized bed reactors, Response surfaces (Statistics)
Abstract: Optimizing flow behaviour and residence time distribution (RTD) is crucial for achieving steady‐state operation in continuous reactors. This study employs a multi‐objective optimization framework to enhance reactor performance by investigating the effects of feeder rotation speed (FRS) and helical screw rotation speed (HSRS) on key RTD parameters. Unlike traditional response surface methodology (RSM), which may struggle with complex factor interactions, this approach integrates definitive screening design (DSD), I‐optimal Design, and desirability analysis to achieve a more precise and robust optimization. Residual analysis confirmed model validity, while perturbation, contour, and 3D surface plots revealed significant non‐linear interactions between FRS and HSRS. The desirability plot identified an optimal region at lower HSRS (10–40 rpm) and moderate to high FRS (50–100 rpm), maximizing mean residence time (MRT), minimizing axial dispersion (Da), and ensuring stable flow conditions. The overlay plot validated this optimal region by confirming that all constraints were simultaneously satisfied. The strong alignment between desirability‐based optimization and constraint‐based feasibility analysis underscores the superiority of this method over RSM, which often struggles to capture such complex interactions effectively. The findings demonstrate that this optimization framework successfully enhances steady‐state operation by precisely controlling MRT, dispersion, and flow behaviour. Moreover, this methodology is not reactor‐specific and can be effectively applied to any continuous reactor system, providing a versatile tool for improving performance in various industrial processes. The study highlights the advantages of a modern, data‐driven optimization approach in accurately predicting and fine‐tuning reactor conditions, making it a superior alternative to conventional RSM‐based methods. [ABSTRACT FROM AUTHOR]
Copyright of Canadian Journal of Chemical Engineering is the property of Wiley-Blackwell and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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DbLabel: Engineering Source
An: 194055743
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PubTypeId: academicJournal
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  Data: Advanced fluidized bed reactor performance: Optimizing residence time distribution through helical screw induced rotation (HSIR).
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  Data: <searchLink fieldCode="AR" term="%22Javanmard%2C+Arash%22">Javanmard, Arash</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> arash.javanmard2020@gmail.com</i><br /><searchLink fieldCode="AR" term="%22Zuki%2C+Fathiah+Mohamed%22">Zuki, Fathiah Mohamed</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> fathiahmz@um.edu.my</i><br /><searchLink fieldCode="AR" term="%22Daud%2C+Wan+Mohd+Ashri+Wan%22">Daud, Wan Mohd Ashri Wan</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Patah%2C+Muhamad+Fazly+Abdul%22">Patah, Muhamad Fazly Abdul</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Canadian+Journal+of+Chemical+Engineering%22">Canadian Journal of Chemical Engineering</searchLink>. Apr2026, Vol. 104 Issue 4, p2104-2120. 17p.
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  Data: <searchLink fieldCode="DE" term="%22Multi-objective+optimization%22">Multi-objective optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Continuous+flow+reactors%22">Continuous flow reactors</searchLink><br /><searchLink fieldCode="DE" term="%22Fluidized+bed+reactors%22">Fluidized bed reactors</searchLink><br /><searchLink fieldCode="DE" term="%22Response+surfaces+%28Statistics%29%22">Response surfaces (Statistics)</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Optimizing flow behaviour and residence time distribution (RTD) is crucial for achieving steady‐state operation in continuous reactors. This study employs a multi‐objective optimization framework to enhance reactor performance by investigating the effects of feeder rotation speed (FRS) and helical screw rotation speed (HSRS) on key RTD parameters. Unlike traditional response surface methodology (RSM), which may struggle with complex factor interactions, this approach integrates definitive screening design (DSD), I‐optimal Design, and desirability analysis to achieve a more precise and robust optimization. Residual analysis confirmed model validity, while perturbation, contour, and 3D surface plots revealed significant non‐linear interactions between FRS and HSRS. The desirability plot identified an optimal region at lower HSRS (10–40 rpm) and moderate to high FRS (50–100 rpm), maximizing mean residence time (MRT), minimizing axial dispersion (Da), and ensuring stable flow conditions. The overlay plot validated this optimal region by confirming that all constraints were simultaneously satisfied. The strong alignment between desirability‐based optimization and constraint‐based feasibility analysis underscores the superiority of this method over RSM, which often struggles to capture such complex interactions effectively. The findings demonstrate that this optimization framework successfully enhances steady‐state operation by precisely controlling MRT, dispersion, and flow behaviour. Moreover, this methodology is not reactor‐specific and can be effectively applied to any continuous reactor system, providing a versatile tool for improving performance in various industrial processes. The study highlights the advantages of a modern, data‐driven optimization approach in accurately predicting and fine‐tuning reactor conditions, making it a superior alternative to conventional RSM‐based methods. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Canadian Journal of Chemical Engineering is the property of Wiley-Blackwell and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1002/cjce.70100
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      – Code: eng
        Text: English
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        PageCount: 17
        StartPage: 2104
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      – SubjectFull: Multi-objective optimization
        Type: general
      – SubjectFull: Continuous flow reactors
        Type: general
      – SubjectFull: Fluidized bed reactors
        Type: general
      – SubjectFull: Response surfaces (Statistics)
        Type: general
    Titles:
      – TitleFull: Advanced fluidized bed reactor performance: Optimizing residence time distribution through helical screw induced rotation (HSIR).
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            NameFull: Javanmard, Arash
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            NameFull: Zuki, Fathiah Mohamed
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            NameFull: Daud, Wan Mohd Ashri Wan
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            NameFull: Patah, Muhamad Fazly Abdul
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            – D: 01
              M: 04
              Text: Apr2026
              Type: published
              Y: 2026
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            – TitleFull: Canadian Journal of Chemical Engineering
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