Analysis of configurational factors that influence the reversibility of nonstoichiometric countercurrent thermal reduction reactors

Recently, thermodynamic modeling has demonstrated that reduction of nonstoichiometric oxides in a counterflow gas current with a single inlet and exit must result in an equilibrium temperature gradient that deviates from the typically assumed isothermal operation at every single point but one, under assumed mass balance constraints. This necessity for a temperature gradient results in real processes that are near isothermal to deviate from the ideal reversible process, except for the single point where the Gibbs free energy change is zero. In this paper, new configurations with additional inlets and exits that can better approximate reversible and isothermal countercurrent flow reactors are considered and thermodynamically modeled. We show that it is possible to decrease irreversibilities while operating under the same maximum temperature, gas flowrates and initial nonstoichiometry simply by employing two or more exits and/or inlets. Under the most optimal conditions where the normalized irreversibilities are lowest, utilizing either an extra exit or extra inlet and exit show improved results in terms of minimizing the Gibbs free energy and lowering the needed separation work for the gases. Generally, as more irreversibilities are generated within the reactor, the more significant the usage of extra inlets/exits becomes.