Numerical solution-based algorithm assisted development of a continuous flow microwave reactor

Continuous flow microwave heating is a sustainable technology favored in the chemical and food processing sectors due to its short residence time and relatively low environmental footprint. To address the complexity of fluid dynamics and electromagnetic field interactions, nuanced evaluation methods beyond conventional reflection coefficient analysis are necessary to predict its efficiency and uniformity. In this study, a numerical solution-based algorithm is utilized to propose synchrony and cumulative index metrics for performance analysis. Although identical S-parameter systems demonstrate approximate electromagnetic power loss density in the fluid region, significant disparities in heating performance are observed, evidenced by outlet temperatures ranging between 108.10 °C and 147.09 °C, and covariances ranging from 0.07 to 0.46. The power loss density is corrected based on velocity to introduce the synchrony index, which is further calculated into the cumulative index. This approach provides accurate predictions of efficiency and uniformity, informing system designs that align with specific performance objectives. To achieve the best uniformity in simulated two-part systems, a combination of 63 % GIM system and 37 % EBH-2 system in terms of power input was found to be optimal. However, when considering temperature dependent dielectric properties, the optimal combination was adjusted to 60 % GIM system and 40 % EBH-4 system. The numerical solution-based algorithm facilitates optimization of complex continuous flow microwave systems, providing invaluable insights into the time–space electromagnetic response mechanism of fluids.