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Improving the synthetic methanol production efficiency is essential foradopting carbon-neutral methanol technologies. In the present computationalfluid dynamics (CFD) study, we investigate synthetic methanol (CH$_3$OH)production in a milli-duct with a rectangular cross-section. The duct involvescatalytic wall reactions with CO$_2$ and H$_2$ as reactants. Direct numericalsimulations are carried out at bulk Reynolds numbers $Re_\mathrm{b} =$ 100,500, 1100 and 2200 spanning laminar and turbulent flow regimes. We investigatea high catalyst loading, corresponding to gas hourly space velocity values ofGHSV = 0.086, 0.44, 0.96 and 1.93 m$^3$/(kg$_\mathrm{cat}$ h). The resultsconsist of the following features. 1) Turbulent mixing may significantlyenhance methanol production under transport-limited chemistry, increasing themethanol mass flow rate at the outlet up to 56.4 % in the duct. 2) The reactionrate reaches local minima/maxima in the turbulent ejection/sweep structuresobserved in the proximity of the catalytic walls, respectively. 3) Thesingle-pass conversion efficiency of CO$_2$ and the methanol yield across theduct decrease monotonically as the Reynolds number increases (lower residencetime), while in contrast, the methanol mass flow rate at the outlet increasesas $Re_\mathrm{b}$ increases (higher reactant inflow). These results suggestthat turbulent transport could be leveraged to improve methanol yield instraight millichannels, albeit at the cost of increased reactant recycling.

Turbulence impacts synthetic methanol production in a square duct flow: a direct numerical simulation (DNS) study