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Volume 109
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Particle-resolved CFD study of liquid axial penetration and lateral spreading in an ordered trickle bed reactor
A. Tavanaei a, D.R. Rieder a b, M.W. Baltussen a *, K.A. Buist a, J.A.M. Kuipers a
a Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, P.O. Box 513, 5600 MB, Eindhoven, the Netherlands
b Department of Mechanical Engineering, Eindhoven University of Technology, P.O. Box 513, 5600 MB Eindhoven, the Netherlands
10.1016/j.partic.2025.12.025
Volume 109, February 2026, Pages 302-311
Received 8 October 2025, Revised 20 December 2025, Accepted 28 December 2025, Available online 12 January 2026, Version of Record 28 January 2026.
E-mail: m.w.baltussen@tue.nl
Highlights

• Systematic study of wetting characteristics of trickle bed reactors.

• Computational fluid dynamics study for wetting in trickle beds.

• Determined the contributing forces that drive the wetting in trickle bed reactors.

• Dominate force in axial spreading of the liquid is gravity.

• Gas flow is a dominant factor in the lateral spreading.


Abstract

Trickle bed reactors are frequently applied in the chemical process industries for gas-liquid-solid contacting. The performance of these reactors is sensitively influenced by the hydrodynamics. This study focuses on investigating the complex interaction between the gas and liquid phases in these reactors. Specifically, the effects of inlet liquid flux, surface wettability, and gas velocity on lateral spreading and axial penetration of the liquid are explored. An ordered trickle bed is used to reduce the effects of the configuration of the particles on these parameters. Using Direct Numerical Simulation (DNS), we determined that the lateral spreading and axial penetration are enhanced with an increased liquid flux, as expected. Interestingly, the initial liquid inertia, represented by the liquid jet velocity, has limited influence on both lateral spreading and axial penetration in the ordered bed, while the gravitational force is the dominant factor for the axial penetration. Furthermore, the contact angle has minimal impact on lateral spreading, indicating the presence of an additional force restricting spreading. Notably, the gas velocity is identified as a crucial factor influencing lateral spreading, as high velocities prevent the capillary forces from spreading the liquid. These insights in the contributing forces on the spreading behaviour in trickle bed reactors facilitate an improved reactor design and optimization.

Graphical abstract
Keywords
Trickle bed; Liquid distribution; Direct numerical simulation; Volume of fluid
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