Reactor in a reactor in a shoebox

In the BMWK joint project “3D-PROCESS”, researchers from Evonik, KIT and Siemens are developing innovative reactor concepts that fit into a shoebox. At KIT the institutes IMVT, IKFT and ITCP contribute to the project. The 3D-printed reactors are designed to reduce the use of resources and the energy required for chemical processes. One possible area of application is the chemical synthesis of complex molecules, for example for active pharmaceutical ingredients. In the production of basic chemicals such as methanol, 3D printing offers the advantage that several functions (reaction, heating, cooling, heat recovery, condensation) can be integrated into one reactor. The special feature: The reactors consist of only one material - which simplifies recycling. The function of the components is based solely on their shape. The digital design process ranges from modelling the thermodynamic process to geometry optimization based on CAD or generative design - including AI and multiphysical 3D simulation. Precisely designed thermofluidic geometries enable maximum heat integration. Maximum heat integration means high energy efficiency of the process.

At Formnex in November 2024, the consortium led by Evonik and Siemens won the “Formnex Design Award”.