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Volume 114
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A numerical study of the influence of pre-wetting on the static liquid hold-up and wetting efficiency in a trickle bed reactor (Open Access)
Arvin Tavanaei, Maike W. Baltussen *, Kay A. Buist, J.A.M. (Hans) Kuipers
Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, P.O. Box 513, 5600 MB, Eindhoven, the Netherlands
10.1016/j.partic.2026.03.032
Volume 114, July 2026, Pages 121-129
Received 26 January 2026, Revised 23 March 2026, Accepted 26 March 2026, Available online 11 April 2026, Version of Record 29 April 2026.
E-mail: m.w.baltussen@tue.nl
Highlights

• Numerical study of the effect of pre-wetting on flow in trickle bed reactors.

• Higher initial wetting leads to increased static holdup.

• Wetting patterns are influenced more by initial wetting than liquid flow rate.

• Wetting efficiency is primarily governed by the liquid flow rate.


Abstract

Trickle beds are widely used in chemical processes due to their significant advantages over other multiphase reactors. However, their operation presents challenges, primarily due to complex hydrodynamic characteristics. One of the most critical challenges is the non-uniform liquid distribution, which leads to inhomogeneous particle wetting and possible adverse effects on process yield and selectivity. In this study, the effects of initial wetting conditions on static liquid hold-up and wetting efficiency were studied using particle-resolved Direct Numerical Simulation (DNS). Our results reveal that the local distribution of initial wetting significantly influences the liquid pathways after start-up, enhancing wetting efficiency compared to that of an initially dry bed. Local variations in pre-wetted beds, however, have minimal impact on wetting efficiency, particularly at high liquid fluxes. Notably, liquid flux plays a more significant role in determining the wetting efficiency of pre-wetted beds.

Graphical abstract
Keywords
Trickle bed; Wetting; Direct numerical simulation; Volume of fluid; Immersed boundary method
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