Design and Finite Element Simulation of Hydrothermal Carbonization Reactor

Abstract

This study presents the design and simulation of a Hydrothermal Carbonization (HTC) bioreactor using finite element analysis (FEA) to evaluate its structural integrity under high temperature and high-pressure operating conditions. The bioreactor, constructed from Stainless Steel 304 with a 5 mm wall thickness and designed to operate at 10 MPa and 300 °C, was analyzed for pressure distribution, thermal stress, Von Mises stress, safety factor, fatigue life, buckling resistance, and combined thermo-mechanical loading. Results showed that the reactor maintains structural stability with stress levels below the material yield limit and acceptable safety factors. Localized fatigue concerns were observed around geometrical discontinuities, emphasizing the need for targeted reinforcement. The combined fatigue thermal–structural life analysis confirms the reactor’s suitability for prolonged cyclic operation. Overall, the bioreactor design is robust and efficient, supporting its application in sustainable biomass conversion processes.