A systematic procedure for the virtual reconstruction of open-cell foams

Open-cell foams are considered a potential candidate as an innovative catalyst support in many processes of the chemical industry. In this respect, a deeper understanding of the transport phenomena in such structures can promote their extensive application. In this contribution, we propose a general procedure to recover a representative open-cell structure starting from some easily obtained information. In particular, we adopt a realistic description of the foam geometry by considering clusters of solid material at nodes and different strut-cross sectional shapes depending on the void fraction. The methodology avoids time-consuming and expensive measuring techniques, such as micro-computed tomography (μCT) or magnetic resonance imaging (MRI). Computational Fluid Dynamics (CFD) could be a powerful instrument to enable accurate analyses of the complex flow field and of the gas-to-solid heat and mass transport. The reconstructed geometry can be easily exploited to generate a suitable computational domain allowing for the detailed investigation of the transport properties on a realistic foam structure by means of CFD simulations. Moreover, the proposed methodology easily allows for parametric sensitivity analysis of the foam performances, thus being an instrument for the advanced design of these structures. The geometrical properties of the reconstructed foams are in good agreement with experimental measurements. The flow field established in complex tridimensional geometries reproduces the real foam behavior as proved by the comparison between numerical simulations and experiments.