CFD Validation of a Methanation Reactor With Cooling Jacket Used in an ISRU Propellant Production System

A digital model of an OxEon Energy methanation reactor (with a cooling jacket) planned for use in a NASA designed In-Situ Resource Utilization (ISRU) propellant production system was developed by the UTEP Aerospace Center using STAR-CCM+ software, a Siemens Computational Fluid Dynamics (CFD) package. The reactor digital model created includes two primary components: (i) a cooling jacket that maintains the required reactor chamber surface temperature and (ii) a reactor core chamber where the exothermic methanation reactions occur. The StarCCM+ digital model has two objectives: (i) maintain the surface temperature of the reactor below a set value so that the extra heat accumulation does not melt or crack the chamber, and (ii) produce the desired amount of methane (CH4) according to test cases completed by OxEon Energy for NASA JSC. The computational digital model was validated with the test data enabling the cooling jacket scale to be predicted based on the reactor's operating temperature. The StarCCM+ simulation of the digital model shows a good agreement with the cooling jacket performance and the CH4 production. One test case for the cooling jacket maintained the reactor wall temperature around 310 °C was validated and the reactor produced 185 g/hr CH₄.