A multi-objective optimization of methylcyclohexane dehydrogenation via microwave-enhanced process: 3D multiphysics simulation and response surface methodology

Microwave enhancement technology has been explored to improve methylcyclohexane (MCH) dehydrogenation. However, comprehensive studies on multiphysics coupling and parameter optimization of these systems remain limited. In this paper, a 3D multiphysics coupling model, integrating chemical reactions, heat transfer, electromagnetic waves, and porous media flow, was developed using COMSOL Multiphysics to study MCH dehydrogenation. Response Surface Methodology (RSM) and Box-Behnken Design (BBD) were used to analyze the influence of parameters and optimize the operating conditions. The results showed that the conversion rate of microwave heating was nearly 70% higher than that of conventional heating, and the feed rate and temperature had the greatest influence on the conversion rate. Under the optimal conditions (623 K, 0.1 bar, carrier-gas ratio 1, feed rate 0.173 g/min), the conversion rate was 86.3%, and the hydrogen production rate was 1820 mmol/gPt/ min. This study provides a theoretical basis for the development of efficient microwave enhanced MCH dehydrogenation reactor.