Numerical investigation of two-phase flow patterns and carbon deposition in a coaxial-type reactor for molten salt electrolysis

The electrodeposition process of carbon in molten lithium carbonate electrolysis and the associated gas-liquid flow hydrodynamics characteristics are for the first time investigated using computational fluid dynamics (CFD). The high-temperature (750 °C) process is challenging for conducting measurements, making CFD a valuable tool for providing insights into the novel coaxial-type cell design. The CFD simulation addresses the electric field distribution, oxygen gas evolution, and electrodeposition of carbon. The effect of gas bubble sizes (1, 0.8, and 0.6mm) on the electrolysis process was examined at different electrical current densities (0.15 ± 0.01 A cm–2). The CFD results reveal that gas holdup increases by decreasing the bubble size and that the bubble size significantly impacts the current density distribution by affecting the two-phase flow dynamics. The study highlights the potential of CFD for optimization of molten salt processes, while also suggesting the need for further improvements in the model.