In this work, we investigate the gas–solid heat and mass transfer in catalytically activated periodic open cellular structures, which are considered a promising solution for intensification of catalytic processes limited by external transport, aiming at the derivation of suitable correlations. Computational fluid dynamics is employed to investigate the Tetrakaidekahedral and Diamond lattice structures. The influence of the morphological features and flow conditions on the external transport properties is assessed. The strut diameter is an adequate characteristic length for the formulation of heat and mass transfer correlations; accordingly, a power-law dependence of the Sherwood number to the Reynolds number between 0.33 and 0.67 was found according to the flow regimes in the range 1–128 of the Reynolds number. An additional −1.5-order dependence on the porosity is found. The formulated correlations are in good agreement with the simulation results and allow for the accurate evaluation of the external transfer coefficients for POCS.

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