Abstract

This study presents the first experimental validation of a theoretical model for predicting pressure drop in dual-cell density monoliths, a configuration aimed at optimizing flow distribution in industrial catalytic reactors. 3D-printed monoliths, featuring two concentric regions — core and ring — were employed to systematically investigate variations in core size and relative permeability between regions. The monoliths were tested over a wide range of Reynolds numbers using a custom-built experimental rig. The results demonstrate strong agreement with the model's predictions and confirm its accuracy in estimating pressure drop under different configurations. Complementary CFD simulations further support the experimental results and provide additional insights into the effects of model assumptions on pressure drop predictions. The study validates the model as a useful tool for engineering applications, offering valuable insights for the design and optimization of non-homogeneous monolith substrates in industrial catalytic systems. © 2025