Phase-change heat transfer enhancement in in-line high shear reactors via a pore-array distributor

High shear reactors (HSRs) are effective for rapid reactions due to their superior micro-mixing and mass transfer capabilities. However, their application in highly exothermic reactions is often constrained by insufficient heat dissipation. Direct contact phase-change heat transfer (DC-PCHT), utilizing low-boiling-point inert fluids for latent heat exchange, presents a potential breakthrough for intensified temperature control, but its integration within HSRs remains underexplored. This study investigates the synergistic coupling of DC-PCHT and HSRs using response surface methodology with n-pentane–water model system, focusing on the role of liquid distributors in enhancing heat transfer performance. By integrating experimental measurements, we quantify heat transfer performance via volumetric heat transfer coefficients and vaporization rates, and systematically evaluate the effects of operating parameters (rotor speed, temperature difference, flow rate) and distributor structure (pore diameter, distributor outer diameter, number of pore rows). Results reveal that distributor-induced pre-dispersion and localized shear significantly boost thermal performance, with up to 8.98% improvement in volumetric heat transfer coefficient. A dimensionless correlation is established to guide scale-up and structural design. This work provides mechanistic insight into phase-change-enhanced heat transfer in HSRs and offers a scalable strategy for managing high thermal loads in multiphase reactive systems.