The reactor is central to most chemical processes, making optimal reactor design crucial for enhancing energy and raw material efficiency. To advance chemical reactor technology and address current limitations, process intensification (PI) must be systematically integrated into reactor design. This thesis presents a model-based design methodology that incorporates PI options for creating innovative, tailor-made reactors. The initial section outlines the fundamentals of reactor design and explains the design framework, centered on the conceptual framework of elementary process functions. It tracks a fluid element through the reactor, optimizing flux profiles to achieve ideal reaction conditions throughout its residence time. A three-step methodology is developed to tackle the complex reactor design challenge. The second part of the thesis explores several industrially significant examples of increasing complexity, including SO2 oxidation, the air and oxygen-based ethylene oxide process, and the hydroformylation of long-chain linear alkenes, showcasing the method's versatility. Ultimately, this reactor design methodology facilitates the creation of optimal, customized chemical reactors, marking a significant step toward more economical, greener, and sustainable chemical processes, as demonstrated through the analysis of three key industrial processes.
