| Summary: | The concentration of residual O<sub>2</sub> in oxy-fuel combustion flue gas needs to be reduced before CO<sub>2</sub> transportation, utilization, or storage. An original application of the printed circuit heat exchanger (PCHE) for catalytic combustion with natural gas (catalytic deoxygenation) is described for reducing the residual O<sub>2</sub> concentration. The PCHE design features multiple adiabatic packed beds with interstage cooling and fuel injection, allowing precise control over the reaction extent and temperature within each reaction stage through the manipulation of fuel and utility flow rates. This work describes the design of a PCHE for methane–oxygen catalytic combustion where the catalyst loading is minimized while reducing the O<sub>2</sub> concentration from 3 vol% to 100 ppmv, considering a maximum adiabatic temperature rise of 50 °C per stage. Each PCHE design differs by the number of reaction stages and its individual bed lengths. As part of the design process, a one-dimensional transient reduced-order reactor model (1D ROM) was developed and compared to temperature and species concentration axial profiles from 3D CFD simulations. The final design consists of five reaction stages and four heat exchanger sections, providing a PCHE length of 1.09 m at a processing rate of 12.3 kg/s flue gas per m<sup>3</sup> PCHE.
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