Numerical Simulation of an Industrial Fluid Catalytic Cracking Regenerator

2015 ◽  
Vol 7 (2) ◽  
Author(s):  
Guangwu Tang ◽  
Armin K. Silaen ◽  
Bin Wu ◽  
Chenn Q. Zhou ◽  
Dwight Agnello-Dean ◽  
...  
Keyword(s):  
Chemical Reactions ◽  
Catalytic Cracking ◽  
Catalyst Surface ◽  
Three Dimensional ◽  
Fluid Catalytic Cracking ◽  
Solid Catalyst ◽  
Reacting Flow ◽  
Momentum Exchange ◽  
Petroleum Refineries ◽  
Two Phases

Fluid catalytic cracking (FCC) is one of the most important conversion processes in petroleum refineries, and the FCC regenerator is a key part of an FCC unit utilized in the recovery of solid catalyst reactivity by burning off the deposited coke on the catalyst surface. A three-dimensional multiphase, multispecies reacting flow computational fluid dynamics (CFD) model was established to simulate the flow and reactions inside an FCC regenerator. The Euler–Euler approach, where the two phases (gas and solid) are considered to be continuous and fully interpenetrating, is employed. The model includes gas–solid momentum exchange, gas–solid heat exchange, gas–solid mass exchange, and chemical reactions. Chemical reactions incorporated into the model simulate the combustion of coke which is present on the catalyst surface. The simulation results were validated by plant data.

Numerical Simulation of an Industrial Fluid Catalytic Cracking Regenerator

2013 ◽  
Author(s):  
Guangwu Tang ◽  
Armin Silaen ◽  
Bin Wu ◽  
Chenn Q. Zhou ◽  
Dwight Agnello-Dean ◽  
...  
Keyword(s):  
Chemical Reactions ◽  
Catalytic Cracking ◽  
Catalyst Surface ◽  
Solid Phase ◽  
Catalyst Activity ◽  
Cylindrical Vessel ◽  
Fluid Catalytic Cracking ◽  
Solid Catalyst ◽  
Momentum Exchange ◽  
Two Phases

Fluid catalytic cracking (FCC) is one of the most important conversion processes in petroleum refineries, and FCC regenerator is a key part of an FCC unit to recover the solid catalyst activity by burning off the deposited coke on the catalyst surface. In modern FCC units, regenerator is a cylindrical vessel. Carrier gas transports the solid catalyst from the stripper and feeds the catalyst into the regenerator through catalyst distributors. The catalyst is fluidized by the air that is injected into the regenerator through air rings in the bottom part of the cylindrical vessel. A three-dimensional multi-phase, multi-species reacting flow computational fluid dynamics (CFD) model was established to simulate the flow inside an FCC regenerator. The two phases involved in the flow are gas phase and solid phase. The Euler-Euler approach, where the two phases are considered to be continuous and fully inter-penetrating, is employed. The model includes gas-solid momentum exchange, gas-solid heat exchange, gas-solid mass exchange, and chemical reactions. Chemical reactions incorporated into the model simulate the combustion of coke which is present on the catalyst surface. The simulation results show a good agreement with plant data.

Numerical Simulation of an Industrial Fluid Catalytic Cracking Riser

2013 ◽  
Author(s):  
Armin Silaen ◽  
Guangwu Tang ◽  
Bin Wu ◽  
Chenn Q. Zhou ◽  
Qingjun Meng ◽  
...  
Keyword(s):  
Kinetic Model ◽  
Catalytic Cracking ◽  
Three Dimensional ◽  
Fluid Catalytic Cracking ◽  
Reacting Flow ◽  
Hybrid Technique ◽  
Gas Phases ◽  
Complex Chemical Reactions ◽  
Multi Phase ◽  
Solid Liquid

A three-dimensional multi-phase, multi-species, turbulent reacting flow computational fluid dynamics (CFD) model was established to simulate fluid catalytic cracking (FCC) process inside an industrial FCC riser. FCC catalyst, oil, and air were used as the solid, liquid, and gas phases, respectively. A hybrid technique for coupling chemical kinetics and hydrodynamics computations was employed, where the simulation was divided into (a) reacting flow hydrodynamic simulation with a small but sufficient number of lumped reactions to compute flow filed properties and (b) and reacting flow hydrodynamics with many subspecies where complex chemical reactions occur. A four-lump kinetic model was used for the major species and a fourteen-lump kinetic model was used for the subspecies model. The results were validated against measurements from the actual riser.

Stabilization of heavy metals on spent fluid catalytic cracking catalyst using marine clay

2001 ◽  
Vol 44 (10) ◽  
pp. 285-291 ◽  
Author(s):  
D.D. Sun ◽  
J.H. Tay ◽  
C.E.G. Qian ◽  
D. Lai
Keyword(s):  
Heavy Metals ◽  
Compressive Strength ◽  
Catalytic Cracking ◽  
Fluid Catalytic Cracking ◽  
Metal Leaching ◽  
Leaching Tests ◽  
Physical Barrier ◽  
Marine Clay ◽  
Clay Matrix ◽  
Petroleum Refineries

Spent fluid catalytic cracking catalyst is a hazardous solid waste generated by petroleum refineries containing vanadium and nickel. The marine clay was used as a matrix to stabilize vanadium and nickel and produce bricks which were then fired at various temperatures. TCLP leaching tests indicated that stabilizing brick had low metal leaching, with a maximum of 6.4 mg/l for vanadium and 19.8 μg/l for nickel. Compressive strength of stabilizing brick was found to range between 20 N/mm2 and 47 N/mm2. It is believed that stabilization and encapsulation mechanisms are responsible for the stabilization of vanadium and nickel. Encapsulation is a process whereby the marine clay matrix forms a physical barrier around the heavy metals which are thus prevented from leaching out into the environment. Incorporation involves the formation of bonds between the marine clay matrix and the heavy metals which thus become incorporated in the clay microstructure.

Three-Dimensional Hydrodynamics and Reaction Kinetics Analysis in FCC Riser Reactors

2007 ◽  
Vol 2 (2) ◽  
Author(s):  
Novia Novia ◽  
Martyn S. Ray ◽  
Vishnu Pareek
Keyword(s):  
Catalytic Cracking ◽  
Three Dimensional ◽  
Fluid Catalytic Cracking ◽  
Fluid Mixing ◽  
Coke Deposition ◽  
Complex Interactions ◽  
Riser Reactor ◽  
Riser Reactors ◽  
Riser Height ◽  
Independent Parameters

Fluid catalytic cracking (FCC) is the refinery process for the conversion of high molecular-weight hydrocarbons to produce higher valuable products such as gasoline. The optimization of FCC process is challenging due to the complex interactions between a large number of dependent and independent parameters. One of the most uncertain aspects of a fluid catalytic cracking (FCC) unit is the description of fluid-solid mixing at the riser entrance. Most of the existing models assume an instant mixing of solids and gaseous reactants. However, a finite mixing length at the bottom of the riser may have a pronounced effect on the FCC operation, particularly, when very short residence times are allowed in the current commercial FCC risers. A good solid-fluid mixing is essential to ensure a complete feed vaporization which is important for several reasons including assuring a thorough catalyst to oil contact and minimizing coke deposition. In this study, the Eulerian-Eulerian multiphase flow and the 3-lump kinetic models were used to simulate the hydrodynamics and cracking reactions occurring in the FCC riser reactors. The model demonstrated the capability of commercial CFD code FLUENT 6.2 to describe the flow field in the riser reactor. The model also takes into account the temperature, the heat of reactions and gasoline distribution along the riser height.

scholarly journals CFD Study of Industrial FCC Risers: The Effect of Outlet Configurations on Hydrodynamics and Reactions

2012 ◽  
Vol 2012 ◽  
pp. 1-16 ◽  
Author(s):  
Gabriela C. Lopes ◽  
Leonardo M. Rosa ◽  
Milton Mori ◽  
José R. Nunhez ◽  
Waldir P. Martignoni
Keyword(s):  
Catalytic Cracking ◽  
Flow Model ◽  
Numerical Study ◽  
Three Dimensional ◽  
Kinetic Scheme ◽  
Operating Conditions ◽  
Fluid Catalytic Cracking ◽  
Geometric Configurations ◽  
Three Phase ◽  
Three Phase Flow

Fluid catalytic cracking (FCC) riser reactors have complex hydrodynamics, which depend not only on operating conditions, feedstock quality, and catalyst particles characteristics, but also on the geometric configurations of the reactor. This paper presents a numerical study of the influence of different riser outlet designs on the dynamic of the flow and reactor efficiency. A three-dimensional, three-phase flow model and a four-lump kinetic scheme were used to predict the performance of the reactor. The phenomenon of vaporization of the liquid oil droplets was also analyzed. Results showed that small changes in the outlet configuration had a significant effect on the flow patterns and consequently, on the reaction yields.

Three-Dimensional Simulation of a Fluid Catalytic Cracking Riser Reactor

2003 ◽  
Vol 42 (12) ◽  
pp. 2602-2617 ◽  
Author(s):  
Asit K. Das ◽  
Edward Baudrez ◽  
Guy B. Marin ◽  
Geraldine J. Heynderickx
Keyword(s):  
Catalytic Cracking ◽  
Three Dimensional ◽  
Fluid Catalytic Cracking ◽  
Riser Reactor ◽  
Dimensional Simulation
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