In this study, a new practical countercurrent regenerator model for in-situ FCC operation optimization was proposed. A three-zone-and-two-phase gas model and a new two-CSTR-with-interchange model were used to give better descriptions on the gas and solids flow patterns, addressing the region-dependent mass transfer rates and the freeboard effect on catalyst regeneration. The model coupled mass and heat balances, hydrodynamics and reaction kinetics. The modeled results are in reasonable agreement with the commercial data from an industrial FCC regenerator under both partial and full CO combustion modes.
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