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Numerical analysis of commercial-scale FCC riser reactors

机译:商业规模FCC立管反应器的数值分析

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Fluidized catalytic cracking (FCC) riser reactors have been widely used by the refining industry to convert heavy oil to more valuable products such as gasoline. The conversion process involves multi-phase hydrodynamics, heat and mass transfer, and cracking reactions. A computational fluid dynamic (CFD) computer code has been developed and validated to simulate the cracking processes of commercial-scale FCC units and investigate the effects of operating and design conditions on product yields and selectivity. The code solves an Eulerian formulation of the liquid, solid, and gas flow in a riser reactor. Phenomenological models of particle-solid interaction, particle-droplet collision heat transfer, spray vaporization, cracking kinetics, and coke formation were developed and added to the CFD code. A hybrid approach was adopted to integrate the flow calculation with the detailed cracking kinetics calculation. A unique methodology was developed to extract rate constants of the selected cracking reactions from a limited number of experimental test data sets. The code was validated with test data of the pilot- and commercial-scaled FCC units. Parametric and optimization studies were performed to investigate the impacts of operating/design parameters on the product yields of an existing commercial FCC riser reactor. Conceptual advanced FCC units were also evaluated. The results showed that optimized product yields and selectively could be achieved by using a CFD tool to guide the design of geometry and adjustment of operating parameters. Examples of the studies and optimizing opportunities are shown in this paper.
机译:流化催化裂化(FCC)立管反应器已被精炼工业广泛使用,以将重油转化为更有价值的产品,如汽油。转换过程涉及多相流体动力学,热量和传质和裂化反应。已经开发并验证了计算流体动力学(CFD)计算机代码以模拟商业规模FCC单元的开裂过程,并调查操作和设计条件对产品产量和选择性的影响。该代码解决了提升管反应器中的液体,固体和气体流动的欧拉配方。开发并加入了颗粒固相互作用,粒子 - 液体碰撞传热,喷雾蒸发,开裂动力学和焦炭形成的现象。采用混合方法与详细的开裂动力学计算集成流量计算。开发了一种独特的方法,以从有限数量的实验测试数据集中提取所选裂缝反应的速率常数。使用试验和商业缩放的FCC单元的测试数据验证了代码。进行参数和优化研究以研究操作/设计参数对现有商业FCC立管反应器的产物产量的影响。还评估了概念的先进FCC单位。结果表明,通过使用CFD工具来指导几何形状和操作参数调整的设计,可以实现优化的产品产量和选择性。本文示出了研究和优化机会的实例。

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