An integrated methodology for the modeling of Fluid Catalytic Cracking (FCC) riser reactor

Abstract

Modeling description of the riser reactor is a highly interesting issue in the development of FCC process. However, one of the challenging problems in the modeling of FCC riser reactors is that sophisticated flow-reaction models with high accuracy need long computational time, while simple flow-reaction models give rise to results with fast computation but low accuracy. This dilemma requires new type of coupled flow-reaction models. The goal of this study was to propose a novel integrated model with timeefficient computation and acceptable accuracy. The integrated model, named equivalent reactor network (ERN) model, was established based on Aspen Plus simulator with considering gas-solid hydrodynamics via built-in modules and catalytic reactions via external FORTRAN subroutines, as well as lump mixtures characterized by real components. Through comparing with pilot-scale experimental data and industrial plant data in two case studies, the developed ERN model was justified to be capable of precisely and quickly modeling FCC riser reactors. Furthermore, the proposed methodology is expected to be readily applied to studies on the dynamic simulation, optimization, and control of FCC units in future studies.

Parameter estimation of a six-lump kinetic model of an industrial fluid catalytic cracking unit

“…For instance, the six-lump model of Souza et al, (2011) is different from the six-lump model of Mu et al (2005). The increase in number of lumps continued to the 5-lump model (Dupain et al, 2003, Jorge Ancheyta Juarez, 1999; the 6-Lump model (Takatsuka et al, 1987, Du et al, 2014, Xiong et al, 2015, Zhang et al, 2017; 7-lump model (Heydari et al, 2010; 8-lump model (Gao et al, 2014, Hagelberg et al, 2002; 9-lump model (You, 2013, You et al, 2006; 10-lump model (Jacob et al, 1976); 11 lump model (Mao et al, 1985, Sa et al, 1985 and so on. In this work, new kinetic parameters are developed for a new six-lump model.…”

“…Where this six lumped kinetic model was used (Du et al, 2014, Xiong et al, 2015, Zhang et al, 2017, the riser model did not account for the heat of reaction, which is the endothermic heat required for the cracking of the feed. This heat of reaction is important and a requirement for the riser model used in this work Chung, 2001a, Han andChung, 2001b).…”

“…This heat of reaction is important and a requirement for the riser model used in this work Chung, 2001a, Han andChung, 2001b). This six-lumped kinetic model (Du et al, 2014, Xiong et al, 2015, Zhang et al, 2017 have their frequency factors and activation energies presented in the literature.…”

Numerical investigation of heavy fuel droplet-particle collisions in the injection zone of a Fluid Catalytic Cracking reactor, Part I: Numerical model and 2D simulations

“…For petroleum fractions, varying properties are usually calculated based on empirical correlations [27], in contrast to single component hydrocarbons [24]. [28]. The fluidizing medium is considered to be water-vapor (H2O), commonly used in the FCC industry.…”

Ten-lump kinetic model for the two-stage riser catalytic cracking for maximizing propylene yield (TMP) process

“…Modeling description of riser reactors is of significance to maintaining the long period run, fault monitoring and operation optimization of FCC units [7,8]. In mathematical models for riser reactors, lumped kinetic models play an essential role [9,10].…”