Abstract The 3D virtual full-loop CFD simulation method with two-fluid model (TFM) was developed to model an industrial two-stage FCC reaction–regeneration system. The virtual connections (mass, species, and energy) between riser reactors, disengager, stripper, and regenerator were realized by defining user-defined functions (UDFs) for boundary conditions according to the reality. Five correction factors were used to correct the reaction rates in the 14-lump FCC reaction kinetics, and two correction factors were used to correct the FCC reaction heat in the first and second riser reactors. As a result, the whole FCC reaction–regeneration system was successfully modeled in one single CFD case. A thorough and comprehensive view of the performance of reaction–regeneration system was obtained by the 3D virtual full-loop CFD simulation, which is helpful for the operating and optimization of FCC unit. The major predicted results were in a good agreement with the industrial data. The effects of operating conditions were also investigated by changing regenerated temperature, catalyst to oil (CTO) ratio, and process capacity.

中文翻译：

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工业两级 FCC 反应再生系统的 3D 虚拟全环 CFD 仿真

摘要 采用双流体模型 (TFM) 的 3D 虚拟全回路 CFD 仿真方法对工业两级 FCC 反应-再生系统进行建模。提升管反应器、分离器、汽提塔和再生器之间的虚拟连接（质量、物质和能量）是通过根据实际情况定义边界条件的用户定义函数（UDF）来实现的。使用五个校正因子来校正 14 块 FCC 反应动力学中的反应速率，并且使用两个校正因子来校正第一和第二提升管反应器中的 FCC 反应热。结果，整个 FCC 反应-再生系统在一个 CFD 案例中成功建模。通过 3D 虚拟全回路 CFD 模拟，获得了反应再生系统性能的全面而全面的视图，有利于FCC装置的运行和优化。主要预测结果与工业数据吻合较好。还通过改变再生温度、催化剂与油 (CTO) 的比率和工艺容量来研究操作条件的影响。