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.
Funding source: Natural Science Basic Research Plan in Shaanxi Province of China
Award Identifier / Grant number: Program No. 2020JQ-764
Funding source: PetroChina Innovation Foundation http://dx.doi.org/10.13039/501100005154
Award Identifier / Grant number: No. 2018D-5007-0402
Acknowledgements
Financial supports from the Natural Science Basic Research Plan in Shaanxi Province of China (Program No. 2020JQ-764) and PetroChina Innovation Foundation (No. 2018D-5007-0402) were greatly appreciated.
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Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
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Research funding: This research is funded by Natural Science Basic Research Plan in Shaanxi Province of China (Program No. 2020JQ-764) and the PetroChina Innovation Foundation (No. 2018D-5007-0402).
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Conflict of interest statement: The authors declare no conflicts of interest regarding this article.
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