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School of Chemical Engineering and Technology, Tianjin University, Tianjin 300072, People's Republic of China
Collaborative Innovation Center of Chemical Science and Engineering (Tianjin), Tianjin University, Tianjin 300072, People's Republic of China
National Engineering Research Centre of Distillation Technology, Tianjin University, Tianjin 300072, People's Republic of China
a r t i c l e
i n f o
Article history:
Received 14 August 2014
Received in revised form 4 March 2015
Accepted 6 March 2015
Available online 20 March 2015
Keywords:
CFD
Phase change
Coke formation
Multiphase ow
Fired furnace
a b s t r a c t
A three dimensional computational uid dynamics (CFD) model is developed to predict the phase change and
reactions inside the tubes of red furnace. The model is constructed within the Eulerian framework in which
the liquid phase is treated as a continuous phase while gas and solid phases are both considered as dispersed
phases, and all phases are treated as interpenetrating continuum having separate transport equations. The thermal cracking kinetic model is validated against experimental data. Calculations are performed using the commercial packages ANSYS CFX 14.0. The temperature distribution, ow eld, liquidgas phase separation, and coke
formation are predicted for different severities of petroleum type and tube wall temperature. The information
predicted by the CFD model can be utilized in the optimal design of industrial red furnaces.
2015 Elsevier B.V. All rights reserved.
1. Introduction
Fired tube furnace is a common type of heating units in the petroleum rening industry, including atmospheric & vacuum furnace in
crude unit, delayed coking furnace, and catalytic reforming furnace.
Oil runs inside the tube pass accompanied with heat transfer, and sometimes phase change and thermal reactions. A chronic problem usually
encountered is the coke formation inside the tubes of red furnaces
caused by a combination of high operating temperature, long residence
time, and inherent instability of the oil [15]. Coke will deposit and
accumulate on the inner wall of the tube. The coke layer causes progressively high tube metal temperatures (TMTs), in turn, promoting coke
formation. As the TMTs get close to the tube metallurgical temperature
limit, the furnace must be shut down to remove coke [6,7]. It has long
been established that the prediction of temperature distribution and
coke formation inside the tubes of red furnaces is necessary for the
operational safety and overall performance. Besides, the understanding
of these heat transfer and thermal reaction phenomena is helpful for the
ne-tuning and optimization of modern furnace design.
Because of progress in computer hardware and software and the
consequent increase of the calculation speed, the computational uid
dynamics (CFD) modeling technique becomes a powerful and effective
tool for understanding the complex transport and reaction phenomena
Corresponding author. Tel./fax: +86 22 27400199.
E-mail address: zhanglvh@tju.edu.cn (L.-H. Zhang).
http://dx.doi.org/10.1016/j.fuproc.2015.03.005
0378-3820/ 2015 Elsevier B.V. All rights reserved.
while gas and solid phases are both considered as dispersed phases.
Within the Eulerian multiphase ow model, all phases are considered
as interpenetrating continuum having separate transport equations,
and certain interphase transfer terms used in momentum, heat, and
other interphase transfer models, are modeled using the Particle
Model and the Free Surface Model. The temperature distribution, ow
eld, liquidgas phase separation and coke formation are predicted for
different severities of petroleum type and tube wall temperature. The
objective of this work is extending the studies by Kseoglu and Phillips
and Fontoura et al., and examining the extent to which CFD models can
be used as an investigative tool in industrial practice.
2. Mathematical model development
19
10
Sresins
k5 Y asphaltenes;l Y mesoasphaltenes;l k3 2k4 Y resins;l
r r u S
t
11
12
For solid phase, Ss represents the mass source term induced by coke
formation.
Ss Scoke k6 Y mesoasphaltenes;l
13
For liquid phase, Sl represents the mass source term induced by both
phase change and coke formation.
Sl Scoke Sdistillate k6 Y mesoasphaltenes;l k1 Y saturates;l
14
4
2.2.2. Momentum equations
Scoke k6 Y mesoasphaltenes;l
15
16
Si;l
r Y r l l ul Y i;l l Di;l Y i;l
t l l i;l
T
r u r u u r eff ; u u
t
r p M r g
20
Fig. 1. Kinetic net of the thermal cracking and phase change of petroleum.
For liquidgas interphase interaction, the drag force coefcient is calculated by the Grace drag model [16] with a volume fraction correction exponent of 4. Lift force and wall lubrication force are calculated using the
model by Tomiyama [17], and the turbulent dispersion force is estimated using the model by Burns et al. [18]. Since the density difference between liquid and gas phases is large, the virtual mass force is ignored in
the simulation.
Fig. 2. Geometry model. (a) Geometry and boundary conditions; (b) mesh generation.
u tur P P b
17
u tur C 1 P C 2 C 1 P b 18
t
where C1, C2, , and are constants, Pb and Pb represent the inuence of the buoyancy force, and Pis the turbulence production due to
viscous forces.
tur
!
19
where C is a constant. Then the effective viscosity is the sum of the molecular viscosity with the turbulent viscosity and can be expressed by:
eff tur :
20
r H r u H r T r
t
XN
p
: u SE Q
Hs Hs
1
21
Table 1
Characteristic parameters for the reactions.
Reaction
B (kJmol1)
1
2
3
4
5
6
29.9
23.43
13.57
17.07
19.34
27.54
175
136
85
96
103
168
Pseudo-component
AR, Yi
VR, Yi
Distillate
Saturates
Aromatics
Resins
Asphaltenes
Mesoasphaltenes
Coke
0
0.57
0.22
0.16
0.05
0
0
0
0.18
0.34
0.32
0.16
0
0
21
Fig. 3. Comparison between experimental and predicted coke formation rates at different temperatures. (a) 703 K; (b) 718 K; (c) 733 K; (d) 748 K.
22
Two-resistance model is employed for interphase heat transfer calculations between the continuous phase and the dispersed phases. A
zero resistance condition is specied on the dispersed phase sides.
This is equivalent to an innite uid specic heat transfer coefcient
where Tw is the wall temperature, and hc, A, and Tnw, denote the heat
transfer coefcient, wall contact area, and near-wall uid temperature
of phase . hc involves the use of turbulent wall functions.
hc
cp u
T
23
Fig. 5. Gas phase holdup. (a) Gas phase holdup prole of AR, Tw = 873 K; (b) gas phase
holdup at different severities of petroleum type and tube wall temperature.
22
Fig. 6. Liquid temperature. (a) Liquid temperature prole of VR, Tw = 873 K; (b) liquid
temperature distribution at different severities of petroleum type and tube wall
temperature.
and its effect is to force the interfacial temperature to be the same as the
phase temperature. RanzMarshall Correlation [22] is used to calculate
the dimensionless Nusselt number of the liquid phase side.
0:5
Nu 2 0:6Re
0:3
Pr
0 Re b 200 0 Pr b 250
24
This is based on boundary layer theory for steady ow past a spherical particle and is the most well tested correlation.
23
Fig. 8. Gas phase velocity proles of AR, Tw = 873 K. (a) Line locations; (b) gas supercial velocity X prole; (c) surface gas velocity streamline in XZ-plane; (d) gas supercial velocity Z
prole.
expressions are monitored and a quasi-steady state is assumed to prevail if the values of them remain constant or show no appreciable
change for a period long enough to determine the time-averaged values
of the various parameters.
4. Results and discussion
The thermal cracking kinetic model is validated against experimental data to examine its reliability. Sawarkar et al. [23] carried out batch
reaction experiments pertaining to the coking of Arabian mix vacuum
residue (AMVR) at different severities of temperature and reaction
time. The S.A.R.A. mass fractions of AMVR they used are 15.00%,
66.28%, 7.60%, and 11.12% respectively. In their experiments, the
reactor was heated by molten tin bath and rocked manually for
Fig. 9. Averaged mass fraction distribution of coke in liquid phase at different severities of
petroleum type and tube wall temperature.
24
As demonstrated in Fig. 6(a), the oil temperature near the tube wall
in each cross section is higher than the central zone as a result of wall
heat transfer, and a gradual increase of bulk oil temperature in the
ow direction is evident. It can be observed from Fig. 6(b) that the
tube wall temperature dominates the liquid phase temperature, as the
liquid temperature of the severities with tube wall temperature of
873 K is far above that of 773 K. While with the same tube wall temperature, AR and VR show very close liquid temperature distributions. It is
observed that with the same tube wall temperature, the liquid temperature of AR is slightly higher than that of VR at the latter part of the tube.
That is because with the same tube wall temperature, the gas phase
holdup of the former is higher than that of the latter, and the convective
heat transfer is enhanced and more heat is transferred from the tube
wall to the liquid phase.
As shown in Fig. 7, the ow eld is uniform at the beginning of the
tube, and straight streamlines are apparent. As the gas phase appears
and accumulates in the tube, the existence of rotational ow near the
tube wall is apparent, while the streamlines near the centerline of the
tube waves in radial direction but no extensive rotation appears. In addition, liquid velocity near the centerline of the tube is far above that
near the tube wall as a result of boundary layer distribution. It can be observed that liquid velocity near the centerline exceeds the inlet velocity
of 2 m/s. Pressure increase induced by the gas phase is expected to
speed up the liquid ow.
Fig. 8 shows the gas phase velocity proles, in which (b) and
(d) show the gas supercial velocity X and Z respectively at four vertical
lines as marked in (a). Fig. 8(c) shows the surface gas velocity streamline in XZ-plane. Velocities X and Z represent the gas velocity at the vertical direction and uid ow direction respectively. The magnitude
saltation locations indicate the interphase between the continuous liquid phase and the continuous gas phase. From line 1 to line 4, the saltation moves in minus X-direction gradually indicating that the gas phase
is accumulating in the upper domain and occupying a larger room in Xdirection. It can be observed that both the supercial velocities X and Z
of the gas phase dispersed in liquid phase are fairly small in magnitude
compared with those of the continuous gas phase, and this is also indicated in the streamline prole shown in Fig. 8(c). Supercial velocity X
in minus X-direction is observed, indicating the gas rebound from the
upper tube wall. It also can be observed from Fig. 8(d) that the magnitude of gas supercial velocity Z increases gradually from line 1 to line
4 as a result of gas accumulation and consequent higher gas phase pressure head.
As shown in Fig. 9, the magnitude of the coke mass fractions in the
tube is small compared with that in the experimental data of Sawarkar
et al. [23], that is because the oil residence time in the tube is very short
(about 9 s, tube length divided by inlet velocity). The coke amount accumulates as the oil ows forward. However, due to the turbulent ow behavior, the distribution of coke in the ow direction does not increase
steadily. As a result, an increasing trend with random uctuation of
the coke mass fraction in the ow direction is observed in Fig. 9. It is
worth noting that since the points in each curve were calculated by averaging over the cross sections with an interval of 1 m, the curves in
Fig. 9 did not exhibit the complete variation trend of the coke mass fraction in the ow direction. However, it still indicates that with the same
tube wall temperature, the coke formation rate of VR is higher than that
of AR. At the beginning of the tube, the oil temperature for all the severities is low, so the coke formation rates are quite close. As the oil temperature increases, the coke formation rates begin to diverge, that is,
the coke formation rates of the severities with higher tube wall temperature and higher contents of asphaltenes and resins increase more
quickly.
5. Conclusions
Acknowledgment
In this work we have attempted to predict the phase change and reactions inside the tubes of red furnace by means of CFD. The thermal
We are grateful for the nancial support from the National Science
Foundation of China (No. 21336007).
Nomenclature
A, B
characteristic parameters for the reactions
A
wall contact area of phase
cp
heat capacity (Jkg1K1)
C1, C2, C constants of k turbulence model
Di,l
kinematic diffusivity of pseudo-component i in liquid phase
(kgm1s1)
g
gravitational force (9.8 ms2)
h
heat transfer coefcient
H
static enthalpy (J)
k16
reaction rate constants (s1)
M
interphase momentum exchange (Nm3)
Nu
Nusselt number
P
pressure (Nm2)
Pk
turbulence production due to viscous forces (Pas1)
Pkb, Pb turbulence production due to buoyancy (Pas1)
Pr
Prandtl number
Q
interphase heat transfer (Js1)
r
volume fraction of phase
R
universal gas constant (Jkg1K1)
Re
Reynolds number
Si,
source term of pseudo-component i in phase
t
time (s)
T
temperature (K)
u
velocity vector (ms1)
Yi,l
mass fraction of pseudo-component i in liquid phase
Greek letters
Subscripts
eff
effective
g
referring to gas phase
i
referring to pseudo-component i or reaction i
l
referring to liquid phase
tur
turbulent
,
referring to phase and phase respectively
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