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Armin K. Silaen
Center for Innovation Through Visualization
and Simulation (CIVS),
Purdue University Calumet,
Hammond, IN 46323
Bin Wu
Center for Innovation Through Visualization
and Simulation (CIVS),
Purdue University Calumet,
Hammond, IN 46323
Chenn Q. Zhou1
Center for Innovation Through Visualization
and Simulation (CIVS),
Purdue University Calumet,
Hammond, IN 46323
Dwight Agnello-Dean
BP Refining and Logistics Technology,
Naperville, IL 60563
Joseph Wilson
BP Refining and Logistics Technology,
Naperville, IL 60563
Numerical Simulation of
an Industrial Fluid Catalytic
Cracking Regenerator
Fluid catalytic cracking (FCC) is one of the most important conversion processes in
petroleum refineries, and the FCC regenerator is a key part of an FCC unit utilized in the
recovery of solid catalyst reactivity by burning off the deposited coke on the catalyst
surface. A three-dimensional multiphase, multispecies reacting flow computational fluid
dynamics (CFD) model was established to simulate the flow and reactions inside an FCC
regenerator. The EulerEuler approach, where the two phases (gas and solid) are considered to be continuous and fully interpenetrating, is employed. The model includes
gassolid momentum exchange, gassolid heat exchange, gassolid mass exchange, and
chemical reactions. Chemical reactions incorporated into the model simulate the
combustion of coke which is present on the catalyst surface. The simulation results were
validated by plant data. [DOI: 10.1115/1.4029209]
Keywords: regenerator, CFD, Eulerian, kinetic theory, drag model, hydrodynamics,
combustion
Qingjun Meng
BP Refining and Logistics Technology,
Naperville, IL 60563
Samir Khanna
BP Refining and Logistics Technology,
Naperville, IL 60563
Introduction
derived from the partial differential equations based on the conservation of mass, momentum and energy. They offer a new
approach to study the hydrodynamics and transfer mechanisms in
gassolid two phases flow with relatively good efficiency and accuracy [3,6].
Fluidization of solid FCC catalyst bed by gas is the most important phenomena in the FCC process. The physical properties of
FCC catalyst particles will affect the fluidization. Geldart [8] classified particles into four groups: A, B, C, and D. Particles in group
A have a small mean size and a low particle density (less than
about 1.4 g/cm3), while particles in group B have a mean size that
ranges between 40 lm and 500 lm and density that ranges between
1.4 g/cm3 and 4 g/cm3. Powders which in any way are cohesive
belong to group C and are very difficult to fluidize. Group D particles are confined to large and very dense particles. FCC catalysts
belong to groups A and B, which can be easily fluidized.
There are two different approaches that can be used in CFD to
model the gassolid two-phase flows that involve particles of
groups A or B: the Lagrangian approach and the Eulerian
approach [5,9,10]. The Lagrangian approach solves the
Newtonian equations of motion for each particle, and takes into
consideration the effects of particle collisions and forces acting on
the particles by gas. Particle collision laws are applied for the
solidsolid collision based on the energy dissipation by means of
the restitution coefficient and friction [11,12]. However, the
ag qg ugj 0
@ xj
@t
(1)
ap qp upj 0
@ xj
@t
(2)
where the first term is the time rate of change of gas phase or solid
phase, and the second term is the advection of the gas phase or
solid phase. Each computational cell is shared by gas and solid
phase, and the total of solid and gas volume fraction is 1
ap ag 1
(3)
@t
@xj
@xi
@xj
b ugi upi qg ag gi
(4)
@t
@xj
@xi
@xj
b upi ugi qp ap gi
(5)
where the terms on the left hand of the equation are the time rate
of change of gas or solid phase and advection term. On the right
hand of the equation, body force (gravity, pressure), shear force
term, and phase interaction terms are considered. b is the gas
solid interphase drag coefficient.
The fluctuations that occur in the solid phase are modeled from
the kinetic theory of gases modified to account for inelastic
collisions between particles [21].
Solid-phase turbulent fluctuating energy equation
3 @ap qp H @ap qp upk H
@
@H
CH
2
@xk
@xk
@t
@xk
2
@upk
@upk @upi @upk
@upk 2
lp
pp
n p lp
c (6)
3
@xi
@xk @xi
@xk
@xk
Transactions of the ASME
(7)
sg;ij lg
@xi
@ xj
Solid-phase stress tensor
sp;ij lp
@upj @upi
@xi
@ xj
@upk
2
dij pp dij
np lp
3
@xk
(8)
(9)
"
g0 1
ap
ap;max
13 #1
(10)
u0p u0p
Cgp
(11)
p
2
ap qp dp pH
2
1 1 e3e 1g0 ap
5
63 e
r
4
H
a2p qp dp g0 1 e
5
p
(20)
!
1
3
Pr
Nup 7 10af 5a2f 1 0:7Re0:2
p
(12)
(13)
6Kg ag ap Nup
dp2
(19)
Granular temperature
1D
(17)
p1
Solid-phase pressure
pp ap qp 1 21 eap g0 H
(14)
1
3
(21)
1
rG
3a rs Crs
(22)
where a is the absorption coefficient, rs is the scattering coefficient, G is the incident radiation, and C is the linear-anisotropic
phase function coefficient
rqr aG 4an2 rT 4
(23)
(16)
15p
2
source between species i and j from solid phase to gas phase, Rate
is the heterogeneous reaction rate, ag is the volume fraction for
gas phase, and Sgi is the rate of creation by addition from the dispersed phase plus any user-defined sources.
The heterogeneous phase interaction reaction rates used for the
reactions [33] are
st
YNR Yi qi VOFip
103 kmol
1000 3
Rate k i1
m s
MWi
b
Tip
E
exp
kA
RTip
Tref
(25)
(26)
Velocity (m/s)
Temperature (K)
Gas volume fraction
Solid volume fraction
Spent catalyst
inlet
Upper
air ring
Lower
air ring
Regenerated
catalyst outlet
5.6
810.8
0
1
12.9
433
1
0
15.7
433
1
0
1.1
0
1
3.3 Boundary and Initial Conditions. The air inlets and catalyst inlets are defined as mass flow inlets. In order to have a constant amount of the regenerated catalyst extracted from the
regenerator, the regenerated catalyst outlets were defined as mass
flow inlets, but with a directional vector pointed outward of the
outlet surface. The cyclone inlets were defined as pressure outlets
with an outside pressure of 1 atm. The walls were set as no-slip
wall boundary conditions for both the solid and gas phases. The
boundary conditions are shown in Table 1.
The catalyst particles were set as the solid phase. Air is used as
the gas phase to fluidize the catalyst particles. The gas superficial
velocities range from 0.6 m/s to 0.7 m/s. The detailed simulation
parameters used in FLUENT 13.0 are listed in Table 2. The phase
properties are shown in Table 3. A certain amount of catalyst
patched bed with solid and gas velocity zero was used as the initial condition. The catalyst bed at t 0 s is 0.3 of the total
Table 2 Detailed simulation parameters
Parameters
Gassolid two-phase flow model
Solver
Flow type
Wall boundary condition
Time step used
Maximum number of iteration
per time step
Residual convergence criteria
Pressure velocity coupling scheme
Under-relaxation factors
Computational domain
Hydrodynamics
Gas
Solid
O2, N2
Catalyst
With reactions
Density
Viscosity
Mixing law
Gidaspow
the discontinuity in the drag coefficient can be avoided. The constants u1 , u2 , u3 are the switch factors when the void fractions
ai for the dividing criteria are 0.80, 0.933, and 0.990, respectively.
ui
(28)
b 1 u1 b1 u1 f1 u2 b2 u2 1 u3 b3 u3 b4 g
(27)
Figure 6 shows the average solid volume fractions on five different heights over time. It can be seen that the fluidized bed has
reached quasi-steady state after 40 s, which is a distinctive characteristic of the BFB and circulation fluidized bed [40]. According
to Fig. 7, the average solid volume fraction along the normalized
regenerator height presents a four-region regenerator, which has a
high solid volume fraction dense bed, subdense bed, low solid volume fraction subdense zone, and a dilute zone. The spike line at
the height around h/H 0.9 is due to the solid catalyst accumulation on the top of the cyclones. The low velocity in the dilute zone
allows the solid catalyst to settle and accumulate on the top of the
cyclones. The predicted solid volume fraction profile in the regenerator shows 0.3 at the tangential line level and 0.01 at the cyclone
inlet level, which matches with plant data. In the real operation,
there are two pressure taps used to measure the pressure located at
h/H 0.83 and h/H 0.13 normalized heights. In normal operation, the pressure drop measured between h/H 0.83 and
h/H 0.13 ranges from 65 to 80 in. water. The pressure drop predicted by the CFD model is approximately 71 in. water which is
within the range.
C 1=2 O2 ! CO
(R1)
C O2 ! CO2
(R2)
CO 1=2 O2 ! CO2
(R3)
H 1=4 O2 ! 1=2 H2 O
(R4)
The kinetic parameters for reactions (R1) and (R2) listed in Table
5 are obtained from the experimental work done by Kanervo et al.
[41], in which reaction rates of combustion of coke on FCC solid
catalyst particles to produce CO and CO2 in a reactor were measured. The kinetic parameters from the experimental work of
hydrogen combustion in carbonaceous deposits on zeolite-type
cracking catalysts reported by Wang et al. [42] was used for the
hydrogen combustion (R4). The kinetics for the CO combustion is
adopted from the work by Dryer and Glassman [43]. This kinetics
does not include the effects of CO combustion promoter which is
used in the actual regenerator operations.
According to the plant measurement, the catalyst used for this
simulation contains 1% coke on its surface, with carbon counting
for 92% and the remaining 8% is hydrogen. The reacting flow
model was developed by incorporating the reaction model with
the kinetic constants listed in Table 5 into the hydrodynamics
model. The results of the flow hydrodynamics, temperature fields
and species concentrations are presented in Figs. 810.
Figure 8 shows the gas temperature change with time from the
initial operation condition to the steady state. It indicates that the
temperature changes rapidly during the first 500 s, then increases
slowly and reaches a steady state after 1000 s. In addition, the
temperatures at different heights indicate that the temperature in
the dense bed is lower than temperature in the dilute phase with a
difference around 20 K. Catalyst temperature is very important to
the crude oil cracking process which occurs in the riser part of an
FCC process. Catalysts leaving the regenerator with low temperature could indicate low coke removal efficiency and may not be
able to crack crude oil in the riser part effectively. However,
Ergun [38]
0.80.933
b1 150
ZP
0.9330.990
0.9901.00
ap 1 ag lg
1:75
8
24
>
<
1 0:15Re0:867
Rep 1000
ap ag dp ug up
p
Rep
CD
Re
p
>
lg
: 0:44
Rep 1000
ap ag qg up ug 2:65
3
ag
b3 CD
4
dp0
ap qg up ug
3
b 4 CD
4
dp0
8
24
>
<
1 0:15Re0:867
Rep 1000
ap ag dp0 ug up
p
Rep
CD
Re
p
>
lg
: 0:44
Rep 1000
catalysts leaving the regenerator with high temperature can potentially damage the catalysts reactivity and cyclones.
The gas temperature contours and average gas temperature
plots in Fig. 9 show the temperature above the dense catalyst bed
is higher than in the bed. The unburned CO produced in the fluidization bed enters into the dilute zone where it is burned. Unlike
in the dense bed, where most of the energy released from any
combustion is absorbed by the solid due to the high solid concentration, most of the heat released by any combustion in the dilute
zone goes to the gas. Temperature contour plots in Fig. 9(a) show
a temperature difference, higher on one side of the regenerator
and lower on the other side. This is due to the opening direction of
the catalyst and air inlets. Figure 9(b) shows the mass-weighted
average temperature at different levels along the regenerator
heights. At the fluidized bed, the average temperature is around
1010 K. The temperature drops are due to the input of low temperature air. Temperature increases from 1010 K to 1026 K gradually
above the fluidized bed. Between the level h/H 0.6 and
h/H 0.8, the gas temperature stabilizes. The sudden drop of temperature at the top of the regenerator is due to the cyclones into
which high temperature gas flows.
Fig. 7 Average solid volume fraction and pressure drop profiles along regenerator height
Reactions
R1
R2
R3
R4
Fig. 6
Heat of
reaction
(kJ/mol)
Pre-exponential
factor, (A)
Activation
energy,
E (J/mol)
118
403
283
600
159,000
110,000
212,000
157,700
Fig. 8
(one in the dense zone and the other in the dilute zone) inside the
regenerator is measured during the regenerator operation. The
error of the pressure drop calculated by the model relative to the
average of the pressure drop range of the actual regenerator is 4%.
The cyclone circulation is the total amount of catalysts that pass
through the cyclones, which shows a 2.74% error compared to the
plant data.
The temperatures calculated by the simulation agree with the
temperature measured at the plant. The relative errors of the temperatures in the dense zone and in the dilute zone are 0.50% and
0.29%, respectively. The volume fraction of CO2 in the gas at the
outlet (cyclone inlets) predicted by the model is very close to the
measured value at the plant (1.2% relative error). The relative
error of CO is high. However, it is important to note that the CO
concentration at the cyclone inlets is extremely low. This high relative error of CO concentration is due to the fact that the kinetics
for the CO combustion used in the model does not take into
account any CO combustion promoters. In the real operations, CO
combustion promoters are added into the catalyst bed to promote
CO combustion in the dense bed. It is desired to have as much CO
as possible burned inside the dense bed thus the amount of CO
that goes CO combustion in the dilute zone can be minimized. As
mentioned earlier, any heat released in the dilute zone can significantly increase the gas temperature which could potentially damage the cyclones. The C reduction rate is calculated as the ratio of
the mass fraction of C on the catalyst surface at the regenerated
catalyst outlets to the mass fraction of C at the catalyst inlets. The
relative error of the C reduction rate predicted by the model is
1.7%. Despite the large relative error of the predicted CO
Table 6 Relative errors of the simulation results when compared to plant data
Relative error (5)
Fig. 9 (a) Gas temperature contours and (b) average gas temperature at time 1000 s
Catalyst circulation
Dense zone temperature
Dilute zone temperature
DP (inH2O)
C reduction rate (%)
Volume fraction at outlets
CO
CO2
O2 (vol. %)
2.74
0.50
0.29
4.0
1.7
8881.8
1.2
14.9
Conclusions
Nomenclature
A
C
CD
Cfr
dp
dps
dp*
e
g
g
g0
h
H
mp
ms
m0
M
MWi
n
p
pC,ps
r
R
Re
Re
Rep
S
st
T
Tip
Tref
u
u
umf
VOFip
Yi
qip
cross-sectional area, m2
correction coefficient
drag coefficient
friction coefficient
diameter of particle, m
average diameter of particle, m
particle effective mean diameter in dense bed, m
restitution coefficient
gravity acceleration, m/s2
mass, kg
radial distribution function
height
regenerator height
single particle mass of phase p, kg
single particle mass of phase s, kg
total mass, kg
phase number
molecular weight of species i
volumetric particle number
pressure, Pa
collision part of particle phase pressure, s
radial coordinate
bed radius, m
bed expansion number
Reynolds number
cluster Reynolds number
number of solid phase
stoichiometric coefficient of reactants
time, mean residence time of binary mixture, s
phase temperature
reference temperature (298 K)
velocity, m/s
superficial gas velocity, m/s
minimum fluidization velocity, m/s
volumetric fraction of phase ip
species i mass fraction
bulk density of phase ip
Greek Symbols
a
ai
b
c
Cdil,h
CH
e
emf
volume fraction
void fraction for the dividing criteria
interphase momentum exchange coefficient, kg/m3 s
dissipation of energy fluctuation, kg s3/m
dilute diffusion coefficient for energy fluctuation, kg s/m
diffusion coefficient for the energy fluctuation, kg s/m
mean void fraction of dense phase
bed voidage at minimum fluidization velocity
g
H
Hp,av
ldil,p
lp
n
q
q
s
segregation efficiency
granular temperature, m2/s2
average granular temperature, m2/s2
particle phase dilute viscosity, Pa s
particle phase shear viscosity, Pa s
solid bulk viscosity, Pa s
density, kg/m3
mean bed density of dense phase, kg/m3
stress tensor, Pa
Subscripts
g
i, j, k
m
NR
p
s
S
gas phase
direction coordinate
phase m
total number of reactants
particle phase
solid phase
solid-phase number
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