Paper ID-A-1291

Computational Fluid Dynamic (CFD) Analysis of

Catalytic Cracking Units (CCU) Reactor Dome
Section with Two-Stage Rough Cut Cyclones
and Secondary Cyclones Configurations
Dr. Biswanath Saha
BPCL, CRDC, Greater Noida
PETROTECH-2016, New Delhi
PETROTECH-2016, New Delhi

12/27/16

MR was experiencing severe Catalysts loss from CCU Reactor after start
up from emergency shut down
Gamma Scanning Results
CCU line2
S3

5000

S1

5000

CCU L3

4000

CCU line1

6000

S2

5000
4000

3000

4000

3000

2000

height in mm

height in mm

height in mm

Severe Catalysts Loss Problem

2000

1000

1000

3000

2000

50

100

150

count rate

200

250

300

50

100

150

count rate

200

250

20

40

60

80

100

120

count rate

140

160

180

200

Radiotracer Results
Secondary cyclone S1 also shows partial filling of catalyst powder. The
quantity of catalyst powder received is 35%
secondary cyclone S2 is filled with powder, quantity of radiotracer catalyst
powder received is least (13%)
Secondary cyclone S3 receives maximum quantity of catalyst powder (52%)

MR CCU Shut Down

MR CCU had forced to take shutdown due to heavy catalyst

loss from CCU reactor.
Coke layers build up was noticed in the cyclone gas outlet
tube and cyclones top (both inside and outside)

Probable cause: During last emergency shutdown, coke may be

spall-off and because of smaller clearance between stabilizer and choked
the cyclone dip leg.
PETROTECH-2016, New Delhi

12/27/16

CFD Simulation & Analysis

Removal of vortex stabilizer

from secondary cyclones
was envisaged to overcome
the problem.

CFD
simulations
were
carried out with and without
vortex
stabilizer
in
secondary cyclones to study
the
effect
of
vortex
stabilizers
on
cyclone
operation
CAD Model of CCU
PETROTECH-2016, New Delhi

12/27/16

CFD Results

PETROTECH-2016, New Delhi

12/27/16

Gas flow inside the cyclones

and dome (Side view)

PETROTECH-2016, New Delhi

12/27/16

Cyclone Vortex Length of MR CCU

Db, Cyclone
Barrel Dia, m
Do, Vortex
Finder Dia, m
H, Inlet Height,
m
Lw, Inlet Width,
m
Ao, Vortex
Finder outlet
Area, m2
Ao/(Lw*H)
Lmin/Db
(from table)
PETROTECH-2016, New Delhi

12/27/16

1.05
0.4
0.895

0.285

0.125
0.493
2.9
7

Cyclone Vortex Length of MR CCU

Vortex
stabilizer
location : 2.0 m
Calculated Lmin
(Vortex length)
using PSRI : 2.9 m
Lmin (from CFD
calculations) : 2.9
m

PETROTECH-2016, New Delhi

12/27/16

CFD Analysis and Recommendations

The CFD results were validated against Particulate

Solid Research, Inc. (PSRI)s Cyclone design
procedure.
Based on the analysis, it is suggested that vortex
stabilizer removal is not possible as the cyclone length
is less than the natural vortex length.
To prevent coke build up, it was suggested to insert
coke anchors, in the stagnant zones.

PETROTECH-2016, New Delhi

12/27/16

Thank you

PETROTECH-2016, New Delhi

12/27/16

10

CFD Simulation Conditions

Initial Conditions
Working Pressure: 2.01atm (g) Temperature: 505
Deg C
Boundary Conditions
Riser Inlet Gas Velocity: 13.5 m/s
Stripper Steam Flow Rate: 2.1 kg/s
Outlet Pressure: 1.65 atm(g)
Reference Conditions
Ref. Pressure: Atmospheric
Turbulent Intensity and Viscosity Ratio:1 % & 10
PETROTECH-2016, New Delhi

12/27/16

11