A new generic approach for the modeling of fluid catalytic cracking (FCC) riser reactor

• Published in: Chemical engineering science Vol. 62; no. 17; pp. 4510 - 4528
• Main Authors: Gupta, Raj Kumar, Kumar, Vineet, Srivastava, V.K.
• Format: Journal Article
• Language: English
• Published: Oxford Elsevier Ltd 01.09.2007; Elsevier
• Subjects: Applied sciences; Catalysis; Catalytic reactions; Chemical engineering; Chemistry; Computational fluid dynamics; Cracking kinetics; Exact sciences and technology; Fluid catalytic cracking; General and physical chemistry; Hydrodynamics of contact apparatus; Mathematical modeling; Pseudocomponents; Reactors; Simulation; Theory of reactions, general kinetics. Catalysis. Nomenclature, chemical documentation, computer chemistry; Fluid catalytic cracking; Mathematical modeling; Cracking kinetics; Simulation; Computational fluid dynamics; Pseudocomponents; Correlation; Parameter estimation; Probability distribution; Modeling; Semiempirical method; Rate constant; Reactor; Riser; Deactivation; Two phase flow; Prediction; Cracking; Boiling; Kinetic model; Correlation analysis; Kinetics; Kinetic parameter; Catalyst activity; Catalyst
• ISSN: 0009-2509; 1873-4405
• DOI: 10.1016/j.ces.2007.05.009

A new kinetic model for the fluid catalytic cracking (FCC) riser is developed. An elementary reaction scheme, for the FCC, based on cracking of a large number of lumps in the form of narrow boiling pseudocomponents is proposed. The kinetic parameters are estimated using a semi-empirical approach based on normal probability distribution. The correlation proposed for the kinetic parameters’ estimation contains four parameters that depend on the feed characteristics, catalyst activity, and coke forming tendency of the feed. This approach eliminates the need of determining a large number of rate constants required for conventional lumped models. The model seems to be more versatile than existing models and opens up a new dimension for making generic models suitable for the analysis and control studies of FCC units. The model also incorporates catalyst deactivation and two-phase flow in the riser reactor. Predictions of the model compare well with the yield pattern of industrial scale plant data reported in literature.