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A new generic approach for the modeling of uid catalytic cracking (FCC)
riser reactor
Raj Kumar Gupta a , Vineet Kumar a, , V.K. Srivastava b
a Department of Chemical Engineering, Thapar University, Patiala 147 004, India
b Department of Chemical Engineering, Indian Institute of Technology, Delhi 110 016, India
Received 17 April 2006; received in revised form 4 November 2006; accepted 14 May 2007
Available online 21 May 2007
Abstract
A new kinetic model for the uid 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 ow in the riser reactor. Predictions of the model compare well with the yield
pattern of industrial scale plant data reported in literature.
2007 Elsevier Ltd. All rights reserved.
Keywords: Fluid catalytic cracking; Mathematical modeling; Simulation; Cracking kinetics; Pseudocomponents; Computational uid dynamics
1. Introduction
Fluid catalytic cracking (FCC) is a process in which
the heavy hydrocarbon molecules are converted into lighter
molecules. The hydrocarbon feed enters a transport bed tubular reactor (riser) through feed atomizing nozzles and comes
in contact with the hot catalyst coming from the regenerator. The feed gets vaporized and cracks down to the lighter
molecules as it travels upwards along with the catalyst. As a
result of cracking, the velocity of the vapors increases along
the riser height. Coke, the byproduct of cracking reactions,
gets deposited on the catalyst surface thus causing the catalyst
to loose its activity. The cracked hydrocarbon vapors are separated from the deactivated catalyst in a separator; the vapors
adsorbed onto the surface of the catalyst are also stripped off
using steam in the catalyst stripper. The cracked hydrocarbon
vapors are sent to the main distillation column for further
carbenium ion through hydrogen addition. Thus, large hydrocarbon molecules can be cracked repeatedly producing successively smaller hydrocarbons. However, as the hydrocarbon
chain becomes smaller, cracking rates become slower. At the
same time, a short, less reactive ion can transfer its charge to a
larger, more reactive molecule by hydrogen transfer that makes
the cracking reaction of larger molecules still faster (Wilson,
1997). Such detailed chemistry of catalytic cracking coupled
with a large number of unknown compounds present in the
feedstock is very difcult to be used in the mathematical modeling of an industrial scale FCC riser reactor because of the
analytical and computational limitations.
The traditional and global approach of modeling of cracking kinetics is based on lumping of compounds. Mathematical
models dealing with riser kinetics can be categorized into two
main types. In one category, the lumps are made on the basis of boiling range of feed stocks and corresponding products
in the reaction system. This kind of model has an increasing
trend in the number of lumps of the cracked components. The
other approach is that in which the lumps are made on the basis of molecular structure, characteristics of hydrocarbon group
composition in reaction system. This category of models emphasizes on more detailed description of the feedstock (Wang
et al., 2005).
These both categories of models do not include chemical
data such as type of reaction and reaction stoichiometry. The
number of kinetic constants in these models increases very
rapidly with the number of lumps. All these models assume
that FCC feed and products are made of a certain number of
lumps, and kinetic parameters for these lumps are estimated
empirically considering the conversion of one lump to the other.
In both of these categories, however, reaction kinetics being
considered is that of conversion of one lump to another and
not the cracking of an individual lump.
As the reactivity of the feed depends on the composition of
the feed, and catalyst composition and reactivity is important
in determining conversion and product selectivity, the values
of kinetic constants obtained by the above discussed models
depend on the particular pair of feedstock and catalyst for which
they are obtained. Hence, these kinetic constants cannot be used
for different feed and catalyst pairs.
Other modeling schemes include, models based upon reactions in continuous mixtures (Aris, 1989), structure oriented
lumping (Quam and Jaffe, 1992), and single-events cracking
(Feng et al., 1993). Nevertheless, the application of these models to catalytic cracking of industrial feedstocks (vacuum gas
oil), is not realized because of the analytical complexities and
computational limitations. Liguras and Allen (1989a) proposed
a lumped kinetic model so as to utilize the pure components
cracking data for the catalytic cracking of oil mixtures. The
authors in their subsequent work (Liguras and Allen, 1989b)
divided the petroleum feedstock into a number of pseudocomponents. These pseudocomponents were characterized by
grouping the feedstock components into compound classes and
selecting a set of representative compounds in a compound
class and then assigning the concentrations to the representative
compounds. This pseudocomponents characterization method
4511
4512
treated as hypothetical pure component with all physical, thermodynamic, and critical properties known. A brief description
for generating these pseudocomponents is given in Appendix
A. For the generation of these lumps, the feedstock is divided
into 12 lumps and average boiling point of each lump is determined by area averaging of the true boiling point (TBP) curve
of the feedstock. Thus one individual lump is a collection of
all compounds having boiling point close to each other. The
temperature range between boiling point of the lightest lump of
the feedstock and the boiling point of propane is divided into
31 equal intervals which were considered to be boiling points
of 31 lumps of liquid products to be formed after cracking.
Molecular weight of each lump is also calculated using empirical correlation proposed by Edmister and Lee (1984) assuming
constant Watson characterization factor for product and feed
lumps. Constituents of dry and wet gas are also considered as
seven lumps consisting of methane, ethane, propane, butene,
butane, pentene, and pentane. Properties of these seven lumps
were taken equal to that of pure components due to the fact that
empirical correlations fail to predict properties of very light hydrocarbons and also due to the fact that gaseous products are
rather known mixtures of these hydrocarbons. Thus we have
lumps of seven pure components and 43 hypothetical components. Henceforth, all these components are collectively called
pseudocomponents and abbreviated as PCs. Apart form these
50 components, a separate coke lump is also considered which
is formed as a byproduct of the cracking reactions.
The pseudocomponent based approach for design and simulation of crude distillation unit is highly successful. Sufcient
empirical correlations are available in literature to predict almost all physico-chemical, thermodynamic, and critical properties of pseudocomponents. Vaporliquid equilibrium of these
pseudocomponents are predicted fairly accurately without resolving these components in aromatics, olens, naphthenes, and
parafns. For applying this approach to FCC modeling, it is assumed that one mole of a pseudocomponent on cracking gives
1 mole each of two other smaller pseudocomponents and some
amount of coke may also form. A schematic diagram of the reaction mechanism is given in Fig. 1. There are total N blocks
in each column of the diagram and each block in a column
represents one pseudocomponent (blocks in a row represents
same pseudocomponent). Pseudocomponents are numbered in
increasing order of normal boiling point, which also ensures increasing order of molecular weight. According to the proposed
scheme, there are several possible ways through which one particular pseudocomponent (say ith pseudocomponent, PCi ) can
crack down to give a pair of pseudocomponents PCm and PCn
along with some amount of coke as cracking byproduct according to the following pseudoreaction mechanism:
ki,m,n
(1)
Reactant
Feed
Product 1
Product 2
Mol. Wt.
MW1
MW2
MW3
1
2
3
1
2
3
1
2
3
MWm
MWn
MWi
MWN-11
MWN
PCi
ki , m ,n
PC m + PC n + coke
N-11
N-11
N-11
4513
coke
(2)
(3)
4514
(5)
Pi,j
.
(ug,j g,j )Ar
(6)
B +1
,
B + exp(A Ccj )
or
N
Pi,j 1 MWi
i=1
(7)
N
Pi,j MWi
i=1
N
m
i
i=1 m=1 n=1
(8)
ri,m,n i,m,n
(9)
(10)
(11)
4515
(14)
(15)
N
Pi,j 1 MWi Cp i (Tj 1 Tj )
i=1
(12)
i
ri,m,n H r i,m,n
(16)
.
for all feasible reactions
Tj = Tj 1
n ri,m,n
H r i,m,n )for
Cp i )
(17)
4516
g g |ug uc |dc
The temperature (Tj ) thus calculated was used for the estimation of kinetic parameters in the next volume element and other
temperature dependent properties of the pseudocomponents.
Re =
2.5. Hydrodynamics
(18)
Assuming the change in the mass of solids along the riser height
as negligible (this assumption is valid as the change in the mass
of solid phase from riser entrance to riser outlet due to coke
deposition is typically less than 1%, hence in a volume element
of the riser the change in the mass of solids will be negligibly
small) solid phase continuity equation can be written as
duc
2fs c
c u2c
c c uc
= Cf (ug uc ) +
c
c g.
dz
D
(19)
The frictional force per unit volume at the gas particle interphase due to differing phase velocities can be calculated by the
following expression (Markatos and Shinghal, 1982):
F = 0.5CD AP
g |ug uc |(ug uc ) = Cf (ug uc ),
(20)
(21)
c =
p (1 c ) +
g c
p (1 c ).
(22)
for Re1000,
g
uc0 =
Mcat
,
c Ar c0
(25)
(26)
where uc0 and c0 are the values of solid phase velocity and
solid phase volume fraction at the entrance of rst volume
element.
The value of cluster volume fraction for the next volume
element is calculated by the equation
cj =
Mcat
.
c Ar ucj
(27)
(28)
c u2c
,
(31)
= c
dz acc
2 z
2fs
c c u2c
dP
=
,
(32)
dz f s
D
dP
dz
=
fg
fg
g u2g
D
(33)
(34)
(23)
(24)
fs = 0.0025u1
c .
(35)
gj =
(37)
RTj
and the gas phase velocity is calculated by
Mst + N
i=1 Pi,j MWi
ugj =
.
Ar
g,j gj
(38)
(z)j
.
uc,j
(39)
4517
4518
Table 1
Parameters used for the simulation of riser reactor
Parameter
Value
Source
32950 kJ/kg
12 kg/kmol
0.5
1.15 kJ/kg K
2.15 kJ/kg K
1.33 kg/s
494 K
96 kJ/kg
1200 kg/m3
75 m
0.9292 g/cm3
6 mm
Austin (1984)
Arbel et al. (1995)
Gupta and Subba Rao (2001)
Ali et al. (1997)
Blasetti and de Lasa (1997)
Blasetti and de Lasa (1997)
Ali et al. (1997)
Gupta and Subba Rao (2001)
Gupta and Subba Rao (2001)
Gupta and Subba Rao (2001)
Pekediz et al. (1997)
Fligner et al. (1994)
Table 2
Plant data used for simulation of riser reactor
Riser height
Riser diameter
Riser pressure
Catalyst temperature
Feed rate
Feed temperature
C/O ratio
33 m
0.8 m
2.9 atm
960 K
20 kg/s
496 K
7.2
(32 m)
1.0 m
3.15 atm
(960 K)
85 kg/s
650 K
5.53
50 m
1.24 m
(2.9 atm)
1025 K
17.5 kg/s
568 K
8.0
Data given in the parentheses are those used in the present work in place of data either not reported or reported in ranges.
a Literature data.
1000
120
Plant data
Gas yield
Gasoline yield
Coke yield
Unconverted
100
Model prediction
Gas yield
Gasoline yield
Coke yield
Unconverted
80
Yields (wt%)
Model predictions
60
40
900
850
20
800
0
750
0
10
15
20
Riser height (m)
25
30
35
10
15
20
Riser height (m)
25
30
35
Fig. 3. Case study 1, comparison with the data reported by Ali et al. (1997).
4519
Plant data
100
Yields (wt%)
80
Model prediction
Gas yield
Gasoline yield
Coke yield
Gas yield
Gasoline yield
Coke yield
Unconverted
Unconverted
60
40
20
10
15
20
25
30
35
The activity of the catalyst also decreases rapidly as byproduct (coke) of the cracking reactions gets deposited on the catalyst surface (Fig. 10). Fig. 11 shows an initial decline in the gas
velocity because of the sharp increase in the gas void fraction
due to increase in the moles of the gas as a result of cracking.
After this initial decline, the gas velocity starts increasing as
the cracking reactions along the riser height continues to increase the moles of the gas causing a continuous decline in the
gas phase density. The initial sharp increase in the catalyst velocity is due to the sharp fall in the solid volume fraction and
drag exerted by the gas. After this initial sharp increase the
Fig. 8. Case study 1, comparison with the data reported by Ali et al. (1997)
with four parameters.
0.55
14
Plant data
12
0.50
Model prediction
950
10
0.45
Velocity (m/s)
4520
900
8
0.40
6
0.35
850
4
Gas phase velocity
Catalyst velocity
2
800
0.30
0.25
0
750
10
15
20
25
30
35
10
15
20
25
30
35
Fig. 11. Predicted catalyst and gas velocity proles and gas phase molar ux
along the riser height.
0.50
1.2
0.45
1.0
0.40
Catalyst activity
0.8
0.6
0.4
0.35
0.30
0.25
0.20
0.15
0.10
0.2
0.05
0.00
0.0
10
15
20
25
30
35
10 15 20 25 30 35
5
The plots for both the values are almost similar because this
value gets adjusted very quickly at the riser entrance itself
(in the rst 2 m of the riser height itself the catalyst volume
fraction value reaches 0.12 for both the cases) and hence the
yield proles remain unaffected.
Since plant data for the product yields were available at the
riser outlet only, few more comparisons were made in subsequent case studies. Even without changing the values of the
parameters the results of the simulation were encouraging.
However, for better comparison, the parameters were adjusted
80
70
60
50
40
Model gasoline
30
Plant gasoline
Model conversion
20
Plant conversion
10
0
0
10
15
20
25
30
4521
35
4. Conclusion
80
Conversion
60
Gasoline
40
Gas+coke
20
0
0
10
20
30
40
50
60
A new technique for modeling the FCC riser has been developed. The model incorporated a more realistic kinetic scheme
for the cracking reactions, and a new correlation to evaluate
Arrhenius type reaction rate constants. The rate constant parameters can easily be obtained for each combination of feed and
catalyst. Although there is signicant variation in the yield pattern of different case studies, activation energy parameter (E0 )
remained same for all cases. However, to account for different characteristics of the feedstock and catalyst, only frequency
factor parameter (k0 ) and feed coking tendency parameter 2
were required to be adjusted to compare the yield patterns of
different case studies with the model results.
The proposed model is capable of predicting overall conversion, products yields, temperature, and catalyst activity along
the riser height. The model results are in close agreement with
the industrial data reported in the literature and the data predicted by other simulators.
The predictions of the FCC riser reactor model are dependent
on the values of cracking reactions rate constants, which can
easily be obtained with the help of proposed kinetic model for
different characteristics of the feedstock, type of catalyst, activity of catalyst, and operating parameters. Therefore, it seems
to be more appropriate to use these rate constant parameters
obtained for a pair of feedstock and catalyst in place of using
the kinetic constants from the literature which are obtained for
a different combination of feedstock and catalyst by regression
analysis. Further, this detailed kinetic model can be easily used
for the other advanced studies (such as control and optimization) of FCC modeling.
Notation
Ar
Cc
Ci,j
4522
Cpcat
Cpi
Cpmix,j
Cpst
Ei
H coke
H comb
Hr
k0,i
ki,m,n
Mcat
Mcokej
Mst
MWi
N
NC
p
Pi,j
ri,m,n
R
tj
t Catj
Tin
Tj
u
uc
ug
Subscripts
i, m, n
j
Greek letters
i,m,n
g,j
mass of coke formed when 1 kmol of pseudocomponent PCi cracks to give 1 kmol each of
PCm and PCn , kg coke/kmol PCi
volume fraction of gas in j th volume element
exponent of molecular weight for frequency
factor
exponent of molecular weight for activation
energy
cat
coke
g,j
1 , 2
j
Appendix A.
Petroleum fractions are mixtures of innumerable components which are difcult to be identied individually. However,
Watson characterization factor can be treated as an indicator of
the composition of various groups of compounds (such as parafn, olen, naphthene, aromatic, etc.) present in the petroleum
fraction. Watson and Nelson (1933) made a remarkable ob1/3
servation that the factor KW (=Tb /sg), known as Watson
characterization factor, is closer to 12 for parafns and olens,
approximately 10 for aromatics, and between 11 and 12 for
naphthenes when the normal boiling point of the component,
Tb , is in Rankin and sg is the specic gravity at 60 /60 F.
The characterization factor of the mixture of hydrocarbons is
given by KW = MeABP1/3 /sg, where MeABP is the mean average boiling point of the mixture (API Data Book, Chapter 2,
Characterization of Hydrocarbons, 1976). Using this, Miquel
and Castells (1993) proposed a method along with a computer
program (Miquel and Castells, 1994) that can represent an oil
fraction by an equivalent mixture of small number of hypothetical components or pseudocomponents. To use this approach,
atmospheric TBP distillation curve and the entire fraction density is required. This method assumes that if the difference in
nal boiling point (FBP) and initial boiling point (IBP) of a
petroleum oil is not too high (i.e., < 300 K) then the Watson
characterization factor of any narrow-boiling fraction (boiling
range between 15 and 25 K) of this oil remains equal to that of
original petroleum oil.
In the present case, due to unavailability of TBP curve for
the FCC feed, SD curve reported by Pekediz et al. (1997) was
used. The SD curve was rst converted to ASTM-D86 curve
and then to TBP curve by the correlation proposed by Daubert
(1994). The two-step conversion of SD data to TBP data is given
in Table A1. To generate pseudocomponents, the TBP curve of
the feed was divided into 12 parts, out of which four were of
5 vol% each and eight of 10 vol% each (shown as vertical bars
in Fig. A1 ). These vertical bars represent 12 pseudocomponents of the feed. The boiling point of each individual pseudocomponent was determined by area-averaging of the TBP curve
(clearly visible in Fig. A1). Considering constant Watson characterization factor, specic gravity of each pseudocomponent
was determined by the equation
1/3
T
sg = 1.21644 b
KW
(where Tb is in K).
(A.1)
4523
Table A1
Distillation data of hydrocarbon feed (Pekediz et al., 1997)
Vol. % distilled (wt%)
SD (K)
ASTM-D86a (K)
TBPa (K)
IBP
10
30
50
70
90
FBP
532
587
621
650
683
730
800
585.5
615.5
632.8
652.3
680.5
721.4
756.6
558.9
604.3
636.4
665.3
700.6
743.9
808.1
4524
Table A2
Properties of pseudocomponents
Component ID
Component name
Molecular weight
H comb (kJ/kmol)a
PC1
PC2
PC3
PC4
PC5
PC6
PC7
PC8
PC9
PC10
PC11
PC12
PC13
PC14
PC15
PC16
PC17
PC18
PC19
PC20
PC21
PC22
PC23
PC24
PC25
PC26
PC27
PC28
PC29
PC30
PC31
PC32
PC33
PC34
PC35
PC36
PC37
PC38
PC39
PC40
PC41
PC42
PC43
PC44
PC45
PC46
PC47
PC48
PC49
PC50
Methane
Ethane
Propane
Butene
Butane
Pentene
Pentane
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
Pseudocomponent
111.65
184.50
231.09
266.90
272.65
303.11
309.21
317.37
325.54
333.70
341.86
350.03
358.19
366.35
374.52
382.68
390.84
399.01
407.17
415.33
423.50
431.66
439.83
447.99
456.15
464.32
472.48
480.64
488.81
496.97
505.13
513.30
521.46
529.62
537.79
545.95
554.11
562.28
570.44
593.12
612.48
628.50
643.76
658.25
674.30
691.91
711.55
733.25
760.13
792.20
16.043
30.070
44.097
56.108
58.124
70.135
72.150
88.563
91.443
94.402
97.443
100.569
103.781
107.083
110.478
113.969
117.558
121.249
125.045
128.948
132.964
137.094
141.343
145.713
150.210
154.835
159.595
164.491
169.530
174.714
180.049
185.538
191.187
197.000
202.982
209.138
215.474
221.995
228.706
248.399
266.496
282.446
298.497
314.565
333.352
355.231
381.318
412.311
454.185
509.673
62764.79
58622.94
51983.86
50464.83
49960.31
49073.02
48952.84
47318.37
47226.62
47137.89
47052.01
46968.81
46888.17
46809.94
46734.00
46660.24
46588.54
46517.73
46445.89
46373.59
46300.89
46227.80
46154.34
46080.57
46006.47
45932.07
45857.39
45782.42
45707.18
45631.67
45555.89
45479.85
45403.53
45326.93
45250.05
45172.88
45095.39
45017.59
44939.46
44720.49
44531.20
44353.16
44187.51
44034.96
43871.15
43697.31
43510.14
43311.36
43075.64
42808.56
PC1 to PC7 are pure components constituting gas; PC8 to PC29 constitute gasoline fraction; PC30 to PC41 constitute light cycle oil fraction; PC42 to PC50
constitute residual fraction whereas feed contains PC39 to PC50 .
a Heat of combustion values are calculated by using Eqs. (12), (13), and (14).
4525
800
Residue
700
Feed
600
LC O
500
Fig. B1. Schematic representation of cracking of a pseudocomponent: (a)
cracking from middle of the molecule (without coke formation), (b) cracking
from side of the molecule (without coke formation), (c) cracking from middle
of the molecule (along with coke formation), (d) cracking from side of the
molecule (along with coke formation).
Gasoline
400
300
Gas
200
100
0
20
40
60
80
100
(B.1)
1
(kmax,i )2
(B.2)
.
(B.3)
(B.4)
4526
Table B1
Kinetic data for the cracking reactions reported by Arbel et al. (1995)
Cracking reaction
HFO to LFO
HFO to gasoline
HFO to coke
LFO to gasoline
LFO to coke
Gasoline to coke
60.7086
23.0274
73.269
23.0274
73.269
41.868
1.422 107
1760.4
3380.4
712.8
2707.2
356.4
172.8
380
380
380
255
255
120
1.026 105
3.704 107
8.215 104
1.852 107
8.555 104
Table B2
Kinetic data for the cracking reactions reported by Lee et al. (1989)
Cracking reaction
68.2495
89.2164
64.5750
52.7184
115.4580
7.978 105
4.549 106
3.765 104
3.255 103
7.957 101
39.364
9.749
6.012
2.470
1.364
380
380
380
120
120
(B.5)
It appears from Table B.1 and Table B.2 that the rate constant for the conversion of a lump to coke is signicantly lower
than the rate constants for the conversion of same lump to other
hydrocarbon lumps. It indicates that the formation of coke is
not favored during the cracking reaction. From this fact an inference can be drawn that the probability (or the rate constant)
of a cracking reaction decreases when coke formation (i,m,n )
is increased. Since we are considering cracking of pseudocomponents, which itself are mixtures of large number of actual
compounds, it seems that the fractional decrease in rate constant with increasing coke formation should be a continuous
function say g(), where is the amount of coke formation
(i,m,n ). Thus the general correlation for the rate constant can
be expressed as the product of these two functions as
ki,m,n = f (x)g().
(B.6)
ei,m,n eMWi
,
1 eMWi
such that,
g(i,m,n ) = 1 at i,m,n = 0 (i.e., no coke formation)
and
g(i,m,n ) = 0 at i,m,n = MWi
(i.e., all hydrocarbon mass is converted to coke).
.
1 eMWi
2
(B.8)
(B.7)
e(MWi (MWm +MWn ))/2 eMWi
.
1.0 eMWi
(B.9)
4527
k0,i = k0 MWi ,
(B.11)
Ei = E0 MWi .
(B.12)
(B.10)
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