Modeling and Simulation of Fluidized Bed Catalytic Reactor Regenerator
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1 September 215 Modeling and Simulation of Fluidized Bed Catalytic Reactor Regenerator S. N. Saha, Professor, Chemical Engg.Dept., Guru GhasidasVishwavidyalaya, Bilaspur (C.G.), India. G. P. Dewangan*, Assistant Professor, Chemical Engg. Dept., Guru GhasidasVishwavidyalaya, Bilaspur (C.G.), India. ABSTRACT Fluidized bed catalytic reactor regenerator has got its various advantages and owing to that, it is gaining more and more prominence in various chemical process industries in particular petrochemical industry. The present paper deals with effect of pressure and temperature on final conversion in Fluidized Bed Reactor Regenerator. The relevant working equations have been simulated using MATLAB software. The results have been listed. The parameters like reactor regenerator temperature, pressure, feed flow rate, gas flow rate and gas hold up, catalyst hold up have been taken up in this mathematical modeling and simulation. Keywords:Fluidized catalytic cracking; Fluidized bed; Modeling; Simulation; Reactor; Regenerator; MATLAB INTRODUCTION There is lot of research work being done for recommendation of application of fluidized bed techniques in various industries (1-17). A prominent application area of FB technique is fluidized catalytic cracking (FCC) process that converts heavy distillates like gas oils or residues to lighter petroleum fractions like gasoline s or LPG using a catalyst. Different types of FCC units are used in industry. The following schematic figure 1 shows a typical unit of FCC consisting of the reactor, regenerator, catalyst transport lines, and several auxiliary units like pre-heater, catalyst cooler, and blowers as used in the relevant industry. The process includes the feedstock to beinjected through the nozzles resulting production of instant vaporization at high temperature. Catalytic cracking reactions take place in the riser with a very short contact time because of high catalyst activity. In the cracking process coke is generated and deposited on the surface of catalyst. Reaction products are separated from catalyst in a cyclone system and the catalyst is sent through a vapor stripper through which the adsorbed products adhered over the catalyst used in the system are removed.the coke is burnt with air in the regenerator for catalyst activation resulting the rising of the temperature. Since a typical FCC unit can convert a large amount of feedstock into more valuable products, the overall economic benefits of a refinery could be considerably increased if proper control and optimization strategies are implemented. But, analysis and control of FCC processes have been known as challenging problems due to the process characteristics inter alia (i) complicated and unknown hydrodynamics, (ii) complex kinetics of both cracking and coke burning reactions, (iii) intense interactions between the reactor and the regenerator, (iv) operating constraints. Because of various advantages the fluidized bed reactorregenerator is gaining more and more prominence particularly in petrochemical industry with the industrial applications like fluid catalytic cracking of petroleum, fluid coking, hydrocracking, besides hydrogenation of ethylene, oxidation of ammonia. Out of the various elements configured in the above fig. 1 like riser, stripper, cyclone, feed injection, reactor and regenerator have been emphasized in this paper. The part of bubbling bed height, distributor, and heat exchange coefficients between bubble-cloud and between cloud-emulsion have been reported in detail elsewhere (1). * Corresponding author who may be contacted 46 S. N. Saha, G. P. Dewangan
2 September 215 Reactor FCC products Riser Stripper Cyclones Flue gas Vaporization Regenerator Feed Injection Air Figure 1.Typical fluid catalytic cracking unit The present paper deals with modeling andsimulation of fluidized bed catalytic reactorregenerator model which can be used for matching with the real life industrial data of various industries including production of acrylonitrile by ammonoxidation of propylene with air as the oxidizing agent. The present paper dealing with the modeling and simulation of FB reactor- Regenerator would be useful for the applicable process industries. The reactor-regenerator design problem involving the gas solid contact results the bubbling bed model which would aptly describe the flow characteristics of gas in the fluidized bed catalytic reactor. Bubbling bed is viewed to consist of two regions namely bubble phase and emulsion phase with gas interchange between phases. MODELLING Equations describing the dynamic behavior of a two vessel fluidized catalytic reactor regenerator system are derived, and a simple model is proposed applicable for the relevant process industry. There are two vessels, as shown in the following figure 2. Component A is fed to the reactor, where it reacts to form product B while depositing component C on the fluidized catalyst. A k1 B +.1C Spent catalyst is circulated to the regenerator, where air is added to burn off C. C + O k2 P Combustion products are vented overhead, and regenerated catalyst is returned to the reactor. Heat is added to or extracted from the regenerator at the rate Q. Plant inputs and outputs are shown in the flow diagram (figure 2). Mathematical description of the dynamic behavior of the process is based on the following Mathematical description of the dynamic behavior of the process is based on the following assumptions 1. The perfect gas law is obeyed in both the vessels. 2. Constant pressure is maintained in both the vessels. 3. Catalyst holdups in the reactor and the regenerator are constant. 47 S. N. Saha, G. P. Dewangan
3 September Heat capacity of the reactants and the products are equal and constant in each vessel. Catalyst heat capacity is also constant. 5. Complete mixing occurs in each vessel. The dynamic behavior of the reactor and regenerator is described by material balances. Product (V 1, T 1, y 1 ) Stack gas (V 2, T 2, y 2 ) Spent Catalyst (w,x) Reactor (M1,X1) Regenerator (M2,X2) Air (V a, T a, y a ) Reactor : Total continuity equation Blower Figure 2. : F.C.C. Reactor Regenerator dn 1 Component B continuity equation d(n 1 y 1 ) Component C continuity equation Equation of state dx M S. N. Saha, G. P. Dewangan = V V 1. (1) = V y V 1 y 1 + N 1 r 1. (2) = Wx 2 Wx 1 +.1N 1 r 1. (3) N 1 = P 1H 1. (4) RT 1 Regenerator : Total continuity equation dn 2 = V a V 2. (5) Component O continuity equation d(n 2 y 2 ) = V a y a V 2 y 2 N 2 r 2. (6) Component C continuity equation dx M 2 2 = Wx 1 Wx 2 N 2 r 2. (7) Equation of state N 2 = P 2H 2 RT 2. (8) Equations 2 to 4 are combined to eliminate N 1 and V 1, giving the following :Equation for the reactor: P 1 H 1. dy 1 RT 1 = V y V y 1 + P 1H 1 RT 1 r 1. (9) M 1 dx 1 = Wx 2 Wx P 1H 1 RT 1. r 1. (1) Feed (V, T, y )
4 Mole frcation of B in gas phase September 215 Likewise N 2 and V 2 are eliminated by combining equation 6 to 8 to give the following equation to regenerator: M 2 d x 2 P 2 H 2. dy 2 RT 2 = V a y a V a y 2 P 2H 2 RT 2 r 2. (11) = Wx 1 Wx 2 P 2H 2 RT 2 r 2. (12) Notation: A, B, C = Reaction components. H = Gas holdup, m 3 M = Catalyst holdup, kg N = Gas holdup, mole P1 = Pressure in reactor, pa P2 = Pressure in regenerator, pa R = Gas constant in eqn. of state (pa.m 3 /mole k) r = Reaction rate (mole reacted/total mole sec) T = Temperature (k) V = Gas flow rate (mole/sec) W = Catalyst circulation rate (kg/sec) x = Content of C on catalyst (kg mole/kg catalyst) y,y 1 = Mole fraction of B in gas phase y a,y 2 = Mole fraction of O in gas phase Subscripts: = Feed stream; 1=Reactor; 2 =Regenerator; a =Air SIMULATION The simulation has been done by using MATLAB simulator. TheRunge-Kutta method has been used to solve the equation 9,1,11 and 12. The user-friendly graphic interface provides the user with graphical representation of simulation results and is prepared by using MATLAB graphic tools. The results have been generated via changing the parameters like temperature and pressure which are shown as in the following 11 cases. Case 1: The operated temperature and pressure are 5 O C and 1 bar using equation Time s Figure 3:Mole fraction of component B in reactor vs time Case 2: The operated temperature and pressure are 5OC and 2 bar using equation S. N. Saha, G. P. Dewangan
5 Mole fraction of O in gas phase Mole fraction of O in gas phase Mole fraction of B in gas phase September Figure 4: Mole fraction of component B in reactor vs time Case 3: The operated temperature and pressure are 1OC and 1 bar using equation Figure 5: Mole fraction of component O in regenerator vs time Case 4: The operated temperature and pressure are 1 O C and 2 bar using equation Figure 6: Mole fraction of component O in regenerator vs time Case 5: The operated temperature and pressure are 4 O C and 1 bar and m 2 =1,w=1,x 2 =.3using equation 1. 5 S. N. Saha, G. P. Dewangan Time, s
6 Mole fraction of C in reactor Mole fraction of C in rector Mole fraction of C in rector September Figure 7: Mole fraction of component C in rector vs time Case 6: The operated temperature and pressure are 1 O C and 1 bar and m 2 =1, w=1, using equation Figure 8: Mole fraction of component C in rector vs time Case 7: The operated temperature and pressure are 1 O C and 2 bar and m 2 =1, w=1, x 2 =.3using equation Figure 9: Mole fraction of component C in rector vs time 51 S. N. Saha, G. P. Dewangan
7 Mole fraction of C in regenerator Mole fraction of C in regenerator Mole fraction of C in regenerator September 215 Case 8: The operated temperature and pressure are 8 O C and 1 bar and m2=1, w=1, x2=.6using equation Figure 1: Mole fraction of component C in regenerator vs time Case 9: The operated temperature and pressure are 1 O C and 1 bar and m2=1, w=1, x2=.6using equation Figure 11: Mole fraction of component C in regenerator vs time Case 1: The operated temperature and pressure are 8 O C and 2 bar and m2=1, w=1, x2=.6using equation Figure 12: Mole fraction of component C in regenerator vs time 52 S. N. Saha, G. P. Dewangan
8 Mole fraction of C in regenerator 53 S. N. Saha, G. P. Dewangan September 215 Case 11: The operated temperature and pressure are 1 O C and 2 bar and m2=1, w=1, x2=.6using equation Figure 13: Mole fraction of component C in regenerator vs time CONCLUSION A computer simulation was done to calculate the best possible dimensions for the fluidized bed catalytic reactor making use of the bubbling bed model. Developing a mathematical model describing the catalytic reactor regenerator system MATLAB was used for establishing the simulated data. Pressure and temperature affect economy of reactor regenerator. The simulated data reveals that in case of Reactor, as the pressure increases, the mole fraction of reaction component B in gas phase decreases. As temperature increases, the mole fraction of B also decreases. In case of Regenerator, as the temperature increases, the mole fraction of component C on catalyst increases. As the gas hold up in Regenerator increases, the carbon deposition on catalyst surface decreases. Also the simulated results reveal and match with the fact that the mole fraction of oxygen decreases with time as the pressure decreases. The present modeling and simulation developed in this study validating by comparing the overall behavior of the system with those in the literature is expected to serve as a valuable tool for various process system studies on FCC processes. REFERENCES 1. Rose, L. M Chemical Reactor Design and Practice Elsevier Science Ltd. 2. Schindler,H.,de Lasa, H.I Regeneration of coked cracking catalyst in a pulse microcatalytic reactor, Proc. Can SocChemEng Quebec, pp Morley, K. de Lasa, H.I On the determination of kinetic parameters for the regeneration of cracking catalyst Can J ChemEng, 65, pp WangYusan, Adams, Ronald L Two-Dimensional Modeling of the Hydrodynamics of Gas-Fluidized Beds, I & EC, vol-28, p Kunii,D. and Levenspiel, O Fluidized Reactor Models for Lean Phase, I & EC Res., 29(7), pp Shnaider, G. S A Two-Phase Model of a Fluidized Bed With Catalyst in Bubbles, I & E C Res., vol-29, p Kunii, D.,Levenspiel, O. and Brenner, H Fluidization Engineering, Elsevier Inc. 8. Elnashaie,S. S. E. H. and Elshishini,S. S Digital simulation of industrial fluid catalytic cracking units -IV. Dynamic behavior, Chemical Engineering Science, 48, pp Theologos, K.N. and Markatos, N.C Advanced modeling of fluid catalytic cracking riser-type reactors AIChE J, 39, pp Saha, S.N Modelling of Fluidized Bed Catalytic Reactor For Petrochemical Complex, Proc. Ind. Chem. Engg. Cong., Bharuch, Dec Saha, S.N.,ChowdhuryA. andrao, B.K.B Study of Yield of Isobutyl Benzene Using Multifunctional Catalyst, Proc., Ind. Chem. Engg. Cong., Bharuch, Dec ,
9 September Ali,H. androhani, S Dynamic modeling and simulation of a riser-type fluid catalytic cracking unit, Chemical Engineering Technology, 2, pp DEllis, R. C.,Li, X. andriggs, J. B Modeling and optimization of a model IV fluidized catalytic cracking unit, American Institute of Chemical Engineering Journal, 44,pp Saha, S.N Nitrogen Pollution Control by Using Fluidized Bed Bio Reactor, Proc., 49 th Canadian Chem. Engg. Conf., Saskatoon. Canada, Oct Han, In -Su,Chung, C. B. and Riggs,J. B. 2. Modeling of a fluidized catalytic cracking process, Comp. & Chem. Engg., vol. 24, issues 2-7, pp Corella,J. 24. On the modeling of the kinetics of the selective deactivation of catalyst. Application to the fluidized catalytic cracking process,indengchem Res, 43, 24, pp Saha, S.N Numerical Analysis of 3D Fluidized Bed Coal Combustion, Int. Jl. of Comp. & Math. Sc., vol. 4, no. 7, pp S. N. Saha, G. P. Dewangan
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