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State-of-the-Art Review of Fluid Catalytic Cracking (FCC) Catalyst Regeneration Intensification Technologies. ENERGIES 2022. [DOI: 10.3390/en15062061] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/10/2023]
Abstract
Fluid catalytic cracking (FCC) is the workhorse of modern crude oil refinery. Its regenerator plays a critical role in optimizing the overall profitability by efficiently restoring the catalyst activity and enhancing the heat balance in the riser reactor. Improvement in the device metallurgy and process operations have enabled industrial regenerators to operate at high temperatures with a better coke burning rate and longer operating cycle. Today, the carbon content of regenerated catalyst has drastically reduced to less than 0.1 wt.%. However, the unit is still plagued with operational complexities and insufficient understanding of the underlying dynamic, multiscale intricacies. Recent process-intensification strategies provide insights into regenerator performance improvement potentials. In this review, the importance of the uniform distribution of spent catalysts through structural modification and operational manipulations of the catalyst distributor is discussed. The knowledge of the role of baffles in enhancing excellent gas–solid interaction has been increasing, but skepticism due to its complex hydrodynamic effects on gas–solid flows fends off operators from its application, a critical evaluation of its implication in the regenerators is covered. The understanding of the contribution of air/steam distributor design and feed gas injection techniques for even contact with spent catalyst leading to the improvement in FCC performance is also investigated. The reliability of FCC components is equally a big concern, as unplanned shutdown and enormous economic losses are being witnessed due to device failure. To this end, mitigation approaches to damaging afterburn and high-temperature erosion problems with respect to process control and geometric adjustment in the bed, freeboard, cyclone separators and collection ducts are explored. Emission limits for fluid catalytic cracking unit (FCCU) and products are consistently ratcheting downward; the commingled turnkey solutions to reducing pollutants generation are also reviewed.
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Ren C, Yang Y, Huang Z, Sun J, Yang Y, Wang J. Effect of the Scale-Up Process on the Reactor Performance within the Riser: Simulation Using Ozone Decomposition. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c01085] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Congjing Ren
- Ningbo Research Institute, Zhejiang University, Ningbo 315100, P. R. China
- College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
| | - Yao Yang
- Zhejiang Provincial Key Laboratory of Advanced Chemical Engineering Manufacture Technology, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
| | - Zhengliang Huang
- Zhejiang Provincial Key Laboratory of Advanced Chemical Engineering Manufacture Technology, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
| | - Jingyuan Sun
- Zhejiang Provincial Key Laboratory of Advanced Chemical Engineering Manufacture Technology, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
| | - Yongrong Yang
- State Key Laboratory of Chemical Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
| | - Jingdai Wang
- State Key Laboratory of Chemical Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
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On the choice of closure complexity in anisotropic drag closures for filtered Two Fluid Models. Chem Eng Sci 2019. [DOI: 10.1016/j.ces.2019.06.006] [Citation(s) in RCA: 28] [Impact Index Per Article: 5.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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Aronsson J, Lyngfelt A, Pallarès D. Effects of the Choice of Gas on the Hydrodynamics of Fluidized Beds. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b00757] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Jesper Aronsson
- Department of Space, Earth and Environment, Chalmers University of Technology, SE-41296 Gothenburg, Sweden
| | - Anders Lyngfelt
- Department of Space, Earth and Environment, Chalmers University of Technology, SE-41296 Gothenburg, Sweden
| | - David Pallarès
- Department of Space, Earth and Environment, Chalmers University of Technology, SE-41296 Gothenburg, Sweden
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Cloete JH, Cloete S, Municchi F, Radl S, Amini S. Development and verification of anisotropic drag closures for filtered Two Fluid Models. Chem Eng Sci 2018. [DOI: 10.1016/j.ces.2018.06.041] [Citation(s) in RCA: 33] [Impact Index Per Article: 5.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/14/2022]
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Zi C, Huang Z, Wang J, Yang Y, Ye X. Numerical Study of the Scaling Rules for Riser with Consideration of Cluster Effect. Ind Eng Chem Res 2016. [DOI: 10.1021/acs.iecr.6b01976] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Can Zi
- State Key Laboratory of Chemical
Engineering, College of Chemical
and Biological Engineering, Zhejiang University, Hangzhou 310027, China
| | - Zhengliang Huang
- State Key Laboratory of Chemical
Engineering, College of Chemical
and Biological Engineering, Zhejiang University, Hangzhou 310027, China
| | - Jingdai Wang
- State Key Laboratory of Chemical
Engineering, College of Chemical
and Biological Engineering, Zhejiang University, Hangzhou 310027, China
| | - Yongrong Yang
- State Key Laboratory of Chemical
Engineering, College of Chemical
and Biological Engineering, Zhejiang University, Hangzhou 310027, China
| | - Xiaofeng Ye
- State
Key Laboratory of Polyolefins and Catalysis, Shanghai Research Institute of Chemical Industrial, Shanghai 200062, China
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Cloete S, Johansen ST, Amini S. Grid independence behaviour of fluidized bed reactor simulations using the Two Fluid Model: Effect of particle size. POWDER TECHNOL 2015. [DOI: 10.1016/j.powtec.2014.08.055] [Citation(s) in RCA: 38] [Impact Index Per Article: 4.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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Saayman J, Xu M, Lim JC, Ellis N. Gas leakage between reactors in a dual fluidized bed system. POWDER TECHNOL 2014. [DOI: 10.1016/j.powtec.2014.06.012] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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Jiang L, Fang-Zhi X, Zheng-Hong L. A CFD modeling of the gas-solid two-phase flow in an FCC riser under the electrostatic conditions. ASIA-PAC J CHEM ENG 2014. [DOI: 10.1002/apj.1793] [Citation(s) in RCA: 15] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Li Jiang
- Department of Chemical and Biochemical Engineering; College of Chemistry and Chemical Engineering; Xiamen University; Xiamen 361005 P. R. China
| | - Xiao Fang-Zhi
- Department of Chemical and Biochemical Engineering; College of Chemistry and Chemical Engineering; Xiamen University; Xiamen 361005 P. R. China
| | - Luo Zheng-Hong
- Department of Chemical Engineering; School of Chemistry and Chemical Engineering; Shanghai Jiao Tong University; Shanghai 200240 P. R. China
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Cloete S, Johansen ST, Amini S. Evaluation of a filtered model for the simulation of large scale bubbling and turbulent fluidized beds. POWDER TECHNOL 2013. [DOI: 10.1016/j.powtec.2012.09.027] [Citation(s) in RCA: 25] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/27/2022]
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Cloete S, Johansen ST, Amini S. An assessment of the ability of computational fluid dynamic models to predict reactive gas–solid flows in a fluidized bed. POWDER TECHNOL 2012. [DOI: 10.1016/j.powtec.2011.08.033] [Citation(s) in RCA: 25] [Impact Index Per Article: 2.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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