Dynamic Modeling And Simulation Platform Development Of FCC Reactor-Regenerator System

Accurate dynamic model and simulation for practical industrial system is the research basement of complex industry process dynamic characters and process optimization. The Fluid Catalytic Cracking (FCC) Reactor-regenerator system is one of the most important processes in a refinery, which converts molecular-weight gas oils into lighter hydrocarbon products like gasoline, diesel, gas and so on. Reactor-regenerator System is the key unit in the process which has the nonlinear, multivariate and strong coupling characters.Firstly, the mechanistic dynamic model was developed for the FCC reactor riser unit and the new techniques of two-stage side-by-side regenerator on the basis of conversation of quality and energy,which is composed of the five lumping reaction kinetics model and the two-stage side-by-side regenerator model. For dealing with the issue of the unknown reaction kinetics parameters in the five lumping model, the parameter evaluate problem was changed to unconstrained convex quadratic optimization problem, and then Advanced Marquardt algorithm was adopted to evaluate model parameters by the industry data.Secondly, fourth order Runge-Kutta method was used to solve the equations of the dynamic model. Axial distribution of lump components in riser and steady-state values of key variables was got, which is identical with the practical design data. The result of the model was compared with the industry data of the production yield.The simulation result shows that the model could describe the products rate with satisfied accuracy. Then it is debated that the system's dynamic response when the first stage air rate changed and the effects on the production yields and these regenerator's variables when the operation conditions changed include raw material flux, catalyst to oil ratio,reactor temperature and so on.At last, the simulation platform of FCC Reactor-regenerator was successfully developed on communication between MATLAB and WinCC using the OPC technology, according to the dynamic model. The system is user-friendly and practical, has the functions of dynamic process display, parameter setting and trend display, and can be used directly in the advanced control and process optimization.