Dynamic Modeling And Simulation Of The Riser Reactor And The Regenerator For FCCU

Fluid catalytic cracking (FCC) unit is one of the key processes in modern petroleum refining. Mainly study the influence of technology innovation on reactive process in domestic and abroad. But FCC reactor and regenerator is a complex system for its multivariable, time-varying and nonlinear characteristics, the modeling of the system of complex kinetics reactions should be studied. A dynamic model is put forward to study the operating characteristics of FCC reactor and regenerator; it is also of great importance for the design, optimization of operation parameters and simulation of FCC reactor and regenerator system.Based on the equations of mass balance, energy balance, a general mathematical model is developed for rigorous dynamic simulations of FCC reactor and regenerator. This paper built up five-lump (including non-conversion raw material oil, diesel oil, gasoline, gas and coke) kinetic model of a riser reactor as well as the temperature of the reactor equations. Carbon burning and flue gas oxygen burning reaction kinetics model is used in FCC regenerator as well as the temperature of the regenerator equations.The reaction kinetics parameters of the lump model were estimated from the operation data and yields data of FCC reactor (per hour) in an industrial plant by Nelder-Mead minimization algorithm. Then simulation is implemented by the ODE15s of Matlab 7.0.The results of the simulation are in a good agreement with the industrial data.According to characteristic of rapidly reaction in the reactor, the gas and the solid phases can be ignored. Compared to the former simulation results, the results of simplified model can also reflect the dynamic characteristics of FCC reactor and regenerator system.Based on the simplified mathematic model, the simulation system of FCC reactor and regenerator is developed on XD-APC, one kind of comprehensive process control software designed by our lab on which appropriate control strategies and optimization technologies can be implemented easily. The system is developed according to the simplified dynamic model above combined with controller equations, which enables the use of physical insight from the dynamic model to be used directly in the analysis and detailed dynamic simulation capability of a process. Simulation of operation process are carried out to study the effects of catalytic content, a reactor temperature, raw material oil, air fluxes on the system. The results agreed well with the industrial data.Finally, the overall dynamic simplified mathematical model is successfully developed which present opportunities for the future establishment of suitable integrated advance control of FCC reactor and regenerator system.