A CFD study on the start-up hydrodynamics of fluid catalytic cracking regenerator integrated with chemical looping combustion

Abstract

ABSTRACT The integration of chemical looping combustion with fluid catalytic cracking (CLC-FCC) is an innovative concept that serves as a cost-effective method for CO2 capture in refineries. This approach has the potential to reduce refinery CO2 emissions by 25–35%, offering a promising solution. As in the conventional FCC unit, it is common for CLC-FCC regenerators to be exposed to an on-off process while they are being maintained and cleaned. The novelty of this research lies in its specific focus on a less-explored phase (start-up) of CLC-FCC regenerators, the application of advanced CFD modeling, and the comprehensive analysis of operational parameters that influence the system’s performance. To validate the CFD simulations of the different drag models for solid-gas granular, bed density profiles under steady-state conditions, collected from industrial processes, were used. For the flow period based on the start-up process of the drag models, the fluidization gas inlet geometry of the regenerator, flow regime (laminar and turbulent), and superficial gas velocity were comprehensively investigated to reveal their effects on hydrodynamic characteristics. The results show that Gidaspow and Syamlal-O’Brien drag models of the solid-gas multiphase granular flow exhibited a better fit with industrial data. The Syamlal-O’Brien and Gidaspow models closely align with industrial data under steady-state conditions, displaying similar bed densities in the dense phase region (230–310 kg/m3 for Syamlal-O’Brien and 235–300 kg/m3 for Gidaspow). During the initial stage (less than 0.2 seconds), both laminar and turbulent models yield comparable bed density profiles, approximately 510 kg/m3 in the dense phase. However, as the process progresses, the dense phase density decreases to about 250–350 kg/m3 at around 0.5 seconds, with laminar flow models showing a slightly better fit with industrial data. Notably, at 0.5 seconds of fluidization time, inlet geometries having better gas distribution achieve a highly diluted phase with bed densities of 10–20 kg/m3. Reaching a steady state, the bed density decreases from around 400 kg/m3 to 260–300 kg/m3, expanding into a higher section of the regenerator where it aligns well with industrial data. The increase in superficial gas velocity would result in the clarification of the difference and well mixing of the solid-gas multiphase flow.