Fluid dynamics and erosion analysis in industrial naphtha reforming: A CFD-DPM simulation approach

Abstract

This paper explores using Computational Fluid Dynamics-Discrete Phase Model simulation in an industrial naphtha reforming unit. It analyzes the reformer process, including the reformer, hopper, and three elbow types. Objectives encompass catalyst residence time, fluid flow, and erosion due to the catalyst in these geometries. Simulation results unveil insights, showing varying erosion rates among the elbows. The 90-degree elbow has the highest erosion rate 4.42×10−8kgm2s, followed by the 60-degree elbow3.49×10−8kgm2s, and the 45-degree elbow with lower erosion rate 2.65×10−8kgm2s. Results align with literature, emphasizing flow dynamics' role in optimization and maintenance. The study validates simulation with only 1.58% deviation from plant data, highlighting model's precision. Catalyst residence time is 1.28 s. Erosion patterns in the hopper pinpoint high-density zones as erosion-prone areas, guiding preventive measures. This research enhances continuous catalytic reformer systems' efficiency and integrity, aiding decisions for design and maintenance, ultimately improving overall process efficiency and stability.