A three-phase reacting flow computational fluid dynamics (CFD) computer code was used to study the major effects of spray injection parameters on mixing, heat transfer, vaporization, and reaction product yields in fluidized catalytic cracking (FCC) riser reactors. The CFD code was validated using experimental or field data. A number of computations were performed with varied injection parameters, including injection velocity, injection angle, and droplet size. Local optimum operating windows for spray injection parameters were identified, and the sensitivity of local optima to variation in spray parameters was also investigated.

1.
Bienstock, M. G., Draemel, D. C., Ladwig, P. K., Patel, R. D., and Maher, P. H., 1993, “A History of FCC Process Improvement through Technology Development and Application,” AIChE Spring National Meeting, Houston, TX.
2.
Weekman
,
V. W.
, and
Nace
,
D. M.
,
1970
, “
Kinetics of Catalytic Cracking Selectivity in Fixed, Moving, and Fluid Bed Reactors
,”
AIChE J.
,
16
(
3
), pp.
397
404
.
3.
Dave
,
N. C.
,
Duffy
,
G. J.
, and
Udaja
,
P.
,
1993
, “
A Four-Lump Kinetic Model for the Cracking/Coking of Recycled Heavy Oil
,”
Fuel
,
72
(
9
), pp.
1331
1334
.
4.
Nigam
,
A.
, and
Klein
,
M. T.
,
1993
, “
A Mechanism-Oriented Lumping Strategy for Heavy Hydrocarbon Pyrolysis: Imposition of Quantitative Structure-Reactivity Relationships for Pure Components
,”
Ind. Eng. Chem. Res.
,
32
, pp.
1297
1303
.
5.
Quann
,
R. J.
, and
Jaffee
,
S. B.
,
1996
, “
Building Useful Models of Complex Reaction Systems in Petroleum Refining
,”
Chem. Eng. Sci.
,
51
(
10
), pp.
1615
1635
.
6.
Sinclair
,
J. L.
, and
Jackson
,
R.
,
1989
, “
Gas-Particle Flow in a Vertical Pipe with Particle-Particle Interactions
,”
AIChE J.
,
35
(
9
), pp.
1473
1486
.
7.
Pita
,
J. A.
, and
Sundaresan
,
S.
,
1993
, “
Developing Flow of a Gas-Particle Mixture in a Vertical Riser
,”
AIChE J.
,
39
(
4
), pp.
541
552
.
8.
Nuri
,
A.
, and
Gidaspow
,
D.
,
2000
, “
Riser Hydrodynamics: Simulation Using Kinetic Theory
,”
AIChE J.
,
46
(
1
), pp.
52
67
.
9.
Theologos
,
K. N.
, and
Markatos
,
N. C.
,
1993
, “
Advanced Modeling of Fluid Catalytic Cracking Riser-Type Reactors
,”
AIChE J.
,
39
(
6
), pp.
1007
1017
.
10.
Theologos
,
K. N.
,
Nikou
,
I. D.
,
Lygeros
,
A. I.
, and
Markatos
,
N. C.
,
1997
, “
Simulation and Design of Fluid Catalytic-Cracking Riser-Type Reactors
,”
AIChE J.
,
43
(
2
), pp.
486
494
.
11.
Jacob
,
S. I.
,
Gross
,
B.
,
Voltz
,
S. E.
, and
Weekman
,
V. W.
,
1976
, “
A Lumping and Reaction Scheme for Catalytic Cracking
,”
AIChE J.
,
22
(
4
), pp.
701
713
.
12.
Gao
,
J.
,
Xu
,
C.
,
Lin
,
S.
,
Yang
,
G.
, and
Guo
,
Y.
,
1999
, “
Advanced Model for Turbulent Gas-Solid Flow and Reaction in FCC Riser Reactors
,”
AIChE J.
,
45
(
5
), pp.
1095
1113
.
13.
Chang
,
S. L.
, and
Lottes
,
S. A.
,
1993
, “
Integral Combustion Simulation of a Turbulent Reacting Flow in a Channel With Cross-Stream Injection
,”
Numer. Heat Transfer, Part A
,
24
(
1
), pp.
25
43
.
14.
Chang
,
S. L.
, and
Lottes
,
S. A.
,
1995
, “
Characteristic of Multiphase Flow with Particle Vaporization in a Combustor with Counter-Flow Injection
,”
Energy Convers. Manage.
,
36
(
11
), pp.
1031
1045
.
15.
Zhou, X. Q., and Chiu, H. H., 1983, “Spray Group Combustion Processes in Air Breathing Propulsion Combustors,” AIAA/SAE/ASME 19th Joint Propulsion Conference, Seattle, Washington, AIAA-83-1323.
16.
Chang, S. L., and Wang, C. S., 1987, “Thermal Radiation and Spray Group Combustion in Diesel Engines,” ASME Winter Annual Meeting, Boston, Mass., HTD-81:25-34 (December 13–18, 1987).
17.
Chang, S. L., Zhou, C. Q., Lottes, S. A., and Petrick, M., 1999, “Modeling of Heating and Vaporization of Larger Feed Droplets in Fluidized Catalytic Cracking Risers,” Proceedings of the Second Asia-Pacific Conference on Combustion, the Combustion Institute, pp. 553–557, Tainan, Taiwan, ROC (May 9–12, 1999).
18.
Williams, F. A., 1985, Combustion Theory, The Benjamin/Cummings Publishing Company, Inc.
19.
Aggarwal
,
S. K.
,
Tong
,
A. Y.
, and
Sirignano
,
W. A.
,
1984
, “
A Comparison of Vaporization Models in Spray Calculations
,”
AIAA J.
,
22
(
10
), pp.
1448
1457
.
20.
Chang, S. L., Lottes, S. A., Zhou, C. Q., and Petrick, M., 1996, “Evaluation of Multiphase Heat Transfer and Droplet Evaporation in Petroleum Cracking Flows,” HTD-Vol. 335, Proceedings of the ASME Heat Transfer Division 4:17–27, International Mechanical Engineering Congress and Exposition, Atlanta, GA (November 17–22, 1996).
21.
Chang, S. L., Lottes, S. A., Zhou, C. Q., and Petrick, M., 1997, “A Hybrid Technique for Coupling Chemical Kinetics and Hydrodynamics Computations in Multiphase Reacting Flow Systems,” HTD-Vol. 352, Proceedings of the ASME Heat Transfer Division 2:149-157, International Mechanical Engineering Congress and Exposition, Dallas, TX (November 16–21, 1997).
22.
Patankar, S. V., 1980, Numerical Heat Transfer and Fluid Flow, Hemisphere, Washington, D.C.
23.
Chang, S. L., Lottes, S. A., and Zhou, C. Q., 2000, “Methodology for Extracting Local Constants from Petroleum Cracking Flows,” ANL Invention Report, ANL-IN-97-074, U.S. Patent No. 6,013,172 (January 11, 2000).
24.
Chang, S. L., Lottes, S. A., and Petrick M., 1995, “Development of a Three-Phase Reacting Flow Computer Model for Analysis of Petroleum Cracking,” Proceedings of 1995 Mid-America Chinese Professional Annual Convention, Itasca, III., pp. 281–288 (June 23–25, 1995).
You do not currently have access to this content.