A two-zone model for fluid catalytic cracking riser with multiple feed injectors

Developments in modeling of the fluid catalytic cracking (FCC) process have progressed along two lines. One emphasizes composition-based kinetic models based on molecular characterization of feedstocks and reaction products. The other relies on computational fluid dynamics. The aim is to develop an FCC model that strikes a balance between the two approaches. Specifically, we present an FCC riser model consisting of an entrance-zone and a fully developed zone. The former has four overlapping, fan-shaped oil sprays. The model predicts the plant data of Derouin et al. and reveals an inherent two-zone character of the FCC riser. Inside the entrance zone, cracking intensity is highest and changes rapidly, resulting in a steep rise in oil conversion. Outside the entrance zone, cracking intensity is low and varies slowly, leading to a sluggish increase in conversion. The two-zone model provides a computationally efficient modeling approach for FCC online control, optimization, and molecular management.