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Modeling Conversion in a Fluid Catalytic Cracking Regenerator in Petroleum Refining

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This article discusses modeling and simulation of non ideal flow in a Fluid Catalytic Cracking (FCC) regenerator assuming mixed and plug flow regimes for various operating conditions using the tank-in-series model. An overall coke-on-catalyst conversion of 88.85% was obtained in the absence of dead volume in a perfectly mixed regenerator (n=1). The conversion reduced to 84.76% when a dead volume of 240.66 m^3 was introduced in the mixed regenerator for n=2. Beyond n=2, the conversion remained constant. A conversion of 99.99% was achieved with coke flow rate of 0.1 m^3/h for n=20. Generally, conversion increased with decreasing coke-on-catalyst flow rate but decreased with increasing dead volume in the mixed flow reactor. Conversion was found to be lower in the plug flow regenerator suggesting that if the regenerator had been designed using the usual plug flow model, its performance would be far less than expected.

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