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<p>This study presents a comprehensive kinetic model and reaction network for simulating the FCC unit of the Abadan refinery, using industrial five- and six-lump catalyst systems. The model is developed based on actual process data and simulates the industrial riser and regenerator through heterogeneous modeling, incorporating energy and mass balance equations. The model operates under steady-state conditions. A sensitivity analysis was conducted to examine how variations in operational parameters, such as temperature and flow rate of the input feed and air, influence the production of key products like gasoline, coke, CO, and CO₂. The results indicated that increasing both the temperature and flow rate of the input feed and catalyst leads to improved conversion and feed utilization. To estimate kinetic parameters for both the riser and regenerator, a genetic algorithm optimization framework was applied. Among the configurations tested, the five-lump kinetic model yielded superior agreement with actual industrial performance. The Average Absolute Relative Error (AARE) between simulation and real data in the riser was 3.097% for the five-lump model, compared to 4.86% for the six-lump model. For the regenerator, the Mean Absolute Error (MAE) was 0.77 for the five-lump model and 4.88 for the six-lump one. The regenerator was modeled by dividing it into dense and dilute phases, and specific coke-burning reaction equations were solved for each region, enabling a more accurate representation of catalyst regeneration behavior.</p>

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Comprehensive Kinetic Modeling and Sensitivity Analysis of Industrial Fluid Catalytic Cracking (FCC) Unit: A Comparative Study of 5-Lump and 6-Lump Models

  • 期刊论文

  • 发表日期：

    2025年7月4日

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  • Seyed Amir Nezam Khaksar,
  • Feridun Esmaeilzadeh,
  • Mohammad Farsi,
  • Mohammadreza Homayoon,
  • Kobra Salehi,
  • Gholamreza Vakili-Nezhaad

摘要

This study presents a comprehensive kinetic model and reaction network for simulating the FCC unit of the Abadan refinery, using industrial five- and six-lump catalyst systems. The model is developed based on actual process data and simulates the industrial riser and regenerator through heterogeneous modeling, incorporating energy and mass balance equations. The model operates under steady-state conditions. A sensitivity analysis was conducted to examine how variations in operational parameters, such as temperature and flow rate of the input feed and air, influence the production of key products like gasoline, coke, CO, and CO₂. The results indicated that increasing both the temperature and flow rate of the input feed and catalyst leads to improved conversion and feed utilization. To estimate kinetic parameters for both the riser and regenerator, a genetic algorithm optimization framework was applied. Among the configurations tested, the five-lump kinetic model yielded superior agreement with actual industrial performance. The Average Absolute Relative Error (AARE) between simulation and real data in the riser was 3.097% for the five-lump model, compared to 4.86% for the six-lump model. For the regenerator, the Mean Absolute Error (MAE) was 0.77 for the five-lump model and 4.88 for the six-lump one. The regenerator was modeled by dividing it into dense and dilute phases, and specific coke-burning reaction equations were solved for each region, enabling a more accurate representation of catalyst regeneration behavior.