Experimental simulation of the reactor section of fluid cokers: comparison of FCC and fluid coke particles.
Song, Xuqi ; Grace, John R. ; Bi, Hsiaotao 等
The hydrodynamics of fluid cokers were studied in a pressurized fully cylindrical cold model of diameter 483 mm, geometrically and
dynamically scaled down by a factor of ~20 from commercial units.
Differential pressure fluctuations, voidage distributions, solids
momentum flux distributions and steady state gas mixing behaviour in the
reactor section are compared for the same operating conditions with two
kinds of particles, FCC and fluid coke. The voidage distributions and
core-annular flow structures in the reactor section were similar enough
that either FCC or fluid coke particles can be used for cold modelling
of fluid cokers.
On a etudie l'hydrodynamique d'unites de cokefaction
fluide dans une maquette froide cylindrique pressurisee de 483 mm de
diametre, geometriquement et dynamiquement reduite d'un facteur 20
par rapport a des unites commerciales. Les fluctuations de pression
differentielles, les distributions de vide, les distributions de flux de
moment des solides et le comportement de melange de gaz a l'etat
stable dans la section du reacteur sont compares pour les memes
conditions operatoires avec deux sortes de particules, soient FCC et
coke fluide. Les distributions de vide et les structures
d'ecoulement noyau-espace annulaire dans la section du reacteur
sont suffisamment semblables pour que des particules de FCC ou de coke
fluide puissent etre utilisees pour la modelisation a froid
d'unites de cokefaction fluide.
Keywords: fluidization, fluid coker, hydrodynamics, voidage, solids
momentum, gas mixing
Fluid cokers convert bitumen or hydrocarbon residues to lower
boiling point hydrocarbons, gases and coke. The thermal cracking process
is carried out in large fluidized beds, where hot coke particles,
introduced from above, carry the heat required for the endothermic reactions and collect solid byproducts on their surfaces. The
hydrocarbon feed is steam-atomized and injected horizontally through
multiple nozzles. Vapour products tend to channel up the centre of the
bed, surrounded by dense, descending particles (Knapper et al., 2002;
Song et al., 2004). Particles from the reactor pass down through a
stripper, in which a counter-current flow of steam strips liquid
hydrocarbon from the particle surface. The coke particles are then
circulated to a fluidized bed burner for re-heating prior to reentering the fluid coker at a higher temperature (Matsen, 1996).
The distribution of liquid feed over the coke particles, which
affects the liquid yield (Gray et al., 2001), is strongly dependent on
the mode in which the spray from the feed nozzles interacts with the
surrounding particles. To improve the understanding of the interaction
between solids and feed jets, the voidage distribution, solids flow
structure and the gas mixing behaviour have been studied in two
geometrically and dynamically scaled cold model facilities using FCC
particles (Knapper et al., 2002; Song et al., 2004, 2005). One of these
units, designed to study the stripper section, was a plexiglas
half-column with a scale ratio of ~1:10. The other is an ~1:20 scale
steel full-column, capable of modest pressurization so that the
hydrodynamic behaviour in the reactor section of the column can be
simulated properly. Either FCC or fluid coke particles can be used in
the cold model equipment, but FCC particles are desirable as more
measurement techniques, such as fibre optical probes, can be deployed.
Whether to use identical particles to those used in actual
high-temperature full-scale processes or other particles designed to
provide better modelling of dimensionless groups is a matter of debate
in the industry and fluidization community. In the present work, the
hydrodynamic behaviour of the bed when operated with FCC and fluid coke
particles is compared in the same cold model column. This paper extends
the studies of Knapper et al. (2002) and Song et al. (2004, 2005) in
which FCC particles were used. Thus, the experimental data for FCC
particles used for comparison with fluid coke particles are mainly taken
from these earlier studies, whereas all of the coke particle data are
reported here for the first time.
EXPERIMENTAL
The experiments were carried out in a fully cylindrical cold model,
geometrically scaled down by a factor of ~20 from two commercial fluid
cokers operated by Syncrude Canada Limited in Fort McMurray, AB, Canada.
A schematic is shown in Figure 1. Details of the experimental facility
can be found elsewhere (Song et al., 2004). The reactor includes a
complete set of nozzles, matching those in the commercial units, and a
stripper section equipped with baffles and aeration to simulate steam
addition in the commercial reactors. An external riser returns solids
removed from the bottom of the stripper to the top of the reactor. Air
is provided by a diesel-driven compressor. Cyclones and baghouses
capture entrained particles. The equipment was designed so that dynamic
similitude, in addition to geometric similitude, could be obtained
between the cold model unit and both commercial units. The reactor
sections in the cold model and commercial units operate in the bubbling
fluidization flow regime. Scaling, based on dimensionless analysis
(Glicksman et al., 1994), was achieved by matching important
dimensionless hydrodynamic parameters
[A.sub.r], [F.sub.r], [[rho].sub.p]/[[rho].sub.g],
[G.sub.s]/[[rho].sub.p][U.sub.f], dimensionless PSD, (1)
and all equipment dimension ratios
[FIGURE 1 OMITTED]
Scaling parameters based on FCC and fluid coke particles are
summarized in Table 1. As seen, matching of the key dimensionless groups
is not perfect, but is as good as can normally be achieved in practical
systems. The cumulative particle size distributions for the FCC and
fluid coke particles are plotted in Figure 2. In order to keep the same
density ratio, [[rho].sub.p]/[[rho].sub.g], as for the commercial units,
the cold model was operated at a slightly elevated pressure. The reactor
section is axisymmetric and tapered, expanding in diameter from 305 mm
at the bottom to 483 mm at the top. Despite the taper, the superficial
gas velocity increases up the feed section because of stagewise addition
of air through a series of horizontal injection rings. The axial profile
of superficial gas velocity with six active feed rings, shown in Figure
3, was similar to that in the commercial units, with the superficial gas
velocity decreasing with height between successive feed nozzle rings
because of the diverging cross-section of the reactor.
[FIGURES 2-3 OMITTED]
In the commercial units, a mixture of bitumen and steam is injected
into the fluidized bed of coke particles through six rings of nozzles.
The jet geometry is assumed to be composed of a cone and a hemisphere
attached to the base of the cone, with the jet half-angle assumed to be
constant and equal to 6.25[degrees] (Merry, 1971). The jet penetration
depth, L, defined as the horizontal distance from the end of the nozzle
to the mean position of the end of the jet region, is estimated from the
semi-empirical correlation of Merry (1971):
L/[d.sub.0] + 4.5 = 5.25
[([[rho].sub.0][u.sup.2.sub.0]/(1-[epsilon][[rho].sub.p]g[d.sub.p]).sup.0.4] [([[rho].sub.g]/[[rho].sub.p]).sup.0.2]
[([d.sub.p]/[d.sub.0]).sup.0.2]. (2)
This equation has previously been found to give good predictions
for our system (Copan, 1999; Knapper, 2000; Song et al., 2004; Donald et
al., 2004; Song et al., 2005). The nozzle diameter was chosen to
maintain the same ratio of jet-penetration-to-column-radius as for the
commercial units.
Capacitance Voidage Probe
As the optical fibre probe measurement system cannot be used in
conjunction with fluid coke particles (because of poor light reflection
from the black coke), a capacitance measurement system, which measures
the local dielectric constant of the fluidized bed (Hage and Werther,
1997), was developed for the coke particles in this work. The probe was
originally used by Brereton and Grace (1993) and was improved by
combining the probe and a reactance converter box to eliminate noise.
After calibration of the output signals for known voidages, the
capacitance probe was used to measure the voidage distribution in a
fluidized bed of fluid coke particles.
The capacitance probe was always mounted horizontally, using one of
the column side ports, between feed nozzle rings. The probe was
traversed horizontally to allow measurements from the axis of the column
to the near wall. Signals were recorded on a computer for periods of 80
s at a sampling frequency of 100 Hz. The signal was then analyzed to
give the time-mean local voidage and the standard deviation of the
voidage about the mean. Figure 4 shows a typical radial profile of
time-mean voidage, whereas the inserts show fluctuations of local
voidage for four radial positions. The time-mean voidage increases
gradually from the wall to the axis of the column. The significant peaks
in voidage in the insets correspond to passing voids containing fewer
solids. The frequency of these voids is seen to increase in traversing
from the wall to the centre of the column.
[FIGURE 4 OMITTED]
The radial voidage profile in the reactor section of FCC particles
was measured by the capacitance probe and compared with the earlier
results obtained by the optical fibre probe (Song et al., 2004), as
shown in Figure 5. The two measurement methods are seen to have given
very similar results for FCC, increasing confidence in the validity of
both types of probe measurements. This degree of validation of the two
types of probes represents one of the contributions of this paper.
[FIGURE 5 OMITTED]
Solids Momentum Flux Measurement System
Solids momentum probes have been used in circulating fluidized beds
to distinguish between upward and downward flow (Bai et al., 1995, Kim
et al., 2004). As the optical fibre particle velocity probe cannot be
used in a fluidized bed of fluid coke particles, a solids momentum probe
was employed to investigate the local solids flow structure in the
reactor section. As shown in Figure 6, the probe was simply made of two
stainless steel tubes having the same inside diameter of 3 mm. Two tips
(facing upward and downward), separated by 9.5 mm, were aligned
vertically at the desired radial position. The pressure difference
across the two tips, [DELTA][P.sub.M], was measured by a differential
pressure transducer. To prevent particles from blocking the tubes,
carefully controlled purge air flows were introduced into the two tubes.
The instantaneous pressure difference across the tips, [DELTA][P.sub.M],
should correspond to the net momentum flux of the gas-solids suspension
flow, i.e.,
[DELTA][P.sub.M] = K[[[rho].sub.P](1-[epsilon])V|V| +
[[rho].sub.g][epsilon][U.sub.g]|[U.sub.g]|] (3)
where K is a constant dependent on the probe geometry. The gas
kinetic energy corresponding to the second term on the right-hand side
in Equation (3) can reasonably be ignored because the solids density is
about seven hundred times the gas density. Thus, averaged over time, we
have
[MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] (4)
[FIGURE 6 OMITTED]
A typical radial profile of measured [MATHEMATICAL EXPRESSION NOT
REPRODUCIBLE IN ASCII] for a given set of operating conditions is shown
in Figure 7. The fluctuations of [DELTA][P.sub.M] for given positions
are also shown in the figure. Note that [MATHEMATICAL EXPRESSION NOT
REPRODUCIBLE IN ASCII] is large, with a positive sign in the core
region, indicating an upward flow of solids. With increasing r/R,
[MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] gradually decreases
and finally becomes negative, corresponding to downflow of solids. The
change in sign of [MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII]
from positive to negative provides an indication of where the flow
direction of solids changes from upward to downward. For the purpose of
determining the distinction between upward and downward flow region,
there is no need to calibrate the probe. We note, however, that the
boundary position from solids momentum flux measurement will probably
differ somewhat from that determined from the location where the
time-mean particle velocity and time-mean solids flux pass through zero
due to likely correlation between fluctuations in local voidage and
local particle velocity (Bi et al., 1996).
[FIGURE 7 OMITTED]
The solids momentum flux probe provides a simple measurement
technique for systems involving fluid coke, where optical fibre probes
cannot work. In addition, it could be applied in commercial units to
study the solid flow structure at elevated temperatures and pressures.
Steady State Gas Mixing
Helium tracer gas was used to study the gas flow behaviour in the
reactor section. Details can be found elsewhere (Song et al., 2005).
Helium was injected at steady state through all nozzles from feed ring
3, and the tracer concentration was measured at several levels upstream
and downstream to monitor the gas mixing behaviour.
RESULTS AND DISCUSSION
Axial Pressure Gradient
Pressure fluctuations provide one of the easiest and least costly
means of studying the hydrodynamics of fluidized beds (Bi et al., 2000,
Ellis et al., 2002). Differential pressure measurements, with the
separation distance between ports of the order of a few centimetres, can
reflect the local flow behaviour. Pressure gradients in the reactor
section were measured at different heights using differential pressure
taps. Dynamic signals of differential pressure fluctuations were
recorded at a sampling frequency of 100 Hz for durations of 85 s.
Time-averaged pressure gradients in the reactor section are compared in
Figure 8 for FCC and fluid coke particles under similar operating
conditions. The average pressure gradients, which are nearly
proportional to the cross-sectional average bed density, are seen to be
very similar for the two materials. Power spectral diagrams of
differential pressure for four axial positions in the reactor section in
Figure 9 also give similar distributions for the FCC and coke,
indicating similar local flow structures.
[FIGURES 8-9 OMITTED]
Voidage Distributions
In experiments with FCC particles, local voidages measured by an
optical fibre probe showed a dense annular region surrounding a more
dilute core region (Song et al., 2004). Radial profiles of local voidage
measured by the capacitance probe in a fluidized bed of fluid coke
particles are compared in Figure 10 with results from the optical fibre
probe in the FCC. All of the measurements were performed under base
conditions with [U.sub.s] = 0.25 m/s and [U.sub.f] = 0.74 m/s. The
distributions are similar, with a dense annular region surrounding a
more dilute core in both cases. The radial distributions of standard
deviation of voidage fluctuation are also close together, indicating
similar local flow structures in the reactor section for the FCC and
coke particles.
[FIGURE 10 OMITTED]
Solids Momentum Flux Distribution
The solids momentum flux probe was used to investigate the solids
flow structure in fluidized beds of FCC and fluid coke particles. The
experimental radial profiles of [MATHEMATICAL EXPRESSION NOT
REPRODUCIBLE IN ASCII], the time-average pressure difference across the
tips of the solids momentum probe, are shown in Figure 11 for three
heights. [MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] indicates
much more non-uniform flow in the upper part of the reactor section than
near the bottom, possibly due to the coalescence of the jets in the core
of the column. In the lower part, i.e. the transition zone between
stripper and reactor sections, [MATHEMATICAL EXPRESSION NOT REPRODUCIBLE
IN ASCII] is positive at all radial positions. Hence, there is no clear
boundary between regions of upward and downward solid momentum flux.
[FIGURE 11 OMITTED]
The effect of the superficial gas velocity on the solids momentum
flux is shown in Figure 12. [MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN
ASCII] decreases significantly with decreasing superficial gas velocity
in the central region. The internal circulation of solids is more
intense at a higher superficial gas velocity. The boundary between zones
of upward and downward solids momentum flux disappeared when the
superficial gas velocity decreased beyond a certain value.
[FIGURE 12 OMITTED]
Measured [MATHEMATICAL EXPRESSION NOT REPRODUCIBLE IN ASCII] values
are compared in Figure 13 for FCC and fluid coke particles for very
similar operating conditions. There is a strong similarity in the radial
profiles of solids momentum and in the boundary between zones of upward
and downward solids momentum flux. These results indicate that the
fluidized beds tested with FCC and fluid coke particles have similar
local solids flow structures for the range of conditions investigated.
[FIGURE 13 OMITTED]
Gas Mixing Behaviour
Gas radial mixing and backmixing in the reactor section can be
evaluated from tracer concentrations monitored downstream and upstream
of the tracer injection level. Details about gas residence time
distributions and backmixing for FCC particles have been provided by
Song et al. (2005). The overall distributions of helium concentration in
the reactor section, both upstream and downstream, with helium tracer
injected continuously from feed ring 3, are compared in Figure 14 for
FCC and fluid coke particles. Radial positions indicating the jet region
were calculated from Equation (2). For the two kinds of particles used,
radial profiles of helium concentration are similar, both upstream and
downstream of the tracer injection level. The helium concentrations
above the jet region are higher than at other locations within a limited
distance downstream of the injection level. The non-uniformity of
concentration across the bed decreases with distance above the tracer
injection ring due, at least in part, to radial gas mixing. In the fully
developed mixing zone far above the tracer injection level, the radial
concentration profiles become almost uniform.
[FIGURE 14 OMITTED]
The upstream tracer concentrations are higher near the wall than in
the core of the column. The radial concentration profiles indicate
considerable axial dispersion of gas near the wall due to downflow of
solids there. Tracer gas, together with solid particles, is entrained by
the feed jets from the downward flowing annular region into the upward
flowing core region. Note that the tracer gas penetrates down to the top
of the stripper section due to the vigorous internal circulation of gas
and solids in the reactor zone.
CONCLUSIONS
Axial and radial distributions of voidage in the reactor section of
a fluid coker cold model were measured by an optical fibre probe and by
a capacitance probe. Both probes gave very similar results for the FCC
particles. The data show a dense annular region surrounding a more
dilute core region for both FCC and fluid coke particles. The voidage
profiles indicate that the voidage increases gradually from the wall to
the axis of the column, rather than showing a sharp transition between
annular and core regions.
The hydrodynamic behaviour of differential pressure fluctuations,
voidage distributions and solids momentum flux distributions in the
reactor section were very similar for FCC and fluid coke particles under
similar operating conditions. This suggests that strict dynamic
similarity is not required for the conditions studied and that either
FCC or fluid coke can be used for cold modelling purposes.
ACKNOWLEDGEMENT
The authors are grateful to Syncrude Canada Limited for sponsoring
this work and for permission to publish the results. We are also
grateful to Chevron Canada Ltd. for providing the FCC particles.
NOMENCLATURE
Ar Archimedes number [MATHEMATICAL EXPRESSION NOT
REPRODUCIBLE IN ASCII]
D column diameter at top of reactor section (m)
[d.sub.0] inner diameter of nozzle (m)
[d.sub.p] particle diameter (m)
F fraction of particles by mass smaller than a given
[d.sub.p](-)
[F.sub.r] Froude number (= [U.sup.f.sub.2]/g[d.sub.p])
g acceleration due to gravity (9.81 m/[s.sup.2)
[G.sub.s] local net solids circulation flux corrected for
cross-sectional area (kg/[m.sup.2]s)
[G.sub.sf] net solids circulation flux based on cross-sectional
area at top of reactor (kg/[m.sup.2]s)
H expanded bed depth in reactor section (m)
K momentum transfer coefficient defined in
Equation (3) (-)
L horizontal jet penetration (m)
[u.sub.0] feed nozzle jet velocity (m/s)
[U.sub.c] transition velocity at which standard deviation of
pressure fluctuations reaches a maximum (m/s)
[U.sub.f] superficial gas velocity at dense phase bed surface (m/s)
[U.sub.g] superficial gas velocity at a given level corrected for
gas flow rate and cross-sectional area (m/s)
[U.sub.s] superficial gas velocity at top of stripper section (m/s)
V particle velocity (m/s)
Z height coordinate measured from top of highest
stripper shed (m)
[Z.sup.*] dimensionless height coordinate (Z / total height
of reactor section) (-)
Greek Symbols
[DELTA][P.sub.M] pressure difference across tips of momentum
flux probe (kPa)
[epsilon] local voidage (-)
[mu] gas viscosity (Pa x s)
[[rho].sub.o] gas density at nozzle tip (kg/[m.sup.3])
[[rho].sub.g] gas density (kg/[m.sup.3])
[[rho].sub.p] particle density (kg/[m.sup.3])
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Manuscript received January 5, 2005; revised manuscript received
December 22, 2005; accepted for publication December 26, 2005.
Xuqi Song (1), John R. Grace (1 *), Hsiaotao Bi (1), C. Jim Lim
(1), Edward Chan (2), Brian Knapper (2) and Craig McKnight (2)
(1.) Fluidization Research Centre, Department of Chemical and
Biological Engineering, The University of British Columbia, 2216 Main
Mall, Vancouver, BC, Canada V6T 1Z4
(2.) Syncrude Research Centre, 9421 - 17 Avenue, Edmonton, AB,
Canada T6N 1H4
* Author to whom correspondence may be addressed.
E-mail address: jgrace@chml.ubc.ca
Table 1. Summary of dimensional similitude based on reactor section
Commercial Syncrude
units, base conditions
Gas Vaporized hydrocarbons
and steam
Temperature, [degrees]C 510~540
Pressure, kPa 360
Gas density, [[rho].sub.g], kg/[m.sup.3] 2.28
Gas viscosity, [mu], Pa.s 2.5 x [10.sup.-5]
Type of particles Fluid Coke
Particle density, [[rho].sub.p], kg/[m.sup.3] 1600
Mean particle diameter, [[??].sub.p] [micro]m 145
Geldart powder group * A
Superficial velocity at top of 0.8
reactor, [U.sub.f], m/s
[U.sub.f]/[U.sup.[yen].sub.c] 0.88
Solids circulation flux at top of 20.3
reactor, [G.sub.sf], kg/[m.sup.2]s
Density ratio, [[rho].sub.p]/[[rho].sub.g],-- 701
Froude number, Fr,-- 485
Archimedes number, Ar,-- 174
Solids-to-gas mass flow ratio, 10.7
[G.sub.sf]/([[rho].sub.g][U.sub.f]),--
Inventory of solids, H/D 2.18
UBC, base conditions
with FCC
Gas Air
Temperature, [degrees]C 25
Pressure, kPa 200
Gas density, [[rho].sub.g], kg/[m.sup.3] 2.34
Gas viscosity, [mu], Pa.s 1.8 x [10.sup.-5]
Type of particles FCC
Particle density, [[rho].sub.p], kg/[m.sup.3] 1700
Mean particle diameter, [[??].sub.p] [micro]m 99
Geldart powder group * A
Superficial velocity at top of 0.74
reactor, [U.sub.f], m/s
[U.sub.f]/[U.sup.[yen].sub.c] 0.92
Solids circulation flux at top of 18.6
reactor, [G.sub.sf], kg/[m.sup.2]s
Density ratio, [[rho].sub.p]/[[rho].sub.g],-- 726
Froude number, Fr,-- 567
Archimedes number, Ar,-- 117
Solids-to-gas mass flow ratio, 10.7
[G.sub.sf]/([[rho].sub.g][U.sub.f]),--
Inventory of solids, H/D 2.15
UBC, base conditions
with Fluid Coke
Gas Air
Temperature, [degrees]C 25
Pressure, kPa 195
Gas density, [[rho].sub.g], kg/[m.sup.3] 2.28
Gas viscosity, [mu], Pa.s 1.8 x [10.sup.-5]
Type of particles Fluid Coke
Particle density, [[rho].sub.p], kg/[m.sup.3] 1600
Mean particle diameter, [[??].sub.p] [micro]m 133
Geldart powder group * AB boundary
Superficial velocity at top of 0.74
reactor, [U.sub.f], m/s
[U.sub.f]/[U.sup.[yen].sub.c] 0.84
Solids circulation flux at top of 18.3
reactor, [G.sub.sf], kg/[m.sup.2]s
Density ratio, [[rho].sub.p]/[[rho].sub.g],-- 701
Froude number, Fr,-- 429
Archimedes number, Ar,-- 251
Solids-to-gas mass flow ratio, 10.7
[G.sub.sf]/([[rho].sub.g][U.sub.f]),--
Inventory of solids, H/D 2.15