Reactive simulation of an industrial‐scale FCC reaction‐regeneration full loop system

Abstract This study pioneers a three‐dimensional, transient reactive simulation of an industrial fluid catalytic cracking full‐loop system. Within a two‐fluid model framework, the simulation incorporates the Energy Minimization Multiscale (EMMS)‐based models to account for the effects of mesoscale flow structures on drag and heat transfer, and integrates a 12‐lumped kinetics model and a coke combustion model to describe catalytic cracking reactions and catalyst regeneration, respectively. It finds the significant impact of reactions on solid concentration and gas velocity distributions throughout the system, particularly in the first reaction zone. The first reaction zone achieves 80% conversion of feedstock oil, with the second reaction zone contributing an additional 19% conversion. These variations in product concentration along the bed height reflect substantial differences in reaction types under varying environments. Furthermore, the simulation captures temperature changes along the solid circulation path, facilitating the determination of the heat exchanger power required to control the reaction temperature.