Computational Fluid Dynamics Analysis and Optimization of Fluidized Bed Reactors for Catalyst Regeneration in Methanol-to-Olefins (MTO) Processes

This study presents a computational investigation of fluidized bed reactor hydrodynamics for catalyst regeneration in Methanol-to-Olefins (MTO) processes using Computational Fluid Dynamics (CFD). The simulations employ a RANS approach with the Eulerian multiphase model, validated against experimental data. Analysis of velocity, density, temperature, and phase fraction fields reveals the formation of core-annular flow patterns, with mixture densities of ۱۳۵۰-۱۵۰۰ kg/m³ in the dense bed region and below ۲۰۰ kg/m³ in the dilute phase. The observed axial temperature gradient (۱۲۰ K) indicates non-uniform coke combustion, highlighting the need for optimized oxygen injection strategies. Turbulence characterization shows peak turbulent kinetic energy of ۰.۲۴۳ m²/s² at the inlet region, approximately ۱۵% higher than experimental measurements. The pressure drop (۹۸۷۰ Pa) and high gas velocities (۹.۳ m/s) at the distributor zone identify key areas for design improvement. The results provide a framework for industrial reactor optimization through: ۱. Geometric modifications of transition zones. ۲. Gas distributor redesign. ۳. Local turbulence control. With deviations below ۱۵% from experimental data, this study demonstrates the reliability of the proposed computational approach for fluidized bed regenerator analysis and design.

کلیدواژه ها:

Fluidized bed reactor ، Catalyst regeneration ، Methanol-to-Olefins ، CFD simulation ، Hydrodynamic optimization