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Modeling and Simulation of Petroleum Coke Calcination in Pot Calciner Using Two-Fluid Model

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Abstract

The aim of this work was to establish a mathematical model for the analysis of calcining process of petroleum coke in a 24-pot calciner via computational fluid dynamics (CFD) numerical simulation method. The model can be divided into two main parts (1) heterogeneous reacting flow of petroleum coke calcination in the pot was simulated using a two-fluid model approach where the gas and solid phase are treated as a continuous phases; and (2) the standard turbulence equations combined with the finite rate/eddy-dissipation combustion model and discrete ordinates model were solved for the turbulent gas reacting flow in the flue. The model of the calcining process was implemented in ANSYS Fluent 15.0 (commercial CFD software) and validated by industrial production data. After the validation research, the model has been applied to inspect the distribution features of the temperature field in the furnace, the concentration field of residual moisture and volatiles in the petroleum coke, and the vector velocity field of gas and solid phases. This research can provide a theoretical basis for optimizing the structure and improving the automatic control level of a pot calciner.

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Abbreviations

A i :

Pre-exponential factor (1/s)

A ij :

Mass fraction of species i in element j

B j :

Mass of element j (kg)

C 1, C 2, C µ :

Turbulence model constants

C p :

Specific heat (J/(kg K))

D :

Diffusion coefficient (m2/s)

d p :

Particle diameter (m)

E i :

Activation energy (J/mol)

F d :

Momentum source term (N/m3)

f w :

Friction at wall (N/m3)

g :

Gravitational acceleration (m/s2)

G k :

Production of turbulence kinetic energy (kg/(m s3))

H :

Mean enthalpy (W/m3)

h:

Heat transfer coefficient (W/(m2 K))

\(h_{j}^{0}\) :

Standard-state enthalpy (J/mol)

k :

Turbulent kinetic energy (m2/s2)

k i :

Reaction rate constant (1/s)

M w,i :

Molecular weight of species i (kg/mol)

M :

Volatiles to gas source term (kg/(m3 s))

m i :

Mass of species i (kg)

p :

Pressure (Pa)

Q c :

Convective heat transfer term (W)

Q g :

Heat of chemical reaction term (W)

Q r :

Heat transfer term associated with radiative heat transfer (W)

R :

Gas constant (J/mol K)

r i,r :

Arrhenius molar rate of creation/destruction of species i in reaction r (mol/(m3 s))

R i :

Chemical reaction of species i mass term (kg/(m3 s))

S h :

Heat term from volatiles (W/m3)

S :

Mass source term (kg/(m3 s))

S s :

Specific surface area (m2/m3)

T :

Temperature (K)

U :

Velocity vector (m/s)

u,v,w :

Velocity magnitude (m/s)

V Loss :

Mass loss fraction of pyrolysis and burning

W in :

Mass of dried petroleum coke (kg)

Y :

Mass fraction of species

α :

Volume fraction

ε :

Turbulent dissipation rate (m2/s3)

ε s :

Bed porosity

σ k , σ ε :

Turbulence model constant

λ :

Thermal conductivity (W/(m K))

ρ :

Density (kg/m3)

µ :

Dynamic viscosity (Pa s)

µ t :

Turbulent viscosity (Pa s)

µ eff :

Effective viscosity (Pa s)

\(\varGamma_{{i,{\text{eff}}}}\) :

Effective diffusion coefficient (m2/s)

\(\varGamma_{i}\) :

Molecular diffusivity of species i (m2/s)

\(\varGamma_{\text{t}}\) :

Turbulent diffusivity of species i (m2/s)

\(\varepsilon_{{\text{ext}}}\) :

Emissivity of the external wall surface (1/m)

eff:

Effective

e:

Element count

g:

Gas phase

w:

Wall

s:

Solid phase

i :

Gas component

j :

Solid component

n, m :

Gas/solid species count

FC:

Fixed carbon and ash

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Acknowledgements

This work was funded by the National Natural Science Foundation of China (51374253). The author is also grateful to Miss Li for the advice on this paper.

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Authors and Affiliations

  1. School of Metallurgy and Environment, Central South University, No.932, Lushan South Road, Changsha, 410083, Hunan, People’s Republic of China

    Jin Xiao, Jindi Huang, Qifan Zhong, Hongliang Zhang & Jie Li

  2. National Engineering Laboratory of Efficient Utilization of Refractory Nonferrous Metal Resources, Changsha, 410083, Hunan, People’s Republic of China

    Jin Xiao & Jie Li

Authors
  1. Jin Xiao
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  2. Jindi Huang
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  3. Qifan Zhong
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  4. Hongliang Zhang
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  5. Jie Li
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Correspondence to Jindi Huang.

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Xiao, J., Huang, J., Zhong, Q. et al. Modeling and Simulation of Petroleum Coke Calcination in Pot Calciner Using Two-Fluid Model. JOM 68, 643–655 (2016). https://doi.org/10.1007/s11837-015-1667-2

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  • DOI: https://doi.org/10.1007/s11837-015-1667-2

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