Reduced-Order Model for Catalytic Cracking of Bio-Oil

This work presents a one-dimensional (1D) model for simulating the behavior of an FCC riser reactor processing bio-oil. The FCC riser is modeled as a plug-flow reactor, where the bio-oil feed undergoes vaporization followed by catalytic cracking reactions. The bio-oil droplets are represented using a Lagrangian framework, which accounts for their movement and evaporation within the gas-solid flow field, enabling the assessment of droplet size impact on reactor performance. The cracking reactions are modeled using a four-lumped kinetic scheme, representing the conversion of bio-oil into gasoline, kerosene, gas, and coke. The resulting set of ordinary differential equations is solved using a stiff, second- to third-order solver. The simulation results are validated against experimental data from a full-scale FCC unit, demonstrating good agreement in terms of product yields. The findings indicate that heat exchange by radiation is negligible and that the Buchanan correlation best represents the heat transfer between the droplets and the catalyst particles/gas phase. Another significant observation is that droplet size, across a wide range, does not significantly affect conversion rates due to the bio-oil’s high vaporization heat. The proposed reduced-order model provides valuable insights into optimizing FCC riser reactors for bio-oil processing while avoiding the high computational costs of 3D CFD simulations. The model can be applied across multiple applications, provided the chemical reaction mechanism is known. Compared to full models such as CFD, this approach can reduce computational costs by thousands of computing hours.