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CFD Simulation of Flue Gas Desulfurization

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This video shows transient computational fluid dynamics model results for an industrial dry flue gas desulfurization system.  A hot gas stream containing 200 PPM SO2 enters and encounters an atomized lime slurry.  The SO2 reacts with the calcium hydroxide to form calcium sulfide.  The water evaporates leaving a dry powder containing the sulfur.  Computational modeling was performed using several unique features of the Barracuda Virtual Reactor including local particle/droplet injection, multi-phase chemistry and evaporation/drying models.  One can easily see the potential for using CFD for design optimization, since the reactions only occur in the aqueous phase of the slurry droplets, but ideally only dry particles remain upon exiting the system.

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CFD Simulation of an FCC Riser

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This video shows the transient, 3D modeling of the thermal and reacting flows inside an FCC riser located on the Arabian Peninsula.  Ecat from the regenerator enters through the standpipe at the left and is transported up the riser.  Vaporized gas oil reacts to form gasoline, lighter gases and deposits coke on the catalyst.  The computational fluid dynamics model is constructed using the Barracuda Virtual Reactor, and includes both gas phase and discrete particle reactions.

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Dense-phase particle engagement into dilute-phase conveyance

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This video shows the transient engagement of densely-loaded spent FCC catalyst exiting from the standpipe into a lift riser for transport into an FCC regenerator.  The bi-direction interaction between the particle and gas phases is clearly visible where the solids displace the high-speed gas flow and, at the same time, the gas flow moves the particles around the bend into the dilute transport regime in the lift riser.  CFD results were obtained using the Barracuda Virtual Reactor.

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CO Emissions from an FCC Regenerator

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This animation was part of a study conducted by a North American refiner using the Barracuda Virtual Reactor to understand and correct the high levels of carbon monoxide (CO) being produced in their FCC regenerator.  The simulations showed that the source of the CO emissions was due to the transient relationship between gas temperature and gas compositions within the FCC regenerator.  In this case, much of the oxygen entering as part of the lift gas (which transports the cooler spent catalyst from the reactor into the fluidized bed regenerator) was not effectively mixing with the over 190,000 lbs of solids in the fluidized bed.  The computational fluid dynamics modeling showed that this flow maldistribution of the relatively cool air created substantial temperature gradients within the dense phase, reducing the CO combustion rates in the regions of the bed where oxygen was present, and ultimately was the source of the high carbon monoxide levels.

More details of the case can be downloaded here >

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Barracuda Virtual Reactor® validation on FCC catalyst fluidization conducted by PSRI

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Experimental unit with gas-solids fluidization of FCC catalysts material performed by PSRI. Simulation of experiment performed for validation of the commercial cfd code Barracuda Virtual Reactor® widely used for 'cat cracker' engineering. Barracuda VR® is developed by CPFD Software, LLC.

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CFD for Sorbent-Based Gas Cleanup System

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Gas streams from reactors such as gasifiers often have a need to 'scrub out' undesirable gas-phase components from the primary product gases. For a gasifier's syngas this is always sulfur.

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CFB Combustor - 3D CFD Simulation in CPFD Barracuda VR

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A model of a full-scale circulating fluidized bed (CFB) boiler in full 3D using the Eulerian-Lagrangian CPFD® method in Barracuda VR™ Fluidized Bed Reactor.

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CFD Simulation of a Full-Scale Commercial FCC Regenerator (Full)

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A model of a full-scale fluidized catalytic cracking (FCC) regenerator using the Eulerian-Lagrangian CPFD method in Barracuda VR.  This video illustrates the use of the Barracuda Virtual Reactor to predict the 100°F afterburn observed at the refinery.  A multi-model approach is used to rule out the lift riser and spent catalyst distributor as the root cause of the asymmetric afterburn.

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CFD Simulation in CPFD Barracuda of a Fluidized Bed Gasifier

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A model of a commercial-scale fluidized bed gasifier and includes the coal gasification chemical kinetics.

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CFD Simulation of a Full-Scale Commercial FCC Regenerator (Short)

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A model of a full-scale fluidized catalytic cracking (FCC) regenerator using the Eulerian-Lagrangian CPFD method in Barracuda VR.  This is a shorter version of the full video which can be found here.