Modelling of a vacuum residue hydrocracking in an industrial slurry phase reactor

Abstract

The upgradation of the bottom of the barrel has gained much interest across the refineries due to severe environmental rules, limitations of conventional oil reserves, and its flexibility to produce light end products which benefit end users. Slurry phase hydrocracking is one of the growing technologies to fulfil the increasing demand for light cut. Modelling of an industrial slurry phase reactor (SPR) for vacuum residue hydrocracking using different kinetic models is proposed. The axial dispersion model (ADM) is used for modelling an industrial SPR. The mathematical model of the reactors is incorporated for the three different lump kinetic models. This study deals with the continuous stirred tank reactor (CSTR) and SPR modelling, followed by industrial SPR modelling. The small lab-scale reactor models are validated with the experimental data reported in the literature. The study's objective was to investigate the one-dimensional and two-dimensional concentration dynamics of each lump along the axial and radial positions of industrial SPR. The vacuum residue conversion into the light fractions was obtained by more than 73% in industrial SPR. Also, the yield of vacuum gas oil and resins were evaluated as 49% and 63%, respectively. The sensitivity analysis was performed to explain the effect of process variables. The optimum range was found as a length of 15 m, liquid hourly space velocity (LHSV) of 0.2 h−1, 1% catalyst concentration, and 420°C reaction temperature to enhance the throughput of the reactor. © 2023 Canadian Society for Chemical Engineering.