Yes / Fluid Catalytic Cracking (FCC) unit is an important unit of modern refineries and any improvement in the unit’s operations and design to increase yield and meet the ever increasing demand for fuel brings about the overall profitability of the FCC. In this work, simulation of an FCC riser of varied diameter was carried out to improve the unit’s operations and design, and the results are compared with risers of different diameters. The riser with varied diameter produces 53.4 wt%, a 3.18% increased yield of gasoline at low catalyst to oil (C/O) ratio of 1.27 compared to 51.7 wt% from a 1 m diameter riser. At increased C/O ratio, more gases and coke are produced in the varied diameter riser. Larger diameter demands more catalyst but yields more gases. Process variables can be directly correlated with yield of gasoline, which can aid process design.

Yes / This work presents a steady-state one-dimensional model of the FCC riser considering the vaporisation of the gas oil feed and subsequent cracking reactions. The evaporation of droplets is studied using three models: the classical homogeneous model and the heterogeneous vaporisation models from the literature. Droplets are modelled using the Lagrangian framework model for particles moving through a fluid. This was coupled with the gas–solid flow field describing the catalyst particulate transport in the riser. Cracking reaction kinetics are modelled using a four-lumped model. The model was then validated against published plant data. The model performed well in terms of gas oil conversion, gasoline yield, pressure drop, and phase temperature profiles. Therefore, it is suitable for use in the design and optimisation of new and existing FCC unit risers, particularly in cost–benefit analysis considering the current push away from petroleum energy sources. It was found that vaporisation models are largely insignificant in terms of gas oil conversion profiles and gasoline yield for usual operation conditions of FCC risers, which is a finding that had yet to be proven in the literature. Vaporisation models are shown to only affect conversion and yield when the initial droplet exceeds 2000 μm.