Muthanna Journal of Engineering and Technology
Volume (13), Issue (3), Year (2025), Pages (130-147)
DOI:10.52113/3/eng/mjet/2025-13-03-/130-147
Research Article By:
Luay abdulhay Mraweh
Corresponding author E-mail:luayabdulhay90@gmail.com
ABSTRACT
This research presents a detailed investigation into the solid–gas hydrodynamics within the Fluid Catalytic Cracking (FCC) riser reactor at the Basra refinery in Iraq. Computational Fluid Dynamics (CFD) simulations were developed using a three-dimensional Eulerian–Eulerian framework with the Gidaspow drag model and the kinetic theory of granular flow (KTGF), and validated against operational data supplied by the South Refineries Company (SRC). The model showed strong predictive capability, with deviations of less than 5% for outlet temperature and pressure drop compared to plant measurements. The validated results revealed a characteristic core–annulus flow structure, with a fast-moving dilute core and a denser annular region exhibiting catalyst back-mixing and wide residence time distribution. Parametric studies quantified the influence of key operating variables. Increasing the C/O ratio from 6.0 to 8.0 raised the riser outlet temperature by about 24 K and slightly increased the pressure drop. At the same time, a feed injection angle of 45° provided the most efficient mixing compared with 30° and 60°. Reducing particle size from 85 μm to 65 μm lowered solid holdup and reduced slip velocity, indicating better gas–solid interaction. These outcomes provide actionable insights for improving energy efficiency, enhancing mixing quality, and optimizing catalyst circulation in FCC riser operation at the Basra refinery. The study demonstrates the practical value of coupling advanced CFD models with field data to deliver reliable guidance for process optimization.
Keywords:
CFD, Fluid Catalytic Cracking (FCC), riser reactor, Basra refinery, Eulerian–Eulerian model, process optimization, energy efficiency.