CFD and Practical Evaluation of Solid–Gas Flow in Basra Refinery Reactors

Abstract

This study investigates the complex hydrodynamics of solid–gas interactions in the Fluid Catalytic Cracking (FCC) riser reactor at the Basra refinery, Iraq. By integrating Computational Fluid Dynamics (CFD) modeling with real operational data from the South Refineries Company, a validated three-dimensional Eulerian–Eulerian two-fluid model was developed. The model employed the Gidaspow drag formulation and the Kinetic Theory of Granular Flow (KTGF) to describe solid phase behavior. Validation against plant measurements demonstrated high reliability, with deviations under 5% for riser outlet temperature and pressure drop. The simulation revealed a typical core–annulus flow pattern, with a dilute, fast-moving core and a dense, slower annulus exhibiting significant catalyst back-mixing and wide residence time distribution. Parametric analyses showed that adjusting the catalyst-to-oil ratio and optimizing the feed injection angle improved mixing and thermal efficiency without compromising stability. Catalyst particle size also influenced reactor performance.The research provides practical insights for optimizing operational efficiency, enhancing product yields, and reducing energy consumption at the Basra refinery. Overall, it highlights the effectiveness of combining advanced CFD tools with industrial data for process optimization in FCC systems.