Comprehensive Simulation and Optimization of an Ethylene Dichloride Cracker Based on the One-Dimensional Lobo–Evans Method and Computational Fluid Dynamics

• Published in: Industrial & engineering chemistry research 2013-01, Vol.52 (2), p.645-657
• Main Authors: Li, Chaochun, Hu, Guihua, Zhong, Weimin, Cheng, Hui, Du, Wenli, Qian, Feng
• Format: Article
• Language: English
• Subjects: Combustion; Computational fluid dynamics; Computer simulation; Ethylene; Furnaces; Mathematical models; Optimization; Reactors
• ISSN: 0888-5885; 1520-5045
• DOI: 10.1021/ie302436r

Coupled simulations of an ethylene dichloride (EDC) cracking furnace and reactor are conducted using one-dimensional Lobo–Evans and computational fluid dynamics (CFD) models. Optimization is performed using the first model, in which the fuel gas allocation operator α is investigated to improve performance indices such as selectivity, conversion, and fuel gas consumption (per vinyl chloride monomer production). The optimum coil outlet temperature (COT) is suggested to make a good compromise among the performance indices. The CFD model is used to validate the optimized results. A standard k−ε two-equation model is applied to simulate turbulence, and a finite-rate/eddy dissipation model is used to model a premixed combustion of the sidewall burners. The discrete ordinate model is applied to simulate the radiative heat transfer of a furnace in a CFD simulation. The EDC cracking process in the reactor, as well as the flow, combustion, and radiative heat transfer in the furnace, is provided in the CFD model.