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    Investigation of the hydrodynamics in the regenerator of fluid catalytic cracking unit integrated by chemical looping combustion
    (Elsevier, 2021) Gulec, Fatih; Erdogan, Ahmet; Clough, Peter T.; Lester, Edward
    Oil refineries are responsible for 4-6% of global CO2 emissions, and 20-35% of these emissions released from the regenerator of Fluid Catalytic Cracking (FCC) units, which are the essential units for the conversion of heavier petroleum residues (vacuum gas oil) into more valuable products. Chemical looping combustion (CLC) has been recently proposed to mitigate the CO2 emissions released from the regenerator of FCC units with a lower energy penalty. However, a detailed experimental and modelling investigation is still necessary in order to identify the hydrodynamics in the regenerator of chemical looping combustion integrated with fluidised catalytic cracking (CLC-FCC). A computational fluid dynamic (CFD) study was conducted to understand the hydrodynamic behaviours of gas-solid two-phase flow in the regenerator of the CLC-FCC unit, based on a three-dimensional multiphase model (Eulerian-Eulerian) with the kinetic theory of granular flow. The results provide a useful insight into regenerator hydrodynamics, in terms of oxygen carrier modified FCC catalysts and FCC coke distribution profiles, in the regenerator of CLC-FCC. The conventional drag models (Syamlal-O'Brien and Gidaspow) predict a bed density profiles of a dense phase (250-300 kg/m3) at the dense phase (0-0.25 of h/H), and a dilution phase from h/H = 0.25 to 0.50 of regenerator. The bed density profile is indistinguishable from the industrial data provided for conventional FCC regenerators. The fluidisation gas (CO2) passes through the centre of the regenerator where the fluidisation gas splits the catalyst particles from the centre to the walls, to create a dilute particle phase in the centre and a dense particle-phase near the wall, which is one of the characteristic flow regimes in circulating fluidised bed reactors. The particles in the centre demonstrate an upward flow trend with a particle velocity above 3.0 m/s while the dense particles near the wall tend to go down with relatively low particle velocity of <0.5 m/s, which creates vortexes and a non-uniform particle distribution in the regenerator. The distribution of the fluidising gas provides better mixing of solid particles in the entrance and the optimisation of the superficial gas velocities (1.0 m/s) to create a distributed flow regime with developed vortexes through the dense and dilute phases. Furthermore, the laminar and turbulent flow models demonstrated no significant differences in terms of axial bed density profile in the regenerator of the CLC-FCC concept. These findings demonstrated that the hydrodynamics of catalysts in the CLC-FCC regenerator successfully predicted with CFD modelling and the prediction results aligned well with the conventional FCC regenerator.
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    Low-temperature chemical looping oxidation of hydrogen for space heating
    (Elsevier Sci Ltd, 2023) Gulec, Fatih; Okolie, Jude A.; Clough, Peter T.; Erdogan, Ahmet; Meredith, Will; Snape, Colin E.
    Chemical looping combustion (CLC) is an advanced combustion process in which the combustion reaction splits into two parts; in the first reaction metal oxides are used as oxygen suppliers for fuel combustion and then in the second reaction, reduced metal oxides are re-oxidised in an air reactor. Although this technology could be applicable for the safe implication of low-temperature oxidation of hydrogen, there is limited understanding of oxygen carrier reduction stages and the oxidation mechanism of hydrogen throughout the process. The novelty of this research lies in its pioneering investigation of low-temperature oxidation of hydrogen through chemical looping technology as a safe and alternative heating system, using three distinct metal oxide oxygen carriers: CuO, Co3O4, and Mn2O3. The oxidation of hydrogen over these oxygen carriers was comprehensively studied in a fixed-bed reactor operating at 200-450 degrees C. XRD analysis demonstrates that CuO directly reduced to metallic Cu at 200-450 degrees C, instead of following a sequential reduction step CuO & RARR;Cu4O3 & RARR;Cu2O & RARR;Cu throughout the temperature. Co3O4 was reduced to a mixture CoO and Co at 450 degrees C, which may refer to a sequential reduction step Co3O4 & RARR;CoO & RARR;Co with increasing the temperature. Decreasing the reduction temperature led to an elevation in CoO formation. Mn2O3 can also reduce to a mixture of Mn3O4 and MnO at temperatures between 250 and 400 degrees C. Compared to temperature, the increase in the residence time did not show any further reduction in Mn2O3. SEM results showed that most of the metal oxide particles were evenly dispersed on the supports. Based on the experimental results, a potential reduction stage of CuO, Co3O4 and Mn2O3 was proposed for low-temperature hydrogen oxidation, which could be a potential application for space heating using safe hydrogen combustion.