Feasibility study of coke combustion and energy exergy analysis in the De-Coke process of cracking furnaces in olefin unit
Abstract This study investigates the numerical simulation of cracking furnaces and the feasibility of coke combustion in the De-Coke flow, utilizing computational fluid dynamics (CFD) and energy-exergy analysis. Employing the Euler-Lagrange approach, we simulate the motion of coke particles within t...
Saved in:
| Main Authors: | , , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Nature Portfolio
2025-08-01
|
| Series: | Scientific Reports |
| Subjects: | |
| Online Access: | https://doi.org/10.1038/s41598-025-16305-w |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1849226423403806720 |
|---|---|
| author | Mostafa Moshtagh Ahmad Azari Marziyeh Hoseinpour Rouhollah Fatehi Farhad Ghadyanlou Rahim Karami Mohammad Rasul Mohammad Akrami |
| author_facet | Mostafa Moshtagh Ahmad Azari Marziyeh Hoseinpour Rouhollah Fatehi Farhad Ghadyanlou Rahim Karami Mohammad Rasul Mohammad Akrami |
| author_sort | Mostafa Moshtagh |
| collection | DOAJ |
| description | Abstract This study investigates the numerical simulation of cracking furnaces and the feasibility of coke combustion in the De-Coke flow, utilizing computational fluid dynamics (CFD) and energy-exergy analysis. Employing the Euler-Lagrange approach, we simulate the motion of coke particles within the model. A turbulent model is applied to assess the combustion processes, while non-premixed models simulate fuel and coke particle interactions. Additionally, we incorporate the Discrete Ordinates Model for radiation and the Discrete Phase Model for coke particle motion simulation. Results indicate that injecting coke particles with dry air leads to a 100% conversion rate. However, increasing the temperature of the De-Coke stream from 454 K to 654 K yields only a slight increase in coke conversion from 52 to 55%, suggesting that sufficient time and temperature are crucial for complete combustion. The energy and exergy efficiency of the combustion furnace during the cracking process stand at 44.8% and 29%, respectively, compared to 93.24% and 96.2% during the coil cracking process. Furthermore, the destruction exergy for the combustion furnace is approximately 36%, whereas the coil experiences destruction exergy of less than 4%. Although energy and exergy distributions reveal similar trends for both conventional and burning-coke De-Coke processes at the coil, the burning-coke method offers increased destruction exergy and enhanced heat transfer, albeit at the cost of efficiency in energy and exergy transfer to the coil compared to conventional methods. |
| format | Article |
| id | doaj-art-5a3fd6e43bd74d0a83c3079a976a71c5 |
| institution | Kabale University |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-08-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Scientific Reports |
| spelling | doaj-art-5a3fd6e43bd74d0a83c3079a976a71c52025-08-24T11:18:55ZengNature PortfolioScientific Reports2045-23222025-08-0115113210.1038/s41598-025-16305-wFeasibility study of coke combustion and energy exergy analysis in the De-Coke process of cracking furnaces in olefin unitMostafa Moshtagh0Ahmad Azari1Marziyeh Hoseinpour2Rouhollah Fatehi3Farhad Ghadyanlou4Rahim Karami5Mohammad Rasul6Mohammad Akrami7Faculty of Petroleum, Gas and Petrochemical Engineering, Persian Gulf UniversityFaculty of Petroleum, Gas and Petrochemical Engineering, Persian Gulf UniversityDepartment of Biosystem Engineering, Faculty of Agriculture, Ferdowsi University of MashhadApplied Computational Fluid Dynamics Research Group, Oil and Gas Research Center, Persian Gulf UniversityFaculty of Petroleum, Gas and Petrochemical Engineering, Persian Gulf UniversitySchool of Engineering, Newcastle UniversityFuel and Energy Research Group, School of Engineering and Technology, Central Queensland UniversityDepartment of Engineering, University of ExeterAbstract This study investigates the numerical simulation of cracking furnaces and the feasibility of coke combustion in the De-Coke flow, utilizing computational fluid dynamics (CFD) and energy-exergy analysis. Employing the Euler-Lagrange approach, we simulate the motion of coke particles within the model. A turbulent model is applied to assess the combustion processes, while non-premixed models simulate fuel and coke particle interactions. Additionally, we incorporate the Discrete Ordinates Model for radiation and the Discrete Phase Model for coke particle motion simulation. Results indicate that injecting coke particles with dry air leads to a 100% conversion rate. However, increasing the temperature of the De-Coke stream from 454 K to 654 K yields only a slight increase in coke conversion from 52 to 55%, suggesting that sufficient time and temperature are crucial for complete combustion. The energy and exergy efficiency of the combustion furnace during the cracking process stand at 44.8% and 29%, respectively, compared to 93.24% and 96.2% during the coil cracking process. Furthermore, the destruction exergy for the combustion furnace is approximately 36%, whereas the coil experiences destruction exergy of less than 4%. Although energy and exergy distributions reveal similar trends for both conventional and burning-coke De-Coke processes at the coil, the burning-coke method offers increased destruction exergy and enhanced heat transfer, albeit at the cost of efficiency in energy and exergy transfer to the coil compared to conventional methods.https://doi.org/10.1038/s41598-025-16305-wCombustionCrackingDe-Coke processNumerical analysisEnergy-exergy analysis |
| spellingShingle | Mostafa Moshtagh Ahmad Azari Marziyeh Hoseinpour Rouhollah Fatehi Farhad Ghadyanlou Rahim Karami Mohammad Rasul Mohammad Akrami Feasibility study of coke combustion and energy exergy analysis in the De-Coke process of cracking furnaces in olefin unit Scientific Reports Combustion Cracking De-Coke process Numerical analysis Energy-exergy analysis |
| title | Feasibility study of coke combustion and energy exergy analysis in the De-Coke process of cracking furnaces in olefin unit |
| title_full | Feasibility study of coke combustion and energy exergy analysis in the De-Coke process of cracking furnaces in olefin unit |
| title_fullStr | Feasibility study of coke combustion and energy exergy analysis in the De-Coke process of cracking furnaces in olefin unit |
| title_full_unstemmed | Feasibility study of coke combustion and energy exergy analysis in the De-Coke process of cracking furnaces in olefin unit |
| title_short | Feasibility study of coke combustion and energy exergy analysis in the De-Coke process of cracking furnaces in olefin unit |
| title_sort | feasibility study of coke combustion and energy exergy analysis in the de coke process of cracking furnaces in olefin unit |
| topic | Combustion Cracking De-Coke process Numerical analysis Energy-exergy analysis |
| url | https://doi.org/10.1038/s41598-025-16305-w |
| work_keys_str_mv | AT mostafamoshtagh feasibilitystudyofcokecombustionandenergyexergyanalysisinthedecokeprocessofcrackingfurnacesinolefinunit AT ahmadazari feasibilitystudyofcokecombustionandenergyexergyanalysisinthedecokeprocessofcrackingfurnacesinolefinunit AT marziyehhoseinpour feasibilitystudyofcokecombustionandenergyexergyanalysisinthedecokeprocessofcrackingfurnacesinolefinunit AT rouhollahfatehi feasibilitystudyofcokecombustionandenergyexergyanalysisinthedecokeprocessofcrackingfurnacesinolefinunit AT farhadghadyanlou feasibilitystudyofcokecombustionandenergyexergyanalysisinthedecokeprocessofcrackingfurnacesinolefinunit AT rahimkarami feasibilitystudyofcokecombustionandenergyexergyanalysisinthedecokeprocessofcrackingfurnacesinolefinunit AT mohammadrasul feasibilitystudyofcokecombustionandenergyexergyanalysisinthedecokeprocessofcrackingfurnacesinolefinunit AT mohammadakrami feasibilitystudyofcokecombustionandenergyexergyanalysisinthedecokeprocessofcrackingfurnacesinolefinunit |