Fuel Consumption Optimization in the Main Furnace of the Fluid Catalytic Cracking Unit Using Numerical Simulation and Operational Data

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Sadeqi Seyed Muhammad; Mohammadzadeh Kazem; Davoodabadi Farahani Somayeh

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Journal Paper

Paper Information

Journal: FARAYANDNO Year:2025 | Volume:20 | Issue:90 Page(s): 57-72

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Information Journal Paper

Title

Fuel Consumption Optimization in the Main Furnace of the Fluid Catalytic Cracking Unit Using Numerical Simulation and Operational Data

Author(s)

Sadeqi Seyed Muhammad | Mohammadzadeh Kazem | Davoodabadi Farahani Somayeh | Issue Writer Certificate

Keywords

Fuel consumption optimization

numerical simulation

Cylindrical furnace

genetic algorithm

Ceramic fiber blanket

Abstract

Optimizing fuel consumption in industrial furnaces plays a crucial role in reducing energy costs and minimizing environmental emissions. This study focuses on improving fuel efficiency in the main furnace of RFCC unit at Imam Khomeini Shazand Refinery. A combined approach of numerical simulation using Aspen EDR and analysis of operational data from the Distributed Control System was employed. Key parameters investigated include excess air ratio, refractory lining thickness, and the application of a 100 mm fibrous ceramic coating. Results indicate that increasing excess air from 15% to 50% leads to a 17. 6% rise in fuel consumption and a 2. 7% reduction in thermal-efficiency. Multi-objective optimization using a genetic algorithm identified optimal operating conditions at 5. 84% oxygen concentration, 60% damper opening, and a feed rate of 450 m³/h, yielding a 1. 8% improvement in thermal efficiency compared to baseline operation. The findings provide practical and cost-effective strategies for enhancing energy efficiency in industrial furnaces.

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