Farayandno

Farayandno

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

Document Type : Original research

Authors
Seyed muhammad Sadeqi 1
Kazem Mohammadzadeh 2
Somayeh Davoodabadi Farahani 3
1 M.Sc. Student, Mechanical Engineering, Arak University of Technology
2 Assistant Professor, Mechanical Engineering, Arak University of Technology
3 Associate Professor, Mechanical Engineering, Arak University of Technology
10.22034/farayandno.2025.2067801.2006
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.
Keywords
Fuel consumption optimization
Numerical simulation
Cylindrical furnace
Genetic algorithm
Ceramic fiber blanket

Subjects

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