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Reactor design and optimization for converting crude (and refinery wastes) to chemicals in one step through revamped fluidized catalytic cracking

    Problem Statement

    Direct catalytic cracking of crude oil to chemicals could soon dominate the petrochemical industry, with lower fuel consumption and increased production of light olefins and aromatics. We aim to simplify the refinery into a single-step conversion scheme to produce the most demanded petrochemicals.

    Using a bottom-up holistic approach, we design a catalytic crude-to-chemicals process toward this goal. We investigate advanced reactors with intrinsic kinetic data and controlled hydrodynamics to improve the process. We study nonlinear multiscale phenomena by coupling hydrodynamics, heat transfer, and reaction kinetics.

    We use particle image velocimetry and optical probes, kinetic modeling, computational particle-fluid dynamics, and optimization approaches to improve operating scenarios and develop innovative reactor prototypes.

    We focus on the catalyst, reactor, and process levels to enhance and intensify the system. We are optimizing several state-of-the-art laboratory- and pilot-scale units, including a CircuBed®, a downer, and a multifunctional fluidized bed reactor.

    C2C-FCC

    Goals

    • Develop and scale up advanced reactors for converting crude oil to chemicals through fluid catalytic cracking, approaching intrinsic kinetics
    • Model process dynamics using reactive particle fluid dynamics coupled with experimental validations
    • Establish a design workflow for short-contact time reactors based on modeling, prototyping, and testing
    • Analyze the novel process developments in fluid catalytic cracking: novel feedstock, process modifications, etc.

    Related People

    Related Publications

    Polyethylene Cracking on a Spent FCC Catalyst in a Conical Spouted Bed
    Ind. Eng. Chem. Res. Year: 2012
    Authors: Elordi, Olazar, Castaño, Artetxe, Bilbao
    • FCC
    • W2C
    • CRE
    Role of Pore Structure in the Deactivation of Zeolites (HZSM-5, Hbeta and HY) by Coke in the Pyrolysis of Polyethylene in a Conical Spouted Bed Reactor
    Appl. Catal. B: Environ. Year: 2011
    Authors: Elordi, Olazar, Lopez, Castaño, Bilbao
    • FCC
    • W2C
    • ANW
    • HCE
    Insights into the Coke Deposited on HZSM-5, Hbeta and HY Zeolites during the Cracking of Polyethylene
    Appl. Catal. B: Environ. Year: 2011
    Authors: Castaño, Elordi, Olazar, Aguayo, Pawelec, Bilbao
    • FCC
    • W2C
    • ANW
    • HCE
    Effect of Hydrogen on the Cracking Mechanisms of Cycloalkanes over Zeolites
    Catal. Today Year: 2010
    Authors: Castaño, Arandes, Olazar, Bilbao, Pawelec, Sedran
    • FCC
    • HPC
    • MKM
    The Role of Zeolite Acidity in Coupled Toluene Hydrogenation and Ring-Opening in One and Two Steps
    Ind. Eng. Chem. Res. Year: 2008
    Authors: Castaño, Pawelec, Aguayo, Gayubo, Arandes
    • HCE
    • HPC
    • FCC
    Effect of the Catalyst Properties in Polypropylene Pyrolysis Waxes Cracking under FCC Conditions
    Catal. Today Year: 2008
    Authors: Arandes, Torre, Azkoiti, Castaño, Bilbao, De Lasa
    • FCC
    • W2C
    • HCE
    Kinetic Modelling of Methylcyclohexane Ring-Opening over a HZSM-5 Zeolite Catalyst
    Chem. Eng. J. Year: 2008
    Authors: Castaño, Gayubo, Pawelec, Fierro, Arandes
    • FCC
    • HPC
    • MKM
    Catalytic Cracking of Waxes Produced by the Fast Pyrolysis of Polyolefins
    Energy & Fuels Year: 2007
    Authors: Arandes, Torre, Castaño, Olazar, Bilbao
    • FCC
    • W2C
    • ANW