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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

    Sherif Alabi
    Muhammed Ikbal Arikan
    Daffer AlYami
    Manel Nasfi
    Jose Ignacio Bielma Velasco
    Talal Aldugman
    Mengmeng Cui

    Related Publications

    Comparative analysis of counter-current and co-current downer reactors using particle image velocimetry and computational particle-fluid dynamics

    by Aldugman, Cui, Alzailaie, Alhareth, Langley, Alfilfil, Almajnouni, Gascon, Thoroddsen, Castaño
    Chem. Eng. J. Adv. Year: 2025 DOI: https://doi.org/10.1016/j.ceja.2024.100687

    Abstract

    We investigated the hydrodynamics in co- and counter-current downer operations using particle image velocimetry (PIV) and computational particle fluid dynamics simulations (CPFD). Pilot-scale experiments were conducted for fluid catalytic cracking (FCC) catalysts and sand, which verified the system stability and provided the validation basis for the simulation strategy. We compared the reactor characteristics of counter-current and co-current downers under different operating modes and conditions using PIV experiments and CPFD simulations. PIV experiments showed that the counter-current downer exhibits a more uniform particle velocity profile, with a gradient of only 8 % of the maximum velocity, compared to the co-current operation, which shows a significantly steeper gradient of 39.5 % from the maximum. Simulations confirmed that the counter-current downer reactor has 69 % higher solid holdup and 98 % longer residence time than the co-current operation. Thus, the counter-current downer reactor demonstrated intermediate behavior between the classical co-current downer and riser reactors, offering flexibility for industrial applications.

    Keywords

    C2C FCC MKM CRE