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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

    Effect of the Support on the Kinetic and Deactivation Performance of Pt/Support Catalysts during Coupled Hydrogenation and Ring Opening of Pyrolysis Gasoline

    by Castaño, Gutierrez, Pawelec, Fierro, Aguayo, Arandes
    Appl. Catal. A: Gen. Year: 2007

    Abstract

    The upgrading of an aromatic-rich feedstock (pyrolysis gasoline) has been investigated over bifunctional Pt catalysts in order to evaluate the effect of the support on conversion, selectivity and deactivation. The experiments were conducted in a fixed-bed reactor at a pressure of 5 MPa and 350–450 °C. Pt was incorporated into five acidic supports: MFI, BEA and FAU zeolites, and an amorphous silica-alumina (ASA). Their surface properties and acidity were then assessed by means of several characterization techniques and related with their intrinsic activity–selectivity–deactivation. Using high hydrogen pressure (to minimize catalyst deactivation), we report the suitability of several catalysts for different purposes: Pt/MFI19 catalyst for a steam cracker feedstock production, Pt/BEA catalyst for isoalkane-rich gasoline pool manufacture and Pt/ASA catalyst for severe aromatic reduction while controlling the extent of ring scission. The results of accelerated deactivation experiments under low hydrogen pressure lead to the conclusion that MFI-supported catalysts (Pt/MFI19 and Pt/MFI95) yield less coke, but Pt/BEA deactivates to a lesser extent during hydrogenation.

    Keywords

    FCC HCE HPC