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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

    Imaging the Profiles of Deactivating-Species on the Catalyst Used for the Cracking of Waste Polyethylene by Combined Microscopies

    by Castaño, Elordi, Olazar, Bilbao
    ChemCatChem Year: 2012

    Abstract

    The catalytic cracking of high‐density polyethylene (HDPE) is an attractive process to valorize wastes throughout the production of the original monomers or fuels.1 The cracking catalyst based on zeolites is able to drive the scission of the polymeric chain, while controlling the final selectivity of monomers or fuels.2 The disadvantage of using a cracking catalyst is the deactivation caused by coke fouling, which hinders the cracking of heavy hydrocarbons and reduces the lifetime of the catalyst.3

    Keywords

    FCC W2C ANW