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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

    Zhandarbek Sapargaliyev
    Momen Hassan
    Altaiyr Khaidarov
    Sherif Alabi
    Muhammed Ikbal Arikan
    Daffer AlYami
    Manel Nasfi
    Jose Ignacio Bielma Velasco
    Talal Aldugman
    Mengmeng Cui

    Related Publications

    Increasing solid holdup and de-clustering in downer reactors by counter-current operation

    by Aldugman, Cui, Aldossary, Raja, Aguirre-Pablo, Alfilfil, Almajnouni, Gascon, Thoroddsen, Castaño
    Fuel Year: 2027 DOI: https://doi.org/10.1016/j.fuel.2026.141109

    Abstract

    In this work, we investigate the fluid dynamics of a counter-current downer using particle image velocimetry and optical fiber probes. The objective is to characterize the hydrodynamic behavior, specifically holdup and clustering, to establish a balance between risers, characterized by relatively high solid holdup and larger clusters, and co-current downers, which typically exhibit lower solid holdup and smaller, transient clusters. Flow patterns and clustering phenomena are quantified for Geldart A and B particles under various operating conditions at two axial positions. The results show that particle flow evolves from an acceleration zone into a more developed, stable region, with notable differences in solid holdup and cluster size distributions between the two measurement locations. By optimizing operating conditions, we achieved a 40% increase in solid holdup for commercial FCC particles and a 47% increase for sand particles, along with a more uniform particle distribution in the case of FCC. Under optimized counter-current operation, cluster size was reduced by 43% for FCC particles and by 33% for sand particles.

    Keywords

    C2C CRE