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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

    Regulating the crude oil–to–chemical process in a multizone fluidized bed reactor using unconventional catalyst formulations

    by Cui, Dikhtiarenko, Kulkarni, Shoinkhorova, Al Aslani, Alabdullah, Mazumder, Medina Flores, Alahmadi, Alfilfil, Morales-Osorio, Almajnouni, Gascon, Castaño
    Powder Tech. Year: 2024 DOI: https://doi.org/10.1016/j.powtec.2024.119573

    Abstract

    Crude oil catalytic cracking to petrochemicals in one step is a profitable pathway for future refineries yet it has significant hurdles. We investigated adding silicon carbide to the formulation and adjusting the crude oil–to–chemicals process in a multizone fluidized bed reactor by improving the morphology for hydrodynamics and thermal conductivity for heat transfer to promote the catalytic cracking performance. First, we synthesized and characterized catalysts with various SiC sizes and contents to select the best based on morphology. Then, we compared this catalyst against an industrial benchmark catalyst using computational particle fluid dynamics to understand the catalyst circulation and heat transfer in realistic crude oil–to–chemicals process conditions. Finally, we performed catalytic cracking experiments using this catalyst and the benchmark under optimal conditions. The higher light olefin yield from the unconventional catalyst formulation validated our workflow for regulating the crude oil–to–chemical process.

    Keywords

    C2C CRE MKM