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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

    Water and methanol cofeeding modulates kinetics in crude-to-chemical cracking

    by Al Aslani, Colom, Lezcano, Alahmadi, Shoinkhorova, Dikhtiarenko, Cui, Alfilfil, Alsalman, Morales-Osorio, Almajnouni, Castaño, Gascon
    React. Chem. Eng. Year: 2026 DOI: https://doi.org/10.1039/d5re00525f

    Abstract

    The co-processing of crude oil with green methanol offers a promising pathway for integrating renewable carbon into conventional refining, yet the presence of water or any hydrophilic components such as methanol can significantly influence catalyst performance, reaction selectivity, and overall process efficiency. We discuss experimental and kinetic modeling aspects of cofeeding water and methanol during crude oil catalytic cracking over a wide range of temperatures (525–650 °C) and catalyst-to-oil ratios (0–4.14) using a microactivity testing unit (MAT). During cofeeding, yields of gas and coke, and propylene-to-ethylene ratios fluctuated at low and high catalyst-to-oil ratios, respectively. Interestingly, cofeeding water and methanol lowered coke formation, while higher selectivity to light olefins over paraffins was observed in the presence of only water. Reparameterization of the kinetic model for Arabian light crude using water cofeeding data revealed changes in the intrinsic kinetic parameters of the cracking reactions. Specifically, the rate constant for the monomolecular cracking pathway leading to propylene increased across the entire temperature range, while the rate constants associated with condensation reactions, responsible for generating coke precursors, were reduced.

    Keywords

    C2C MKM