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Reactor design and optimization for converting crude (and refinery wastes) to chemicals in one step through steam-fluidized catalytic cracking

Problem statement

The direct catalytic cracking from crude oil to chemicals could dominate the petrochemical industry shortly, with less fuel consumption and increasing production of light olefins and aromatics. We aim to simplify the refinery into a unique one-step conversion scheme, targeting the production of the most demanded petrochemicals.

Using a bottom-up holistic approach, we design a catalytic crude-to-chemicals process toward this goal using a bottom-up holistic approach. We investigate advanced reactors with intrinsic kinetic data and controlled hydrodynamics to improve the process. We study the non-linear multiscale phenomena by coupling the hydrodynamics, heat transfer, and reaction kinetics.

We use particle image/tracking velocimetry experiments, kinetic modeling, computational particle fluid dynamic modeling, and optimization approaches to improve operating scenarios and develop innovative reactor prototypes.

We focus on the catalyst, reactor, and process levels for system enhancement and intensification. We are optimizing several state-of-the-art laboratory and pilot-scale units, including a circulating Berty, downer, and multifunctional fluidized bed reactors.

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…
C2C-FCC2023

Related People

Manel Nasfi
Salman Aldossary
Isa Al Aslani
Jose Ignacio Bielma Velasco
Talal Aldugman
Mengmeng Cui

Related Publications

Comprehensive Approach for Designing Different Configurations of Isothermal Reactors with Fast Catalyst Deactivation

by Cordero-Lanzac, Aguayo, Gayubo, Castaño, Bilbao
Chem. Eng. J. Year: 2020

Abstract

A methodology for simulating the performance of different reactor configurations for processes with complex reaction networks and fast catalyst deactivation has been proposed. These reaction configurations are: packed bed, moving bed and fluidized bed reactors with and without catalyst circulation. From kinetic parameters collected in a packed bed reactor and a rigorous consideration of the activity, modifications in the convection-dispersion-reaction equation have led to the prediction of the catalyst performance in each reactor configuration. The circulating fluidized bed reactor has been simulated with an original model of parallel compartments, which allows for determining its performance in the steady state from the evolution of the transitory period. The methodology has been used for simulating the dynamics of SAPO-34 fast deactivation during the methanol-to-olefins (MTO) process. For each reactor configuration, concentration profiles and their evolution with time have been simulated, thus predicting the effect of reaction conditions and water content (formed and/or co-fed) on the activity profile or the activity distribution function (in the case of circulating fluidized bed reactor). The olefin yield and distribution have also been compared for each reactor configuration.

Keywords

O2H FCC CRE MKM