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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

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

Related Publications

Coupling catalytic bed fluidization with impeller rotation for improved hydrodynamic characterization of Berty reactors

by Cui, Kulkarni, Abu-Naaj, Wagner, Berger-Karin, Weber, Nagy, Castaño
React. Chem. Eng. Year: 2024 DOI: https://doi.org/10.1039/D4RE00074A

Abstract

We developed an integrated modeling framework to capture the gas–solid mixing patterns in internal circulating Berty reactors operating under batch fluidized mode. Our framework combines computational fluid dynamics for the gas phase with impeller rotation and computational particle fluid dynamics for solid fluidization in the catalyst basket. We proposed several key hydrodynamic indicators for the Berty-type reactor and compared the prediction results from the integrated simulation strategy with previous settings without considering the actual bed fluidization. Deviations in bed velocity, gas–solid contact time, and recirculation rate underscored the necessity of employing accurate hydrodynamic characteristics when designing Berty-type reactors. The consistent impeller relationships under various fluidization conditions suggested that the hydrodynamics in internal circulating Berty reactors are predominantly influenced by impeller rotation, irrespective of bed status. In this context, we introduced a fluidized bed expansion correlation to the impeller relationship, offering a more reliable hydrodynamic explanation for the Berty fluidized bed reactor in batch mode. This can also serve as a design foundation for internal recycling reactors.

Keywords

FCC C2C CRE MKM