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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

Effect of the Acidity of the HZSM-5 Zeolite Catalyst on the Cracking of High Density Polyethylene

by Elordi, Olazar, Artetxe, Castaño, Bilbao
Appl. Catal. A: Gen. Year: 2012

Abstract

The catalytic cracking of high density polyethylene (HDPE) has been carried out at 500 °C in a conical spouted bed reactor with two catalysts prepared with HZSM-5 zeolites with SiO2/Al2O3 ratios of 30 and 80. The polyethylene has been fed continuously (1 g min−1) over 10 h to a 30 g catalyst bed. The results show the good performance of the conical spouted bed reactor in minimising the limitations of the physical steps of the process. The deactivation of the catalysts is very low and it is demonstrated that the moderation of the acidity is useful in modifying the product distribution. The SiO2/Al2O3 ratio increment involves a decrease in the total acidity and in the acid strength, resulting in a higher yield of C2–C4 olefins and that of the non-aromatic C5–C11 fraction, and a decrease in the yields of aromatic components and C1–C4 paraffins. The yield of the C2–C4 olefins obtained with the HZSM-5 zeolite catalyst with a ratio of Si/Al2O3 = 80 is 59.8 wt% (that of propylene is 29.6 wt%) and the yield of the gasoline fraction (C5–C11) accounts for 32.1 wt%. The coke deposited on the catalyst has a heterogeneous nature and is constituted by two types of coke, which are deposited on the exterior and the interior of the crystalline channels of the HZSM-5 zeolite. The evolution of the coke is attenuated as the SiO2/Al2O3 ratio of the zeolite is increased.

Keywords

FCC W2C HCE