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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

Identification of the coke deposited on an HZSM-5 zeolite catalyst during the sequenced pyrolysis-cracking of HDPE

by Ibanez, Artetxe, Lopez, Elordi, Bilbao, Olazar, Castaño
Appl. Catal. B: Environ. Year: 2014

Abstract

The pyrolysis–cracking of high-density polyethylene (HDPE) has been studied in two sequenced steps: (1) flash pyrolysis in a conical spouted bed reactor, and (2) catalytic cracking of the volatiles (waxes) in a fixed bed reactor containing a HZSM-5 zeolite catalyst, aiming light olefins as final products. The pyrolysis and cracking have been carried out isothermally at 500 °C, with a continuous feed of HDPE (1 g min−1) for up to 5 h (300 g of HDPE fed). We have correlated the catalytic deactivation by coke (carbonaceous deposits), in terms of amount and composition, with the profiles of gas composition along time on stream and space time. The amount and composition of coke in three axial positions of the catalytic bed have been elucidated using thermogravimetric (TG-TPO) and spectroscopic techniques (13C CP-MAS NMR, Raman, FTIR, FTIR-TPO-MS and FTIR-pyridine). Our results show that there are two pathways of coke formation: (i) initiation, during the first hour on stream and particularly in the inlet of the catalytic reactor; and (ii) steady coke formation, after the first hour on stream which is more severe in the last axial position of the catalytic reactor. The initiation step stems from the degradation of the waxes produced in the pyrolysis of HDPE and causes a dropping in the mesopore area of the catalyst. The steady coke formation step is caused by the condensation of light olefins and causes the degradation of the micropore area and the Brønsted acidity of the catalyst.

Keywords

FCC W2C ANW