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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

Regulating the crude oil–to–chemical process in a multizone fluidized bed reactor using unconventional catalyst formulations

by Cui, Dikhtiarenko, Kulkarni, Shoinkhorova, Al Aslani, Alabdullah, Mazumder, Medina Flores, Alahmadi, Alfilfil, Morales-Osorio, Almajnouni, Gascon, Castaño
Powder Tech. Year: 2024 DOI: https://doi.org/10.1016/j.powtec.2024.119573

Abstract

Crude oil catalytic cracking to petrochemicals in one step is a profitable pathway for future refineries yet it has significant hurdles. We investigated adding silicon carbide to the formulation and adjusting the crude oil–to–chemicals process in a multizone fluidized bed reactor by improving the morphology for hydrodynamics and thermal conductivity for heat transfer to promote the catalytic cracking performance. First, we synthesized and characterized catalysts with various SiC sizes and contents to select the best based on morphology. Then, we compared this catalyst against an industrial benchmark catalyst using computational particle fluid dynamics to understand the catalyst circulation and heat transfer in realistic crude oil–to–chemicals process conditions. Finally, we performed catalytic cracking experiments using this catalyst and the benchmark under optimal conditions. The higher light olefin yield from the unconventional catalyst formulation validated our workflow for regulating the crude oil–to–chemical process.

Keywords

C2C CRE MKM