Micro Downflow Technology

Test catalysts and feeds for Fluid Catalytic Cracking (FCC) under relevant process conditions but with laboratory scale budgets

The micro downflow unit (MDU) is based on a lab-scale technology and offers an entrained catalyst flow reactor system analogous to commercial fluid catalyst cracking units (FCCUs). It can be operated within a wide range of process conditions, including elevated pressures which are typical for FCCUs. Furthermore, the MDU is fully automated and cost-efficient as only small amounts of catalysts and feeds are required. Processability of a broad range of feedstocks has been demonstrated, ranging from naphtha and vacuum gas oil to residue feeds and crude oils. It includes the latest software solution myhte™ for integrating, storing, retrieving, analyzing, and visualizing data.

Features of Micro Downflow Unit (MDU)

Entrained flow reactor as commercial FCCU
Pressures typical for an FCCU or a riser can be adjusted
Since catalyst and feed move in the direction of gravity back-mixing is low
Size, required material amounts, and operating expenditures in the range of laboratory methods
Experiments at catalyst reactor residence times / contact times comparable to riser reactors
Capability of simulating high severity operations (high cat-to-oil ratio)

Cost-efficient (operation, catalyst, feedstock)
Fully automated lab system
5 crackings per 8 hour shift w/ optional increase to 18 crackings per day
Mass balances 98 +/- 2 %
Reproducible results matching well with circulating riser units and commercial FCCUs
Flexible and broad parameter range
Variety of feedstocks possible: VGO, high resid VGO, light cut naphtha, pyrolysis oils, biogenic feeds and full crude oil
Feedstocks with CRC’s 0-10 % can be processed

Reactor set-up of the MDU

Typical process parameters


Operating pressure	0.2 - 3.5 barg
Reactor temperature	up to 700 °C
Catalyst inlet temperature	up to 750 °C
Oil pre-heat	up to 250 °C
Oil feed rate	3 - 12 g/min
Cat-to-oil ratio	3 - 50
Experiment duration	1 min (can be adjusted)

Comparison of yields vs. conversion for ACE-CRU-MDU

MDU infrastructure requirements

infrastructure requirements for a Micro Downflow Unit

LABORATORY:

Typical footprint 1.5 m x 3.5 m x 1.2 m (WxHxD) plus room for GC and PC workplace (height depending on the length of the reactor)
Only local fume hood exhaust necessary