Published December 2004
This review describes and examines the SUPERFLEX™ process for light olefins originally developed by Arco Chemical Technology, Inc. (now Lyondell Chemical Company) and now licensed exclusively worldwide by Kellogg Brown and Root (KBR). This proprietary process uses a fluidized catalytic reactor system with a proprietary catalyst to convert low value, olefin-rich feedstocks, preferably in the carbon range of C4 to C8, into valuable propylene and ethylene products. The fluidized reactor system, very similar to a normal fluid catalytic cracking (FCC) unit, is composed of a riser reactor, regenerator, preheating system, and flue gas system. The fluidized design allows for continuous movement of catalyst between reactor and regenerator. From a typical feedstock of light FCC naphtha, the SUPERFLEX process can potentially provide ultimate yields of 40 wt% propylene and 20 wt% ethylene.
In this Review, the economics of catalytically cracking FCC light naphtha are determined based upon a 20,000 B/SD grass-roots Superflex unit operating on the U.S. Gulf Coast.
