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.
By Richard Nielsen
