Spherizone

Spherizone is a process used in the petrochemical industry for the catalytic cracking of heavy hydrocarbon feedstocks. Developed by Shell, it is designed to maximize the yield of lighter, more valuable products like gasoline and light olefins from crude oil fractions. The process utilizes a unique reactor design that employs a vigorously fluidizing bed of catalyst particles. This swirling, or "spheroidal," motion of the catalyst within the reactor is a key characteristic and gives the process its name.

The Spherizone process operates at elevated temperatures and pressures, in the presence of a fluid cracking catalyst. Heavy hydrocarbons are fed into the reactor and come into contact with the hot catalyst, causing the large hydrocarbon molecules to break down into smaller ones. The intense mixing within the reactor ensures efficient contact between the feedstock and the catalyst, leading to high conversion rates. The catalyst, which becomes deactivated over time by coke deposition, is continuously circulated. It is then sent to a regenerator where the coke is burned off, restoring its activity before being returned to the reactor.

The main advantages of the Spherizone process include its high yield of gasoline and light olefins, its flexibility in handling various feedstocks, and its ability to achieve high conversion. It is considered an advanced fluid catalytic cracking technology, contributing to the efficient production of transportation fuels and petrochemical feedstocks. The distinctive swirling motion of the catalyst bed is central to its operational efficiency and product selectivity.