Thermafor (also referred to as “thermofor” in some sources) Cracking Process was introduced for better integration of thermochemistry (endothermic cracking and exothermic catalyst regeneration) by introducing a moving-bed configuration, rather than a fixed-bed, as shown in Figure 7.6. Catalysts used in this process were synthetic alumina/silica beads that have more homogeneous and consistent properties (e.g., activity) than the natural minerals. Catalysts particles and the feed are introduced from the top of the reactor and the catalyst particles move downward with gravity as the cracking reactions take place on the catalyst surfaces. Steam is injected from the bottom of the reactor to carry the cracking products to the fractionator for recovery. As the particles move down the reactor, they are deactivated by coke build-up on active sites. The deactivated catalysts removed from the bottom of the reactor are sent to a regenerator unit where the coke on catalysts surfaces are burned off and the heated catalysts particles are recycled to the top of the reactors by bucket elevators. Hot catalyst particles provide most of the heat necessary for the cracking reactions in the reactor. Although the thermal efficiency of TCC is higher than that of the Houdry process, there was still a significant amount of heat loss during transport of heated catalyst particles by bucket elevators.

Figure 7.6. Process configuration for Thermafor Catalytic Cracking (TCC) process.