Group 5 Cracking
Group 5 Cracking
SUBMITTED TO
OF
FACULTY OF ENGINEERING
BY
GROUP E
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Table of Contents
Catalytic Cracking............................................................................................18
Pyrolysis ...........................................................................................................23
REFERENCES.....................................................................................................25
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WHAT IS PETROLEUM?
Petroleum, also called crude oil, is a naturally occurring liquid found beneath the
earth’s surface that can be refined into fuel. A fossil fuel, petroleum is created by the
decomposition of organic matter over long period of time, and can be extracted to
be used to power vehicles, heating units, and machine, and can be converted into
plastics. Petroleum is gotten from the Latin word “Petra” meaning “rock,” and
“oleum” meaning “oil.” It consists of hydrocarbons of various molecular weights
and other organic compounds. Majority of the world relies on petroleum for many
goods and services. This has made the petroleum industry a major influence on world
politics and the global economy. Petroleum is recovered from underneath the earth
surface by drilling and then refined and separated into different types of fuels of
differing molecular weights and varying compositions. Key components of
petroleum include hydrocarbons such as methane, ethane, propane, and complex
molecules like benzene. After extraction, crude oil undergoes refining processes to
separate and purify its components, yielding products like gasoline, diesel, jet fuel,
and petrochemicals.
Refining of Petroleum
Petroleum refining is a complex industrial process that transforms crude oil into a
variety of valuable products, meeting market demands and regulatory standards.
Petroleum refining begins with the distillation, or fractionation, of crude oils into
separate hydrocarbon groups. The resultant products are directly related to the
characteristics of the crude processed. Most distillation products are further
converted into more usable products by changing the size and structure of the
hydrocarbon molecules through cracking, reforming, and other conversion
processes.
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Distillation in Petroleum Refining
Distillation, being the fundamental step in petroleum refining, serves as the initial
separation process to obtain various hydrocarbon fractions from crude oil. The
process begins with the crude oil feedstock, a mixture of hydrocarbons obtained
from beneath the earth’s surface. The crude oil is pretreated to a high temperature to
facilitate ease in distillation. After pretreatment, the crude in introduced into a
distillation tower, also known as crude unit, where the crude undergoes fractionation
into different components based on their boiling points. As the crude moves up the
tower, it encounters decreasing pressure, causing it to vaporize. The hydrocarbons
vaporize at different heights within the tower. The vaporized hydrocarbons rise
through the tower and are condensed back into liquid form as the meet cooler
temperatures at higher levels of tower or a passed through a condenser.
The rate of cracking and the end products are strongly dependent on
the temperature and presence of catalysts. Cracking is the breakdown of a
large hydrocarbons into smaller, more useful alkanes and alkenes. Simply put,
hydrocarbon cracking is the process of breaking a long chain of hydrocarbons into
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short ones. This process requires high temperatures More loosely, outside the field
of petroleum chemistry, the term "cracking" is used to describe any type of splitting
of molecules under the influence of heat, catalysts and solvents, such as in processes
of destructive distillation or pyrolysis. Fluid catalytic cracking produces a high yield
of petrol and LPG, while hydrocracking is a major source of jet fuel, diesel
fuel, naphtha, and again yields LPG.
• Initiation: Here a single molecule breaks down into 2 free radicals. Only a
smaller portion of freed radicals undergoes initiation, but it is sufficient to
produce free radicals that are necessary to carry forward the reaction.
CH3CH3 → 2CH3
• Abstraction of Hydrogen: Here the second molecules become a free radical
as it removes a hydrogen atom from another molecule
CH3● + CH3CH3 → CH4 + CH3CH2●
• Radical Decomposition: Here free radicals break into other free radical and
an alkane. This reaction gives rise to alkene products.
CH3CH2● → CH2=CH2 + N
• Radical Addition: This reaction results in the formation of aromatic products.
Here radical reacts with an alkene to produce a free radical.
CH3CH2● + CH2=CH2 → CH3CH2CH2CH2●
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• Termination: Here 2 radicals react with each other to form products that are
not free radicals. This reaction results in two forms namely recombination and
disproportionation.
CH3● + CH3CH2● → CH3CH2CH3
CH3CH2● + CH3CH2● → CH2=CH2 + CH3CH3
The first thermal cracking method known as the Shukhov cracking process was
further in 1913 by William Merriam Burton, a chemist who worked for the Standard
Oil Company (Indiana), which later became the Amoco Corporation. Burton used
improvements to thermal cracking were introduced into the 1920s. Also in the 1920s,
French chemist Eugène Houdry improved the cracking process with catalysts to
obtain a higher-octane product. His process was introduced in 1936 by the Socony-
Vacuum Oil Company (later Mobil Oil Corporation) and in 1937 by the Sun Oil
Company (later Sunoco, Inc.). Catalytic cracking was itself improved in the 1940s
with the use of fluidized or moving beds of powdered catalyst. During the 1950s, as
demand for automobile and jet fuel increased, hydrocracking was applied to
petroleum refining. This process employs hydrogen gas to improve the hydrogen-
carbon ratio in the cracked molecules and to arrive at a broader range of end
products, such as gasoline, kerosene (used in jet fuel), and diesel fuel. Modern low-
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temperature hydrocracking was put into commercial production in 1963 by the
CRACKING PROCESS
The cracking process is very important for the commercial production of light fuels
such as gasoline, fuel oil, and gas oils. Because the simple distillation of crude oil
produces amounts and types of products that are not consistent with those required
accomplishing this change is through cracking. There are two main cracking
1. Thermal cracking
2. Catalytic cracking
Thermal Cracking
Thermal cracking is a crucial process in the petroleum industry. It allows for the
efficient production of useful products such as gasoline, diesel fuel, and jet fuel from
range of 450 °C to 750 °C) and pressures (up to about 70 atmospheres) to break the
large hydrocarbons into smaller ones. Thermal cracking gives mixtures of products
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containing high proportions of hydrocarbons with double bonds - alkenes. Some
Visbreaking
significantly lowers the viscosity of heavy crude-oil residue without affecting the
boiling point range. The conversion of the residues is achieved by heating the residue
passed through a soaking zone, located either in the furnace or in an external drum,
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under controlled temperature and pressure. The heater effluent is then quenched with
a quenching medium (usually gas oil) to stop the reaction and control overcracking.
Atmospheric vacuum residues and Solvent Deasphalter bottoms are typical feeds of
the Visbreaking unit which transforms the feed to gas, gasoline, gas oil, and
characteristics. It is one of the not very popular in the petroleum refineries compared
Product stability of the visbreaker residue is the main concern in selecting the
lead to a reduction in the visbroken fuel oil viscosity. However, fuel oil stability will
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to predetermined heater outlet temperatures and rapid quenching of furnace outlets
facilitates the thermal cracking and altered viscosity necessary for further
processing. The feedstock is introduced into the heated coil in the furnace and
slightly cracked. Reaction temperatures range from 450 to 495 °C while working
After exiting from the furnace, the visbroken products are quickly quenched to stop
the cracking reactions. To avoid coking in the fractionation tower, the quenching
phase is crucial. The most frequent quenching streams are gas oil and Visbreaker
section, where it is flashed. The fractionator separates the yield into gas, gasoline,
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gas oil, and Visbreaker tar (residue). The fractionated gas oil is steam stripped to
remove volatile components before being mixed with the Visbreaker bottoms or
hydrocracking.
The main advantage of the coil-type design is the two-zone fired heater. This type of
heater provides a high degree of flexibility in heat input, resulting in better control
of the material being heated. With the coil-type design, decoking of the heater tubes
The soaker-type Visbreaking process is very similar to the coil-type process except
the conversion is proceeded mainly in a vessel called Soaker after the heater. It
achieves some conversion within the heater. However, the majority of the conversion
The soaker drum design allows the heater to operate at a lower outlet temperature
by providing the residence time required to achieve the desired cracking reactions.
This lower heater outlet temperature results in lower fuel cost which is the advantage
over the coil-type visbreaking process. The basic configuration of the Soaker Process
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includes the heater, soaker, and fractionators, and a vacuum tower can also be applied
Soaker cracking often involves less capital investment, uses less energy, and has
longer on-stream durations. Product qualities and yields from the coil and soaker
drum design are essentially the same at a given severity and are independent of the
visbreaker configuration.
Steam Cracking
or ethane is diluted with steam and briefly heated in a furnace in the absence of
oxygen. Typically, the reaction temperature is very high, at around 850 °C. The
reaction occurs rapidly with the residence time of the order of milliseconds and flow
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rates approaching the speed of sound. After the cracking temperature has been
reached, the gas is quickly quenched to stop the reaction in a transfer line heat
The products produced in the reaction depend on the composition of the feed, the
time. Light hydrocarbon feeds such as ethane, LPGs, or light naphtha give mainly
feeds give some of the same products, but also those rich in aromatic
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A higher cracking temperature (severity) favors the production
of ethene and benzene, whereas lower severity produces higher amounts of propene,
butene and liquid products. The process also results in the slow deposition of coke,
a form of carbon, on the reactor walls. This degrades the efficiency of the reactor, so
furnace can usually only run for a few months at a time between de-coking’s.
Decoking requires the furnace to be isolated from the process and then a flow of
steam or a steam/air mixture is passed through the furnace coils. This converts the
hard solid carbon layer to carbon monoxide and carbon dioxide. Once this reaction
Coking
Coking is a severe method of thermal cracking used to upgrade heavy residuals into
lighter products or distillates. It is often considered to be the last stage in the refining
process since the heaviest fractions (tar) are converted into very useful products such
as catalytic cracking feedstock. The process so completely reduces hydrogen that the
Different types of coking processes exist but the two most common processes are:
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1. Delayed coking
Delayed Coking
The process includes a fractionator, furnace, two coke drums, and stripper. the
feedstock is charged directly to the fractionator, where it is heated, and the lighter
fractions are removed as middle distillates. The bottom of the fractionator is pumped
to the coking furnace and then heated to the temperature range of 485–500°C. The
heated feedstock enters one of the pairs of coking drums, where the cracking
perform the cracking reaction when the coking drum is filled. In the furnace, steam
formation of coke in the furnace, short residence time and high mass velocity in the
furnace are required. Overhead stream in the coking drum, gases, naphtha, middle
distillates and coker heavy gas oil are sent to the fractionator for separation, then
separated and sent to downstream units for post-treatment and coke deposits on the
inner surface. For continuous operation, two coke drums are used; while one is
onstream, the other is decoking. The temperature in the coke drum ranges from 415
to 465°C and the pressure varies between 2 and 6 bar. Coker heavy gas oil is recycled
as a coker feed and combined with fresh preheated feed and fed to the furnace, or
Fluid Coking
Fluid coking is a thermal cracking process consisting of a fluidized bed reactor and
a fluidized bed burner. Vacuum residue is preheated and fed to a scrubber that
and the feed is converted to vapour and lighter gases, which enter the scrubber after
passing through the cyclones at the top of the reactor. From the scrubber, the reactor
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products are sent to the fractionator. Steam enters from the bottom of the reactor to
remove heavy hydrocarbons from the coke surface. The evolution of vapour from
the cracking of the feed, and the addition of steam, gives intense mixing of the coke
particles within the reactor. The coke formed in the reactor flows continuously to the
burner, where it is heated to 593–677°C and burns with partial combustion of 15–
30% of the coke by injecting air into the burner. Coke combustion produces flue
gases with low heating value which are rich in carbon monoxide. Parts of the heated
coke particles are returned to the reactor to provide energy for the endothermic
cracking reactions and to maintain the reactor temperature. After cooling, the
‘petroleum coke’ and is burned in power plants or cement industries. This coke is
very isotropic, rich in ash and sulphur and therefore not used in the carbon and
graphite industry.
The lower limit on operating temperature for fluid coking is set by the behaviour of
the fluidized coke particles. If the conversion to coke and light ends is too slow, then
the coke particles become sticky and agglomerate within the reactor. This
phenomenon occurs in localised zones of the reactor, likely near the nozzles that
inject the (colder) liquid bitumen feed, giving rise to chunks of coke that fall to the
bottom of the bed. For this reason, optimising the method for introducing feed into
the reactor is crucial. This process generally yields less coke and more gas oil and
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olefins compared to the delayed coking process. One disadvantage of the fluid
coking process is the high rate of coke accumulation inside the unit. The reactor
during operation. The reactor must be shut down for a month or more every 2 or 3
years to remove the accumulated coke, which can grow to be as thick as 1 meter on
the interior walls of the coker. The second disadvantage is the emission of significant
amounts of hydrogen sulphide and sulphur dioxide from the reactor burner.
Catalytic Cracking
Catalytic cracking is similar to thermal cracking except that catalysts facilitate the
material that assists a chemical reaction but does not take part in it) in the cracking
reaction increases the yield of improved-quality products under much less severe
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operating conditions than in thermal cracking. Typical temperatures are from 850°-
950° F at much lower pressures of 10-20 psi. The catalysts used in refinery cracking
units are typically solid materials such as zeolite, aluminum hydrosilicate, treated
bentonite clay, fuller’s earth, bauxite, and silica-alumina. They are used in the form
This process is used in petroleum refineries to convert the low-value heavier long-
chain hydrocarbon refinery fractions such as heavy vacuum gas oils into greater
economic value lighter products, mainly gasoline, distillate, and LPG. The rapid
cracking reactions of the FCC unit depend upon the circulating or fluidization of a
powder zeolite catalyst with the liquid feed into a riser of the FCC reactor for a few
seconds. This unit is normally, installed to produce more gasoline with high octane
There are various amounts of contaminants present in the FCC feed such as sulfur,
nitrogen, conradson carbon residue (CCR), and metals, particularly in high boiling
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Hydrodesulfurization, Hydrodenitrogenation, Hydrodemetallization, Aromatic
The FCC feed is heated up to a temperature of about 315~425oC and mixed with hot
regenerated catalyst (640~760 oC) at the bottom of the riser, which is a long vertical
pipe. The liquid feed is vaporized due to the hot catalyst and goes up in the riser for
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The temperature at the riser outlet is a key factor in determining conversion and
product quality. At the top of the riser, the temperature reaches nearly 550 oC. The
riser is the main reactor in which the endothermic reactions take place. High
From the top of the riser, the gaseous products flow into the fractionator column,
while the separated catalyst and some heavy liquid hydrocarbons flow back into the
disengaging zone of the FCC reactor. Steam is also injected into the stripper section
to remove the oil from the spent catalyst. The oil is stripped from the catalyst and
moves along with rising vapors to the fractionator. The spent catalyst is sent to the
The coke on the spent catalyst, produced in the FCC cracking reactions, is burned
off in the regenerator by introducing air. The produced hot flue gases exit at the top
of the regenerator that contains carbon dioxide, carbon monoxide, water, and excess
air at the regenerator temperature. The flue gases can also be sent to the power
The FCC unit operation remains at a steady state as long as a heat balance exists
between the heat produced in the regenerator and the heat consumed in the reactor.
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In both the reactor and the regenerator, hydro cyclones are installed to remove any
A hydrocracking unit, takes gas oil which is heavier and has a higher boiling range
than distillate fuel oil, and cracks the heavy molecules into distillate and gasoline in
heavy gas oils from the atmospheric or vacuum distillation tower, the fluid catalytic
cracker, and the coking units into high-quality, clean-burning jet fuel, diesel, and
gasoline.
There are two main chemical reactions occurring in the hydrocracker: catalytic
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saturation of these newly formed hydrocarbons with hydrogen. The catalytic
cracking of the heavier hydrocarbons uses heat and causes the feed to be cooled as
it progresses through the reactor. The saturation of the lighter hydrocarbons releases
heat and causes the feed and products to heat up as they proceed through the reactor.
Hydrogen is also used to control the temperature of the reactor—it is fed into the
reactor at different points. This keeps the reactor temperature from cooling to the
point that cracking will not occur and from rising too high as to jeopardize the safety
of the operation
Pyrolysis
air with the application of heat. Pyrolysis of higher alkanes to produce a mixture of
lower alkanes and alkenes are referred to as cracking. Usually, it is carried out by
heating the higher alkanes to high temperatures (670K – 970K) under pressure
ranging from 6-7 atm, either in the presence or absence of a catalyst. The chemical
When alkane vapors are passed in the absence of air through red-hot metal, it breaks
down into smaller or simpler hydrocarbons. This specific process occurs at high
pressure and high temperatures without a catalyst. But can be carried out at lowed
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pressures and temperatures in the presence of a catalyst such as palladium or
platinum.
Pyrolysis can be used to extract materials from items like tires or remove organic
contaminants from oily sludges and soils, and make biofuel from crops and waste.
It can assist in the breakdown of vehicle tires into some useful components on the
other hand also reducing the environmental impact of disposal of tires. Simply put,
cracking operations are essentially pyrolysis but not all pyrolysis operations are
cracking operations.
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