In the refining process, in general, the longer the hydrocarbon molecule, the higher the temperature it takes to boil it out of crude oil. It is the integration of these process technologies, however, that offers the greatest economic potential. Western canada has one of the largest deposits of heavy oil in the world. Therefore, catalyst used for heavy oil hydrocracking process is different from the normal distillate hydrocracking process. Pep report 211c hydrocracking by slurry process ihs markit. Canadas oil sands and heavy oil resources are among the worlds great petroleum deposits. Hydrocracking in petroleum processing springerlink. Conventional hydrocracking technologies have a difficult time handling lowquality feedstocks that are rich in undesirable asphaltene molecules, for. Western canadian residue hydrocracking jon isley, p. The process is employed by modern refineries to upgrade heavy oil fractions into fuels suitable for transportation andor as petrochemical plant feedstock. Therefore, catalyst used for heavy oil hydrocracking process is.
Hydrocracking and hydrotreating refining processes needed. With the finite conventional fossil fuel reserves, the production based on. To provide a process of hydrocracking heavy oil capable of obtaining cracked light oil with higher yields andor milder reaction conditions than the conventionally proposed hydrocracking process in a suspended bed method using an ironbased catalyst when hydrocracking heavy oil containing heavy metal components produced in a refining process of. Hydrocracking is a catalytic chemical process used in petroleum refineries for converting the highboiling hydrocarbons in petroleum to lowboiling products such as gasoline, kerosene, jet fuel and diesel oil. Hydrocracking is an important source of diesel and jet fuel source. This pep report provides an overview of the heavy oil hydrocracking process. The original goal of the process was to upgrade heavy crude and refinery residuals into higher quality, higher value products, such as naphtha and lighter. The xrd and xps patterns suggested that the major existence form of dispersed mo catalyst in slurryphase hydrocracking was mos 2. Current situation of emerging technologies for upgrading. Uops uniflex mc process is a slurry hydrocracking process which achieves the highest conversion and produces the maximum naphtha and diesel yield compared. They include the vast oil sands of northern alberta, and the heavy oil reservoirs that surround the small city of lloydminster, which sits on the border between alberta and saskatchewan. Changing refinery configuration for heavy and synthetic. Hydrocracking reactions proceed through a bifunctional mechanism.
Furthermore, heavy oil is hard to recover and challenging to process because the production and the market value of heavy crude oil is faced with many technical and commercial hurdles, due to their extremely high viscosity greater than cp, low american petroleum institute api gravity less than 20oapi, poor mobility, high carbon to hydrogen atomic ratio. Hydrocracking of heavy oils and residua chemical production. The heavier feed components in the blends cover heavy coker gas oil hcgo, heavy vacuum gas oil hvgo, light cycle oil lco and deasphalted oil dao. We then develop process economics for two bitumen upgrading processes that both integrate hydrocracking with. Zeolitebased catalysts for heavy oil hydrocracking frontiers.
This pep report provides an overview of the heavy oil hydrocracking process, feed and product supply and demand, hydrocracking chemistry, catalysts and. History of the petroleum industry in canada oil sands and. Director, process technology calgary, alberta, canada. Hydrocracking is the refining process in which middle and heavy distillate fractions are cracked broken into smaller molecules. In the process, a slurry feed of 1 fresh heavy hydrocarbon oil feedstock and a heavy hydrocarbon recycle and 2 from about 0. Process of hydrocracking heavy oil kabushiki kaisha. Hydrocracking of residual oils mainly increases the production of high quality. Thermal hydrocracking and catalytic hydrocracking of heavy oil and model reactant have been carried out to investigate the effect of dispersed mo catalyst on slurryphase hydrocracking. The main feedstock is vacuum gas oil, a heavy fraction of petroleum. The hydrocracking process is overall exothermic, it is necessary to control this surplus of energy through quenching of cold hydrogen in the reactor. Hydrocracking technologies have been widely studied over the years, mainly by countries with large heavy oil reserves like mexico and venezuela. A comparative study on the hydrocracking for atmospheric. Heavy crude oil reserves are proven to be abundant, and the active heavy oilproducing countries. Major products from hydrocracking are jet fuel, diesel, relatively highoctane rating.
Hydrocracking of heavy oils in presence of petroleum coke. Zeolitebased catalysts for heavy oil hydrocracking. Transfer hydrocracking of heavy oil and its model compound. Slurryphase hydrocracking of heavy oil and model reactant. The hydrotreated crude oil enters then the atmospheric distillation column, where six main products were distilled lpg, light naphtha, heavy naphtha, kerosene and residual crude. Therefore, there is a growing need to develop more efficient technologies in order to process heavy oils to produce lighter products with minimum environmental impacts. Us patent for hydrocracking of heavy hydrocarbon oils with. In the modelbased analysis, the crude hdt process configuration was completed first using kirkuk crude oil, and to confirm the significance of the study, siberian. So the petroleum industry is increasingly concerned about extra. This paper focuses on the processing of heavy and synthetic crude blends using innovative process integration across several technology platforms to produce clean fuels. Advances in chevron rds technology for heavy oil upgrading flexibility. To provide a process of hydrocracking heavy oil capable of obtaining cracked light oil with higher yields andor milder reaction conditions than the conventionally proposed hydrocracking process in a suspended bed method using an ironbased catalyst when hydrocracking heavy oil containing heavy metal components produced in a refining process of crude oil into lighter oil. Chevron unveils new refining technology that converts.
The temperature needed to boil out gasoline might be only 40 celsius while a temperature of over 400 celsius might be needed for heavy gas oil. Us4963247a hydrocracking of heavy oil in presence of. The process is characterized by the use of an iron compound having particle sizes of. They are then reformed in presence of hydrogen at extreme pressures and temperatures. Unesco eolss sample chapters petroleum engineering downstream future technology in heavy oil processing jorge ancheyta, mohan s. The process design will depend on many factors such as feed type, desired cycle length, and the desired product slate.
Further, heavy oil that is derived from different geographical areas possess different properties. Hydrocracking process of fuel oil using halloysite modified by. Petroleum refineries change crude oil into petroleum products for use as fuels for transportation, heating, paving roads, and generating electricity and as feedstocks for making chemicals refining breaks crude oil down into its various components, which are then selectively reconfigured into new products. The extraheavy oil and bitumen are estimated to have about 5. Compared to the typical catalytic cracking process, hydrocracking can process a wider range of petroleum heavy distillates with great production flexibility.
The problem of processing heavy petroleum the situation of worldwide reserves of crude oils is very clear. Under mild process conditions, gas oil hydrocracking catalysts may also be. This slurry is pumped via feed pump 11 through inlet line 12 into the bottom of an empty tower. Hydrocracking processes distillate hydrocracking is a refining process for conversion of heavy gas oils and heavy diesels or similar boilingrange heavy distillates into light distillates naphtha, kerosene, diesel, etc. In relatively low amounts of hydrogenation centers, secondary processes can occur which lead to the production of light hydrocarbons, also to. Vrsh has the potential to significantly increase yields of gasoline, diesel and jet fuel from heavy and ultraheavy crude oils and could be used to. This study focused on hydrocracking process for atmospheric residue ar of mongolian crude oil in the first time compared to those of other countries.
At the industrial scale, the hydrocracking process is affected by the process design, the choice of catalyst and the selected reaction parameters. The hoil rc rc stands for resid cracking process uses ebullatedbed hydrocracking technology to process heavy feedstock residues atmospheric and vacuum residue with high metals, sulfur, nitrogen, asphaltenes and solid contents. Recently, the application of the hydrocracking process to valorize crude oil fractions into these fuels especially the diesel is attracting industrial attention. It produces highquality gasoline, aviation jet fuels, and lowcondensation diesel products, which can alleviate the demand for clean transportation fuels. Above, we compare catalytic cracking fcc a carbon rejection process with hydrocracking hydrcrc with respect to the major attributes of both projects. These feed blends are processed in hydrocracking units with various objectives and flow schemes including singlestage oncethrough and recycle as well as twostage and separate hydrotreat. With increasing demand for clean fuels, the cracking processes used to handle heavy feedstocks for the petroleum refining industry need to be equipped to produce highquality petroleum products. Operation of the canmet hydrocracking process in a. Refinery process modeling, a practical guide to steady state modeling of petroleum processes, 1sted. An overview of canadian residue hydrocrackers will be given along with a discussion of some of the challenges and expertise that has grown from these opportunities. In the time of volatile crude oil prices, worsen quality of supplied crude oil and of oil reserves hajji et al. A hydroconversion process is described in which a feed slurry comprising a heavy hydrocarbon oil and an iron compound additive is contacted with a hydrogencontaining gas in a hydroconversion zone at hydroconversion conditions to convert at least a portion of said oil to lower boiling products. Hydrocracking is an alternative to solvent refining technology which allows production of a far more pure and stable base stock. However, when processing heavy fractions, such as heavy gas oils or.
A hydrocracking unit, or hydrocracker, 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 the presence of hydrogen and a catalyst. Exploiting these reserves has spurred the development of 5 major residue hydrocracker projects over the years. Hydrocracking of heavy oils is one of the most commonly used processes for heavy oil upgrading. Hydrocracking of heavy oil feedstock being an acidcatalyzed process should be dependent on the sial ratio of the synthesized zeolite systems as documented in the previous subsections.
The extent of these resources is well known, but better technologies to produce oil from them are still being. What is hydrocracking technology in petroleum refining. A heavy hydrocarbon oil, a substantial portion of which boils above gree. The hydrocracker upgrades lowquality heavy gas oils. Pdf hydrocracking kinetics of a heavy crude oil on a liquid. An oil industry expert, professor emeritus peter odell, suggested that by 2100, the oil industry will be larger than in 2000 but up to 90% dependent on unconventional crude oils highacid crude oils, heavy crude oils, bitumen, and oil sand. Rising demand for transportation fuels and petrochemicals as well as the rising supply of heavy residue of crude oil have resulted in a renewed interest in the processing of heavy residue to generate useful lighter fuels and chemicals. Hydrocracking of heavy oils and residua is increasingly import to refiners due to increased global production of heavy and extra heavy crude oils coupled with increased demand worldwide for low sulfur middle distillates and residual fuel oils. Chevron corporation plans to build a precommercial plant at its refinery in pascagoula, miss. Hydrocracking is an important source of diesel and jet. Imp configuration is a catalytic hydrotreatmenthydrocracking process of heavy oil at mild operating conditions, able to achieve high removal of metals, sulfur compounds, asphaltenes and a large conversion of the heavier share of the oil stream to more valuable distillates. Unlike a hydrotreater, hydrocracking uses hydrogen to break cc bonds hydrotreatment is conducted prior to hydrocracking to protect the catalysts in a hydrocracking process. Hydrocracking, processing heavy feedstocks to maximize high quality distillate fuels. Hydrocracking catalysts based on hierarchical zeolites.
The production and processing of heavy oils will be influenced by the. Therefore, it is important to have a specific designed catalyst that is suitable to the targeted heavy oil hydrocracking. Catalysts for hydroprocessing of heavy oils and petroleum. In todays refining environment, where refining margins are getting tighter, processing opportunity crudes is desirable. Canmet hydrocracking is a hydrocarbon upgrading process which was developed in response to a forecast need to develop canadas heavy oil and oil sands reserves.
Hydrocracking, processing heavy feedstocks to maximize. Us20080156693a1 process of hydrocracking heavy oil. These crudes, however, tend to have increased levels of contaminants and usually contain increased amounts of vgo and residue. Hydrocracking is a process that is suitable to produce products that meet or exceed all of the present environmental regulations. Upgrading heavy and residual oils into valuable lighter fuels has attracted much attention due to growing worldwide demand for light petroleum product. Clearly, in a flexible refinery with a wide range of crude oil feedstocks, both processes are needed for the optimum conversion of the crude oil into desirable refinery products.
Us patent for hydrocracking of heavy oil in presence of. This pep report provides an overview of the heavy oil hydrocracking process, feed and product supply and demand, hydrocracking chemistry, catalysts and hardware technology since pep report 228, refinery residue upgrading, issued in 2000. Heavy crude oil, oil sands and bitumen reserves represent over 50% of the total global crude oil and it is hoped that its production will increase from to 18 mmbd between 2015 and 2035 62. Slurry hydrocracking offers the maximum amount of upgrading and produces zero fuel oil. Uops uniflex mc process is a slurry hydrocracking process which achieves the highest conversion and produces the maximum naphtha and diesel yield compared to other residue conversion technologies.