Scribd
Upload
347 views25 pages

Hydro Cracking

Hydrocracking is a process that converts heavier petroleum fractions into gasoline and jet fuels in the presence of hydrogen and a catalyst. It involves hundreds of simultaneous reactions including catalytic cracking, hydrogenation, and isomerization. Feedstocks such as light and heavy coker gas oils and light cycle oils are treated with hydrogen over dual functional catalysts containing both metallic and acidic sites. The reactions promote cracking, hydrogenolysis, hydrogenation, and other conversions to produce valuable products like naphtha, diesel, and jet fuels.

Uploaded by

Bharat Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
347 views25 pages

Hydro Cracking

Hydrocracking is a process that converts heavier petroleum fractions into gasoline and jet fuels in the presence of hydrogen and a catalyst. It involves hundreds of simultaneous reactions including catalytic cracking, hydrogenation, and isomerization. Feedstocks such as light and heavy coker gas oils and light cycle oils are treated with hydrogen over dual functional catalysts containing both metallic and acidic sites. The reactions promote cracking, hydrogenolysis, hydrogenation, and other conversions to produce valuable products like naphtha, diesel, and jet fuels.

Uploaded by

Bharat Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 25

HYDROCRACKING

OUTLINE
HYDROCRACKING
I.Principles
II.Hydrocracking reaction
III.Feed preparation
IV.Process requirements
V.Hydrocracking Catalyst
HISTORY
• Hydrocracking is the conversion of higher boiling
point petroleum fractions to gasoline and jet
fuels in the presence of a catalyst.
• Hydrocracking process was commercially
Hydro Conversion
Hydroconversion is a term used to describe
all different processes in which hydrocarbon reacts
with hydrogen.
To describe the process of the removal of
Hydrotreating
sulphur, nitrogen and metal impurities in the
feedstock by hydrogen in the presence of a
catalyst.
The process of catalytic cracking of feedstock
Hydrocracking
to products with lower boiling points by
reacting them with hydrogen.

Hydrogenation aromatics are saturated by hydrogen to


the corresponding naphthenes.
5
PRINCIPLES
• Hydrogenation – oldest catalytic processes used in
petroleum refining.
• Why hydrocracking?
• Demand shifted to high
demand of ratios of gasoline and
petroleum fuel compared with
jet
the usages of diesel fuel
products
and home heating oils.
•By-product hydrogen at
low cost and in large
amounts has become
available from catalytic
WHY? reforming
By-product • Environmental
operations concern
Environmental hydrogen limiting sulfur and
concern at low cost aromatic compound
concentrations in motor
fuels have increased.
ADVANTAGES OF
• HYDROCRACKING
Hydrocracking is one of the most versatile
process, which facilitate product balance with the
market demand.

Improved gasoline
pool octane numbers
MODERN REFINERY
• Catalytic cracking (FCC) & hydrocracking work as
a team.
• FCC takes more easily cracked paraffinic gas oils
as charge stocks, while hydrocracker is capable of
using aromatics and cycle oils and coker distillates as
feed (these compounds resist FCC)
• Cycle oils and aromatics formed in FCC
make satisfactory feedstock for hydrocracking.
• Middle distillate and even light crude oil can be used
in hydrocracking.
FEEDSTOCK
•Typical hydrocracker
feedstock is shown below

• LCGO = light coker gas oil


• LCO = light cycle oil (produced in FCC, high in
aromatics
and sulfur)
• HCGO = heavy coker gas oil
HYDROCRACKING PROCESSES
• There are a number of hydrocracking
processes available for licensing.
• These processes are fixed bed catalytic
processes, in which liquid is moving
downward and gas is moving
upward/downward.
• The process employs either single stage or
two stage hydrocracking.
• The temperature and pressure may vary with the
age of catalyst, desired products and the
properties of feedstock.
HYDROCRACKING PROCESSES
PROCESS COMPANY
Unicracking UOP
GOFining EXXON Research & Eng
Ultracracking British Pet.Amoco
Shell Shell Development Center
BASF-IFB Badische Anilin, IFP
Unibon UOP, LLC
Isomax Chevron, UOP, LLC

There are other processes such as LC-


Fining, which are not based on fixed bed
reactors. (expanded bed reactor with
continuous on stream addition and
withdrawal of catalyst)
HYDROCRACKING OBJECTIVE
NITROGEN

NAPHTHA

REMOVE FEED
CONTAMINANT
S CONVERT
METAL SULFUR LOW VALUE
S GAS OILS
ULTRA
TO
CLEAN LUBE VALUABLE MIDDLE
BASE DISTILLATE
STOCKS PRODUCTS S
PRIMARY PROCESS TECHNIQUE

Hydrogenation in Followed by one or more


reactors with fixed hydrocracking
fixed hydrotreating catalyst beds to dealkylate
catalyst bed to aromatic rings, open naphthene
improve H/C ratios & rings & hydrocrack parafin chains
remove feed
contaminants
HYDROCRACKING BFD
HYDROCRACKING PROCESS FLOW
Fresh feed is mixed with H2 and recycle gas
(high in H2 content) and passed through a
heater to the first reactor
Feed that high in sulfur & nitrogen a guard
reactor is employed to convert sulfur to H2S and
N2 to NH3 ( to protect precious catalyst in the
following reactor)
HC reactors are operated at high temp to
produce materials with boiling point below 400
F
HYDROCRACKING PROCESS
Reactor gaseous effluent goes tru heat
FLOW
exchangers and a high pressure separator
where the H2 rich gases are separated and
recycled to the first stage.

Liquid product from the reactor is sent to a distillation


column where C4 and lighter gases are taken off and
the jet fuel, naphta and diesel fuel streams are
removed as liquid side streams

Distillation bottom product is sent back to hydrocracker


REACTIONS
• Hundreds of simultaneous chemical
reactions
occuring in hydrocracking
Assumption – mechanism of hydrocracking
is that of FCC with hydrogen superimposed
In FCC, the C-C Hydrogenation – Cracking – Hydrogenation –
bond is broken H2 is added to endothermic exothermic
C=C reaction reaction
MAIN CHEMICAL REACTIONS

CATALYTIC
CRACKING SATURATION
of the newly
of heavy formed HYDRO
hydrocarbo hydrocarbons
ns into CRACKING
with
lighter hydrogen
unsaturate
d
hydrocarbo
ns
HYDROCRACKING REACTIONS
CRACKING & HYDROGENATION AS BELOW –
the
scission of a C-C followed by hydrogenation
HYDROCRACKING
REACTIONS
Aromatics
which are
difficult to
process in
FCCU are
converted to
useful products
in
Hydrocrackers
HYDROCRACKING REACTIONS
• Cracking provides olefins for hydrogenation and
hydrogenation provides heat for cracking.
• Overall reaction provides excess of heat as
hydrogenation produces much larger heat than
the heat required for cracking operation.
• Therefore the process is exothermic and
quenching
, (rapid cooling) is achieved by injection
cold hydrogen into the reactor and apply
other means of heat transfer
•Isomerization is another type of reaction, which
occurs in hydrocracking.
CATALYST
•Hydrocracking Scatalyst are dual functional
(having metallic and acidic sites) promoting
cracking and hydrogenation.

Cracking

Hydrogenolysis Hydrogenation
of naphthenic – unsaturated
structure hydrocarbons

Hydrogenation
of aromatic
compounds
CATALYST SITE
FUCNTIONS
Cracking is promoted by metallic sites of
catalyst
To minimize coke
Acid sites transform the formation a
proper balance
alkenes formed into
must be
ions achieved
with the two
Hydrogenation reactions
sites on the
also occurs on metallic sites catalyst, depends
on the
conditions of the
Both metallic and acidic operation
sites take part in the 4th
reactions
HYDROCRACKING CATALYSTS
• Generally a crystalline silica alumina base.
• Catalysts susceptible to sulfur poisoning if
hydrogen sulfide is present in large quantities.
• Catalysts not affected by ammonia.
• Sometimes necessary to remove moisture to
protect the catalyst.
• Catalyst deactivate and coke does form even
with
hydrogen present.
• Hydrocarbons require periodic regeneration of
the fixed bed catalyst systems.

You might also like