T E C H N O LO G I C A L D E V E LO P M E N T I N C H E M I C A L I N D U ST RY F RO M

THERMAL CRACKING TO
CATALYTIC CRACKING

SUBJECT- CHEMICAL PROCESS TECHNOLOGY

SEMESTER- 4
DEPARTMENT OF CHEMICAL ENGINEERING
SCHOOL OF ENERGY TECHNOLOGY
HARSH TRIVEDI ADTIYA GHELANI
2 2 B C H 0 5 3 2 2 B C H 0 5 1
MANAV GAJERA SANAJANA SAHU
2 2 B C H 0 4 9 2 2 B C H 0 4 3
DEVANG KAKADIYA
2 2 B C H 0 5 9
NEER GAJERA BRIJESH RAVAL
2 2 B C H 5 2 2 2 B C H 0 2 0
FENIL RUPAPARA
2 2 B C H 0 5 6
OUTLINE
-BRIEF OVERVIEW

-INTRODUCTION

-THERMAL CRACKING

- C ATA LY T I C C R A C K I N G

- C O M PA R I S I O N B E T W E E N T H E R M A L
C R A C K I N G A N D C ATA LY T I C C R A C K I N G

-CASE STUDIES/REAL WORD EXAMPLES

-CONCLUSION

3
Brief Overview of the importance of cracking process in the
petroleum refining
The importance of cracking processes in petroleum refining cannot be overstated, as they are fundamental to the
production of valuable fuels and petrochemical feedstocks.

Figure-1.1 Maximizing Product Yield Figure-1.2 Petrochemical Feedstock Production

Figure-1.3 Meeting Demand for Transportation Fuels Figure-1.4 Process of Cracking
 Thermal Cracking
Introduction

Thermal cracking is the oldest and, in a way, the simplest cracking process. It
basically aims at the reduction of molecular size by application of heat without any
additional sophistication such as catalyst or hydrogen. At a temperature level of 450-
500 C, the larger hydrocarbon molecules become unstable and tend to break
spontaneously into smaller molecules of all possible sizes and types. By varying the
time, temperature and pressure under which a particular feedstock remains under
cracking conditions, the desired degree of cracking (conversion) can be controlled.
Temperature and time (residence time) are important process variables pressure plays
a secondary role.

The cracking conditions to be applied and the amount and type of cracked products
will depend largely on the type of feedstock. In practice, the feedstock for thermal
cracking is a mixture of complex heavy hydrocarbon molecules left over from
atmospheric and/or vacuum distillation of crude. The nature of these heavy, high
molecular weight fractions is extremely complex and much fundamental research has Figure-2.1 Thermal Cracking
been carried out on their behaviour under thermal cracking conditions.
 Thermal Cracking
Principles of thermal cracking:

• Heat Input: Heat can be supplied through various means, such as steam, electricity, or direct flame.

• Temperature: High Temp Required 500-900C

• Pressure: Low pressure required

• Catalysts: Thermal cracking is often a non-catalytic process, meaning it does not require the presence of a
catalyst

• Process Mechanism: There are two main types: visbreaking, which reduces viscosity for further processing, and
delayed coking, which converts heavy residues into products like petroleum coke, liquid distillates, and gas. Both
processes are crucial in refining to upgrade crude oil fractions and maximize the production of valuable fuels
and industrial materials.
Products Obtained:
1. Vis-breaking:
 Reduced-viscosity residual oils: These are lighter, less viscous hydrocarbons suitable for further processing in downstream refining units.
2. Delayed Coking:
 Petroleum Coke: A solid carbonaceous material used in industrial processes, such as steel production.
 Liquid Distillates: Intermediate liquid hydrocarbons that can be sent to downstream refining units for further processing.
 Gases: Various gaseous products, including methane, ethane, propane, and butanes.

Figure-2.2 Process of Visbreaking Figure-2.3 Process of Delayed Coking

Advantages of Thermal Cracking:
1. High Yield of Lighter Products: Thermal cracking processes typically yield a high proportion of lighter hydrocarbons such as gasoline and
diesel, which are in high demand as transportation fuels.
2. Simplified Process: Thermal cracking generally requires less sophisticated equipment and catalysts compared to catalytic cracking, resulting
in lower capital investment and operating costs. 3. Flexibility in Feedstock: Thermal cracking can process a wide range of feedstocks, including
heavy oils and residues, making it versatile for different types of crude oil and petroleum products.
4. Ability to Handle Contaminated Feedstock: Thermal cracking can effectively process feedstocks with impurities or contaminants, such as
sulfur or metals, without significant catalyst deactivation.
5. Energy Self-Sufficiency: Thermal cracking processes often generate excess heat, which can be utilized within the refinery for other purposes
such as steam production or power generation, enhancing overall energy efficiency.

Disadvantages of Thermal Cracking:

1. Low Selectivity: Thermal cracking tends to produce a wide range of hydrocarbon products, leading to lower selectivity for desired products
compared to catalytic cracking processes.
2. High Energy Consumption: Thermal cracking processes typically require high temperatures and energy inputs, leading to higher energy
consumption and greenhouse gas emissions compared to catalytic cracking.
3. Formation of Undesirable Byproducts: Thermal cracking can lead to the formation of undesirable byproducts such as olefins, aromatics, and
coke, which may require additional processing or disposal.
4. Equipment Degradation: Thermal cracking can cause equipment degradation due to high temperatures and thermal stresses, leading to
increased maintenance requirements and downtime.
5. Environmental Impact: Thermal cracking processes can contribute to air pollution and environmental degradation due to emissions of
greenhouse gases, volatile organic compounds (VOCs), and other pollutants associated with high-temperature operations.
Catalytic Cracking
 Catalytic Cracking

Figure-3.1 Fixed Bed Catalytic Cracking

 Catalytic Cracking

Figure-3.2 Moving Bed Catalytic Cracking

Advantages of Catalytic Cracking:
1. Higher Product Selectivity: Catalytic cracking processes offer greater control over product distribution, leading to higher selectivity for
desired products such as gasoline and light olefins.
2. Lower Energy Consumption: Catalytic cracking operates at lower temperatures and pressures compared to thermal cracking, resulting in
reduced energy consumption and greenhouse gas emissions.
3. Increased Process Flexibility: Catalytic cracking units can be tailored to process specific feedstocks and optimize product yields, providing
greater flexibility in refinery operations.
4. Reduced Formation of Undesirable Byproducts: Catalytic cracking produces fewer undesirable byproducts such as coke and heavy
hydrocarbons compared to thermal cracking, resulting in higher product quality and less waste.
5. Extended Catalyst Lifetime: Catalysts used in catalytic cracking processes can be regenerated and reused multiple times, leading to longer
catalyst lifetimes and lower operating costs compared to thermal cracking.

Disadvantages of Catalytic Cracking:

1. Higher Capital Investment: Catalytic cracking units require more complex equipment and catalyst systems, leading to higher capital
investment and operating costs compared to thermal cracking.
2. Catalyst Deactivation: Catalysts used in catalytic cracking can be deactivated by contaminants such as metals, sulfur, and nitrogen
compounds present in the feedstock, necessitating frequent regeneration or replacement.
3. Limited Feedstock Compatibility: Catalytic cracking may have limitations in processing certain types of feedstocks, particularly heavy and
highly contaminated crude oils, which can impact process efficiency and product quality.
4. Catalyst Handling and Management: Catalytic cracking units require careful handling and management of catalysts, including storage,
transportation, and regeneration processes, which can add complexity to refinery operations.
5. Environmental Concerns: While catalytic cracking processes offer environmental advantages over thermal cracking, they still produce
emissions of pollutants such as sulfur dioxide, nitrogen oxides, and particulate matter, which can contribute to air pollution and environmental
degradation if not properly controlled.
Comparison Between Thermal Cracking and Catalytic Cracking
Petroleum refining is the processing of crude oil in order to obtain desired products. There are
several petroleum refining processes that are helpful in converting crude oil into useful
products. A refinery is a large industrial area that is composed of a number of processing units.
The reactions that take place in a refinery includes distillation, cracking reactions, reforming
reactions, polymerization, isomerization, etc. Thermal cracking and catalytic cracking are such
reactions that are used to break down large molecules into smaller compounds. The main
difference between thermal cracking and catalytic cracking is that thermal cracking uses heat
energy for the breakdown of compounds whereas catalytic cracking involves a catalyst to
obtain products.
 Comparison factor
Feedstock Suitability
Product Yield and Composition
Energy Efficiency
Environmental Impact
Economic Considerations
Application Areas and Industrial Relevance
Thermal Cracking
Typically used for heavy hydrocarbon
feedstocks such as crude oil fractions or
residues.
Produces a mix of lighter hydrocarbons,
including olefins, aromatics, and some
hydrogen, with a higher proportion of
unsaturated compounds.
Typically less energy-efficient due to the high Generally more energy-efficient as it operates at lower
temperatures and pressures required.
Higher environmental impact due to the
higher energy consumption and emission of
more pollutants such as sulfur compounds
and nitrogen oxides.
Generally lower capital investment but
higher operating costs due to energy
consumption.
Historically used in the production of olefins,
aromatics, and other high-value products.
Still relevant in certain industries and
regions.
Catalytic Cracking
More versatile, capable of processing a wider range of
feedstocks including heavy oils, gas oils, and even
some lighter fractions.
Yields a higher proportion of gasoline-range
hydrocarbons and tends to produce more branched
and cyclic compounds, which are valuable for gasoline
production.
temperatures and pressures and utilizes a catalyst to
facilitate the reactions.
Lower environmental impact due to the lower energy
consumption and reduced emissions facilitated by the
catalyst.
Higher initial capital investment due to the need for
catalysts and reactors, but lower operating costs due
to higher efficiency and lower energy consumption.
Widely used in petroleum refining for gasoline
production and maximizing the yield of valuable
products from heavier feedstocks. It's a key process in
modern refineries.
 Conclusion
In conclusion, thermal cracking and catalytic cracking are both vital processes in modern petroleum refining, each
offering unique advantages and challenges. Thermal cracking, characterized by its simplicity and versatility, relies
on high temperatures to break down hydrocarbons, yielding a broad spectrum of products. While it provides
flexibility in feedstock processing and is capable of handling various types of crude oil, thermal cracking is
associated with lower product selectivity, higher energy consumption, and increased environmental impact.

Conversely, catalytic cracking utilizes catalysts to control reactions, resulting in higher product selectivity, lower
energy consumption, and reduced environmental emissions. Despite requiring higher capital investment and
operational complexity, catalytic cracking offers superior efficiency and product quality, making it a preferred
choice in many refineries. Both processes are essential for maximizing the yield of valuable fuels and
petrochemicals from crude oil, meeting the demand for transportation fuels, and supporting economic
development worldwide.

Looking forward, advancements in cracking technologies will focus on enhancing efficiency, product quality, and
sustainability. This includes the development of advanced catalysts with improved activity and selectivity, as well
as the integration of innovative process control systems and renewable energy sources to reduce environmental
impact and enhance energy efficiency. The future of cracking technologies lies in their ability to adapt to changing
market demands, regulatory requirements, and technological innovations, ensuring the continued viability and
competitiveness of the petroleum refining industry. By embracing innovation and sustainability, the refining sector
can contribute to a more efficient, cleaner, and resilient energy future.
References –