CHAPTER 9

VISBREAKING AND
AQUACONVERSION

Visbreaking is an effective and inexpensive way to produce more

valuable products from heavy residues.1 Initially it was used to
reduce the viscosity and/or pour point of a fuel oil. It is currently
employed to obtain additional cat cracker feed and to reduce fuel
oil production. Residual fuel oil is the least valuable of the refiners
products, selling at a price below that of crude oil. Therefore, it is
in the interest of the refiner to minimize its production.

Visbreaker process description

Visbreaking is a mild thermal cracking process. There are two
versions practicedthe furnace process and the soaker process.
The furnace version is most widely practiced. It consists of a
furnace and a fractionator. The reaction takes place in the furnace.
The furnace effluent is quenched to stop further reaction prior to
fractionation. Figure 91 is a simplified process flow diagram.
In the soaker version, a vessel is interposed between the fur-
nace and the fractionator. This vessel is the soaker and it provides
additional time for reaction. In fact, most of the reaction takes place
in the soaker. The reactants are held for a longer period of time but
at a lower temperature than in the case of the furnace process.
All the visbreaker products require further processing or treating
with the possible exception of the resid (if it meets fuel oil specifica-
tions for viscosity, sulfur, etc.). An easy way to take care of the naph-

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Fig. 91 Visbreaking Unit

tha is to feed it to the FCC fractionator. The heavy naphtha can be hydrotreat-
ed and reformed, providing its nitrogen content will permit. The gas oil can be
fed to the FCC (directly or after hydrotreating) or to a hydrocracker.

Visbreaking data correlation

Early visbreaking correlations used the API of the feed as the primary
parameter. This was a carryover from the thermal cracking of gas oils. The
author has found, as have others, conversion to be a satisfactory parameter.
Conversion is defined as the yield of gas plus gasoline. Some workers use
gas plus gasoline plus distillate (also defined by cut temperature).
A major concern in visbreaking is the stability of the fuel oil resulting.
It is important that the asphaltenes in the blended fuel oil remain in solu-
tion until used. Asphaltenes are soluble in aromatics; insoluble in paraffins.
Therefore, the cutback oil blended with the visbroken resid must be com-
patible with the resid. (Cutback oil is a low viscosity oil blended with resid
to lower its viscosity into specification.)
Allan, et al.,2 report that the limiting conversion (maximum conversion
for asphaltenes to remain in solution) for a resid correlates very well with
its asphaltene content.

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 CHAPTER 9 VISBREAKING AND AQUACONVERSION

According to Rhoe and Bignieres,3 conversions of 6% to 7% were the

practice when viscosity reduction was the purpose; 8% to 12%, when max-
imizing distillate production.
Table 91 is the database used in correlating visbreaking yields. There
were fewer sets (30) of VB data (on a weight percent basis) found in the lit-
erature than in the case of SDA. However, it will be observed that there are
far fewer gaps in the VB data. The data are for visbreaking of both atmo-
spheric and vacuum resids as is evident from the API gravity of the feed.
The main difficulty experienced with these data was the frequent absence
of cut temperatures defining the boiling ranges of the various cuts. This
became particularly evident when distillate and gas oil data were plotted
against conversion.

Table 91 Visbreaker Database

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A summary of some of the visbreaking correlation results is presented

in Table 92. Very satisfactory results were obtained for gas and gasoline
using the single independent variable conversion.

Table 92 Summary of Results of Visbreaker Correlations

In the case of resid, the addition of the gas oil end point as an independent
variable, improved the result considerably. Distillate results were significantly
improved by the addition of the square of the conversion as an independent
variable. Lacking clear and precise definition and corresponding yield data for
material boiling between gasoline and resid, namely, distillate and gas oil, one
may resort to some indirect derivations.
By definition, the 400F plus material is equal to 100 minus gas plus
gasoline. With a reasonable correlation for resid, the yield of distillate plus
gas oil can be obtained by subtracting yield of resid from yield of 400 plus.
A satisfactory correlation of 400950 material was obtained using a second
order polynomial in conversion. A composite plot of the yields is shown in
Figure 92.
Table 93 gives an average composition of the butanes and lighter pro-
duced in visbreaking, with H2S excluded since it is a function of sulfur con-
tained in the feed as well as of the extent of conversion. The few sets of data
on H2S (5) were regressed using conversion and sulfur in feed as indepen-
dent variables. The results are plotted in Figure 93. The few sets of data
and the narrow range of conversion (7.2 to 14.1) and of sulfur in feed (2 to
4) on which this plot is based, should be borne in mind by the user.

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 CHAPTER 9 VISBREAKING AND AQUACONVERSION

Fig. 92 Visbreaker Yields

Table 93 Visbreaker Yields

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PETROLEUM REFINERY P ROCESS ECONOMICS

Fig. 93 Visbreaker H2S Yield (Sulfur in Feed as Parameter)

The following additional correlations were developed and the results

are depicted in the indicated figures: Research Octane of VB Gasoline (Fig.
94), Motor Octane of Visbreaker Gasoline (Fig. 95), Visbreaker Gasoline
API Gravity (Fig. 96), Visbreaker Distillate API Gravity (Fig. 97),
Visbreaker Gas Oil API Gravity (Fig. 98), Visbreaker Resid API Gravity
(Fig. 99), Conradson Carbon Residue 650+ (Fig. 910), Conradson
Carbon Residue of Visbreaker Resid (Fig. 911), Sulfur in Visbreaker
Products (Fig. 912), Visbreaker Lv % vs. Wt % (913).

Comparison with other correlations

Beuther, et al.,1 presented a set of curves with volume percent of 10
Reid vapor pressure (RVP), 300F end point gasoline as the independent
variable. By means of the volume percent vs. weight percent chart, volume
percent yields were read from their curves and converted to weight percent.
The results agreed very well over the conversion range of the authors cor-
relations. Beuther, et al., went to much higher conversions. They also pre-

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Fig. 94 Research Octane of Visebreaker Gasoline

Fig. 95 Motor Octane of Visebreaker Gasoline

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PETROLEUM REFINERY P ROCESS ECONOMICS

Fig. 96 Visebreaker Gasoline API Gravity

Fig. 97 Visebreaker Distillate API Gravity

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 CHAPTER 9 VISBREAKING AND AQUACONVERSION

Fig. 98 Visebreaker Gas Oil API Gravity

Fig. 99 Visebreaker Resid API Gravity

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PETROLEUM REFINERY P ROCESS ECONOMICS

Fig. 910 Conradson Carbon Residue of Visbreaker 650+ (Feed CCR is Parameter)

Fig. 911 Conradson Carbon Residue of Visbreaker Resid

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 CHAPTER 9 VISBREAKING AND AQUACONVERSION

Fig. 912 Sulfur in Visbreaker Products

Fig. 913 Visebreaker Lv% vs. Wt%

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PETROLEUM REFINERY P ROCESS ECONOMICS

sented gasoline and naphtha yields at maximum severity in terms of normal

pentane insolubles and of ring and ball softening point of the feedstock.
These yields represented lower conversions than the other set of curves.
However, this second set could not be checked because the properties of the
feed used were not available in the authors database.
Bakshi and Lutz4 correlated their yields in terms of pentane insolubles
also. Their curves for distribution of sulfur in the products was in terms of
the sulfur content of the feed and agreed very well with the author.
Wuithier of Institut Francais du Petrole published a set of charts5 for
visbreaking based on producing a Bunker C fuel (300 SSF at 122F). The
API gravity and the K factor were used as parameters to characterize the
feed. The yields were volume percent of feed. For the limited comparisons
made, there was good agreement with the authors correlations.
Kuo6 reported on pilot plant research into stability limits in visbreaking.
Unfortunately, there are no numerical scales in his yield chart, so no check
was possible.

Operating requirements
The following average values can be used for most purposes:

Fuel 80 kBtu per bbl

Electric power 0.5 kWh per bbl
Steam (50) pounds per bbl (produced)
Cooling water essentially zero, maximum air cooling

Capital cost
Of a total of 25 plant costs noted in the literature in the past 14 years,
seven announcements of domestic projects were considered appropriate for
consideration. Scaling these data to 25,000 BPD and January, 1991 as illus-
trated under SDA, a value of $24 million was calculated.

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 CHAPTER 9 VISBREAKING AND AQUACONVERSION

Aquaconversion
Aquaconversion is a new hydrovisbreaking technology (that) uses a dual
catalyst system to achieve higher conversion levels, lower asphaltene, and
Conradson carbon contents, and more stabilized residue than conventional
visbreaking technologies. It is currently being promoted as either a replace-
ment of, or a modification to, conventional visbreaking.7
In the presence of the proprietary catalyst, water dissociates into hydro-
gen and oxygen. This nascent hydrogen reacts with aromatic free radicals
and inhibits their condensing to asphaltenes.
In a commercial demonstration, conversion to material boiling lower
than 662F was as high as 31 WT% and conversion to material boiling
below 330F was 7.8 WT%.8

Notes
1. Beuther, H., Goldthwait, R.G., and Offutt, W.C., Oil & Gas
Journal, Vol. 57, no. 46, pp. 7884

2. Allan, D.E., Martinez, C.H., Eng, C.C., and Barton, W.J.,

Chemical Engineering Progress, January 1983, pp. 8590

3. Rhoe, A., and Blignieres, C., Hydrocarbon Processing, January

1979, pp. 131136

4. Bakshi, A.S., and Lutz, I.H., Oil & Gas Journal, July 13, 1987,
pp. 8487

5. Wuithier, P., Revue de lInstitut Francais du Petrole, Vol. XIV, no.

9, pp. 1,1601,163 and 1,1741,180

6. Kuo, C.J., Oil & Gas Journal, September 24, 1984, pp. 100102

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PETROLEUM REFINERY P ROCESS ECONOMICS

7. Marzin, R., Pereira, P., McGrath, M.J., Feintuch, H.M., and

Thompson, G., Oil & Gas Journal, November 2, 1998, ff. 79

8. Ibid.

References
Aiba, T., and Kaji, H., Chemical Engineering Progress, February
1981, pp. 3744

Akbar, M., and Geleen, H., Hydrocarbon Processing, May 1981, pp.
8185

Allan, D.E., Martinez, C.H., Eng, C.C., and Barton, W.J., Chemical
Engineering Progress, January 1983, pp. 8590

Allen, J.G., Little, D.M., and Waddill, P.M., Oil & Gas Journal, June
14, 1951, pp. 7884

Anon., Hydrocarbon Processing, May, 1986, pp. 4244

Anon., Oil & Gas Journal, May 26, 1975, pp. 96103

Anon., Oil & Gas Journal, November 6, 1978, pp. 5659

Bakshi, A.S., and Lutz, I.H., Oil & Gas Journal, July 13, 1987, pp.
8487

Beuther, H., Goldthwait, R.G., and Offutt, W.C., Oil & Gas Journal,
Vol. 57, No. 46, 1959, pp. 151157

Gadda, L., Oil & Gas Journal, October 18, 1982, pp. 120122

Hournac, R., Kuhn, J., and Notarbartolo, M., Hydrocarbon

Processing, December 1979, pp. 97102

Hus, M., Oil & Gas Journal, April 13, 1981, pp. 109120

Kuo, C.J., Oil & Gas Journal, September 24, 1984, pp. 100102

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 CHAPTER 9 VISBREAKING AND AQUACONVERSION

Nelson, W.L., Oil & Gas Journal, February 23, 1950, p. 195

Ibid, June 29, 1950, p. 88

Ibid, February 25, 1952, p. 185

Ibid, March 10, 1952, p. 129

Ibid, March 24, 1952, pp. 208209

Ibid, March 31, 1952, pp. 114115

Ibid, May 26, 1952, p. 219

Ibid, September 15, 1952, p. 141

Ibid, April 13, 1953, p. 143

Ibid, April 20, 1953, p. 167

Ibid, March 14, 1960, p. 189

Ibid, November 10, 1969, p. 229

Ibid, December 7, 1970, pp. 6264

Ibid, April 17, 1978, pp. 106108

Notarbartolo, M., Menegazzo, C., and Kuhn, J., Hydrocarbon

Processing, July, 1979, pp. 114118

Rhoe, A., and de Blignieres, C., Hydrocarbon Processing, January,

1979, pp. 131136

Wood, J.R., Oil & Gas Journal, April 22, 1985, pp. 8084

Wuithier, P., Revue de lInstitut Francais du Petrole, Vol. XIV, No. 9,

pp. 1,1601,163 and 1,1741,180

Yepsen, G.L., and Jenkins, J.H., Hydrocarbon Processing, September,

1981, pp. 117120

137