Cracking

Cracking Definition
Cracking is the process whereby complex organic molecules such as kerogens or long-
chain hydrocarbons are broken down into simpler molecules such as light hydrocarbons, by the breaking
of carbon-carbon bonds in the precursors. 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 alkane into
smaller, more useful alkenes. This process requires high temperatures and high pressure.

Cracking types:
In petroleum refining, different cracking processes are used to break bonds of higher hydrocarbons, which
are as follows:

 Thermal Cracking
 Hydro-Cracking
 Fluidised Catalytic Cracking

Thermal Cracking:
Thermal cracking is a refining process in which heat and pressure are used to break down, rearrange, or
combine hydrocarbon molecules. Thermal cracking is an extraction process in which hydrocarbons such
as crude oil are heated to a high temperature to break the molecular bonds.

Feedstock
Thermal cracking is used for conversion of residues and higher Mol. wt. hydrocarbons into more useful
products by cracking the large hydrocarbon molecules into smaller ones at a specific temperature and
pressure.

Process condition
 High Pressure 7000 kPa
 High Temperature 400°C to 900°C
 Free Radical Mechanism
 Homolytic fission
 Produces mostly alkenes ...e.g. ethene for making polymers and ethanol
 Produces Hydrogen ... used in the Haber Process and in margarine manufacture
Block diagram

Fluidized –Bed Catalytic Cracking

The fluidized catalytic cracking (FCC) unit is the heart of the refinery and is where heavy low-value petroleum
stream such as vacuum gas oil (VGO) is upgraded into higher value products, mainly gasoline and C3/C4 olefins,
which can be used in the alkylation unit for production of gasoline (C7– C8 alkylates).

Process condition
The temperature used for this process is about 475-530ºC. The pressure is about 20 atm

Catalyst
Catalysts used in fluidized catalytic cracking is alumina, silica, or zeolites.

Feedstock
The main feedstock used in a FCC unit is the gas oil , which can be considered mixtures of aromatic, naphthenic
and paraffinic molecules.

Diagram
Hydrocracking
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.

Process condition
The temperature and pressure may vary with the age of catalyst, desired products and the properties of
feedstock. Typical process condition. The temperature used for this process is about 260-245ºC. The
pressure is about 35-200 bar.

Feedstock
The feed for hydrocracking is vacuum gas oil (VGO) , atmospheric gas oil (AGO) and straight run diesel.

Hydrocracking Catalysts
The catalyst use in hydrocracking is dual function. Catalyst use is alumina , zeolites ,Co ,Mo ,Nickel and platinum.
Process Diagram

Major Differences
Thermal cracking Fluidized cracking Hydrocracking

Uses heat energy for the Involves a catalyst to obtain Hydrocracking is a catalytic
breakdown of compounds( at products (along with moderate cracking process in the presences
high temperatures and high temperature and pressure) of hydrogen and catalyst
pressures

The temperature used for this The temperature used for this The temperature used for this
process is about 400-900oC. process is about 475-530ºC process is about 260-245 oC