H-Oil gas oils have a higher density and higher nitrogen content, and consequently much lower reactivity than straight-run vacuum gas oils during fluid catalytic cracking (FCC). The conversion of H-Oil gas oils observed in a laboratory catalytic cracking unit at constant operating conditions showed a 20 wt.% lower conversion rate than straight-run hydrotreated vacuum gas oil. Thus, a revamp of commercial FCC units, and the selection of a higher activity catalyst with lower coke selectivity is needed to provide the stable trouble-free operation of the unit. The performed revamp of the commercial FCC unit allowed a stable operation at a higher throughput. It also allowed an increased riser outlet temperature from 532 to 550 °C; increased maximum allowable regenerator temperature from 705 to 730 °C; decreased afterburning from 12 to 6 °C; decreased NOx emissions in the flue gas from 250 to 160 mg/Nm³; improved catalyst regeneration; decreased catalyst losses to 0.0142 kg/t feed; and improved catalyst circulation at a higher throughput. It was confirmed in the commercial FCC unit that the H-Oil light vacuum gas oil is the least reactive H-Oil gas oil during catalytic cracking.

Petroleum refining has been, is still, and is expected to remain in the next decades the main source of energy required to drive transport for mankind. The demand for automotive and aviation fuels has urged refiners to search for ways to extract more light oil products per barrel of crude oil. The heavy oil conversion processes of ebullated bed vacuum residue hydrocracking (EBVRHC) and fluid catalytic cracking (FCC) can assist refiners in their aim to produce more transportation fuels and feeds for petrochemistry from a ton of petroleum. However, a good understanding of the roles of feed quality and catalyst characteristics is needed to optimize the performance of both heavy oil conversion processes. Three knowledge discovery database techniques—intercriteria and regression analyses, and artificial neural networks—were used to evaluate the performance of commercial FCC and EBVRHC in processing 19 different heavy oils. Seven diverse FCC catalysts were assessed using a cascade and parallel fresh catalyst addition system in an EBVRHC unit. It was found that the vacuum residue conversion in the EBVRHC depended on feed reactivity, which, calculated on the basis of pilot plant tests, varied by 16.4%; the content of vacuum residue (VR) in the mixed EBVRHC unit feed (each 10% fluctuation in VR content leads to an alteration in VR conversion of 1.6%); the reaction temperature (a 1 °C deviation in reaction temperature is associated with a 0.8% shift in VR conversion); and the liquid hourly space velocity (0.01 h-1 change of LHSV leads to 0.85% conversion alteration). The vacuum gas oil conversion in the FCC unit was determined to correlate with feed crackability, which, calculated on the basis of pilot plant tests, varied by 8.2%, and the catalyst ΔCoke (each 0.03% ΔCoke increase reduces FCC conversion by 1%), which was unveiled to depend on FCC feed density and equilibrium FCC micro-activity. The developed correlations can be used to optimize the performance of FCC and EBVRHC units by selecting the appropriate feed slate and catalyst.

A gas chromatography high temperature simulation distillation (HTSD: ASTM D 7169), and physical vacuum distillation (ASTM D 1160) were employed to characterize H-Oil vacuum distillates, straight run vacuum distillates, and hydrotreated vacuum distillates with the aim to determine their content of diesel fraction and evaluate the possible higher extraction of diesel fraction from the heavy oils. The ASTM D 7169 reported about six times as high diesel fraction content in H-Oil heavy distillates as that reported by the ASTM D 1160 method. Performing a commercial distillation column test along with a simulation of the column operation using data of both ASTM methods and a software process simulator revealed that the HTSD is the more valid method for proper determination of the diesel fraction content in heavy oils. The software process simulation of the commercial distillation column operation suggests that the HTSD could be considered as a true boiling point distillation method for heavy oils. The separation of the diesel fraction from the H-Oil heavy distillates quantified by the HTSD could deliver oil refining profit improvement in the amount of six digits USD per year.

The Urals and Siberian vacuum residues are considered difficult to process in the ebullated bed hydrocracking because of their increased tendency to form sediments. Their achievable conversion rate reported in the literature is 60%. Intercriteria analysis was used to assess data from a commercial vacuum residue hydrocracker during processing blends from three vacuum residues: Urals, Siberian Light, and Basra Heavy. The analysis revealed that the main contributors to conversion enhancement is hydrodemetallization (HDM) and the first reactor ΔT augmentation. The increase of HDM from 40 to 98% and the first reactor ΔT (ΔT(R1)) from 49 to 91 °C were associated with a vacuum residue conversion enhancement of 62.0 to 82.7 wt.%. The developed nonlinear regression prediction of conversion from HDM and ΔT(R1) suggests a bigger influence of ΔT(R1) enhancement on conversion augmentation than the HDM increase. The intercriteria analysis evaluation revealed that the higher first reactor ΔT suppresses the sediment formation rate to a greater extent than the higher HDM. During processing Basrah Heavy vacuum residue, a reduction in hydrodeasphaltization (HDAs) from 73.6 to 55.2% and HDM from 88 to 81% was observed. It was confirmed that HDM and HDAs are interrelated. It was found that the attainment of conversion of 80 wt.% and higher during processing Urals and Siberian Light vacuum residues is possible when the HDM is about 90% and LHSV ≤ 0.19 h⁻¹.

Feedstock quality has been proven to be the single variable that most affects fluid catalytic cracking (FCC) unit performance, but catalyst characteristics have also been reported in the literature to have a considerable effect on cracking process performance. How these two main variables of the FCC process complement each other in the search for ways to optimize the performance of the FCC unit is the subject of current research. Twenty-one feedstocks with K_W-characterizing factors ranging from 11.08 to 12.06, Conradson carbon contents ranging from 0.05 to 12.8 wt.%, and nitrogen contents ranging from 800 to 3590 ppm (wt/wt) (basic nitrogen from 172 to 1125 ppm (wt/wt)) were cracked on 21 catalysts with micro-activity between 67% and 76% (wt/wt) in a laboratory-based advanced catalytic evaluation (ACE) unit at a reaction temperature of 527 °C, catalyst–to-oil ratios between 3.5 and 12.0 wt/wt, and a catalyst time on stream of 30 s. Some of the feeds and catalysts tested in the laboratory FCC ACE unit were also examined in a commercial short-contact-time FCC unit resembling a UOP side-by-side design. It was found that conversion can be very well predicted in both the laboratory ACE and the commercial FCC units using multiple linear correlations developed in this work from information about the following feed properties: K_W-characterizing factor, nitrogen content, and micro-activity of the catalyst. The coke on the catalyst that controls the catalyst-to-oil ratio and the regenerator temperature in the commercial FCC unit could be calculated using the correlations developed in this work for the laboratory ACE and commercial FCC units, based on feed characteristics and catalyst micro-activity. Due to the greater slope of the Δ coke/Δ micro-activity dependence observed in the ACE FCC unit, the more active catalysts show weaker results compared to the less active catalysts at a constant coke yield. In contrast, catalysts with higher activity are preferable for operation in the commercial FCC plant because they provide higher conversion at the same coke yield due to the lower slope of the Δ coke/Δ micro-activity relationship.

The vacuum residue hydrocracker naphtha (VRHN) is a chemically unstable product that during storage changes its colour and forms sediments after two weeks. It cannot be directly exported from the refinery without improving its chemical stability. In this research, the hydrotreatment of H-Oil naphtha with straight run naphtha in a commercial hydrotreater, its co-processing with fluid catalytic cracking (FCC) gasoline in a commercial Prime-G+ post-treater, and its co-processing with vacuum gas oil (VGO) in a commercial FCC unit were discussed. The hydrotreatment improves the chemical stability of H-Oil naphtha and reduces its sulphur content to 3 ppm. The Prime-G+ co-hydrotreating increases the H-Oil naphtha blending research octane number (RON) by 6 points and motor octane number (MON) by 9 points. The FCC co-cracking with VGO enhances the blending RON by 11.5 points and blending MON by 17.6 points. H-Oil naphtha conversion to gaseous products (C₁–C₄ hydrocarbons) in the commercial FCC unit was found to be 50%. The use of ZSM 5 containing catalyst additive during processing H-Oil naphtha showed to lead to FCC gasoline blending octane enhancement by 2 points. This enabled an increment of low octane number naphtha in the commodity premium near zero sulphur automotive gasoline by 2.4 vol.% and substantial improvement of refinery margin. The processing of H-Oil naphtha in the FCC unit leads also to energy saving as a result of an equivalent lift steam substitution in the FCC riser.