Reaction Kinetics Model for a Slurry Hydrocracking Process Using Limonite Catalyst

Abstract

Kobe Steel, Ltd. and Chiyoda Corp. developed the KOBELCO Slurry Phase Hydrocracking (SPH) process for the ultimate heavy oil upgrading, both at upstream wells and refineries with a cracking rate higher than 90 %. Generally, with the heavy oil hydrocracking process, a higher cracking rate is associated with a greater sludge formation rate due to a radical reaction, large molecular condensation and polymerization induced by thermal cracking. This research objective is to apply optimized operation conditions, obtained through experimental results, to the new process system’s development for the pilot and commercial plants by achieving a more than 95 wt% VR cracking rate, more than 80 wt% of oil yield, and minimizing sludge generation. For this purpose, the reaction time, amount of limonite content, reaction pressure, and reaction temperature in the 1 L autoclave are tested to find the optimal reaction point. To scale up the SPH process to pilot plants and commercial plants, a new reaction model, for which reaction conditions are theorized, must be developed. This study proposes a new reaction model by simulating the autoclave tests, verifying its validity, and discussing future challenges and plans.