Uncovering the Hydrocracking Efficiency of Iron-Based Catalysts: A Novel Approach to Asphaltene Transformation in Iranian Heavy Oil

Abstract

In the quest for optimal asphaltene conversion, this study investigated a range of cost-effective and easily accessible catalyst precursors, targeting both high yields of lighter products and minimal coke formation. The hydrocracking experiments were conducted within a 10 ml bomb-type reactor equipped with a reciprocating stirrer operating at a reciprocation rate of 200 times per minute. The experiments were performed at a temperature of 425°C for a duration of 90 minutes, with an initial hydrogen pressure of 100 bar. The outcomes of each experiment were assessed in terms of liquid products, coke production and C5- gas products. To analyze the Iranian heavy asphaltene, Nuclear Magnetic Resonance (1H NMR), Gel Permeation Chromatography (GPC) and elemental analysis were employed. Gas products were characterized using Gas Chromatography (GC). The investigation aimed to identify the catalyst precursor mixture that would maximize asphaltene conversion while minimizing coke production. A series of catalyst precursors, encompassing FeSO4·H2O, its binary mixtures with metal oxides (Fe2O3, Al2O3, CaO, SiO2), and combinations of Fe2O3, Al2O3, and SiO2 with elemental sulfur, were evaluated. The experimental results demonstrated that the toluene-soluble fraction (TSF), which includes the middle distillate portion, could be increased to a maximum of 56% while concurrently reducing the coke yield to 19%, down from the initial 36.9% when no precursor was used.