Cracking (chemistry) in the context of "Catalysis"

An oil refinery or petroleum refinery is an industrial process plant where petroleum (crude oil) is transformed and refined into products such as gasoline (petrol), diesel fuel, asphalt base, fuel oils, heating oil, kerosene, liquefied petroleum gas and petroleum naphtha. Petrochemical feedstock like ethylene and propylene can also be produced directly by cracking crude oil without the need of using refined products of crude oil such as naphtha. The crude oil feedstock has typically been processed by an oil production plant. There is usually an oil depot at or near an oil refinery for the storage of incoming crude oil feedstock as well as bulk liquid products. In 2020, the total capacity of global refineries for crude oil was about 101.2 million barrels per day.

Oil refineries are typically large, sprawling industrial complexes with extensive piping running throughout, carrying streams of fluids between large chemical processing units, such as distillation columns. In many ways, oil refineries use many different technologies and can be thought of as types of chemical plants. Since December 2008, the world's largest oil refinery has been the Jamnagar Refinery owned by Reliance Industries, located in Gujarat, India, with a processing capacity of 1.24 million barrels (197,000 m) per day.

Heavy fuel oil (HFO) is a fuel oil of a tar-like consistency. Also known as bunker fuel, or residual fuel oil, HFO is the residual mixture leftover from the distillation and cracking of crude oil in oil refineries. Generally, it has a boiling temperature between 350 and 500 °C and a significantly increased viscosity compared to diesel. As it is created through the extraction of more valuable components of its petroleum precursor, HFO contains various undesirable compounds and elements, which includes aromatics, sulfur, nitrogen, vanadium, and others. These non-hydrocarbon contaminants significantly increase toxic gas and particulate emissions upon combustion, such as sulfur dioxide, carbon monoxide, and nitrogen oxides.

As the fuel is cheap, it is predominantly utilized for marine vessel propulsion in marine diesel engines due to its relatively low cost compared to cleaner fuel sources such as diesel fuel or distillates. The emission-heavy nature of the fuel also contributes to this method of usage; marine vessels, such as oil tankers and cruise ships, are generally distant from population centers, sailing in open seas and oceans for the majority of the time, minimizing the exposure of humans to harmful aerosols and gaseous emissions. Ships utilizing heavy fuel oil may switch to cleaner alternatives such as diesel when approaching land. The use and carrying of HFO in seafaring vessels presents several environmental concerns, such as accidental oil spills due to adverse weather or routine handling, which are common due to their universal and dominant usage in marine transportation.

Petroleum coke, abbreviated coke, pet coke or petcoke, is a final carbon-rich solid material that derives from oil refining, and is one type of the group of fuels referred to as cokes. Petcoke is the coke that, in particular, derives from a final cracking process—a thermo-based chemical engineering process that splits long chain hydrocarbons of petroleum into shorter chains—that takes place in units termed coker units. (Other types of coke are derived from coal.) Stated succinctly, coke is the "carbonization product of high-boiling hydrocarbon fractions obtained in petroleum processing (heavy residues)". Petcoke is also produced in the production of synthetic crude oil (syncrude) from bitumen extracted from Canada's oil sands and from Venezuela's Orinoco oil sands.In petroleum coker units, residual oils from other distillation processes used in petroleum refining are treated at a high temperature and pressure leaving the petcoke after driving off gases and volatiles, and separating off remaining light and heavy oils. These processes are termed "coking processes", and most typically employ chemical engineering plant operations for the specific process of delayed coking.

This coke can either be fuel grade (high in sulfur and metals) or anode grade (low in sulfur and metals). The raw coke directly out of the coker is often referred to as green coke. In this context, "green" means unprocessed. The further processing of green coke by calcining in a rotary kiln removes residual volatile hydrocarbons from the coke. The calcined petroleum coke can be further processed in an anode baking oven to produce anode coke of the desired shape and physical properties. The anodes are mainly used in the aluminium and steel industry.

Destructive distillation is a chemical process in which decomposition of unprocessed material is achieved by heating it to a high temperature; the term generally applies to processing of organic material in the absence of air or in the presence of limited amounts of oxygen or other reagents, catalysts, or solvents, such as steam or phenols. It is an application of pyrolysis. The process breaks up or "cracks" large molecules. Coke, coal gas, gaseous carbon, coal tar, ammonia liquor, and coal oil are examples of commercial products historically produced by the destructive distillation of coal.

Destructive distillation of any particular inorganic feedstock produces only a small range of products as a rule, but destructive distillation of many organic materials commonly produces very many compounds, often hundreds, although not all products of any particular process are of commercial importance. The distillate are generally lower molecular weight. Some fractions however polymerise or condense small molecules into larger molecules, including heat-stable tarry substances and chars. Cracking feedstocks into liquid and volatile compounds, and polymerising, or the forming of chars and solids, may both occur in the same process, and any class of the products might be of commercial interest.