Hydrocracking converts low-value heavy oil into lighter products using a catalyst and hydrogen.
In a hydrocracker, heavy hydrocarbon molecules are broken into smaller molecules while hydrogen is added. The process operates at high temperature and pressure over catalysts. Depending on the unit and operating conditions, products can include jet fuel, diesel, naphtha, and other lighter fractions.
Hydrocracking became increasingly valuable as refineries faced heavier crude oils and stricter fuel specifications. Hydrogen helps remove sulfur and nitrogen compounds while also saturating some hydrocarbon molecules, producing cleaner and more stable fuels than many untreated heavy streams.
Hydrocracking differs from catalytic cracking. Catalytic cracking breaks large molecules mainly through heat and catalysts, whereas hydrocracking uses substantial hydrogen and can produce highly saturated products. Delayed coking is another upgrading process, but it produces petroleum coke as a characteristic solid by-product.