Recovery of useful lighter fuels from petroleum residual oil by oxidative cracking with steam using iron oxide catalyst

In petroleum industry, it is desirable to produce lighter hydrocarbons such as gasoline, kerosene and gas–oil from unused heavy oils. Thus we have developed zirconia-supporting iron oxide catalysts (ZrO2–FeOXcatalyst) to decompose petroleum residual oil (atmospheric distilled residual oil) with steam. In addition, we have found that the incorporation of Al2O3Al2O3 among FeOXFeOX crystals is effective in improving the catalytic activity and stability of the ZrO2–FeOX   catalyst. In this study, the effects of Al2O3Al2O3 and ZrO2ZrO2 content in FeOXFeOX–based catalysts on catalytic activity and stability were investigated. Furthermore, the FeOXFeOX–based catalyst was applied to the decomposition of extra heavy oils such as vacuum distilled residual oil and Orimulsion. These extra heavy oils were effectively decomposed over the ZrO2–Al2O3–FeOX catalyst with steam, and the yields of lighter hydrocarbon reached to above 60%