This work deals with an efficient
two-step thermal upgrading process
for converting extra-heavy fuel oil to light olefins (ethylene, propylene,
and butenes) and fuels (gasoline and diesel fuel). In the first step,
mild thermal pretreatment was implemented at different temperatures
(360–440 °C) in the liquid phase to obtain a more suitable
feedstock for an olefin production unit. Thanks to this cost-effective
pretreatment, the upgraded feedstock demonstrated considerable flowability
and crackability compared to the initial fuel oil, making the subsequent
vapor-phase operation easier to handle at temperatures as high as
800 °C with no severe operational impediments. The quantitative 1H and 13C NMR studies shed light on the enhanced
features of the thermally treated feedstock toward lighter and more
valuable products. As a result, remarkable olefin production (74.7
or 55.1 wt % light olefins based on the upgraded or the original feedstock)
was accomplished in this two-step process. The process could be alternatively
stopped at the first stage for maximum liquid fuels (69.3 wt %) with
gasoline as the larger constituent. The detailed kinetic investigations
of the thermal decomposition of the feedstock using several reliable
approaches revealed that the activation energy predictions (42.3–272.9
kJ/mol) by the Kissinger–Akahira–Sunose method almost
perfectly matched the trend of a reference Starink model over the
whole range of conversion. All model-free methods correlated with
a coefficient of determination above 97.9%. Avrami’s theory
was further applied to determine the reaction order, and the values
were slightly smaller than those from a five-lump kinetic model of
the semibatch operation. However, the apparent activation barrier
in the reactor was in good correspondence with the range from the
microscale nonisothermal decomposition.