Petroleum conversion processes are core refining operations used in oil refineries to transform low-value crude oil fractions into higher-value transportation fuels and petrochemical feedstocks. The primary objective of conversion processes is to change the molecular structure of hydrocarbons through thermal, catalytic, and hydrogen-based reactions in order to maximize the yield of gasoline, diesel, jet fuel, and LPG while meeting strict environmental and product quality specifications.

Major Petroleum Conversion Processes

Fluid Catalytic Cracking (FCC)

Fluid Catalytic Cracking is one of the most widely used conversion processes in oil refineries. FCC converts heavy gas oils into lighter products such as gasoline, LPG, and light olefins through catalytic cracking reactions.

Key features:

• Operates without hydrogen
• Uses fine powdered catalysts in a fluidized state
• Produces high-octane gasoline blending components

FCC units are central to maximizing gasoline production and improving refinery economics.

Hydrocracking

Hydrocracking is a hydrogen-intensive conversion process used to upgrade heavy feedstocks into high-quality middle distillates such as diesel and jet fuel.

Key benefits:

• Deep conversion of vacuum gas oil (VGO)
• Simultaneous sulfur and nitrogen removal
• Flexible operation for fuel or petrochemical feedstock production

Hydrocracking is essential for refineries processing heavy or high-sulfur crudes.

Visbreaking

Visbreaking is a mild thermal cracking process designed to reduce the viscosity of heavy residues and improve fuel oil blending properties.

Key objectives:

• Lower fuel oil viscosity
• Reduce cutter stock requirements
• Increase distillate yield

Visbreaking is commonly applied where deep conversion severity is not required.

Catalytic Reforming

Catalytic reforming upgrades low-octane naphtha into high-octane reformate and hydrogen by rearranging hydrocarbon molecules.

Key outputs:

• High-octane gasoline blending components
• Hydrogen for hydrotreating and hydrocracking units
• Aromatic-rich reformate

Reforming units are critical hydrogen sources within modern refineries.

Catalysts

Catalysts are fundamental to petroleum conversion processes, directly impacting conversion efficiency, selectivity, and unit cycle length.

Common catalyst types include:

• FCC Catalysts – zeolite-based cracking catalysts
• Hydrocracking Catalysts – Ni-Mo, Ni-W on alumina or silica-alumina
• Reforming Catalysts – platinum-based bifunctional catalysts
• Resid Conversion Catalysts – specialized formulations for heavy feeds

Leading global catalyst manufacturers:

• Honeywell UOP
• Axens
• Haldor Topsoe
• Albemarle
• Criterion (Shell subsidiary)

OGSCM Group supports refineries by sourcing and supplying refinery-approved conversion catalysts with full technical documentation and handling support.

Chemicals

Process Chemicals

Petroleum conversion units require various process chemicals to maintain stable operation, protect equipment, and support catalyst performance.

Common chemicals include:

• Hydrogen (H₂)
• Sulfiding agents (DMDS, TBPS)
• Antifoaming agents
• Corrosion inhibitors
• Catalyst additives

Standard Industrial Packaging for these chemicals including Bulk supply (pipeline, tanker, ISO tank), IBC containers (1,000 L) and Steel drums (200–220 L). OGSCM Group supplies high-quality conversion process chemicals in approved industrial packaging formats, ensuring safe logistics and uninterrupted refinery operation.

Major Global Chemical Brands

Widely recognized chemical manufacturers supporting petroleum conversion processes include:

• BASF
• Shell Chemicals
• Dow
• Clariant
• LANXESS
• Innospec
• Arkema

OGSCM works with approved suppliers to ensure consistent quality and compliance with licensor requirements.

Main Equipment

Conversion Reactors and Vessels

Conversion reactors are designed to operate under severe temperature and pressure conditions and house fixed-bed or fluidized catalyst systems.

Well-known manufacturers and suppliers:

• UOP (Honeywell)
• Axens
• L&T Heavy Engineering
• Doosan Enerbility
• Mitsubishi Heavy Industries (MHI)

OGSCM provides sourcing and supply services for conversion reactors, internals, catalyst handling systems, and associated mechanical components.

Heat Exchangers and Furnaces

Heat exchangers and fired heaters are essential for feed preheating, effluent cooling, and energy integration.

Leading suppliers include:

• Alfa Laval
• API Heat Transfer
• Kelvion
• Hisaka
• Tranter

OGSCM Group supplies heat exchangers, heater components, and spare parts for petroleum conversion units.

Instrumentation

Precise instrumentation ensures safe and optimized operation of high-severity conversion processes.

Major brands:

• Emerson
• Yokogawa
• Honeywell
• Endress+Hauser
• ABB

Valves

Valves are critical for process control, isolation, and safety in high-temperature and high-pressure services.

Major manufacturers:

• Emerson (Fisher, Vanessa)
• Cameron (SLB)
• Flowserve
• L&T Valves
• Neway
• Kitz

OGSCM Group offers comprehensive procurement solutions for industrial valves required in petroleum conversion processes, including control, safety, isolation valves, and spare parts.