Visbreaking is a thermal cracking process used to reduce the viscosity of heavy fuel oil (HFO) to produce lighter, more valuable products. However, one of the major challenges in visbreaking units is fouling—the accumulation of carbon deposits and other contaminants on heat exchanger surfaces, reactor walls, and pipelines. Fouling reduces heat transfer efficiency, increases energy consumption, and leads to frequent shutdowns for cleaning. To mitigate these issues, specialized additives play a crucial role in minimizing fouling and improving operational efficiency.

How Fouling Occurs in Visbreaking Units

During visbreaking, heavy hydrocarbon molecules are broken down into lighter fractions under high temperatures. However, unstable free radicals can recombine to form polyaromatic hydrocarbons (PAHs) and coke, which deposit on equipment surfaces. Additionally, asphaltenes and other heavy fractions can precipitate, further contributing to fouling.

The Role of Additives in Fouling Control

Additives designed for visbreaking units work through several mechanisms:

Radical Scavenging – Some additives act as free radical inhibitors, preventing the recombination of cracked hydrocarbon fragments into larger, fouling-prone molecules.

Asphaltene Dispersion – Certain additives stabilize asphaltenes, preventing their agglomeration and deposition on metal surfaces.

Metal Passivation – Additives can neutralize catalytic metals (such as nickel and vanadium) present in HFO, which otherwise promote coke formation.

Anti-Oxidant Properties – Oxidation can accelerate fouling; antioxidants in additives help reduce oxidative degradation of hydrocarbons.

Benefits of Using Additives

Extended Run Times – Reduced fouling allows for longer operation between shutdowns.

Improved Heat Transfer – Cleaner heat exchanger surfaces maintain optimal thermal efficiency.

Lower Maintenance Costs – Fewer mechanical cleanings and less downtime lead to cost savings.

Enhanced Product Quality – Controlled cracking reduces unwanted heavy residues.

Conclusion

Fouling in HFO visbreaking units is a persistent issue, but the right additives can significantly mitigate its effects. By incorporating anti-fouling additives, refiners can enhance operational efficiency, reduce maintenance costs, and maximize the yield of valuable products. As visbreaking remains a key process for upgrading heavy oils, ongoing advancements in additive technology will continue to play a vital role in optimizing performance.