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Distillation Distillation Application Application in Petroleum in Petroleum

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Page 1: Distillation Petroleum

Distillation Distillation ApplicationApplication

in Petroleum in Petroleum

Page 2: Distillation Petroleum

DistillationDistillation►Distillation separates chemicals by the Distillation separates chemicals by the

difference in how easily they vaporize. The difference in how easily they vaporize. The two major types of classical distillation two major types of classical distillation include continuous distillation and batch include continuous distillation and batch distillation. Continuous distillation, as the distillation. Continuous distillation, as the name says, continuously takes a feed and name says, continuously takes a feed and separates it into two or more products. Batch separates it into two or more products. Batch distillation takes on lot (or batch) at a time of distillation takes on lot (or batch) at a time of feed and splits it into products by selectively feed and splits it into products by selectively removing the more volatile fractions over removing the more volatile fractions over time.time.

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►Other ways to categorize distillation Other ways to categorize distillation are by the equipment type (trays, are by the equipment type (trays, packing), process configuration packing), process configuration (distillation, absorption, stripping, (distillation, absorption, stripping, azeotropic, extractive, complex), or azeotropic, extractive, complex), or process type (refining, petrochemical, process type (refining, petrochemical, chemical, gas treating).chemical, gas treating).

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►Many industries use distillation for Many industries use distillation for critical separations in making useful critical separations in making useful products. These industries include products. These industries include petroleum refining, beverages, petroleum refining, beverages, chemical processing, petrochemicals, chemical processing, petrochemicals, and natural gas processing.and natural gas processing.

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Distillation CategoriesDistillation Categories System compositionSystem composition

System refers to the chemical System refers to the chemical components present in the mixture components present in the mixture being distilled. The two main groups being distilled. The two main groups are binary distillation and are binary distillation and multicomponent distillation.multicomponent distillation.

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► Binary distillation is a separation of only two Binary distillation is a separation of only two chemicals. A good example is separating ethyl chemicals. A good example is separating ethyl alcohol (ethanol) from water. Most of the basic alcohol (ethanol) from water. Most of the basic distillation teaching and a lot of theoretical work distillation teaching and a lot of theoretical work starts with looking at binary distillation; it's a lot starts with looking at binary distillation; it's a lot simpler.simpler.

► Multicomponent distillation is the separation of a Multicomponent distillation is the separation of a mixture of chemicals. A good example is petroleum mixture of chemicals. A good example is petroleum refining. Crude oil is a very complex mixture of refining. Crude oil is a very complex mixture of hydrocarbons with literally thousands of different hydrocarbons with literally thousands of different molecules. Nearly all commercial distillation is molecules. Nearly all commercial distillation is multicomponent distillation. The theory and practice multicomponent distillation. The theory and practice of multicomponent distillation can be very complex.of multicomponent distillation can be very complex.

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Processing ModeProcessing Mode

► Processing mode refers to the way in which feed Processing mode refers to the way in which feed and product are introduced and withdrawn from the and product are introduced and withdrawn from the process. Distillation occurs in two modes, process. Distillation occurs in two modes, continuous distillation and batch distillation.continuous distillation and batch distillation.

► Continuous distillation is feed is sent to the still all Continuous distillation is feed is sent to the still all the time and product is drawn out at the same the time and product is drawn out at the same time. The idea in continuous distillation is that the time. The idea in continuous distillation is that the amount going into the still and the amount leaving amount going into the still and the amount leaving the still should always equal each other at any the still should always equal each other at any given point in time.given point in time.

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► Batch distillation is when the amount going into Batch distillation is when the amount going into the still and the amount going out of the still is the still and the amount going out of the still is not supposed to be the same all the time. The not supposed to be the same all the time. The easiest example to use is like old fashioned spirit easiest example to use is like old fashioned spirit making. The distiller fills a container at the start, making. The distiller fills a container at the start, then heats it, as time goes by the vapors are then heats it, as time goes by the vapors are condensed to make the alcoholic drink. When the condensed to make the alcoholic drink. When the proper quantity of overhead (drink) is made, the proper quantity of overhead (drink) is made, the distiller stops the still and empties it out ready for distiller stops the still and empties it out ready for a new batch. This is only a simple case, in a new batch. This is only a simple case, in industrial usage what goes on gets very complex.industrial usage what goes on gets very complex.

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Processing SequenceProcessing Sequence► Fractionation systems have different Fractionation systems have different

objectives. The major processing objectives set objectives. The major processing objectives set the system type and the equipment the system type and the equipment configuration needed. The common objectives configuration needed. The common objectives include removing a light component from a include removing a light component from a heavy product, removing a heavy component heavy product, removing a heavy component from a light product, making two products, or from a light product, making two products, or making more than two products. We will call making more than two products. We will call these major categories are called stripping, these major categories are called stripping, rectification, fractionation, and complex rectification, fractionation, and complex fractionation.fractionation.

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►Stripping systems remove light Stripping systems remove light material from a heavy product.material from a heavy product.

►Rectification systems remove heavy Rectification systems remove heavy material from a light product.material from a light product.

►Fractionation systems remove a light Fractionation systems remove a light material from a heavy product and a material from a heavy product and a heavy material from a light product heavy material from a light product at the same time.at the same time.

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► Complex fractionation makes multiple Complex fractionation makes multiple products from either a single tower or a products from either a single tower or a complex of towers combined with recycle complex of towers combined with recycle streams between them. A good example of streams between them. A good example of a multiple product tower is a refinery crude a multiple product tower is a refinery crude distillation tower making rough cuts of distillation tower making rough cuts of naphtha (gasoline), kerosene (jet fuel), and naphtha (gasoline), kerosene (jet fuel), and diesel from the same tower. A good diesel from the same tower. A good example of a complex tower with internal example of a complex tower with internal recycle streams is a Petlyck (baffle) tower recycle streams is a Petlyck (baffle) tower making three on-specifications products making three on-specifications products from the same tower.from the same tower.

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System TypeSystem Type ►The behavior of the chemicals in the The behavior of the chemicals in the

system also determines the system system also determines the system configuration for the objectives. The configuration for the objectives. The three major problems that limit three major problems that limit distillation processes are close-boilers, distillation processes are close-boilers, distributed keys, and azeotropes. distributed keys, and azeotropes.

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► Close boiler systems include chemicals that Close boiler systems include chemicals that boil at temperatures very close to each other. boil at temperatures very close to each other. So many stages of distillation or so much reflux So many stages of distillation or so much reflux may be required that the chemicals cannot be may be required that the chemicals cannot be separated economically. A good example is separated economically. A good example is separation of nitro-chloro-benzenes. Up to 600 separation of nitro-chloro-benzenes. Up to 600 theoretical separation stages with high reflux theoretical separation stages with high reflux may be required to separate different isomers.may be required to separate different isomers.

►Distributed keys are systems where some Distributed keys are systems where some chemicals that we do not want in either the chemicals that we do not want in either the heavy or the light product boil at a heavy or the light product boil at a temperature between the heavy and the light temperature between the heavy and the light product.product.

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►Azeotropic systems are those where Azeotropic systems are those where the vapor and the liquid reach the the vapor and the liquid reach the same composition at some point in same composition at some point in the distillation. No further separation the distillation. No further separation can occur. Ethanol-water is a perfect can occur. Ethanol-water is a perfect example. Once ethanol composition example. Once ethanol composition reaches 95% (at atmospheric reaches 95% (at atmospheric pressure), no further ethanol pressure), no further ethanol purification is possible.purification is possible.

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ReactionReaction ►Reactive distillation uses a reaction in Reactive distillation uses a reaction in

the distillation equipment to help the the distillation equipment to help the separation. The reaction may or may separation. The reaction may or may not use a catalyst. DMT manufacture not use a catalyst. DMT manufacture uses reactive distillation without a uses reactive distillation without a catalyst. One process to make methy-catalyst. One process to make methy-tert-butyl-ether uses a catalyst inside tert-butyl-ether uses a catalyst inside the distillation tower. The reaction the distillation tower. The reaction changes the composition, allowing changes the composition, allowing the distillation to work better the distillation to work better

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Equipment TypeEquipment Type ► Distillation equipment includes two Distillation equipment includes two

major categories, trays and packing.major categories, trays and packing.► Trays force a rising vapor to bubble Trays force a rising vapor to bubble

through a pool of descending liquid.through a pool of descending liquid.► Packing creates a surface for liquid to Packing creates a surface for liquid to

spread on. The thin liquid film has a spread on. The thin liquid film has a high surface area for mass-transfer high surface area for mass-transfer between the liquid and vapor.between the liquid and vapor.

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PETROLEUM PETROLEUM ►Petroleum is a complex mixture of organic Petroleum is a complex mixture of organic

liquids called crude oil and natural gas, liquids called crude oil and natural gas, which occurs naturally in the ground and which occurs naturally in the ground and was formed millions of years ago. Crude was formed millions of years ago. Crude oil and natural gas are of little use in their oil and natural gas are of little use in their raw state; their value lies in what is raw state; their value lies in what is created from them: fuels, lubricating oils, created from them: fuels, lubricating oils, waxes, asphalt, petrochemicals and waxes, asphalt, petrochemicals and pipeline quality natural gas.pipeline quality natural gas.

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HOW OIL WAS FORMED?HOW OIL WAS FORMED?►Oil was formed from the remains of Oil was formed from the remains of

animals and plants that lived millions animals and plants that lived millions of years ago in a marine (water) of years ago in a marine (water) environment before the dinosaurs.   environment before the dinosaurs.   Over the years, the remains were Over the years, the remains were covered by layers of mud.  Heat and covered by layers of mud.  Heat and pressure from these layers helped the pressure from these layers helped the remains turn into what we today call remains turn into what we today call crude oil .  The word "petroleum" crude oil .  The word "petroleum" means "rock oil" or "oil from the earth." means "rock oil" or "oil from the earth."

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Where We Get Oil?Where We Get Oil? The world's top five crude oil-The world's top five crude oil-

producing countries are: producing countries are: Saudi Arabia Saudi Arabia Russia Russia United States United States Iran Iran China China

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Petroleum Hydrocarbon Petroleum Hydrocarbon StructuresStructures

►ParaffinsParaffins►HydrocarbonsHydrocarbons►Naphthenes Naphthenes

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Oil Refining Production Oil Refining Production ProcessProcess

►Desalting and DewateringDesalting and Dewatering►DistillationDistillation►ReformingReforming►CrackingCracking►AlkylationAlkylation► Isomerisation Isomerisation ►PolymerisationPolymerisation►HydrotreatingHydrotreating

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Desalting and DewateringDesalting and Dewatering► Crude oil is recovered from the reservoir mixed Crude oil is recovered from the reservoir mixed

with a variety of substances: gases water and with a variety of substances: gases water and dirt (minerals). Desalting is a water – washing dirt (minerals). Desalting is a water – washing operation performed at the production field and operation performed at the production field and at the refinery site for additional crude oil at the refinery site for additional crude oil cleanup. If the petroleum from the seperators cleanup. If the petroleum from the seperators contains water and dirt, water washing can contains water and dirt, water washing can remove much of the water – soluble minerals remove much of the water – soluble minerals and entrained solids. If these crude oil and entrained solids. If these crude oil contaminants are not removed, they can cause contaminants are not removed, they can cause operating problems during refinery processing, operating problems during refinery processing, such as equipment plugging and corrosion as such as equipment plugging and corrosion as well as catalyst deactivation. well as catalyst deactivation.

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DistillationDistillation ► The first and the most fundamental step in the refining process The first and the most fundamental step in the refining process

(after the crude oil has been cleaned and any remnants of brine (after the crude oil has been cleaned and any remnants of brine removed) is distillation, which is often referred to as the removed) is distillation, which is often referred to as the primary refining process. Distillation involves the separation of primary refining process. Distillation involves the separation of the different hydrocarbon compounds that occur naturally in a the different hydrocarbon compounds that occur naturally in a crude oil into a number of different fractions (a fraction is often crude oil into a number of different fractions (a fraction is often referred to as a cut). In the atmospheric distillation process referred to as a cut). In the atmospheric distillation process (Fig.), heated crude oil is separated in a distillation column (Fig.), heated crude oil is separated in a distillation column (distillation tower, fractionating tower, atmospheric pipe still) (distillation tower, fractionating tower, atmospheric pipe still) into streams that are then purified, transformed, adapted, and into streams that are then purified, transformed, adapted, and treated in a number of subsequent refining processes, into treated in a number of subsequent refining processes, into products for the refinery's market. The lighter, more volatile, products for the refinery's market. The lighter, more volatile, products separate out higher up the column, whereas the products separate out higher up the column, whereas the heavier, less volatile, products settle out toward the bottom of heavier, less volatile, products settle out toward the bottom of the distillation column. The fractions produced in this manner the distillation column. The fractions produced in this manner are known as straight run fractions ranging from (atmospheric are known as straight run fractions ranging from (atmospheric tower) gas, gasoline, and naphtha, to kerosene, gas oils, and tower) gas, gasoline, and naphtha, to kerosene, gas oils, and light diesel, and to (vacuum tower) lubricating oil and residuum. light diesel, and to (vacuum tower) lubricating oil and residuum.

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► The feed to a distillation tower is heated by flow The feed to a distillation tower is heated by flow through pipes arranged within a large furnace. The through pipes arranged within a large furnace. The heating unit is known as a pipe still heater or pipe still heating unit is known as a pipe still heater or pipe still furnace, and the heating unit and the fractional furnace, and the heating unit and the fractional distillation tower make up the essential parts of a distillation tower make up the essential parts of a distillation unit or pipe still. The pipe still furnace heats distillation unit or pipe still. The pipe still furnace heats the feed to a predetermined temperature— usually a the feed to a predetermined temperature— usually a temperature at which a predetermined portion of the temperature at which a predetermined portion of the feed will change into vapor. The vapor is held under feed will change into vapor. The vapor is held under pressure in the pipe in the furnace until it discharges as pressure in the pipe in the furnace until it discharges as a foaming stream into the fractional distillation tower. a foaming stream into the fractional distillation tower. Here the unvaporized or liquid portion of the feed Here the unvaporized or liquid portion of the feed descends to the bottom of the tower to be pumped descends to the bottom of the tower to be pumped away as a bottom nonvolatile product, whereas the away as a bottom nonvolatile product, whereas the vapors pass up the tower to be fractionated into gas vapors pass up the tower to be fractionated into gas oils, kerosene, and naphtha.oils, kerosene, and naphtha.

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Reforming Reforming ►Reforming is a process which uses Reforming is a process which uses

heat, pressure and a catalyst (usually heat, pressure and a catalyst (usually containing platinum) to bring about containing platinum) to bring about chemical reactions which upgrade chemical reactions which upgrade naphthas into high octane petrol and naphthas into high octane petrol and petrochemical feedstock. petrochemical feedstock.

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CrackingCracking► Cracking processes break down Cracking processes break down

heavier hydrocarbon molecules (high heavier hydrocarbon molecules (high boiling point oils) into lighter boiling point oils) into lighter products such as petrol and diesel. products such as petrol and diesel. These processes include: These processes include:

1.1. catalytic crackingcatalytic cracking2.2. thermal crackingthermal cracking3.3. hydrocrackinghydrocracking

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Alkylation Alkylation ►Alkylation refers to the chemical Alkylation refers to the chemical

bonding of these light molecules with bonding of these light molecules with isobutane to form larger branched-isobutane to form larger branched-chain molecules (isoparaffins) that chain molecules (isoparaffins) that make high octane petrol.make high octane petrol.

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IsomerisationIsomerisation► Isomerisation refers to chemical Isomerisation refers to chemical

rearrangement of straight-chain rearrangement of straight-chain hydrocarbons (paraffins), so that they hydrocarbons (paraffins), so that they contain branches attached to the main contain branches attached to the main chain (isoparaffins). chain (isoparaffins).

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PolymerisationPolymerisation ► Under pressure and temperature, over an Under pressure and temperature, over an

acidic catalyst, light unsaturated hydrocarbon acidic catalyst, light unsaturated hydrocarbon molecules react and combine with each other molecules react and combine with each other to form larger hydrocarbon molecules. Such to form larger hydrocarbon molecules. Such process can be used to react butenes (olefin process can be used to react butenes (olefin molecules with four carbon atoms) with iso-molecules with four carbon atoms) with iso-butane (branched paraffin molecules, or butane (branched paraffin molecules, or isoparaffins, with four carbon atoms) to obtain isoparaffins, with four carbon atoms) to obtain a high octane olefinic petrol blending a high octane olefinic petrol blending component called polymer gasoline.component called polymer gasoline.

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Hydrotreating Hydrotreating ► Hydrotreating is one way of removing many Hydrotreating is one way of removing many

of the contaminants from many of the of the contaminants from many of the intermediate or final products. In the intermediate or final products. In the hydrotreating process, the entering feedstock hydrotreating process, the entering feedstock is mixed with hydrogen and heated to 300 - is mixed with hydrogen and heated to 300 - 380oC. The oil combined with the hydrogen 380oC. The oil combined with the hydrogen then enters a reactor loaded with a catalyst then enters a reactor loaded with a catalyst which promotes several reactions:which promotes several reactions:

hydrogen combines with sulphur to form hydrogen combines with sulphur to form hydrogen sulphide (H2S) .hydrogen sulphide (H2S) .

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Petroleum ProductsPetroleum Products ► Aviation Gasoline Aviation Gasoline ► Gas Diesel Oil/(Distillate Fuel Oil) Gas Diesel Oil/(Distillate Fuel Oil) ► Heavy Fuel Oil Residual Heavy Fuel Oil Residual ► KeroseneKerosene► Jet FuelJet Fuel► LPGLPG► Motor GasolineMotor Gasoline► NaphthaNaphtha► Petroleum CokePetroleum Coke► Refinery Gas Refinery Gas

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Products Made From OilProducts Made From Oil ► Ink Toys Dolls Tires Tents ShoesGlue Skis Dyes Cameras CInk Toys Dolls Tires Tents ShoesGlue Skis Dyes Cameras C

ombs Dice Mops Purses Dresses Pajamas Pillows Candles ombs Dice Mops Purses Dresses Pajamas Pillows Candles Boats Crayons Caulking Balloons Curtains Milk Boats Crayons Caulking Balloons Curtains Milk jugs Putty Tool racks Slacks Yarn Roofing Luggage Fan jugs Putty Tool racks Slacks Yarn Roofing Luggage Fan belts Carpeting Lipstick  Aspirin  Dishwashing belts Carpeting Lipstick  Aspirin  Dishwashing liquids Unbreakable dishes Car sound liquids Unbreakable dishes Car sound insulation Motorcycle helmets Refrigerator insulation Motorcycle helmets Refrigerator linings Electrician's tape Roller-skate wheels Permanent linings Electrician's tape Roller-skate wheels Permanent press clothes Soft contact lenses Food press clothes Soft contact lenses Food preservatives Transparent tape Disposable diapers Sports preservatives Transparent tape Disposable diapers Sports car bodies Electric blankets Car battery cases Synthetic car bodies Electric blankets Car battery cases Synthetic rubber Vitamin capsules Rubbing alcohol Ice cube rubber Vitamin capsules Rubbing alcohol Ice cube trays Insect repellent Roofing shingles Shower trays Insect repellent Roofing shingles Shower curtains Plywood adhesive Beach umbrellas Faucet curtains Plywood adhesive Beach umbrellas Faucet washers Antihistamines Drinking cups Petroleum washers Antihistamines Drinking cups Petroleum jelly Tennis rackets Wire insulation Ballpoint pens Artificial jelly Tennis rackets Wire insulation Ballpoint pens Artificial turf Artificial limbs Shaving creamturf Artificial limbs Shaving cream

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►   Paint brushes Telephones Insecticides Antiseptics Fishing Paint brushes Telephones Insecticides Antiseptics Fishing lures Deodorant Linoleum Sweaters Paint rollers Floor lures Deodorant Linoleum Sweaters Paint rollers Floor wax Plastic wood Model cars Trash bags Soap dishes Hand wax Plastic wood Model cars Trash bags Soap dishes Hand lotion Clothesline Shampoo Panty hose Fishing rods Oil lotion Clothesline Shampoo Panty hose Fishing rods Oil filters Anesthetics Upholstery TV cabinets Cassettes Salad filters Anesthetics Upholstery TV cabinets Cassettes Salad bowls House paint Awnings Ammonia Safety glass Hair bowls House paint Awnings Ammonia Safety glass Hair curlers VCR tapes Eyeglasses Movie film Ice curlers VCR tapes Eyeglasses Movie film Ice chests Loudspeakers Ice buckets Credit chests Loudspeakers Ice buckets Credit cards Fertilizers Water pipes Toilet seats Fishing boots Life cards Fertilizers Water pipes Toilet seats Fishing boots Life jackets Garden hose Golf jackets Garden hose Golf balls Umbrellas Detergents Rubber cement Sun balls Umbrellas Detergents Rubber cement Sun glasses Cold cream Bandages Hair coloring Nail glasses Cold cream Bandages Hair coloring Nail polish Guitar strings False teethToothpaste Golf polish Guitar strings False teethToothpaste Golf bags Toothbrushes Perfume Folding doors Shoe bags Toothbrushes Perfume Folding doors Shoe polish Shower doors Cortisone Heart valves LP polish Shower doors Cortisone Heart valves LP records Hearing aids Vaporizers Wading pools Parachutesrecords Hearing aids Vaporizers Wading pools Parachutes

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Oil and The EnvironmentOil and The Environment ► AirAir►WaterWater►LandLand

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AirAirPreserving air quality around a refinery Preserving air quality around a refinery

involves controlling the following involves controlling the following emissions:emissions: sulphur oxides sulphur oxides hydrocarbon vapours hydrocarbon vapours smoke smoke smells smells

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WaterWater►The majority of the water discharged The majority of the water discharged

from the refinery has been used for from the refinery has been used for cooling the various process streams. cooling the various process streams. The cooling water does not actually The cooling water does not actually come into contact with the process come into contact with the process material and so has very little material and so has very little contamination.contamination.

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►Rainwater falling on the refinery site Rainwater falling on the refinery site must be treated before discharge to must be treated before discharge to ensure no oily material washed off ensure no oily material washed off process equipment leaves the refinery. process equipment leaves the refinery.

►Process water has actually come into Process water has actually come into contact with the process streams and contact with the process streams and so can contain significant so can contain significant contamination. contamination.

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LandLand► The refinery safeguards the land The refinery safeguards the land

environment by ensuring the appropriate environment by ensuring the appropriate disposal of all wastes.disposal of all wastes.

►Within the refinery, all hydrocarbon wastes Within the refinery, all hydrocarbon wastes are recycled through the refinery slops are recycled through the refinery slops system. This system consists of a network of system. This system consists of a network of collection pipes and a series of dewatering collection pipes and a series of dewatering tanks. The recovered hydrocarbon is tanks. The recovered hydrocarbon is reprocessed through the distillation units.reprocessed through the distillation units.