Download - Introduction To Oil Refining
Introduction to Oil Refining
1 Paraguana Refining Center Judibana, Falcon, Venezuela 940,000 2 SK Corporation Ulsan, South Korea 817,0003 LG-Caltex Yosu, South Korea 633,6004 ExxonMobil Refining Singapore Jurong/Pulau Ayer Chawan 568,5005 Reliance Petroleum Ltd Jamnagar, India 540,0006 Hovensa LLC Saint Croix, Virgin Islands 525,0007 S-Oil Corp. Onsan, Korea 520,0008 ExxonMobil Refining, USA Baytown, TX 516,5009 ExxonMobil Refining USA Baton Rouge, LA 488,500
10 Sidanco Angarsk, Russia 440,70011 Norsi Kstovo, Nizhny Novgorod, Russia 437,79212 BP Amoco plc Texas City, TX 437,00013 Kuwait National Petroleum Co Mina Al-Ahmadi, Kuwait 427,50014 BP Amoco plc Whiting, IN 410,00015 Shell Eastern Petroleum Pte Ltd Pulau Bukom, Singapore 405,00016 National Iranian Oil Co Abadan, Iran 400,000
Source: Oil and Gas Journal
World’s Largest Refineries*
* Plants with 400,000 b/cd or more capacity
Crude CapacityCompany Location b/cd
1 1 Royal Dutch/Shell 4,230,0002 2 Exxon Corp. 3,646,0003 7,16 BP Amoco plc 2,793,0004 3 Petroleos de Venezuela SA 2,595,0005 4 Sinopec 2,507,0006 5 Mobil Corp. 2,117,0007 6 Saudi Aramco 1,922,0008 9 China National Petroleum Corp. 1,763,0009 8 Petroleo Brasileiro SA 1,760,000
10 10 Petroleos Mexicanos 1,662,00011 20, — TotalFina SA 1,587,00012 12 National Iranian Oil Co. 1,474,00013 13 Texaco Inc. 1,429,00014 11 Chevron Corp. 1,418,00015 23, — Repsol-YPF SA 1,145,00016 14 Kuwait National Petroleum Co. 1,058,00017 15 Agip Petroli SpA 1,030,00018 — Nippon Mitsubishi Oil 998,00019 17 Elf Aquitaine 956,00020 18 Marathon Ashland Petroleum LLC 935,00021 19 Pertamia 930,00022 21 Tosco Corp 920,00023 22 Bashneftekhimzavody 866,00024 25 Conoco, Inc. 832,00025 24 SK Corp. 817,000
Source: Oil and Gas Journal
How the World’s Largest Refiners RankRank (1-1-00) Rank (1-1-99) Company Crude Capacity, b/cd*
* Includes partial interest in refineries not wholly owned by the company.
Asia-Pacific 203 19,643,997 3,575,998 2,491,615 1,942,422 706,710 3,193,520
Western Europe 108 14,434,402 5,098,283 2,128,556 2,131,002 674,753 2,401,548
E. Europe & FSU 100 12,048,607 3,996,517 862,466 1,485,416 152,435 99,500
Middle East 45 5,952,940 1,955,370 290,900 584,384 572,050 470,964
Africa 46 3,044,152 470,067 390,804 417,018 107,885 127,694
North America 182 19,977,640 8,756,195 6,340,150 4,092,918 1,698,870 1,850,100
S. America & 72 6,448,058 2,848,724 1,254,802 400,060 107,600 416,810Caribbean
Total Regions 756 81,549,796 26,701,154 13,759,293 11,053,220 4,020,303 8,560,136
Source: Oil and Gas Journal
Regional Look at Worldwide Refining Operations
Catalytic CatalyticCrude Vacuum Catalytic Catalytic Hydro- Hydro-
No. of Distillation, Distillation, Cracking Reforming cracking refiningRegion Refineries b/cd b/cd b/cd b/cd b/cd b/cd
Companies with 200,000+B/CD Capacity Located in the U.S.
1 BP Amoco plc 7 1,418,6002 Exxon Co. USA 4 1,175,5003 Chevron USA Products Co. 6 969,0004 Marathon Ashland Petroleum LLC 7 935,0005 Mobil Oil Corp. 4 928,7006 Tosco Refining Co. 5 920,0007 Motiva Enterprises LLC 4 842,0008 Equilon Enterprises LLC 5 739,5509 Sunoco, Inc. 4 707,000
10 Citgo Petroleum Corp. 4 617,97511 Koch Refining & Marketing 2 577,00012 Valero Energy Corp. 5 564,30013 Clark Refining & Marketing 4 534,00014 Conoco, Inc. 4 531,60015 Atlantic Richfield Co. 4 512,22016 Ultramar Diamond Shamrock Corp. 5 417,50017 Phillips Petroleum Co. 3 355,00018 Williams Co. 2 350,00019 Tesoro Petroleum Corp. 3 275,20020 Coastal Refining & Marketing, Inc. 3 275,00021 Lyondell-Citgo Refining LP 1 268,80022 Fina Oil & Chemical Co. 2 237,00023 Orion Refining Corp. 1 200,000
Total 89 14,350,945Source: Oil and Gas Journal
Number of Crude CapacityRank Company Refineries b/cd
Companies with 200,000+B/CD Capacity Located in Western Europe
1 Exxon Corp. 9 1,656,5402 Royal Dutch/Shell 12 1,507,6323 TotalFina SA 7 1,333,3354 BP Amoco plc 6 1,179,8005 Agip Petroli SpA 7 1,008,2006 Repsol YPF SA 5 790,0007 Elf Aquitaine 5 762,4308 Cia Espanola de Petroles 3 304,3009 Petrogal EP 2 334,300
10 Seras SpA 1 285,00011 Veba Oel/Huhr Oel 1 246,00012 Isab SpA 1 235,00013 Louis Dreyfus (Wilhelmshafen) 1 225,00014 DEA Mineraloel AG 2 220,00015 PCK Schwedt AG 1 210,00016 OMV AG 1 208,60017 Neste Oy 1 200,00018 Statoil Mongstad 1 200,000
Total 67 10,969,837Source: Oil and Gas Journal
Number of Crude CapacityRank Company Refineries b/cd
Companies with 200,000+B/CD Capacity Located in Latin America
1 Exxon Corp. 9 1,656,5402 Royal Dutch/Shell 12 1,507,6323 TotalFina SA 7 1,333,3354 BP Amoco plc 6 1,179,8005 Agip Petroli SpA 7 1,008,2006 Repsol YPF SA 5 790,0007 Elf Aquitaine 5 762,4308 Cia Espanola de Petroles 3 304,3009 Petrogal EP 2 334,300
10 Seras SpA 1 285,00011 Veba Oel/Huhr Oel 1 246,00012 Isab SpA 1 235,00013 Louis Dreyfus (Wilhelmshafen) 1 225,00014 DEA Mineraloel AG 2 220,00015 PCK Schwedt AG 1 210,00016 OMV AG 1 208,60017 Neste Oy 1 200,00018 Statoil Mongstad 1 200,000
Total 67 10,969,837Source: Oil and Gas Journal
Number of Crude CapacityRank Company Refineries b/cd
Companies with 200,000+B/CD Capacity Located in Asia Pacific
1 Exxon Corp. 9 1,656,5402 Royal Dutch/Shell 12 1,507,6323 TotalFina SA 7 1,333,3354 BP Amoco plc 6 1,179,8005 Agip Petroli SpA 7 1,008,2006 Repsol YPF SA 5 790,0007 Elf Aquitaine 5 762,4308 Cia Espanola de Petroles 3 304,3009 Petrogal EP 2 334,300
10 Seras SpA 1 285,00011 Veba Oel/Huhr Oel 1 246,00012 Isab SpA 1 235,00013 Louis Dreyfus (Wilhelmshafen) 1 225,00014 DEA Mineraloel AG 2 220,00015 PCK Schwedt AG 1 210,00016 OMV AG 1 208,60017 Neste Oy 1 200,00018 Statoil Mongstad 1 200,000
Total 67 10,969,837Source: Oil and Gas Journal
Number of Crude CapacityRank Company Refineries b/cd
Reformate
Crude Distillation
GAS & LIQUIFIED PETROLEUM GAS (LPG)
Crude Oil
VAPOR VAPOR RECOVERYRECOVERY
STRAIGHT RUN GASOLINE
HYDROHYDROTREATINGTREATING
HYDROHYDROTREATINGTREATING
NAPTHAHigh Octane Gasoline
MIDDLE DISTILLATE
FCCHEAVY GAS OIL
VACUUM GAS OIL
Gasoline between FCC/Hydrocracking
CATCATCRACKINGCRACKING
HYDROHYDROTREATINGTREATING
REFORMINGREFORMING
SOLVENTSOLVENTEXTRACTIONEXTRACTION
PROPANEPROPANEDEASPHALTERDEASPHALTER
SOLVENTSOLVENTDEWAXINGDEWAXING
HYDROHYDROCRACKINGCRACKING
VISBREAKERVISBREAKER
DELAYEDDELAYEDCOKERCOKER
GASOLINE &NAPHTHA
LUBE OILS
WAXES
GASOLINE & NAPHTHA
FUEL OIL
ASPHALT
GASOLINE & NAPHTHACOKE
REFINERY FUEL GAS
LPG
REGULAR GASOLINE
PREMIUM GASOLINE
SOLVENTS
AVIATION FUELS
DIESELS
HEATING OILS
LUBE OILS
GREASES
ASPHALTS
INDUSTRIAL FUELS
REFINERY FUEL OILS
COKE
TYPICAL PRODUCTS
TREA
TIN
G A
ND
BLE
ND
IG
Refinery Flow OverviewRefinery Flow Overview
GASOLINE
LUBE STOCKS
Crude Distillation First major processing unit in the refinery DistillationDistillation - - Breaking down the constituents
according to boiling point There are normally two steps involved:
Atmospheric Distillation and Vacuum Distillation
This is the process that uses theThis is the process that uses themost number of pumps in the refinerymost number of pumps in the refinery
Pump application: Crude Charge Reflux and Tops Intermediate Reflux
Gas Oil Naphtha, Kerosene & Diesel Topped Crude
Atmospheric Distillation Unit
WATERGAS
COMPRESSOR
REFLUX DRUM
HEATER250OF
REFLUX PUMP 150 - 200OF
STEAMNAPHTHA
GASOLINE
GAS OIL
700OFTOPPED CRUDETO VACUUM TOWER
DESALTER
HEATER750OF ATMOSPHERI
CTOWER
300 - 400OF
SIDE CUTSTRIPPERS
CRUDE CHARGE
400 - 500OF
500 - 600OF
STEAM
IntermediateReflux Pump
Vacuum Distillation Unit
TO VACUUM EJECTORS
WATER
EXCHANGER
EXCHANGER LIGHT GAS OIL
HEAVY GAS OIL
EXCHANGER
ASPHALT
FLASHERBOTTOMS
PUMP
VACUUMTOWER
(FLASHER)
Suction750OF
25-5025-50MM HgMM Hg
HEATER
TOPPED CRUDE
850OF
Catalytic Cracking Refining process used for the manufacture of the
gasoline and petrochemical feedstocks from the heavier portions of the heavier portion of the crude oil
Cracking occurs at 25 to 35 psig
Centrifugal single and multistage pumps for coldand hot service
Special attention to be paid to the slurry oil pump
Utilize a special catalyst, crystalline alumina silicate to promote the cracking of the heavy hydrocarbon molecules into light ones
WATER
SLURRY PUMP600-700OF
SLURRY PUMP600-700OF
REACTORREGENERATOR
FLUE GAS TO POWER RECOVERY
25-35 psig1200-1300OF
25-35 psig1000OF
STEAMSLURRY SETTLER
FRESH FEED
RECYCLE
REGEN CATALYST
FRACTIONATOR
AIR
AIRBLOWER
SPENT CATALYST
SLURRY DECANT OIL
HEAVY GAS OIL
LIGHT GAS OIL
GASOLINE
GAS TO ADSORBER
WET GASCOMPRESSOR
Catalytic Cracking Unit
RISER(MIXER)
1000OF
Hydrocracking Another process for making gasoline out of
heavier feedstocks
Able to crack those oils that are not easily cracked by catalytic cracking
Able to make distillates and light oils fromresidual oils
External supply of hydrogen + catalyst is required
Cracking occurs at 1000 to 2000 psig
Multistage barrel type centrifugal pumps designed to operate at temperatures of 700-800OF and pressure above 200 psig
RECYCLE COMPRESSOR
FURNACE
FURNACE
FURNACE
FRACTIONATOR
TO FUEL GAS
COOLERHYDRAULIC TURBINES
H2 MAKE UPCOMPRESSOR
1st STAGE FEED PUMP
RECYCLECOMPRESSOR
COOLER
CRUDE 2nd STAGE FEED PUMP
2nd STAGE REACTOR
700-800OF
DIESEL
GAS
800OF2000 PSIG
1st STAGE REACTOR
H2 RECYCLE
H2 RECYCLE
H2 MAKE UPCOMPRESSOR
Hydrocracker
2000 PSIG 600OF NAPHTHA
HH22
CATALYSTFIXED BED
LOW PRESSURESEPARATOR
HIGH PRESSURESEPARATOR
H2 SEPARATED FROM LIQUID
Catalytic Reforming A process to produce high octane gasoline
without the addition of lead The final product is blended with the other gasoline produced
in the Cat Cracker and Hydro Cracker to meet the required octane
Hydrogen molecules are not broken up but simply rearranged Catalyst containing platinum Hydrogen atmosphere Small number of process pumps required
Mostly single stage overhung for medium temperature and pressure
Catalytic Reforming Unit
H2 RECYCLECOMPRESSOR
H2 MAKE UPCOMPRESSOR
NET HYDROGEN
TO H2 SYSTEM
REFLUXPUMP
COOLER
REACTOR900OF
REACTOR900OF
REACTOR900OF
COOLER
REBOILER
STEAM
HEATERHEATERHEATER
NAPHTHA
FEED PUMP
SEPARATOR
COOLER
PlatinumCatalyst
(Reheating to maintain temp.)
EXCHANGER
STABILIZER
H2 & oilheated together)
New H2 produced during reaction
To Separate H2
High Octane Gasoline
High Octane Gasoline
Hydrotreating
Process of removing undesirable elements(e.g.: sulphur, nitrogen) from products and feedstocks by reacting them with hydrogenand catalyst: H2 + S = H2S
Hydrotreaters are popular to meet the new environmental standards.
Major pump application is the feed pump. Pump type is usually a horizontally-split,
multi-split type. Pressure range is about 1200 psig.
Hydrotreater
REBOILER
STEAM
H2 RECYCLECOMPRESSOR
H2 MAKE UPCOMPRESSOR
H2 RECYCLE
PROPANE & LIGHTER
VENT GAS COMPRESSOR
HYDRAULIC TURBINE
REFLUX PUMP
WATER
DESULPHURIZED PRODUCT
HYDROGENSEPARATOR
STRIPPER
COOLER
REACTOR700-800OF
HEATER
EXCHANGER
FEEDPUMP
H2S, NH3stick to catalyst
WATER
Hydrogen Plant
SHIFTCONVERTER
STEAM
METHANATOR
WATER
WATER
H2
H2 COMPRESSOR
REFORMER FURNACE
GAS COOLER
STEAM
STEAM
FEED GAS
FLUE GAS
REGENERATOR
CO2
CO2 ADSORBER
CO2 REMOVAL PROCESS
WATER
FabricFabricFabricFabric
Spun YarnSpun YarnSpun YarnSpun YarnTextured/Twisted/Dyed YarnTextured/Twisted/Dyed YarnTextured/Twisted/Dyed YarnTextured/Twisted/Dyed Yarn
PVCPVCProductsProducts
PVCPVCProductsProducts
MoldingMoldingMoldingMolding
PolyesterPolyesterProductsProductsPolyesterPolyesterProductsProducts
PolyesterPolyesterGranulateGranulatePolyesterPolyesterGranulateGranulate
Vertically Integrated Hydrocarbon Processing Plant
PolyethylenePolyethylenePolyethylenePolyethylene PolypropylenePolypropylenePolypropylenePolypropylene
Fuel GasFuel GasFuel GasFuel Gas MethaneMethaneMethaneMethane TouleneTouleneTouleneToulene
PolymerPolymerFilament YarnFilament Yarn
PolymerPolymerFilament YarnFilament Yarn
PolymerPolymerFibreFibre
PolymerPolymerFibreFibre
Polyester ResinsPolyester ResinsPolyester ResinsPolyester Resins PTAPTAPTAPTA PXPXPXPX
PropylenePropylenePropylenePropylene XyleneXyleneXyleneXylene BenzeneBenzeneBenzeneBenzene
Linear AlkylLinear AlkylBenzeneBenzene
Linear AlkylLinear AlkylBenzeneBenzene
MEGMEGMEGMEG
EOEOEOEO OxygenOxygenOxygenOxygen
EthyleneEthyleneEthyleneEthylene
FEEDSTOCK CRACKERFEEDSTOCK CRACKERFEEDSTOCK CRACKERFEEDSTOCK CRACKER
N-ParaffinsN-ParaffinsN-ParaffinsN-Paraffins
OIL & GAS EXPLORATION & PRODUCTIONOIL & GAS EXPLORATION & PRODUCTIONOIL & GAS EXPLORATION & PRODUCTIONOIL & GAS EXPLORATION & PRODUCTION
LPGLPGLPGLPG NaphthaNaphthaNaphthaNaphtha GasolineGasolineGasolineGasoline KeroseneKeroseneKeroseneKerosene DieselDieselDieselDiesel SulphurSulphurSulphurSulphurNaturalNaturalGasGas
NaturalNaturalGasGas Fuel OilFuel OilFuel OilFuel Oil
OIL REFINERYOIL REFINERYOIL REFINERYOIL REFINERY
Finished Products
Fibres &Fibre
Intermediate
Polymers& Chemicals
Refining
Oil & Gas
PolyvinylPolyvinylChloridesChloridesPolyvinylPolyvinylChloridesChlorides
VCMVCMVCMVCM
EDCEDCEDCEDC
CC1212CC1212 CausticCausticCausticCaustic
Caustic UnitCaustic UnitCaustic UnitCaustic Unit
SaltSaltSaltSalt
VALUE
ADDED
MoldingMoldingMoldingMolding
Fibres and Petrochemicals ComplexProcess Block Diagram
Kerosene N-ParaffinN-ParaffinN-ParaffinN-Paraffin
Para XylenePara XylenePara XylenePara Xylene
DGDGDGDG
STGSTGSTGSTG
BOILERBOILERBOILERBOILER
Central UtilitiesCentral Utilities
LABLABLABLAB
PTAPTAPTAPTA
PSFPSFPSFPSF PFYPFYPFYPFY PolymerPolymerChipsChips
PolymerPolymerChipsChips
Benzene
Naphtha
Acetic Acid
MEG
MNP
LAB
PTA
PolymerChips
PFYPSF
Acetic AcidPTAPTAPTAPTA
HRSGHRSGHRSGHRSG
GT/STGGT/STGGT/STGGT/STG
Central UtilitiesCentral Utilities
MEGMEGMEGMEG PETPETPETPET
PPPPPPPP
VCMVCMVCMVCM
CrackerCrackerCrackerCracker
Caustic/Caustic/EDC PlantEDC PlantCaustic/Caustic/
EDC PlantEDC Plant
PX
NH3
EthyleneEDC
NaphthaNGL
PEPEPEPE
SaltCaustic Soda
Water
Gas
PET/POY
EOD
EOEG
PVC
HDPE/LLDPE
PP
C4 + HeavierPolymers
PVC
HDPEHDPEHDPEHDPE
VCMVCMVCMVCM
MEGMEGMEGMEG
PVCPVCPVCPVC
CC44 + Heavier + HeavierCC44 + Heavier + Heavier
PVCPVCPVCPVC
EODEODEODEOD
POYPOYPOYPOY
CC22
CC33
CC44
Petrochemicals and Polymers ComplexProcess Block Diagram
Power
Process Pump (ANSI)
Process Pump (ANSI)
Double Row Angular Contact Ball Bearings
30O Contact Angle High Load Capacity High Speed Rating Normal and CB Clearance Steel Cage Conrad (A Suffix) and Filling
Slot (E Suffix) Designs Seals (RS1 Suffix) and
Shields (Z Suffix) Snap Rings (NR Suffix)
SKF 3200, 3300, 5200, and 5300 Series
40O Contact Angle Optimized Ball Complement High Load Capacity High Speed Rating CB Clearance Standard Dimensionally Interchangeable
with 3300/5300 Series Machined Brass Cage
Double Row Angular Contact Ball Bearings
SKF DR 2000 Series
Heavy Duty Process Pump (API)
Heavy Duty Process Pump (API)
40O Contact Angle Universally Matchable High Load Capacity High Speed Rating CB Clearance Standard Cage Options
Machined Brass (M) Pressed Brass (Y) Pressed Steel (J) Polymer (P)
Single Row Angular Contact Ball Bearings
SKF 7200 and 7300 SeriesBack-to-Back
Face-to-Face
Matched Set of 40O and 15O Contact Angle Bearings
Machined Brass Cage High Load Capacity High Speed Rating Insensitive to Skidding Should Only be Used When the
Axial Load is Predominantly in One Direction
Chevron to be Oriented in the Direction of Load
Single Row Angular Contact Ball Bearings
MRC Pumpac 8000 Series
Thrust LoadDirection
40O
15O
Questions on an Oil Refinery
What is the size of the plant in terms of crude oil processing?
What kind of processes are employed: atmospheric distillation, vacuum distillation, cat reforming, cat cracking, hydro cracking, hydro treatment?
What products are made: gasoline, fuel oil, lube oil, petrochemical feed stock?
Are downstream petrochemical plants part of the refinery?
How many pumps, electric motors, blowers, compressors, fans, etc. are used?
Oil Refinery Bearing Sales Potential
1000 barrels/day yield a total bearing potential of USD 300-500 depending on maintenance practices
50% of the total bearing potential is for pump bearings
100 pumps yield a total bearing potential ofUSD 800-1200
MTBF is 1.5 to 7 years depending on maintenance practices
Potential for mechanical seals is 4 to 6 times that of bearings
Annual Total Maintenance Costs
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47
6.00
5.00
4.00
3.00
2.00
1.00
0.00
%
Plant Number
As a % of Plant Replacement Value
Data Supplied By Reliability Technologies©