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Overview of Petroleum RefiningOverview of Petroleum Refining
Dept. of Petroleum Engineering & Dept. of Petroleum Engineering & Petrochemical EngineeringPetrochemical Engineering
Presented byProf. K. V. RaoProgramme DirectorPetroleum Courses
JNTUK
III Year, I Sem., B. Tech. Petrochemical Engineering Petroleum Refinery Engineering
University College of Engineering (A) Kakinada
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Agenda
Introduction What is the Purpose of an Oil Refinery? What Goes In/Out of the Refinery How Do You Get from Crude Oil to
Products? – Separations– Chemical Reactions cont...
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Agenda - Cont.
How Do You Get from Crude Oil to Products? – Separations– Chemical Reactions– Major Equipment – Minimizing Pollution
What do The Petrochemical/Chemical Engineers Do?
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Overview
THE PURPOSE OF AN OIL REFINERY IS TO TRANSFORM RELATIVELY LOW VALUE CRUDE OIL INTO HIGH VALUE PRODUCTS AS EFFICIENTLY, PROFITABLY AND ENVIRONMENTALLY FRIENDLY WAY AS POSSIBLE
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Overview - Cont.
The price and quality of crudes is constantly changing. The price and specifications of the products is constantly changing. Government regulations add additional constraints. There is not much differential between the price of crude and products.
HOW DO I KEEP IN BUSINESS?
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How Do I Keep In Business ?
I need to design and revamp the plant utilizing the latest technology to be more efficient
I need to make the plant more flexible and responsive
I need to operate (control) the plant in the most efficient manner possible
I need to keep the equipment running all the timeI NEED PETROCHEMICAL/CHEMICAL
ENGINEERS!
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OK, But...
WHAT GOES ON IN AN OIL REFINERY?
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Very SimplifiedPetroleum andPetrochemical
Flowchart
OilW ell
CrudeOil
Separations
Conv
ersi
ons
Sepa
ratio
nsan
dPu
rific
atio
ns
NaturalGas
Propane &Butane
Naphtha(C 5 - C10)
G as S tove
Fuel
G asoline
Jet Fuel
Fuel
R X Ethylene Polyethylene (G lad Bags)R X
R X Polym ers (7 UP Bottles) (Barbeque G rills)
R X
R X O rganic C hem icalsM ore Polym ers
(Aspirin, H air Spray)(Football H elm et, AstroTurf, N ylon)
Hom e HeatingO il, LubricatingO il, W ax
D iesel Fuels
Kerosene &
Gas O ils (C10+)
Coke(C arbon M aterial S im ilar to C oal)
Steel M aking
AsphaltR oads Pot Holes
Purifications rem ove sulfur and heavy m etals
R X = C hem ical Reactions
G raphite F ibers(Tennis R acquets)
THE REFINERYMethaneEthane
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What Is Crude Oil?
Crude Oil is a liquid mixture of thousands of organic chemicals found underground. It is the result of organic matter decaying over thousands of years; hence the name fossil fuel
Crude oil is found all over the world and varies tremendously in its density, aromatics, sulfur, and metals content
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Major Refinery Products LPG (Propane/Butane) GASOLINE (hundreds of blends) KEROSENE JET FUELS DIESEL FUELS HEATING OILS GREASES ASPHALTS COKE (not the kind you drink )
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Gasoline SpecificationsGasoline must meet many criteria which change with
the time of year and geographic location. Some critical specifications are:
Vapor Pressure Octane Aromatics / Benzene Content Sulfur ContentGasolines are always a blend of a number of streams
in the refinery
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Other Specifications
Other refinery products must meet other specifications such as:
Cetane number Density Pour Point Flash Point Viscosity
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So, How Do You Make Good Stuff Out Of That Gooey Crude?
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So, How Do You Make Good Stuff Out Of That Gooey Crude?
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So, How Do You Make Good Stuff Out Of That Gooey Crude?
REACTIONS&
SEPARATIONS
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So, How Do You Make Good Stuff Out Of That Gooey Crude?
Separate crude into fractions Convert low octane components to higher octane
components Convert the very heavy stuff to heavy oils Convert heavy oils to gasoline,diesel,jet fuel Remove sulfur/nitrogen through reaction Blend intermediate streams together to meet
product specifications
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SEPARATIONS
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SEPARATIONS -CRUDE FRACTIONATION
HUGE DISTILLATION COLUMNS– ATMOSPHERIC DISTILLATION– VACUUM DISTILLATION
TYPICAL SIZE: 150,000 BARRELS/DAY 750 DEGREES F
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OTHER SEPARATIONS
FLASH DISTILLATION ABSORPTION ADSORPTION SETTLING (WATER/OIL)
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REACTIONS
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REACTIONS
Almost all the reactions in the refinery use special catalysts that increase the rate and selectivity of the reaction. This improves efficiency and reduces unwanted byproducts.
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Reactions to Make Higher OctaneISOMERIZATION
C-C-C-C-C-C --> C C nC6 C-C-C-C iC6
REFORMINGC-C-C-C-C-C-C --> C nC7 C C-CH3 C C toluene C
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Reactions To Make Higher Octane
ALKYLATION
C CC=C-C + C-C-C --> C-C-C-C-C Cpropylene isobutane isoheptane (2,2,dmp)
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Reactions To Convert Heavy Oils
HYDROCRACKING H2 + heavy oil --> gasoline + diesel
550 F 300 F 450 F use boiling point to describe oils
CAT CRACKING heavy oil --> gasoline + propylene, butane,
other “light ends” 550 F 300 F
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Reactions To Convert Resid
Resid is the “bottom of the barrel” - the material that is left in the bottom of the crude/vacuum distillation towers
COKING resid + heat --> coke + heavy oil> 900 F solid 550 F
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Reactions To Remove SulfurHYDRODESULFURIZATION
2 R-SH + H2 --> 2 R + 2 H2S mercaptan hydrocarbon
SULFUR RECOVERYconvert H2S to elemental sulfur:
2 H2S + 2 O2 --> SO2 + S + 2 H2O2 H2S + SO2 --> 3S + 2 H2O
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MAJOR REFINERY EQUIPMENT
Vessels-Reactors, Separators, Storage Tanks Pumps & Compressors Furnaces Heat Exchangers Instruments (measure flow, temperature,
pressure, composition) Control Systems
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MINIMIZING POLLUTION
Operate Furnaces Efficiently Waste Material Goes To The Flare Stack Avoid Spills & Accidental Releases Special Treatment of Sewer Water Lots of Paper Work!
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WHAT HAPPENS TO THE BAD STUFF IN THE CRUDE?
Sulfur– converted to elemental sulfur– in high sulfur fuel oil– in coke
Heavy Metals (nickel, vanadium)– in high sulfur fuel oil and coke
Nitrogen (organic nitrogen)– most is converted to ammonia and neutralized– in high sulfur fuel oil and coke
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WHAT ROLE DO ENGINEERS PLAY IN THE
REFINERY?
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What Role Do Petrochemical Engineers Play? Operations Engineer Maintenance Engineer Control Systems Engineer Design Engineer Health/Safety/Environmental Engineer Planning / Scheduling Engineer Reliability Engineer Plant Manager
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Other Ways Petrochemical Engineers Support The Refining
Industry Research & Development Engineers Technical Sales Engineers Engineering & Construction Engineers Governmental Regulators University Professors
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Other Engineering Disciplines In The Refinery
Mechanical Engineers - design & maintenance of compressors, vessels …
Electrical Engineers - electrical, instrumentation, controls
Computer Scientists - main plant control & information systems
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Summary
Refineries are very complicated chemical processing plants that use reactions and separations to convert crude oil into gasoline and other valuable products
Petrochemical/Chemical engineers play an important role in keeping these plants running safely and efficiently
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