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


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


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



Companies with 200,000+B/CD Capacity Located in Latin America





Companies with 200,000+B/CD Capacity Located in Asia Pacific





Reformate

Crude Distillation

GAS & LIQUIFIED PETROLEUM GAS (LPG)

Crude Oil

VAPOR VAPOR RECOVERYRECOVERY

STRAIGHT RUN GASOLINE

HYDROHYDROTREATINGTREATING


NAPTHAHigh Octane Gasoline

MIDDLE DISTILLATE

FCCHEAVY GAS OIL

VACUUM GAS OIL

Gasoline between FCC/Hydrocracking

CATCATCRACKINGCRACKING


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


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


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 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)

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)

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©

introduction to oil refining

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