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

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...

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?

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

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?

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!

OK, But...

WHAT GOES ON IN AN OIL REFINERY?

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

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

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 )

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

Other Specifications

Other refinery products must meet other specifications such as:

Cetane number Density Pour Point Flash Point Viscosity

So, How Do You Make Good Stuff Out Of That Gooey Crude?

So, How Do You Make Good Stuff Out Of That Gooey Crude?

So, How Do You Make Good Stuff Out Of That Gooey Crude?

REACTIONS&

SEPARATIONS

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

SEPARATIONS

SEPARATIONS -CRUDE FRACTIONATION

HUGE DISTILLATION COLUMNS– ATMOSPHERIC DISTILLATION– VACUUM DISTILLATION

TYPICAL SIZE: 150,000 BARRELS/DAY 750 DEGREES F

OTHER SEPARATIONS

FLASH DISTILLATION ABSORPTION ADSORPTION SETTLING (WATER/OIL)

REACTIONS

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.

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

Reactions To Make Higher Octane

ALKYLATION

C CC=C-C + C-C-C --> C-C-C-C-C Cpropylene isobutane isoheptane (2,2,dmp)

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

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

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

MAJOR REFINERY EQUIPMENT

Vessels-Reactors, Separators, Storage Tanks Pumps & Compressors Furnaces Heat Exchangers Instruments (measure flow, temperature,

pressure, composition) Control Systems

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!

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

WHAT ROLE DO ENGINEERS PLAY IN THE

REFINERY?

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

Other Ways Petrochemical Engineers Support The Refining

Industry Research & Development Engineers Technical Sales Engineers Engineering & Construction Engineers Governmental Regulators University Professors

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

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