Principle refinery operations

Refineries

• Refineries are operated continuously and with high degree of automation

• High processing capacitiescompared to other chemical industries

• A medium-sized refinery e.g. has a crude capacity of 10.000 t per day

• The crude distillation determines the refinery capacity

H/C ratio versus carbon number

• Refinery operations balance H/C ratio and carbon number• Hydrogen needed in general

Process scheme of a simple refinery

Process scheme of a complex refinery

Process units in a refinery

Some definitions

• bbl = barrel (volume measurement)– 1 bbl = 159 ltr– 1 to = ca 7.5 bbl– 100.000 bbl/day = 5 mln to/a

• API Grade = density measurement– Low API = high density = high residue content

• 1 $/bbl = ca 6,- Euro/to

• > 45 API NGL• 25-45 API conventional crude oil• 10-25 API heavy crude oil• < 10 API extreme heavy crude oil, oil sand, et

Crude oil grades

Gasoline pool characteristics - European refineries

8

Gasoline specifications in Europe

1999 2000 2005

Sulfur, max ppm wt. 500 150 50 (10)*

Aromatics, max vol.% no spec. 42 35

Benzene, max vol.% 5 1 1

Octane RON min 95/98 95/98 95/98

Olefins, max vol.% no spec. 18 18

RVP max kPa 80 60 60

*“Sulfur free“

30.220

11.8 9.2

62.3

46 42.437.8

43.1

49.6

47.2 49.5

17.9

28

2426.9

16.118.9

28.5 28.7

9.414.1

21 22.2

5.5 5.5 5.5 5.55.5 5.5 5.5 5.5

1.51.5

1.5 1.5

1.51.5 1.5 1.5

0

10

20

30

40

50

60

70

80

90

100

Hydroskimming Thermal Cat Cracker Complex Hydroskimming Thermal Cat Cracker Complex

Residual Fuel Gasoil&Kerosene Gasoline Naphtha LPG

Nigerian Light 38 API

Arabian Heavy 27 API

Yield structure by refinery type

Identify suitable residue conversion options

Driving forces steer best fit-for-purpose option

Cracked Residue

Carbon rejection Hydrogen addition

Atm. Residue

Vac. Residue

Oxidation

… and many combinations

Conventional FCC based refinery

Chemistry integrated FCC based refinery