refining technology presentation

8/8/2019 Refining Technology Presentation

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Introduction toPetroleum Refinery

Processing

Dr.G.Balachandran

1



Course outliney 1.Introduction to the Refinery Flow sheet

y

2.Hydrocarbon chemistry y 3.Crude oil:Properties,tests,sources,Assays

y 4.Fuel ProductsMTBE

y 5.Atmospheric and vaccum distillation

y

6.FCC(Fluid catalytic cracking)y 7.Catalytic Reforming and aromatics recovery

y 8.Isomerisation,Alkylation and Polymerisation

y 9.Hydroprocessing of sulfur,nitrogen and aromatics

reductiony 10.Sweetening and sulphur recovery.

y 11.Residual processing.Coking,Hydrocracking etc,.

y 12.Refinery operations for tomorrows fuel.

y 13.Future Refinery configurations. 2



1.Introduction to the Refinery Flow sheet

3



5



Y ear Process Purpose By products

1940 Alkylation Increase gasoline octane &

yield

High-octane aviation gasoline

1940 Isomerization Produce alkylation

feedstock

Naphtha

1942 Fluid catalytic cracking Increase gasoline yield &

octane

Petrochemical feedstocks

1950 Deasphalting Increase cracking feedstock Asphalt

1952 Catalytic reforming Convert low-quality

naphtha

Aromatics

1954 Hydrodesulfurization Remove sulfur Sulfur

1956 Inhibitor sweetening Remove mercaptan Disulfides

1957 Catalytic isomerization Convert to molecules with

high octane number

Alkylation feedstocks

1960 Hydrocracking Improve quality and reduce

sulfur

Alkylation feedstocks

1974 Catalytic dewa ing Improve pour point a

1975 Residual hydrocracking Increase gasoline yield

from residual

Heavy residuals

6



y Crude oil is a mixture of hydrocarbon molecules, which are organic compounds of carbon and hydrogenatoms that may include from one to 60 carbon atoms.

y The properties of hydrocarbons depend on thenumber and arrangement of the carbon and hydrogenatoms in the molecules.

y The simplest hydrocarbon molecule is one carbonatom linked with four hydrogen atoms: methane. Allother variations of petroleum hydrocarbons evolvefrom this molecule.

y Hydrocarbons containing up to four carbon atoms areusually gases, those with 5 to 19 carbon atoms areusually liquids and those with 20 or more are solids.

2.Hydrocarbon chemistry

7



Hydrocarbon chemistry-Cont.y The refining process uses chemicals, catalysts, heat,

and pressure to separate and combine the basic typesof hydrocarbon molecules naturally found in crude oil

into groups of similar molecules.y The refining process also rearranges their structures

and bonding patterns into different hydrocarbonmolecules and compounds.

y

Therefore it is the type of hydrocarbon (paraffinic,naphthenic, or aromatic) rather than its specificchemical compounds that is significant in the refiningprocess.

8



Hydrocarbon chemistry-Conty Principal Groups of Hydrocarbon-

y Paraffins - The paraffinic series of hydrocarbon

compounds found in crude oil have the generalformulaCnH2n+2 and can be either straight chains(normal) or branched chains (isomers) of carbonatoms. The lighter, straight chain paraffin molecules

are found in gases and paraffin waxesy Aromatics - Aromatics. are unsaturated ring-type

(cyclic) compounds which react readily because they have carbon atoms that are deficient in hydrogen.

9



Hydrocarbon chemistry-Conty Example of simple aromatic compound: Benzene (C6H6),Examples of simple double-ring aromatic compound:Naphthalene (C

10

H8

)

y Naphthenes - Naphthenes are saturated hydrocarbongroupings with the general formula CnH2n, arranged inthe form of closed rings (cyclic) and found in allfractions of crude oil except the very lightest.

y Example of typical single-ring naphthene: C yclohexane(C6H12), Examples of naphthene with same chemicalformula (C6H12) but different molecular structure: Methylcyclopentane (C6H12).

10



3.Cru e oi properties-tests,assaysCrude

source

(% vol)

Paraffin

s (%

vol)

Aromati

cs (%

vol)

Naphth

enes (%

wt)

Sulfur

(approx.)

API

gravity

(% vol)

Naphtha

Yield

(typical)

Octane No

Nigerian-

Light

37 9 54 0.2 36 28 60

Saudi-

Light

63 19 18 2 34 22 40

Saudi-

Heavy

60 15 25 2.1 28 23 35

Venezuel

a-Heavy

35 12 53 2.3 30 2 60

Venezuel

a-Light

52 14 34 1.5 24 18 50

USA-

Midcont.

Sweet

- - - 0.4 40 - -

USA -W.

Texas

Sour

46 22 32 1.9 32 33 55

North

Sea-

50 16 34 0.4 37 31 50

11



CRUDE OIL DESALTING FLOW

DIAGRAM

12



CRUDE OIL DESALTINGy Crude oil often contains water, inorganic salts, suspended

solids, and water-soluble trace metals.

y The two most typical methods of crude-oil desalting,chemical and electrostatic separation, use hot water as the

extraction agent.y In chemical desalting, water and chemical surfactant

(demulsifiers) are added to the crude, heated so that saltsand other impurities dissolve into the water or attach to the

water, and then held in a tank where they settle out.y Electrical desalting is the application of high-voltage

electrostatic charges to concentrate suspended waterglobules in the bottom of the settling tank.

13



Electrostatic Desalting Flow diagram

14



Desalting Process

Feedstock From Process Typical products-to-Unit

Crude oil Storage treating Desalted crude to Atmosphericdistillation tower Waste water toTreatment

15



4.Fuel products-MTBEy Methyl tert-butyl ether, also known as methyl

tertiary butyl ether and MTBE, is a chemical

compound with molecular formulaC

5H12O.y MTBE is a volatile, f lammable and colorless liquid that

is immiscible with water.

y MTBE has a minty odor vaguely reminiscent of diethyl

ether, leading to unpleasant taste and odor in water.y MTBE is a gasoline additive, used as an oxygenate and

to raise the octane number.

16



MTBE-Structure-3D

17



MTBE-Chemical structural formula

18



3D arrangements of atoms in the MTBE

molecule

19



5.Atmospheric and Vaccumm distillation

20



Atmospheric distillation-Process description

y The desalted crude feedstock is preheated using

recovered process heat.y The feedstock then flows to a direct-fired crude charge

heater where it is fed into the vertical distillationcolumn just above the bottom, at pressures slightly

above atmospheric and at temperatures ranging from650° to 700° F (above these temperatures undesirablethermal cracking may occur).

y All but the heaviest fractions flash into vapor. As the

hot vapor rises in the tower, its temperature is reduced.

21



Atmospheric distillationy Heavy fuel oil or asphalt residue is taken from the

bottom. At successively higher points on the tower, the

various major products including lubricating oil,heating oil, kerosene, gasoline, and uncondensedgases (which condense at lower temperatures) aredrawn off.

22



Atmosspheric distillation-cont.

Feedstock From Process Typical products -

to - unit

Cr e esalti e arati y Gases

t s eric

istillati t er

y

a tas.ef r i r

treati

y Ker se e r

istillates

reati

y Gas il

Catal tic crac i

y esi al

ac t er r

is rea er 23



Vacumm distillation-process flow diagram

24



Vacuum distillation process

y The process takes place in one or more vacuum distillationtowers.

y The principles of vacuum distillation resemble those of fractional distillation except that larger diameter columns areused to maintain comparable vapor velocities at the reducedpressures.

y A typical first-phase vacuum tower may produce gas oils,lubricating-oil base stocks, and heavy residual for propanedeasphalting.

y . second-phase tower operating at lower vacuum may distillsurplus residuum from the atmospheric tower, which is notused for lube-stock processing, and surplus residuum fromthe first vacuum tower not used for deasphalting.

25



Vacuum Distillation Process

Feedstock From Process Typical

products -

to - unit

Residuals Atmospheric

tower g

Separation y as oils To

Catalytic cracker

y Lubricants To

Hydrotreating or

solvent

y Residual To

Deasphalter,

visbreaker, or

coker 26



FLUID CATALYTIC CRACKING

FLOW DIAGRAM

27



TURBO EXPANDER FOR FCC UNIT

28



CATALYTIC HYDRO CRACKING

FLOW DIAGRAM

29



DELAYED COKING FLOW DIAGRAM

30



FLUID COKING/FLEXI COKING

FLOW DIAGRAM

31



VIS-BREAKING PROCESS

32



CATALYTIC REFORMING FLOW

DIAGRAM

33



DELAYED COKING HARDWARE UNIT

34



SULPHURIC ACID BASED

ALKYLATION

35



HYDRO-FLUORIC ACID BASED

ALKYLATION

36



CATALYTIC HYDROTREATMENT

FLOW DIAGRAM

37



LUBRICATING OIL MANUFACTURE

FLOW DIAGRAM

38



SULFUR MANAGEMENT IN

REFINERY

39



CLAUS PROCESS FLOW

DIAGRAM

40



MEROX PROCESS FLOW

DIAGRAM

41

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