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Oil Refining

Oil Refining. Presented by Gautam Datta. Introduction. Mr Gautam Datta , Principal Process Engineer

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Oil Refining

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  1. Oil Refining Presented by Gautam Datta

  2. Introduction • Mr Gautam Datta, Principal Process Engineer Gautam has 20 years experience in downstream Refining/Petrochemicals. Expertise includes process design & operations covering Hydroprocessing, RFCCU, CCR, Gas Concentration, LPG Merox, propylene recovery, ethylene recovery and refinery/chemicals interface along with R&D, process development of C7 isomerisation technology, licensing and team management. • The goal of today's workshop is to quickly and effectively bring you up to speed with the language, concepts and key issues in the refining industry. It has been designed for managers, engineers, graduates, operators and other personnel who are new or are requiring insight into the Refining and Petrochemicals industry. • The workshop will provide an excellent overview for people from technical, non-technical and commercial backgrounds, who have limited experience and wish to improve their familiarity with some of the systems and technologies involved.

  3. AGENDA Section 1: The Nature of Crude Petroleum Section 2: The automobile and how Petroleum Refining was driven. Section 3: Refinery Streams from CDU/VDU Section 4: End of the century XX Refineries Section 5: Product Specifications. Section 6: Crude Distillation Unit (Atmospheric + Vacuum) Section 7: Processing Light Ends Section 8: Gasoline Manufacturing Overview Section 9: Gasoline Isomerisation Section 10: Naphtha Reforming Section 11: Hydrotreating Section 12: Catalytic Cracking Section 13: Alkylation and Polymerisation Section 14: Hydrocracking of Gas Oil Section 15: Delayed Coking of the Vacuum Residuum Section 16: Visbreaking of the Vacuum Residuum Section 17: Solvent Deasphalting of Vacuum Residuum Section 18: The Use of Hydrogen in Refineries Section 19: References and Additional Resources Section 20: Refinery vision for the XXI century Section 21: Global refining capacity advances; refining business faces uncertain future with state of the art technology

  4. General • How many Refineries are there in the UK?? • Answer: There are 11 Refineries in the UK • What is the Refining Capacity in the UK?? • The UKrefining capacity of 1.9 million bbl/d. • Is the UK self sufficient in Refinery Products. • The UK is net exporter of Petrol, Diesel/Gasoil and Fuel Oil and net importer of Jet/Kerosene • Diesel vs Petrol ?? • Demand for Diesel is growing faster than that of Petrol.

  5. Overview The purpose of an oil refinery is to transform relatively low value crude into high value products as efficiently, profitably and environmentally sound a way as possible

  6. What is Crude Oil? • Crude oil is liquid mixture of thousands of organic chemicals found underground and can be separated into a variety of different boiling point fractions. 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, sulphur and metals

  7. Crude Oil Composition

  8. Origin of Crude oil • Biogenic: From organics, by bacterial transformation. Organic matter( carbohydrates / proteins / lipid/ lignin both from plant & animal origin -----> decay in the presence and / or absence of air into HC rich sediments which in presence of micro organism undergoes biological/ physical and chemical alterations to form Kerogen(geopolymer) which may be coaly or sapropelic. Sapropelic Kerogen under high pressure and temperature further gets converted into oil and gas.

  9. Major refinery Products • LPG(Propane / Butane) • Gasoline • Jet Fuels • Diesel Fuels • Heating Oil • Greases • Asphalt • COKE(not the kind you drink)

  10. 1. The Nature of Crude Petroleum • Crude Oil is a mixture of different Hydrocarbon:

  11. 1. The Nature of Crude Petroleum • Crude Oil contains impurities: Benzothiophene Dibenzothiophene

  12. 1. The Nature of Crude Petroleum Sour Crude Oil Sweet Crude Oil

  13. 1. The Nature of Crude Petroleum

  14. Crude Oil Classification • Paraffinic Base Waxy, high paraffins, less asphaltic, low sulfur, high pour points, light crudes • Mixed Base Paraffinic-naphthenic, relatively less waxy/less asphaltic / low pour point • Naphthenic Base High sulphur / high asphalt / nitrogen – relatively heavy crudes

  15. Crude Oil Classification-Empirical Correlations • API Gravity API = (141.5/SP. GR)-131.5 • Light Crude Oil > 31 • Mixed based > 22-31 • Heavy crude < 22 API is a major factor for crude pricing

  16. Effect of Contaminants in Crude Oil

  17. 1.The Nature of Crude Petroleum Qualities of crudes commonly processed in refineries around the world:

  18. 2. The automobile and how Petroleum Refining was driven History, Explaining the Demand for Gasoline World War I heavily influenced by motorized transport saw a drastic increase in oil refining rates. Gasoline introduced as a refined product for the thermal combustion engine. Initially Kerosene was the only refining product, used exclusively for lighting. Rapid improvement in gasoline quality and increased demand

  19. 2. The automobile and how Petroleum Refining was driven History, Explaining the Development of the Refining Industry Thermal cracking of gas oil to gasoline leading to increased production. Primitive Refinery operations. Catalytic Isomerisation Catalytic reforming Production of gasoline as a fuel. Alkylation Fluid catalytic cracking

  20. 3. Refinery Feed Streams: Streams from the Atmospheric and Vacuum Towers Atmospheric Distillation Tower Light Ends Straight Run Gasoline 37-102 C Naphtha 102-157 C Distillate 157-235 C Heavy Distillate 235-350 C Crude Oil

  21. 3. Refinery Feed Streams: Streams from the Atmospheric and Vacuum Towers Vacuum Distillation Tower Light Vacuum Distillate

  22. 3. Refinery Feed Streams: Streams from the Atmospheric and Vacuum Towers Vacuum Distillation Atmospheric Distillation

  23. 4. End of the XX century Refineries HIGHER OCTANE NUMBER HIGHER COMPRESSION RATIO

  24. 4. End of the XX century Refineries Saturates Gas plant Sulphur Light Ends Fuel Gas LPG Atmopheric column Gasoline Isomerisation Gasoline Naphtha Naphtha Hydrotreating To Aromatics Naphtha Reforming Light Distillate Light Distillate Hydrotreating Kerosene & Jet Fuels Heavy Distillate Diesel & Heating Oil Heavy Distillate Hydrotreating Olefins Atmospheric Gas Oil Catalytic Craking Alkylation Gas Oil Hydrotreating Gas Oil LVGO Hydro -cracking MVGO Long Residuum Vacuum Column Lube Fraction Lube Treating HVGO Lube Oils Heavy Fuel Oil Delayed Coking Resid Green Coke Coke Coke Calcining Resid Visbreaking Heavy Fuel Oil Resid Asphalt Solvent Deasphalting Asphalt Treating Asphalt Resid Asphalt/Roofer

  25. 4. End of the XX century Refineries, Fuel Saturates Gas plant Sulphur Light Ends Fuel Gas LPG Atmopheric column Gasoline Isomerisation Gasoline Naphtha Naphtha Hydrotreating To Aromatics Naphtha Reforming Light Distillate Light Distillate Hydrotreating Kerosene & Jet Fuels Heavy Distillate Diesel & Heating Oil Heavy Distillate Hydrotreating Olefins Atmospheric Gas Oil Catalytic Craking Alkylation Gas Oil Hydrotreating Gas Oil LVGO Hydro -cracking Long Residuum Vacuum Column MVGO Lube Fraction HVGO Lube Treating Lube Oils Resid Green Coke Delayed Coking Coke Calcining Coke Resid Visbreaking Heavy Fuel Oil Resid Asphalt Solvent deasphalting Asphalt Treating Asphalt Resid Asphalt/Roofer

  26. 4. End of the XX century Refineries, Lube/Asphalt Saturates Gas plant Sulphur Light Ends Fuel Gas LPG Atmopheric column Gasoline Isomerisation Gasoline Naphtha Naphtha Hydrotreating To Aromatics Naphtha Reforming Light Distillate Light Distillate Hydrotreating Kerosene & Jet Fuels Heavy Distillate Diesel & Heating Oil Heavy Distillate Hydrotreating Olefins Atmospheric Gas Oil Catalytic Craking Alkylation Gas Oil Hydrotreating Gas Oil LVGO Synthetic Lube Oils Hydro -cracking Long Residuum Vacuum Column MVGO Lube Treating Lube Fraction HVGO Lube Oils Resid Green Coke Delayed Coking Coke Calcining Coke Resid Visbreaking Heavy Fuel Oil Resid Asphalt Solvent Deasphalting Asphalt/Roofer Asphalt Treating Asphalt Resid

  27. 4. End of the century XX Refineries, Petrochemicals Saturates Gas plant Sulphur Light Ends Fuel Gas LPG Steam Cracker Atmopheric column Gasoline Isomerisation Integrated with Petrochemicals Naphtha Naphtha Hydrotreating Naphtha Reforming Integrated with Aromatics NOTE: Steam cracker and FCC shares separation of C2/C2= and C3/C3 Light Distillate Light Distillate Hydrotreating Kerosene & Jet Fuels Olefins Heavy Distillate Diesel & Heating Oil Heavy Distillate Hydrotreating High Severity Catalytic Craking Atmospheric Gas Oil Catalytic Craking Alkylation Gas Oil Hydrotreating Gas Oil LVGO Hydro -cracking Long Residuum Vacuum Column MVGO Lube Treating HVGO Lube Fraction Lube Oils Green Coke Delayed Coking Coke Calcining Coke Resid Resid Visbreaking Heavy Fuel Oil Resid Asphalt Solvent Asphalt Treating Asphalt Resid Asphalt

  28. 4. End of the XX century Refineries • Yield structures of refinery conversion schemes for Arabian light crude processing:

  29. 5. Product Specifications • Liquid products from refineries are blended to meet required specifications. • Product specifications developed by ASTM (American Society for Testing and Materials). ASTM Specification Numbers for Hydrocarbon Fuels:

  30. 5. Product Specifications • The refinery streams used for product blending must meet specifications in properties such as: Vapour pressure, density, sulfur, distillation, etc..

  31. 5. Product Specifications Limits on Sulfur in Fuels:

  32. 6. Crude Distillation Unit Typical Crude Distillation Unit:

  33. 6. Crude Distillation Unit (B) • Within this process there are 3 steps.1. Desalting and Pre heating2. Furnace3. Distillation 2 1 3

  34. 6. Crude Distillation Unit (B) • Within in this process there are 3 sections.1. Flash Zone2. Steam stripping section3. Bottom Recycle and Product Cooling • 4. Wash Section • 5. Steam Ejectors and Vacuum Pumps 5 4 3 1+2

  35. 7. Processing Light Ends • Light end processing, processes methane through to Butane to remove contaminants mainly sulphur and separating the components. • Normally at least 2 light end processing units in a refinery:1. Saturate Gas Plant2. Catalytic Cracking Gas Plant

  36. 7. Processing Light Ends • Saturates Gas plant:

  37. 7. Processing Light Ends • Catalytic Cracker Gas Plant

  38. 8. Gasoline Manufacturing • Gasoline accounts for 45% of the total demand for refined products. • The composition of Gasoline addresses 2 main issues:1. Performance2. Emissions

  39. 8. Gasoline Manufacturing • Engine Performance • Detonation, Pre-ignition • Volatility

  40. 8. Gasoline Manufacturing

  41. 9. Gasoline Isomerisation (B) • The purpose of isomerisation is to improve the octane rating of straight run gasoline. • This is accomplished by the isomerisation of n-paraffins to produce branched isoparaffins.

  42. 9. Gasoline Isomerisation Gasoline isomerisation Process:

  43. 9. Gasoline Isomerisation Gasoline Isomerisation Unit:

  44. 10. Naphtha Reforming (B) • Naphtha Reforming enhances the aromatic content in Naphtha used a feed stock to aromatic complex. • Improves the octane rating of feed stocks to gasoline. • The Shape of the Hydrocarbon molecules plays an important role in determining its properties.

  45. 10. Naphtha Reforming

  46. 10. Naphtha Reforming • CCR Catalytic Reforming

  47. 11. Hydrotreating Hydrotreating Process:

  48. 11. Hydrotreating Hydrotreating Process: Licensor: UOP LLC

  49. 12. Catalytic Cracking • Catalytic Cracking Process

  50. 12. Catalytic Cracking Fluid Catalytic Cracking (Riser Reactor):

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