(*) MEANS DI KASALI SA SLIDE AH, EXPLANATION UN.

SO KUNG SINO
MAGREREPORT NUN BASAHIN TAPOS IEXPLAIN NA LANG SA HARAP WITHOUT
COPY NA AH :D :D

Petrochemicals are chemicals made from petroleum or natural gas. Primary

petrochemicals are divided into three groups, depending on their chemical
structure:

1. Olefins include ethylene, propylene, and butadiene. Ethylene and

propylene are important sources of industrial chemicals and plastics
products. Butadiene is used in making synthetic rubber. Olefins are
produced by cracking.
2. Aromatic petrochemicals include benzene, toluene, and xylenes. Benzene
is used in the manufacture of dyes and synthetic detergents. Toluene is
used in making explosives. Manufacturers use xylenes in making plastics
and synthetic fibers. Aromatics are produced by reforming.
3. Synthesis gas (SynGas) is a mixture of carbon monoxide and hydrogen,
and is used to make the petrochemicals ammonia and methanol. Ammonia
is used in making fertilizers and explosives, where methanol serves as a
source for other chemicals.
- is formed by steam reforming between methane and steam to create a
mixture of carbon monoxide and hydrogen. It is used to make ammonia,
e.g., for fertilizer urea, and methanol as a solvent and chemical
intermediary. Syngas is also feedstock for other processes such as the
FischerTropsch process that produces synthetic diesel.

The primary petrochemicals are not end products, but form building blocks for a
wide range of materials. Therefore, each primary petrochemical gives name to a
chain of reactions leading to those materials.

Natural gas and crude oils are the main sources for hydrocarbon
intermediates or secondary raw materials for the production of petrochemicals.

Natural gas is defined as gas obtained from a natural underground reservoir and
is generally considered non-renewable fossil fuel.

*Natural gas is considered a fossil fuel because natural gas was formed from the
remains of tiny sea animals and plants that died 300 to 400 million years ago. When
these tiny sea animals and plants died, they sank to the bottom of the oceans where
they were buried by layers of sediment that turned into rock. Over the years, the layers
of sedimentary rock became thousands of feet thick, subjecting the energy-rich plant
and animal remains to enormous pressure. Most scientists believe that the pressure,
combined with the heat of the Earth, changed this organic mixture into petroleum and
natural gas. Eventually, concentrations of natural gas became trapped in the rock layers
like sponge traps water.

TYPES OF RAW NATURAL GAS

Raw natural gas comes primarily from any one of three types of wells: crude oil
wells, gas wells, and condensate wells.

1. Natural gas that comes from crude oil wells is typically termed associated
gas. This gas can exist separate from the crude oil in the underground
formation, or dissolved in the crude oil.
2. Natural gas from gas wells and from condensate wells, in which there is
little or no crude oil, is termed non-associated gas. Gas wells typically
produce only raw natural gas

Natural gas mixtures fall into two general categories: ( FOR GAS WELL)

1. dry or lean natural gas has high concentrations of methane

and ethane (typically 95 percent or more),
2. wet, or rich, gases have higher concentrations of propane,
butane and the intermediate-weight hydrocarbons pentane (C5)
through heptane (C7). As the proportions of heavier molecules
in a hydrocarbon mixture increase, it is more likely to exist as
a liquid at atmospheric conditions.

3. Condensate wells produce raw natural gas along with a low-boiling

point mixture of liquid hydrocarbons called natural gas
condensate (sometimes also called natural gasoline, casinghead
gasoline or simply condensate').
* Naturally occurring hydrocarbons come from the decomposed remains of ancient
plants and animals. Through a sequence of geologic events that occurred over millions
of years, organic material was deposited on the Earth's surface and then transported to
depressions or basins, where it accumulated and gradually became buried at great
depths under layers and layers of sediments. There, in what geologists refer to
as source rocks, it was subjected to much higher pressures and temperatures. Over
time, and through a series of intermediate chemical reactions, some of this material
eventually turned into petroleum.
In general, the deeper a rock formation is located in the Earth's crust, the higher its
temperature will be. Thus, the type of petroleum that formed through these processes
depended largely on the depth of the source rocks.

In relatively shallow source rocks, where temperatures ranged from about 60 to

80C [140 -176F], the organic matter was converted into heavy oil.

At lower depths and higher temperatures, from about 80C to 175C [176F to
347F], the heavier, long-chain organic molecules began to break up into shorter
molecules and form medium and light oil.

Where temperatures exceeded 175C [347F], the molecules became even

shorter and lighter, with more and more matter transformed to rich gas until, by
the time it had reached 600F [315C], all of it had been transformed to dry
gas (methane).

Composition of raw natural gas:

Raw natural gas typically consists primarily of methane, the shortest and
lightest hydrocarbon molecule. It also contains varying amounts of:

1. Heavier gaseous hydrocarbons: ethane (C2H6), propane (C3H8), normal

butane](n-C4H10), isobutane (i-C4H10), pentanes and even higher molecular
weight hydrocarbons. When processed and purified into finished by-
products, all of these are collectively referred to as Natural Gas Liquids
(NGL)).
2. Acid gases: carbon dioxide (CO2), hydrogen sulfide (H2S) and mercaptans
such as methanethiol (CH3SH) and ethanethiol (C2H5SH).
3. Other gases: nitrogen (N2) and helium (He).
4. Water: water vapor and liquid water.
5. Liquid hydrocarbons: perhaps some natural gas condensate (also referred
to as casinghead gasoline or natural gasoline) and/or crude oil.
6. Mercury: very small amounts of mercury primarily in elemental form, but
chlorides and other species are possibly present.

Natural gas processing

Gas processing consists of separating the various hydrocarbons and fluids
from the pure natural gas to produce what is known as pipeline quality dry
natural gas. Major transportation pipelines usually impose restrictions on the
makeup of natural gas that is allowed into the pipeline. Before the natural gas can
be transported it must be purified.
*Whatever the source of the natural gas, once separated from crude oil (if present) it
commonly exists in mixtures with other hydrocarbons, principally ethane, propane,
butane and pentanes.
The separation of the hydrocarbons, known as NGL (C2 plus) is carried out
next producing methane as the sole product commercially marketed as natural
gas.
Associated hydrocarbons, known as natural gas liquids (NGL), are used
as raw materials for oil refineries or petrochemical plants and as sources of
energy.
* While the ethane, propane, butane, and pentanes must be removed from natural gas,
this does not mean that they are all waste products. In fact, associated hydrocarbons,
known as natural gas liquids (NGL), can be very valuable byproducts of natural gas
processing. NGLs include ethane, propane, butane, iso-butane, and natural gasoline.
These are sold separately and have a variety of different uses such as raw materials for
oil refineries or petrochemical plants, as sources of energy, and for enhancing oil
recovery in oil wells. Condensates are also useful as diluents for heavy crude.
1. Exploration and Drilling
Natural gas can be difficult to find since it is usually trapped in
porous rocks deep underground. Geologists use many methods to find
natural gas deposits.
They may look at surface rocks to find clues about underground
formations. They may set off small explosions or drop heavy weights on
the Earths surface and record the sound waves as they bounce back from
the sedimentary rock layers underground. They also may measure the
gravitational pull of rock masses deep within the Earth. If test results are
promising, the scientists may recommend drilling to find the natural gas
deposits. Natural gas wells average more than 8,600 feet deep and can cost
hundreds of dollars per foot to drill, so its important to choose sites
carefully.
Once the well has been drilled, it must be completed. Completing a
well consists of a number of steps, such as installing the well casing,
completion, installing the wellhead, and installing lifting equipment or
treating the formation, if required.
(Brief lang dito nadiscuss naman na ni maam to)

2. Separation
* As described earlier, the well-stream may consist of crude oil, gas,
condensates, water and various contaminants. The purpose of the separators is
to split the flow into desirable fractions.
 There are four basic functions a well designed separator must accomplish.
First, it must cause a primary-phase separation between liquid
hydrocarbons from gaseous hydrocarbons by creating a momentum
reduction. The second step is a second separation of liquid mist from the
gases. Then, further refinement occurs by removing gas suspended in the
previously separated liquid. The final step is the discharge of the separated
gas and liquid from the vessel without mixing the newly separated
products.
THREE BASIC TYPES OF SEPARATOR

Factors which influence the design of a separator:

1. Flow rate- Flow rates must be accounted for both liquids and gases
entering and exiting the separator.
*These flow rates are usually measured in barrels per day for liquids and million
standard cubic feet (MMscf ) per day for gases
2. Specific gravities of the compounds in the well stream- The difference in
the specific gravities will allow for some separation by merely allowing
gravity to act on the oil, water, and gases.
3. Required retention time of the product within the separator for separation
4. operating temperature and pressure of the separator
5. Number of phases the separator will handle- It should be noted that the
term phase is not used in the standard thermodynamics sense. Rather, it is
a term used in the petroleum industry to refer to the type of product being
used. Therefore, the deciding factor for the number of phases in a
separator depends on the content of the well stream. Also related to the
content of the well stream is the amount of solid impurities the separator
must be able to handle.
if the separator is designed to be a two-phase design, it handle only
oil and gas.
a three-phase design will be capable of separating oil, gas, and
water.

* Thus, this brings us to the three most basic types of separators: vertical, horizontal,
and horizontal double-barrel.

1. Vertical Separators- are often used for low to intermediate ratios of

gas to oil in a well stream, and they are often employed for well
streams which produce large slugs of liquid
- the primary advantage of the vertical separator is
the relatively small amount of oor space it requires.
This can become a very important design factor for
 o
shore processing rigs.

*see https://www3.nd.edu/~msen/Teaching/DirStudies/Petroleum.pdf for further

explanation ng types of separators (basahin niyo na lang hahahahaha) Pakikuha
na lang ung pic sa pdf na yan tapos wag na lagyan ng explanation ung reporter
na lang bahala magexplain :D :D

2. Horizontal separator - the horizontal separator provides a much

greater gas-liquid interface area allowing the horizontal separator to
handle well streams with much higher ow rates. It also has a few
economic advantages in that it is less expensive to construct, easier
to clean and service, and it is easier to hook up
3. Double-barrel horizontal separators possess all of the advantages of
a normal horizontal separator, it uses the same components for the
scrubbing process, however, it is capable of handling a much higher
liquid capacity than the normal horizontal separator. Instead of
retaining liquid in the base of the vessel, it is drained directly into
the second barrel. Thus, the gas velocities may be much higher
since over ow of the liquids is not as great of a concern.

Stage separation is the separation of vapor and liquid phases of gaseous and
liquid hydrocarbons by two or more equilibrium ashes at consecutively lower
pressures.

*A two-stage separation requires one separator and one storage tank. Similarly, a three-
stage separation is composed of two separators and one storage tank, and a four-stage
separator follows this same pattern. In each case, the tank is considered the final stage
for vapor-liquid separation since the final equilibrium ash occurs in the storage tank.

The purpose of using a stage separation such as this is that at high

pressures, petroleum liquids usually contain high quantities of liquefied
propanes, butanes, and pentanes. Thus by using a stage separation to lower the
pressure on the liquids, a more complete separation of the products is produced
for the storage tank, due to the vaporization of the liquefied propanes, butanes,
and pentanes.
First stage separator- about 3-5 MPa (30-50 times atmospheric pressure). Inlet
temperature is often in the range of 100- 150 C.

The retention period is typically 5 minutes, allowing gas to bubble out,

water to settle at the bottom and oil to be taken out in the middle. In this platform
the water cut (percentage water in the well flow) is almost 40%, which is quite
high. In the first stage separator, the water content is typically reduced to less
than 5%.

*At the crude entrance, there is a baffle slug catcher that will reduce the effect of
slugs (large gas bubbles or liquid plugs). However, some turbulence is desirable as this
will release gas bubbles faster than a laminar flow. At the end, there are barriers up to a
certain level to keep back the separated oil and water. At the end, there are barriers up
to a certain level to keep back the separated oil and water. The main control loops are
the oil level control loop (EV0101 20 above) controlling the oil flow out of the separator
on the right, and the gas pressure loop at the top (FV0105 20, above). The loops are
operated by the control system. Another important function is to prevent gas blow-by,
which happens when a low oil level causes gas to exit via the oil output, causing high
pressure downstream. There are generally many more instruments and control devices
mounted on the separator. These will be discussed later. The liquid outlets from the
separator will be equipped with vortex breakers to reduce disturbance on the liquid table
inside. This is basically a flange trap to break any vortex formation and ensure that only
separated liquid is tapped off and not mixed with oil or water drawn in through these
vortices. Similarly, the gas outlets are equipped with demisters, essential filters that
remove liquid droplets in the gas.

Second stage separator- In addition to output from the first stage, it also receives
production from wells connected to the low pressure manifold. The pressure is
now around 1 MPa (10 atmospheres) and temperature below 100C. The water
content will be reduced to below 2%.

*An oil heater can be located between the first and second stage separator to reheat the
oil/water/gas mixture. This makes it easier to separate out water when initial water cut is
high and temperature is low. The heat exchanger is normally a tube/shell type where oil
passes though tubes in a heating medium placed inside an outer shell.

Third stage separator - The final separator is a two-phase separator, also called a
flash drum. The pressure is now reduced to atmospheric pressure of around 100
kPa, so that the last heavy gas components can boil out.

* In some processes where the initial temperature is low, it might be necessary to heat
the liquid again (in a heat exchanger) before the flash drum to achieve good separation
of the heavy components.There are level and pressure control loops.

- As an alternative, when production is mainly gas, and remaining liquid

droplets have to be separated out, the two-phase separator can be a knockout
drum (K.O. drum).

Coalescer - After the third stage separator, the oil can go to a coalescer for final
removal of water. In this unit, water content can be reduced to below 0.1%. The
coalescer is completely filled with liquid: water at the bottom and oil on top.

Electrostatic desalter - If the separated oil contains unacceptable amounts of

salts, they can be removed in an electrostatic desalter

* The salts, which may be sodium, calcium or magnesium chlorides, come from the
reservoir water and are also dissolved in the oil. The desalters will be placed after the
first or second stage separator depending on GOR and water cut.

Water treatment- On an installation such as this, where the water cut is high,
there will be a huge amount of water produced. In our example, a water cut of
40% gives water production of about 4,000 cubic meters per day (4 million liters)
that must be cleaned before discharge to sea. Often, this water contains sand
particles bound to the oil/water emulsion.
Produced water treatment (yan ung pic)

* This illustration shows a typical water treatment system. Water from the separators
and coalescers first goes to a sand cyclone, which removes most of the sand. The sand
is further washed before it is discharged. The water then goes to a hydrocyclone, a
centrifugal separator that removes oil drops. The hydrocyclone creates a standing
vortex where oil collects in the middle and water is forced to the side. Finally the water
is collected in the water de-gassing drum. Dispersed gas slowly rises and pulls
remaining oil droplets to the surface by flotation. The surface oil film is drained, and the
produced water can be discharged to sea. Recovered oil in the water treatment system
is typically recycled to the third stage separator.

3. Gas treatment and compression

Heat exchangers - For the compressor to operate efficiently, gas
temperature should be low. The lower the temperature, the less energy will
be used to compress the gas for the given final pressure and temperature.
However, both gas from separators and compressed gas are relatively hot.
* When gas is compressed, it must remain in thermodynamic balance, which
means that the gas pressure times the volume over the temperature (PV/T) must
remain constant. (PV = nkT). This ends up as a temperature increase.
- Heat exchangers of various forms are used to cool the gas.
* The cooling fluid is often pure water with corrosion inhibitors.

Scrubbers and reboilers - The separated gas may contain mist and other
liquid droplets. Drops of water and hydrocarbons also form when the gas is
 cooled in the heat exchanger, and must be removed before it reaches the
compressor.
* If liquid droplets enter the compressor, they will erode the fast rotating blades.
A scrubber is designed to remove small fractions of liquid from the gas.

Compressors, anti-surge and performance - Compressors are used in

many parts of the oil and gas process, from upstream production to gas
plants, pipelines, LNG and petrochemical plants.

4. Oil and gas storage, metering and export

The final stage before the oil and gas leaves the platform consists of
storage, pumps and pipeline terminal equipment.

GAS PROCESSING

KUNG SINO MAGREREPORT DITO PAKIKABISADUHIN UNG MGA TERMS NA

NASA GAS PLANT NA NASA BABA. WAG NA ILAGAY SA PPT EXPLAIN NA
LANG PARA DI MASYADO MADAMI YUNG SLIDES NATIN, KONTING
EXPLANTION EACH LANG , YUNG IMPORTANTE LANG. ETO UNG PDF PAGE 71
https://library.e.abb.com/public/34d5b70e18f7d6c8c1257be500438ac3/Oil%20and
%20gas%20production%20handbook%20ed3x0_web.pdf
 TYPICAL GAS PLANT

PETROCHEMICAL PRODUCTS FROM METHANE

(YUNG SA PDF NA KUMPLETO NA YUN MAY SYNTHESIS GAS NA DUN) YUN NA

YUN PAOUTLINE NA LANG DIRETSO MO NA SA SLIDE SAKIT SA KAMAY
MAGTYPE HAHAHAHAHAHAHA
YUNG MAGREREPORT DITO BASAHIN NA LANG YUNG PDF