1862.oil Refinery Walk Through. Rev-04
1862.oil Refinery Walk Through. Rev-04
1862.oil Refinery Walk Through. Rev-04
1862
Rev-2
The petroleum refining industry converts crude oil into more than 2500 refined products, including liquefied petroleum gas, gasoline, kerosene, aviation fuel, diesel fuel, fuel oils,
lubricating oils, and feedstocks for the petrochemical industry. Petroleum refinery activities start with receipt of crude for storage at the refinery, include all petroleum handling and
refining operations, and they terminate with storage preparatory to shipping the refined products from the refinery.
The petroleum refining industry employs a wide variety of processes. A refinery’s processing flow scheme is largely determined by the composition of the crude oil feedstock and
the chosen slate of petroleum products. The example refinery flow scheme presented in Figures in page-4/5/6/7/8 shows the general processing arrangement used by refineries in
the United States for major refinery processes. The arrangement of these processes will vary among refineries, and few, if any, employ all of these processes. Petroleum refining
processes having direct emission sources are presented on the figure in bold-line boxes.
Listed below are 5 categories of general refinery processes and associated operations:
Rev-2
Conversion Processes -
To meet the demands for high-octane gasoline, jet fuel, and diesel fuel, components such as residual oils, fuel oils, and light ends are converted to gasolines and other light fractions.
Cracking, coking, and visbreaking processes are used to break large petroleum molecules into smaller ones.
Polymerization and alkylation processes are used to combine small petroleum molecules into larger ones. Isomerization and reforming processes are applied to rearrange the
structure of petroleum molecules to produce higher-value molecules of a similar molecular size.
Rev-2
LPG BLENDING
LPG FROM
HYDROTREATER
BUTANES X
LPG (ASTM D1835-12)
OTHER GASES STORAGE SPHERES
32 °C GAS PROCESSING MEROX TREATERS
LPG
GAS+NAPHTA
TRAIN-1, CRUDE OIL TANKS LPG FROM
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H2 GAS H2 GAS
ATMOSPHERIC LIGHT X
NAPHTA
GASOLINE BLENDING
DISTILLATION HYDROTREATER ISOMERIZATION
ISOMERATE
32-104 °C
BLENDING
X GASOLINE (ASTM
H2 D4814-12)
GAS H2 GAS
X STORAGE TANK
HEAVY
NAPHTA
HYDROTREATER CATALYTIC REFORMER
DESALTER
CDU
REFORMATE
104-157 °C
DIESEL BLENDING
H2 GAS
ATMOSPHERIC DIESEL (ASTM D975-
1 GAS OIL
HYDROTREATER 12A)
DIESEL OIL
232-427 °C STORAGE TANKS
CRUDE OIL
GAS
VACUUM
DISTILLATION H2
427 °C AND ABOVE
HYDROCRACKER
GAS OIL
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VDU
HEAVY VACUUM X
GAS OIL
HVGO
REFINERY FUEL
5 FOR FURNACES AND
2 9 POWER GENERATION
LPG TO
AIR
CRUDE RESIDUE
BLENDING
E-16
E-18 DELAYED COKER GASIFICATION UNIT PETROLEUM COKE
BITUMEN BLOW VACUUM RESIDUE
THE REFINERY WILL BE DESIGNED TO PROCESS
BITUMEN
2X50,000 BPSD CRUDE OIL (URAL LIGHT)
Rev-2
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11 DESULPHURAZATION
NESTEROV
SEPERATION
HEAVY METALS
ADAMANTAN
DISTILLATION
UNIFICATION
ALTERATION products. Treatment may include
removal or separation of aromatics
and naphthenes, impurities and
undesirable contaminants.
Treatment may involve chemical or
physical separation e.g. dissolving,
absorption, or precipitation using a
variety and combination of processes
including desalting, drying,
-90
hydrodesulfurizing, solvent refining,
sweetening, solvent extraction, and
solvent dewaxing.
100
OSBL UNITS
BOOK-1715.41
Rev-2
S
H
https://link.springer.com/content/pdf/ HIGH COMPLEXITY REFINERIES
L
10.1007%2Fs12182-016-0137-y.pdf
M
MEDIUM COMPLEXITY REFINERIES
GASPROM OMSK REFINERY
Rev-2
Auxiliary Facilities -
A wide assortment of processes and equipment not directly involved in the refining of crude oil is used in functions vital to the operation of the refinery. Examples are
boilers, waste water treatment facilities, hydrogen plants, cooling towers, and sulfur recovery units. Products from auxiliary facilities (clean water, steam, and process heat) are
required by most process units throughout the refinery.
REFINERY PROCESS HAND BOOK REFINERY PROCESS HAND BOOK-ONE SAMPLE PROCESS
MAJOR PROCESS SCHEMATICS
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Rev-2
To raise the boiling point of the light-end carbons so that refinery cooling water can be used to condense some of
the C3 and C4 in the overhead condenser.
To place the uncondensed gas under sufficient pressure to allow it to flow to the next piece of processing
equipment.
Crude oil is preheated in exchangers and finally vaporized in a fired furnace until approximately the required overhead and sidestream pro ducts are vaporized. The furnace
effluent is flashed into the crude column flash zone, where the vapor and liquid separate. The liquid leaving the flash zone still contains some distillate components, which are
recovered by steam stripping. After steam stripping, the bottom product, also known as reduced crude, is discharged from the tower. The bottom temperature is limited to 700-
750°F to prevent cracking.
The atmospheric residue is fed to a furnace, heated to 730-770°F and next to a vacuum tower operated at a minimum practical vacuum (80-llO mm Hg). The operating
conditions are dictated by cracking and product quality required. The objectives of vacuum distillation is gener ally to separate vacuum gas oil (VGO) from reduced crude. The
VGO may become feedstock for FCCU or hydrocracker units or used to make lube base stocks. Depending on the end use, there may be one or more sidestreams. The bottom
stream from the vacuum distillation unit may be used to produce bitumen or used for fuel oil production after mixing it with small amounts of cutter stocks (in the diesel/kerosene
range).
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Rev-2
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Rev-2
Unlike water, crude is not a single chemical compound, but rather thousands of different chemical compounds. Some of
these compounds are as simple as methane (CH4) or more complex such as isooctane (C8H18). The important point to
remember is that each one of these compounds has its own boiling temperature. For example, if a vessel filled with a
medium weight crude is heated until it reaches a temperature of about 15F (66C), the oil will begin to boil. If enough
heat is applied to keep the vessel at 150F (66C), soon the vessel will stop boiling. If the heat is applied to raise the
temperature to 350F (177C), the vessel will begin to boil again and stop after a period of time.
This process can be repeated many times, boiling off more crude with each step and increase in temperature. The
compounds that boil at a temperature below 150F (66C), vaporized in the first step, while the compounds that boil at a
temperature between 150F and 350F (66and 177C) vaporized in the second step, and so forth. With this process, a
distillation curve can be developed, which is a plot of temperature on one scale and the percent evaporated on the other.
Each type of crude oil has a unique distillation curve that determines what kinds of chemical compounds are in the crude
(Figure 3).
Crude oil compositions may vary widely. Light crude oil tends to have more gasoline, naphtha and kerosene; heavy crude
oil tends to have more gas oil and resi- due. Generally, the heavier the compound, the higher the boiling temperature.
Liquid boiling above 800F (427C) does not vaporize and exits from the bottom of the column (Figure 5). Inside the
distilling column are trays with perforations in them. The perforations permit the vapors to rise through the column.
When the crude liquid/vapor charge reaches the inside of the distilling column, gravity causes the denser (heavier) liquid to
drop toward the column bottom, but the less dense (lighter) vapors start moving through the trays toward the top.
The perforations in the trays are fitted with a device called bubble caps (Figure 6). The bubble caps force the vapor
coming up through the trays to bubble through the liquid standing several inches deep on that tray. This bubbling is essential
for the distilling operation. The hot vapor bubbles through the liquid and transfers heat to the liquid during the bubbling. As
the vapor bubbles cool, some of the hydrocarbons in the bubbles will change from vapor to a liquid state. As heat
transfers from vapor to a liquid, the temperature of the vapor drops. The lower temperature of the liquid causes some of
the compounds in the vapor to condense and liquefy.
After the gas has passed through the liquid and
sheds some of the heavier hydrocarbons, the
vapor then moves up to the next tray where the
same process takes place. The amount of liquid on
each tray grows as some of the hydrocarbons from
the vapor are stripped out. A downcomer is
installed to permit excess liquid to overflow to the
next lower tray. This cycle is continuous and
repetitive. Some of the molecules in the
compounds make several round trips: up a couple
of trays as vapor, finally condensing, then down
a few trays via the down-comer as a liquid
(Figure 7). This mixing of liquid/ vapor creates the
separation.
Rev-2
Several processes are designed outside the distilling column to facilitate the operation. To assure purity and to eliminate carry-over, a portion of
the vapor will be run through a cooler. Condensed liquid is reintroduced to a lower tray, while remaining vapor is sent off as product to the
distillation column. This process is called reflux (Figure 9).
At the bottom of the column, some of the light hydro-carbons could be entrained with the heavy hydrocarbons. A portion of the bottoms is
normally recirculated through a heater to vaporize any light hydrocarbons, which are then reintroduced into the distilling column as a vapor.
This process is called reboiling (Figure 9).
The distillation column is the primary separation portion of a refinery. From the distillation column, the initial product cuts are made, and the
products flow to other plants within the refinery for further refining (Figure 10).
Separation Processes -
The first phase in petroleum refining operations is the separation of crude oil into its major constituents using 3 petroleum separation
processes: atmospheric distillation, vacuum distillation, and light ends recovery (gas processing). Crude oil consists of a mixture of
hydrocarbon compounds including paraffinic, naphthenic, and aromatic hydrocarbons with small amounts of impurities including sulfur,
nitrogen, oxygen, and metals. Refinery separation processes separate these crude oil constituents into common boiling-point fractions.
Conversion Processes -
To meet the demands for high-octane gasoline, jet fuel, and diesel fuel, components such as residual oils, fuel oils, and light ends are
converted to gasolines and other light fractions. Cracking, coking, and visbreaking processes are used to break large petroleum
molecules into smaller ones.
Polymerization and alkylation processes are used to combine small petroleum molecules into larger ones. Isomerization and reforming
processes are applied to rearrange the structure of petroleum molecules to produce higher-value molecules of a similar molecular size.
Rev-2
In the vacuum distillation unit, topped crude is heated with a process heater to temperatures ranging from 370 to 425°C (700 to 800°F). The heated topped crude is flashed into a multitray vacuum distillation
column operating at absolute pressures ranging from 350 to 1400 kilograms per
square meter (kg/m2) (0.5 to 2 pounds per square inch absolute [psia]). In the vacuum column, the
topped crude is separated into common boiling-point fractions by vaporization and condensation. Stripping steam is normally injected into the bottom of the vacuum distillation column to assist the separation by
lowering the effective partial pressures of the components. Standard petroleum fractions withdrawn from the vacuum distillation column include lube distillates, vacuum oil, asphalt stocks, and residual oils. The
vacuum in the vacuum distillation column is usually maintained by the use of steam ejectors but may be maintained by the use of vacuum pumps.
The major sources of atmospheric emissions from the vacuum distillation column are associated with the steam ejectors or vacuum pumps. A major portion of the vapors withdrawn from the column by the
ejectors or pumps is recovered in condensers. Historically, the noncondensable portion of the vapors has been vented to the atmosphere from the condensers. There are
approximately 0.14 kg of noncondensable hydrocarbons per m3 (50 lb/103 bbl) of topped crude processed in the vacuum distillation column.2,12-13 A second source of atmospheric emissions from
vacuum distillation columns is combustion products from the process heater. Process heater requirements for the vacuum distillation column are approximately 245 megajoules per cubic meter (MJ/m3)
(37,000 British thermal units per barrel [Btu/bbl]) of topped crude processed in the vacuum column. Process heater emissions and their control are discussed below. Fugitive hydrocarbon emissions from
leaking seals and fittings are also associated with the vacuum distillation unit, but these are minimized by the low operating pressures and low vapor pressures in the unit. Fugitive emission sources are also
discussed later.
Treating Processes -
Petroleum treating processes stabilize and upgrade petroleum products by separating them from less desirable products and by removing objectionable elements. Undesirable
elements such as sulfur, nitrogen, and oxygen are removed by hydrodesulfurization, hydrotreating, chemical sweetening, and acid gas removal. Treating processes, employed
primarily for the separation of petroleum products, include such processes as deasphalting. Desalting is used to remove salt, minerals, grit, and water from crude oil feedstocks
before refining. Asphalt blowing is used for polymerizing and stabilizing asphalt to improve its weathering characteristics.
Auxiliary Facilities -
A wide assortment of processes and equipment not directly involved in the refining of crude oil is used in functions vital to the operation of the refinery. Examples are boilers,
waste water treatment facilities, hydrogen plants, cooling towers, and sulfur recovery units. Products from auxiliary facilities (clean water, steam, and process heat) are required by
most process units throughout the refinery.
Rev-2
LPG BLENDING
LPG FROM
HYDROTREATER
BUTANES X
LPG (ASTM D1835-12)
OTHER GASES STORAGE SPHERES
32 °C GAS PROCESSING MEROX TREATERS
LPG
GAS+NAPHTA
TRAIN-1, CRUDE OIL TANKS LPG FROM
https://yadi.sk/i/mjMG4xGDz2Y6BA DELAYED COKER
H2 GAS H2 GAS
ATMOSPHERIC LIGHT X
NAPHTA
GASOLINE BLENDING
DISTILLATION HYDROTREATER ISOMERIZATION
ISOMERATE
32-104 °C
BLENDING
X GASOLINE (ASTM
H2 D4814-12)
GAS H2 GAS
X STORAGE TANK
HEAVY
NAPHTA
HYDROTREATER CATALYTIC REFORMER
DESALTER
CDU
REFORMATE
104-157 °C
DIESEL BLENDING
H2 GAS
ATMOSPHERIC DIESEL (ASTM D975-
1 GAS OIL
HYDROTREATER 12A)
DIESEL OIL
232-427 °C STORAGE TANKS
CRUDE OIL
GAS
VACUUM
DISTILLATION H2
427 °C AND ABOVE
X LIGHT VACUUM
HYDROCRACKER
GAS OIL
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VDU
HEAVY VACUUM X
GAS OIL
HVGO
REFINERY FUEL
5 FOR FURNACES AND
2 9 POWER GENERATION
LPG TO
AIR
CRUDE RESIDUE
BLENDING
E-12
E-10 DELAYED COKER GASIFICATION UNIT PETROLEUM COKE
BITUMEN BLOW VACUUM RESIDUE
THE REFINERY WILL BE DESIGNED TO PROCESS
BITUMEN
2X50,000 BPSD CRUDE OIL (URAL LIGHT)
Rev-2
Rev-2
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Rev-2
Rev-2
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Rev-2