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Petroleum Refinery
Petroleum Refinery
Petroleum Refining
What is it?
Petroleum Refining is the process of taking crude oil and
reprocessing it into a number of different products
Crude Oil - a yellow/black liquid found underneath the surface of the
earth which contains various hydrocarbons and other liquid organics
Typical refineries are very large industrial complexes made up of
many primary and auxiliary units
No two refineries are identical in that each handles varying amounts
of crude oil and produces vary amounts of products depending on
location and demand
Products
Light Distillates
Heavy Distillates
Gasoline (Petrol)
Middle Distillates
Petroleum Naphthas
Kerosine
Solvents
Diesel Fuels
Elemental Sulfur
Heating Fuels
Petrochemicals
Vacuum Distillation
Vacuum distillation units are found in
80+% of refineries
At very low pressure, the leftovers from
the initial distillation tower can be
vaporized without cracking
These oils can later be cracked with
the aid of catalysts to control the
product formation
They are primarily used to produce
addition gasoline
No reaction occur during vacuum
distillation
Naphtha Hydrotreater
Naphtha - a flammable oil made up of various hydrocarbons with sulfur atoms
By treating the naphtha fraction with hydrogen, refineries are able to desulfurize the
hydrocarbons
The purpose of this is to reduce the SOx emissions generated from using the fuels
produced
Nitrogen and Olefins will be removed as well
Primary Reactions
C-S + 3/2 H2 > R-C-H + H2S
C=C + H2 > H-C-C-H
C-N + 2 H2 > C-H + NH3
Catalytic Reforming
Catalysts are used to convert the desulfurized naphtha into higher-octane
molecules know as reformates
N.B. - Octane rating measure the compression which can be withstood
before ignition
The reformates are rearranged and cracked versions of the hydrocarbons
These are a component of the final gasoline product
Primary Reactions:
R-R + H2 > R-H + R-H
R-C-R > C-R-R (and similar rearrangements)
Alkylation
Conversion of isobutane and butylene into alkylate,
another high-octane component of the gasoline product
The process is typically done in sulfuric acid of hydrofluoric
The product alkylate can either be used directly or farther
alkylated in order to produce a higher premium product for
aviation fuels
Primary Reaction: butene + isobutane > 2,2,4 trimethylpentane
Isomerization
The two distinct isomerization process are butane isomerization and pentane/
hexane isomerization
In this process, the straight chains are catalyticlly rearranged into their branched
isoparaffins of a higher octane number
For low temperature butane isomerization, aluminium chloride and HCl are
typically used, whereas with high temperature isomerization, platinum or other
metal catalysts are used
The reaction is simply a catalytic rearrangement similar to the following: R-C-R
> C-R-R
The above is a generic sense of the rearrangement. The catalyst will
determine the exact isomerization product
Distillate Hydrotreater
Similar to the Naphtha hydrotreater,
it uses hydrogen gas to desulfurize
other fractions of the crude oil
distillate in order to reduce the
production of Sox gases from use
It will also remove nitrogen and
aromatics; exactly what depends on
the feed
Primary Reactions:
(Claus Unit)
Hydrocracker
Uses hydrogen gas to break large
carbon chains into smaller ones of a
higher octane rating
The process works by pumping the
hydrogen gas and crude oil distillate
at high pressures over towers of
catalyst
The main products of this are jet fuel
and diesel
Primary Reaction:
R-R + H2 > R-H + RH
Visbreaker
This unit is responsible for thermally cracking
the heavy residual oils of the vacuum
distillation into more valuable products with a
reduced viscosity
While they are old, straight forward units, they
will continue to be present in refineries for
many years to come with more modernized
designs that help decrease energy losses and
increase conversion efficiencies
Thermal Cracking Reaction:
+
Delayed Coking
Converts heavy residual oils into petroleum coke, a
carbonaceous solid, in addition to naphtha and other gas
oils
The coke is referred to as fuel grade, meaning it is high in
sulfur and metals) and anode grade (low in sulfur and
metals)
Coke that is primarily carbon can be sold for use in fuel,
whereas anode grade coke sees use in the aluminium
and steel industries
Sources
http://www.elmhurst.edu/~chm/vchembook/513refining.html
http://www.pavementinteractive.org/article/asphalt-production-and-oil-refining/
http://www.eia.gov/todayinenergy/detail.cfm?id=9130
http://www.eoearth.org/view/article/149994/
http://www.eoearth.org/view/article/153923/
http://www.pescova.com/oil_recovery/hydrotreating_system.shtml
http://www.uop.com/?document=uop-the-role-of-the-merox-process-in-ultra-low-sulfur-transport-fuels-production-techpaper&download=1
http://www.newpointgas.com/amine_treating.php
http://www.eia.gov/todayinenergy/detail.cfm?id=9150
http://www.refiningnz.com/visitors--learning/classroom--learning-resources/learning-centre/how-it-works---the-refining-process/
hydrocracker.aspx
http://www.sciencedirect.com/science/article/pii/S1026309812000612#
http://www.punjlloydgroup.com/landmark-projects-gallery/visbreaker-unit-and-sulphur-block