Agenda

• Global crude oil overview - Session 1 (October 28)

• Crude oil basics - Session 1
• Crude oil refining and refinery configurations - Session 2
– Sarnia Area Refineries (November 26)
• Refining process units and their functions - Session 2-4
– (December 16, January 15)
• Refining costs - Session 4
• Turnaround scheduling - Session 4
• Drivers and ongoing improvements - Session 5 (Feb 5)
• Emerging regulations - Session 5
• Supply planning process - Session 5
Crude oil refining and refinery
configurations
 Crude oil characteristics
Crude Oil Characteristics Volume Yield
3%
Naphtha
30%
Sweet > 330 API GRAVITY
Kerosene, Jet Fuel
(e.g. WTI, MSW, < 0.5 % Sulphur 34% Diessel, Heating Oil
AGO

Brent, Bonny Light) MOST EXPENSIVE

~ 20 % of Global Supply 33% Heavy Oil

Light/ Medium 28 - 330 API GRAVITY

3%
22% Naphtha

Sour 0.5 – 2.5 % Sulphur 28%

Kerosene, Jet Fuel
Diessel, Heating Oil
AGO
(e.g. Arab Light, LESS EXPENSIVE
Arab Medium) ~ 65 % of Global Supply 47% Heavy Oil

Heavy Sour < 280 API GRAVITY 2% Naphtha

17%
(e.g. Maya, Cold > 2.5 % Sulphur Kerosene, Jet Fuel
22% Diessel, Heating Oil
Lake, Western Cdn LEAST EXPENSIVE
AGO

Select) ~ 13 % of Global Supply 59% Heavy Oil

API Gravity = (141.5/ Specific Gravity) -131.5

 Crude oil characteristics
Crude Oil Characteristics Volume Yield
3%
> 330 API GRAVITY 21%
Naphtha

Synthetic < 0.3 % Sulphur Kerosene, Jet Fuel

MOST EXPENSIVE 41% Diessel, Heating Oil

(e.g. Syncrude) AGO

~ 2 % of Global Supply 35% Heavy Oil

API Gravity = (141.5/ Specific Gravity) -131.5

 Examples of light, medium sour
heavy sour & synthetic crude oils
Crude Oil API Gravity Wt % Sulphur
Bonny Light 33 0.2
Brent 38 0.4
MSW 39 0.4
WTI 39 0.5

Alaska North Slope 30 1.1

Mixed Sour Blend 30 1.8
Arab Light 32 1.9

Venezuela 16 2.6
Arab Heavy 28 3.0
Western Canadian Select 21 3.3
Maya 22 3.4
Cold Lake 21 3.6

Syncrude 33 0.2
API Gravity = (141.5/ Specific Gravity) -131.5
 Crude oil TBP curves
700 Cold Lake
Vacuum Residue

Light Sour Blend

600
Mixed Sweet Blend

500
Syncrude
Vacuum Gas Oil

0 C 400

Heavy Gas Oil

300

Fuel Oil, Kerosene, Diesel

200
Medium Naphtha

100
Light Naphtha

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
% Liquid Volume
 Crude oil refining and
product disposition PROPANE AND FURTHER
• FUEL GAS
• PROPANE
BUTANES PROCESSING
< 35 0C • BUTANES
• PETROCHEMICALS

LIGHT NAPHTHA • GASOLINE

FURTHER
30 - 105 0C cut PROCESSING • PETROCHEMICALS

MEDIUM/HEAVY NAPHTHA • GASOLINE

FURTHER
105 - 170 0C cut PROCESSING • JET FUEL

CRUDE
TOWER # 2 FUEL OIL/ KEROSENE/DIESEL • JET FUEL
FURTHER • KEROSENE
PROCESSING • DIESEL
170 - 290 0C cut
• HEATING FUEL # 2

HEAVY GAS OIL FURTHER

• GASOLINE
• DIESEL
290 - 345 0C cut PROCESSING
• HEATING FUEL # 2

CDU
FURNACE

• GASOLINE
VACUUM GAS OIL FURTHER • DIESEL
DESALTER PROCESSING
VDU 345 - 550 0C cut • HEATING FUEL # 2
FURNACE V ACUUM
TOWER
• GASOLINE
CRUDE
• DIESEL
OIL
• HEATING FUEL # 2
VACUUM BOTTOMS FURTHER • LUBES
PROCESSING
5500C+ cut • ASPHALT
 Major refinery process concepts
• Topping or Fractionation
– Atmospheric Distillation
– Vacuum Distillation
– Distillative separation (e.g P-P splitter, Reformate splitter)
• Other Separation Processes
– Extractive – based on solubility differences
– Membrane – based on diffusion differences
– Mole Sieve – based on molecule size differences
• Cracking
– Catalytic cracking
– Catalytic Hydrocracking
– Coking
– Thermal or Visbreaking
• Re-arranging or Combining
– Alkylation
– Catalytic Reforming
– Isomerization
– Polymerization
• Treating
– Absorbing/Drying
– Amine Treating
– Desalting
– Desulphurization
– Hydrotreating/Hydroprocessing
 Review of various refinery
configurations
• Basic Hydroskimming Refinery
– Separation of crude oil fractions, plus basic level of conversion capability to
gasoline and range of diesel and distillate products.
(Low capital. Low complexity. Basic conversion capability to produce gasoline, range of diesel. High
residual yield. Typically relies on sweet crude oil. Not competitive. Last such refinery in N. America
built in 1970s)

• Medium Conversion Refinery (e.g. IOL Dartmouth, IOL Nanticoke, IOL

Strathcona, Suncor, Shell Canada in Sarnia)
– Moderate upgrading refinery, diverse range of conversion units capable of higher
gasoline yield, a range of diesel and distillate products.
(Higher capital. Medium complexity. Conversion capability to produce high volume of gasoline, range of
diesel, lower residual yield. Typically processes sour crude oil, low bottoms sour synthetics)

• High Conversion Refinery (e.g. Imperial Oil in Sarnia, Lyondell, Valero)

– Complex refinery upgrading heavy and more sour crude oil to maximum gasoline
and a range of diesel and distillate products and lowest yield of low value residual
oil. Typically employs a coker for maximum upgrading/resid destruction.
(Highest capital. High complexity. High conversion capability)

• Integrated Petrochemical Refinery (e.g. ExMobil B’Rouge, Shell Deer Pk.)

– Medium or High conversion refinery producing a range of refinery products and
also linked to onsite primary petrochemicals and derivatives facilities.
 Typical yields from various refinery
configurations
Hydroskimming Medium Conversion High Conversion

Propane & Butane

4% 8% 7%

Gasoline
Conventional
CARB 30 % 45 % 58 %
Premium
RFG
Distillates
Jet Fuel
Kerosene
34 % 27 % 28 %
Diesel
Heating Oil
Heavy fuel oil
Heavy Fuel 32 % 24 % 15 %
Oil & Other
100 % 104 % 108 %
 Hydroskimming refinery
(SIMPLE LOW UPGRADING CAPABILITY REFINERY. TENDS TO RUN SWEET CRUDE)
PROPANE
C3/C4
SPLITTER
LPG BUTANE TO SALES
AND GASOLINE

SULPHUR LIGHT NAPHTHA TO GASOLINE

REMOVAL
NAPHTHA
SPLITTER HYDROGEN
DE-
BUTANIZER HYDROGEN
LPG
NAPHTHA CATALYTIC
HYDROTREATER REFORMER
HIGH OCTANE
GASOLINE

HYDROGEN

CRUDE
TOWER JET FUEL /KEROSENE JET/KERO JET FUEL /KEROSENE
HYDROTREATER

HYDROGEN

# 2 FUEL OIL/ DIESEL DISTILLATE # 2 FUEL OIL/ DIESEL

HYDROTREATER

ACID GAS
SULPHUR
SULPHUR PLANT
CDU
FURNACE

DESALTER
VDU VACUUM GAS OIL TO SALES
FURNACE V ACUUM
TOWER

CRUDE OIL
VACUUM BOTTOMS RESDUAL OIL TOFUEL/ SALES

55
NOTE: NAPHTHA, JET/KERO & DISTILLATE HYDRO TREATERS, CATALYTIC REFORMER HAVE THEIR HEATERS, DISTILATION TOWERS ALSO
 Medium conversion refinery
(MODERATE UGRADING REFINERY. RUNS MORE SOUR CRUDE TO PRODUCE HIGHER VALUE PRODUCTS)
HYDROGEN
HYDROGEN
NAT GAS PLANT PROPANE
C3/C4
SPLITTER
LPG BUTANE TO SALES
AND GASOLINE

SULPHUR LIGHT NAPHTHA TO GASOLINE

REMOVAL
NAPHTHA
SPLITTER HYDROGEN
DE-
BUTANIZER HYDROGEN
LPG
NAPHTHA CATALYTIC
HYDROTREATER REFORMER
HIGH OCTANE
GASOLINE
HYDROGEN HYDROGEN

CRUDE
TOWER
JET FUEL /KEROSENE
JET/KERO JET FUEL /KEROSENE
HYDROTREATER

HYDROGEN

# 2 FUEL OIL/ DIESEL DISTILLATE # 2 FUEL OIL/ DIESEL

HYDROTREATER
CDU
FURNACE
ACID GAS
SULPHUR PLANT SULPHUR
LIGHT CYCLE OIL

- ALKYLATE
DESALTER C3 /C4- ALKYLATION
UNIT
TO GASOLINE
VDU
FURNACE V ACUUM FCC GASOLINE
FLUID CATALYTIC
TOWER VACUUM UNIT TO GASOLINE
GAS OIL HYDROTREATER
VACUUM BOTTOMS RESDUAL OIL TOFUEL/ SALES
CRUDE OIL
56
NOTE: NAPHTHA, JET/KERO & DISTILLATE HYDRO TREATERS, CATALYTIC REFORMER AND FLUID CATALYTIC UNIT HAVE THEIR HEATERS, DISTILATION TOWERS ALSO
 High conversion refinery
(COMPLEX REFINERY. RUNS HEAVY AND MORE SOUR CRUDE TO PRODUCE HIGHER VALUE PRODUCTS)
HYDROGEN
HYDROGEN
NAT GAS PLANT PROPANE
C3/C4
SPLITTER
LPG BUTANE TO SALES
AND GASOLINE
SULPHUR
LIGHT NAPHTHA TO GASOLINE
REMOVAL
NAPHTHA
SPLITTER
DE- HYDROGEN
BUTANIZER LPG
NAPHTHA CATALYTIC
HYDROTREATER REFORMER HIGH OCTANE
GASOLINE

HYDROGEN
JETFUEL /KEROSENE JET/KERO
CRUDE HYDROTREATER JETFUEL /KEROSENE
TOWER
HYDROGEN

# 2 FUEL OIL/ DIESEL # 2 FUEL OIL/ DIESEL

DISTILLATE
HYDROTREATER
LPG
HYDROCRACKATE TO GASOLINE
HEAVY GASOIL
CDU
CDU HYDROCRACKER ULS JET/ DIESEL
FURNACE
FURNACE
SULPHUR
LIGHT CYCLE OIL SULPHUR PLANT

ACID GAS ALKYLATE

-
C3 /C4- ALKYLATION TO GASOLINE
DESALTER UNIT
FLUID CATALYTIC FCC GASOLINE
VDU
V ACUUM
VACUUM CRACKING UNIT
FURNACE TO GASOLINE
TOWER GAS OIL
HYDROTREATER
ASPHALT COKER OFF GAS, NAPHTHA, FUEL OIL
SOLVENT
DEASPHALTIING
DELAYED COKE
COKER
CRUDE OIL VACUUM BOTTOMS 57
NOTE: NAPHTHA, JET/KERO & DISTILLATE HYDRO TREATERS, CATALYTIC REFORMER, FLUID CATALYTIC UNIT, HYDROCRACKER, DELAYED COKER
HAVE THEIR HEATERS, DISTILATION TOWERS ALSO
 Corunna Crude Topping Unit
(BASIC COMPONENT SEPARATION. RUNS SWEET CRUDE, NO CONVERSION UNITS)
LPG TO OLEFINS UNIT

NAPHTHA TO OLEFINS UNIT

# 2 FUEL OIL/ DIESEL

CRUDE
PRE- TOWER
FLASH
TOWER

HEAVY GAS OIL TO OLEFINS UNIT

CDU
FURNACE

VDU VACUUM GAS OIL

FURNACE V ACUUM
TOWER
CRUDE &
CONDENSATE

VACUUM BOTTOMS
41
 Current Nova Corunna Configuration
ETHANE, PROPANE, BUTANES

EXTERNAL NAPHTHA RECYCLE ETHANE HYDROGEN

EXTERNAL GAS OIL METHANE

LPG ETHYLENE
OLEFINS
SEPARATION PROPYLENE
CRACKING
UNIT
NAPHTHA FURNACES MIXED C4s

# 2 FUEL OIL EXTERNAL MIXED C4s

CRUDE /DIESEL
PRE- TOWER
FLASH PFO
TOWER

HEAVY GAS OIL

C5 DIENES
DCPD
DIENES
UNIT
C9 RESIN
OIL
UNIT C9 RESIN OIL
ATMOSPHERIC
BOTTOMS

BENZENE
EXT. PYGAS DPG & TOLLUENE/XYLENES
V ACUUM
AROMATICS
TOWER C6-C8 RAFFINATE TO OLEFINS or REFINERY
LIGHT OIL UNIT
C9-200 TO GASOLINE
#2 FUEL OIL/DIESEL
CRUDE &
CONDENSATE VACUUM GAS OIL
25
VACUUM BOTTOMS RESIDUAL OIL
Sarnia Area Refineries

Imperial Oil
Site

Suncor Site

Shell Canada Site

Corunna Site

35
 Sarnia refineries
IOL NOVA Shell Sunoco
Crude Unit, KBD 121 80 71 80
Vacuum Unit, KBD 32 33 24 20
Coker, KBD 24 - -
FCC Unit, KBD 30 - 14 17 (Houdry)
Cat Reformer, KBD 17/17 - 22 26
Hydrocracking, KB 18 - 6 25
Hydrotreating, KBD 15.7/21.3/ 12 15/ 6 25/6/10
5.6/53.0
Alkylation, KBD - - - 6
Poly, KBD - - 1.3 -
Aromatics, KBD 6 10 3 10
Isomerization, KBD - - - -
Lubes, KBD 5.6 - - -
Hydrogen, MMSCFD 27.4/27.4/25.1 Y - 41
Coke, T/D 850 - - -
Sulphur, T/D 170 - - 52
Asphalt, KBD - - - 6

53
Refining process units and their
functions
 Crude tower
GAS, PROPANE
` AND BUTANES
REFLUX TO GAS PLANT
DRUM

SOUR WATER
TO STRIPPER
PUMP AROUND
NAPHTHA TO
SAT GAS STRIPPER

` KERO
PREHEAT
CRUDE STRIPPER
STEAM

PUMP AROUND CRUDE

TOWER KEROSENE/JET FUEL
PREHEAT TO HYDRO TREATER
CRUDE PREHEAT
` WITH CRUDE

` LGO
REFLUX STEAM STRIPPER
DRUM``

# 2 FUEL OIL
PRE-FLASH LIGHT GAS OIL/DIESEL
TOWER PREHEAT
WITH CRUDE/
TO HYDRO TREATER
CDU
DEBUTANIZER
FURNACE HAGO REBOIL
STRIPPER
STEAM STEAM
DESALTER
WATER BRINE TO SOUR
WATER STRIPPER HEAVY GAS OIL
PREHEAT PREHEAT
WITH PRODUCTS WITH CRUDE/
NAPHTHA SPlITTER
CRUDE REBOIL
OIL
ATMOSPHERIC RESIDUE TO VACUUM FURNACE
Crude tower internals
 Vacuum tower
TO VACUUM JET
` EJECTORS

TO SOUR WATER
STRIPPER

LIGHTVACUUM
GAS OIL TO FCC UNIT
PREHEAT OR HYDROCRACKER
WITH CRUDE

PUMP AROUND

`
PREHEAT
CRUDE

HEAVY VACUUM
GAS OIL TO FCC UNIT
PREHEAT
STEAM WITH CRUDE
VDU
ATMOSPHERIC RESIDUE FURNACE
FROM CRUDE UNIT

STEAM

VACUUM RESIDUE
TO COKER OR
PREHEAT
DEASPHALTING UNIT
WITH CRUDE/ DEBUTANIZER
OR NAPHTHA SPlITTER AND/OR FUEL
REBOIL
Vacuum tower internals
 Saturated gas plant and naphtha splitter FUEL GAS
TO FUEL GAS
HEADER
LEAN OIL
FOM MAIN
SECONDARY FRACTIONATOR
ABSORBER
NAPHTHA FROM
CRUDE UNIT ` `
PRIMARY
`
ABSORBER

RICH OIL
TO MAIN
FRACTIONATOR

PROPANE
LPG TO STORAGE
MEROX LIGHT
UNIT NAPHTHA
HP TO ISOM OR
SEPARATOR DEPROPANIZER
DEBUTANIZER GASOLINE
STRIPPER HYDRO-
BLOWER `` TREATER
NAPHTHA
` SPLITTER

OFF GAS
FOM CRUDE
TOWER
OVERHEADS
BUTANES
TO ALKYLATION

DEBUTANIZED
MEDIUM NAPHTHA TO
NAPHTHA NAPHTHA SPLITTER
TO NAPHTHA
HYDROTREATER
`