OIL REFINING PROCESSES ver1

OIL
 REFINING
 PROCESSES
Advanced
 course
Assoc.Prof.
 Pham
 Huyen



References
• Chang
 Samuel
 Hsu
 and
 Paul
 R.
 Robinson,
 Practical
 Advances
 in
 
Petroleum
 Processing,
 Vol 1,
 Springer,
 2006
• Mohamed
 A.
 Fahim,

 Taher A.
 Alsahhaf and
 Amal Elkilani,
 
Fundamentals
 of
 Petroleum
 Refining,
 Elsevier,
 2010


Outline
Unit
 1.
 Introduction
Unit
 2.
 Refinery
 Feedstocks and
 Products
Unit
 3.
 Modern
 Petroleum
 Processing
 
Unit
 4.
 Auxiliary

 Processes
 &
 Utilities
 


Unit
 1.
 Introduction
Largest  Worldwide   Refineries
Approximately
650  Refineries   in
the  world

Source:   Oil  &  Gas  Journal


Unit
 1.
 Introduction
• High   sulfur,  heavy  crude  is  lowest   cost.  
àRequires   extremely  complex  
refinery  to  convert  into  high  value  
products.
• Low  sulfur,  light  crude  is  highest  cost.    
à Simple  refining  yields  high  value  
products.
• a  function  of  location   of  crude  supply  
versus  refining  centers.
à Refiners  close  to  crude  production  

enjoy  advantage   over  refineries  
distant  from   supply


Unit
 1.
 Introduction


Unit
 1.
 Introduction

Note:
 product
 blending
 and
 sulfur
 
recovery
 units
 are
 not
 shown,
 but
 
these
 are
 almost
 always

 present


Unit
 1.
 Introduction
• DQR
 Introduction
• NSRP
 Introduction


Unit
 2.
 Refinery
  Feedstocks and
 Products
2.1.
 Composition
 of
 Crude
 Oils
2.2.
 Products
 Composition
2.3.
 Physical
 Property
 Characterization
 Data

2.4.
 Chemical
 Analysis
 Data


2.1.
 Composition
  of
 Crude
 Oils
Impurities
 (sulphur,
  nitrogen,
 oxygen
 
and
 metals):
-­‐ low
 concentrations
-­‐ undesirable
-­‐ affect
 the
 quality
 of
 the
 produced
 
products
-­‐ Catalyst

 poisoning
  and
 corrosion
 


2.1.
 Composition
  of
 Crude
 Oils
Hydrogen
 to
 carbon
 ratios
 affect
 the
 physical
 properties
 of
 crude
 oil.
 
-­‐ As the hydrogen to carbon ratio decreases, the gravity and boiling
point of the hydrocarbon compounds increases.
-­‐ the
 higher
 the
 hydrogen
 to

 carbon
 ratio
 of
 the
 feedstock,
 the
 higher
 its
 
value
 is
 to
 a
 refinery
 because
 less
 hydrogen
 is
 required.


2.1.
 Composition
  of
 Crude
 Oils


2.1.
 Composition

  of
 Crude
 Oils
Hydrocarbons:
-­‐ Paraffins
-­‐ Olefins are
 not
 naturally
  present
 in
 crude
 oils
 
but
 they
 are
 formed
 during
  the
 conversion
 
processes
-­‐ Naphthenes (cycloalkanes):
 
Mutli-­‐ring
  naphthenes are
 present
 in
 the
 heavier

 
parts
 of
 the
 crude
 oil
-­‐ Aromatics
Polynuclear aromatic
 compounds
 are
 found
 in
 
the
 heavy
 petroleum
  cuts
à cause
 catalyst
 deactivation
  and
 coke
 
deposition
  during
  processing
à environmental
  problems
 

2.1.
 Composition
  of
 Crude
 Oils


2.1.
 Composition
  of
 Crude
 Oils
-­‐ Sulphur Compounds

• varies
 from
 less
 than
 0.05
 to
 more
 than
 10
 
wt%
 (but
 generally

  falls
 in
 the
 range
 1–4
 
wt%).
 
• Crude
 oil
 with
 less
 than
 1
 wt%
 sulphur is
 
referred
 to
 as
 low
 sulphur or
 sweet,
 and
 
that
 with
 more
 than
 1

 wt%
 sulphur is
 
referred
 to
 as
 high
 sulphur or
 sour.
• Sulphur heteroatoms
• inorganic
  forms:
 elemental
 sulphur S,
 
dissolved
  hydrogen
 sulphide
  H2S,
 
carbonyl
 sulphide
  COS
• organic
 forms:
 mercaptans and
 
sulphides,
  Sulphides and
  disulphides,

 
Thiophenes


2.1.
 Composition
  of
 Crude
 Oils
-­‐ Oxygen
 Compounds
• less
 than
 2
 wt%.
 
• include
  alcohols,
  ethers,
 carboxylic
  acids,
 
phenolic
  compounds,
  ketones,
 esters
 and
 
anhydrides.
 

• causes
 the
 crude
 to
 be
 acidic
 with
 
consequent
 processing
  problems
 such
 as
 
corrosion.


2.1.
 Composition
  of
 Crude
 Oils
-­‐ Nitrogen
 Compounds

• Crude
 oils
 contain
 very
 low

 amounts
 of
 
nitrogen
 compounds.
 
• the
 more
 asphaltic
  the
 oil,
 the
 higher
 its
 
nitrogen
 content.
 
• more
 stable
 than
 sulphur compounds
  à harder
 
to
 remove.
 
• be
 responsible
  for

 the
 poisoning
  of
 a
 cracking
 
catalyst,
 and
 contribute
 to
 gum
 formation
  in
 
finished
  products.
• The
 nitrogen
  compounds
  in
 crude
 oils
 may
 be
 
classified
 as
 basic
 or
 non-­‐basic.

 
• Basic
 nitrogen
 compounds:
 pyridines.
• Non-­‐basic
 nitrogen
 compounds:
 pyrrole types.


2.1.
 Composition
  of
 Crude
 Oils
-­‐ Metallic
 Compounds
•
•
•
•
•
•
•
•

exist
 in
 all

  crude
 oil
 types
  in
 very
 small
 amounts
cause
 operational
 problems
 and
 contaminate
 the
 products,
 affect
 upgrading
 processes
cause
 poisoning
 to
 the
 catalysts used
 for
 hydroprocessing and
 cracking.
 
small
 amounts
 of
 metals

 (iron,
 nickel
 and
 vanadium)
 in
 the
 feedstock
  to
 the
 catalytic
 cracker
 affect
 
the
 activity
  of
 the
 catalyst
 à increased
 gas
 and
 coke
  formation
 and
 reduced
 gasoline
 yields.
For
 high-­‐temperature
 power

 generators,
 the
 presence
 of
 vanadium
 in
 the
 fuel
 may
 lead
 to
 ash
 
deposits on
 turbine
 blades
 and
 cause
 severe
 corrosion,
 and
 the
 deterioration of
 refractory
 furnace
 
linings.
inorganic
 water-­‐soluble
 salts,

 mainly
 as
 chlorides
 and
 sulphates of
 sodium,
 potassium,
 magnesium
 
and
 calcium
 à removed
 in
 desalting
 operations.
 
oil-­‐soluble
 organometallic
 compounds:
 Zinc,
 titanium,
 calcium
 and
 magnesium
 appear
 in
 the
 form
 
of

 organometallic
 soaps.
oil-­‐soluble
 compounds:
 vanadium,
 nickel,
 copper
 and
 iron
 àcomplexing with
 pyrrole compounds.


2.1.
 Composition
  of
 Crude
 Oils
-­‐ Asphaltenes:
-­‐ condensed
  polynuclear aromatic
 layers
 linked
  by
 saturated
 links,
 
-­‐ lead
 to
 coke

 formation
 and
  metal
 deposition
  on
 the
 catalyst
 surface
 causing
 catalyst
 
deactivation.
-­‐ Resins
 
-­‐ polar
  molecules
 in
 the
 molecular
  weight
 range
 of
 500–1000,
-­‐ insoluble
  in
 liquid
  propane
  but
 soluble
  in

 n-­‐heptane.
 
-­‐ responsible
  for
 dissolving
  and
 stabilizing
  the
 solid
 asphaltene molecules
  in
 petroleum.
 
The
 resin
 molecules
  surround
  the
 asphaltene clusters
 (micelles)
 and
  suspend
 them
 in
 
liquid
  oil.
 Because
 each
 asphaltene is

 surrounded
  by
 a
 number
 of
 resin
 molecules,
 the
 
content
 of
 resins
 in
 crude
 oils
 is
 higher
 than
 that
 of
 the
 asphaltenes.


2.2.
 Products
 Composition
-­‐ Liquefied
  Petroleum
 Gas

 (LPG)
-­‐ Gasoline
-­‐ Kerosene
-­‐ Jet
 Fuel
-­‐ Diesel
 Fuel
-­‐ Fuel
 Oil
 (Residual
 Fuel
 Oil)
-­‐ Lube
 Oil
-­‐ Asphalt
-­‐ Petroleum
 Coke


2.2.
 Products
 Composition


2.2.
 Products
 Composition


2.2.

 Products
 Composition