Fundamentals_of_Oil_Refinery

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Chapter- 5

Oil Refining



Refining Crude Oil

Why do we need to refine the crude oil?

Why cant we build engines that run on crude oil?

That is why the crude oils must be purified and transformed into productshaving an almost constant composition, well adapted to their use. Thesetransformations are carried out in refineries.

Lets learn more about the refining

and refineries

We need to refine the crude oil because

Crude oil is an unstable mixture of several hydrocarbons in varyingquantities according to the density of the products

There is not one type of crude oil but a multitude of different crudes

Different crudes contain dissolved gases, sulfur or acid products which arevery corrosive for metals



Introduction to Petroleum Refinery

A refinery is a factory. Just as a paper mill turns lumber into paper, a refinery takes crude oil andturns it into gasoline and hundreds of other useful products. A typical refinery costs billions of dollars

to build and millions more to maintain A refinery runs twenty-four hours a day, 365 days a year andrequires a large number of employees to run. A refinery can occupy as much land as several hundredfootball fields. Workers ride bicycles to move from place to place inside the complex.

Typical refinery products are LPG, Gasoline, Kerosene, Diesel, Fuel oil, Lubricating oil,Paraffin wax, Asphalt and Tar

Petroleum is also the raw material for products such as fertilizers, pesticides, plastics andother polymers which are used in the manufacturing of fabrics such as silk.



What does refining actually do?

Essentially, refining breaks crude oil down into its various components, which then are

selectively reconfigured into new products. All refineries perform four basic steps:a) Separation (Distillation), b) Conversion (Cracking) and c) Reforming d)Blending & Treatment

Crude oil contains many components which differ in boiling points, relative solubility.Moreover crude oil can be categorized under

Light

Heavy (Asphaltic)Sweet (Non-sulfurous-less than 1% of sulfur)Sour (Sulfurous-more than 1% of sulfur))

Crude oil processing consists of two partsPrimary Processing- Output is raw (primary) productsSecondary Processing- Output is commercial products which are used by us

PrimaryProcessingCrude Oil Secondary

Processing

RawProducts

CommercialProducts

Separation Conversion



Primary processing involves distillation at atmospheric pressure or under vacuum. Distillationcauses separation of breaking up of crude oil into various petrochemicals.

Primary Processing-Separation

Inside the towers, the liquidsand vapors separate intocomponents or fractionsaccording to weight andboiling point. The lightest

fractions, including gasolineand liquid petroleum gas(LPG), vaporize and rise tothe top of the tower, wherethey condense back to liquids.Medium weight liquids,including kerosene and diesel

oil distillates, stay in themiddle. (Heavier liquids,called gas oils, separate lowerdown, while the heaviest fractions with the highest boiling points settle at thebottom.)

Source- http://www.eia.doe.gov/kids/energyfacts/sources/non-renewable/refinery.html

Distillation is done using two methods; a) Atmospheric distillation b) VacuumDistillation



Secondary Processing-Conversion

Primary products require further adjustment of chemical composition in order to becomesuitable for sale or petrochemical processing. This transformation takes place during

conversion stage. The most widely used conversion method is called cracking because it uses heat and pressure to "crack" heavy hydrocarbon molecules into lighter ones. A crackingunit consists of one or more tall, thick-walled, bullet-shaped reactors and a network of furnaces, heat exchangers and other vessels.

Conversion is directed towards maximum gasoline production

Cracking is not the only form of conversion.Other refinery processes, instead of splittingmolecules, rearrange them to add value. Alkylations, for example, makes gasolinecomponents by combining some of thegaseous byproducts of cracking.

The process, which essentially is cracking in

reverse, takes place in a series of large,horizontal vessels and tall, skinny towers that loom above other refinery structures.Reforming uses heat, moderate pressure andcatalysts to turn naphtha, a light, relativelylow-value fraction, into high-octane gasolinecomponents.

Well learn more about these processes

Cracking unit

Source- http://www.eia.doe.gov/kids/energyfacts/sources/non-renewable/refinery.html



Secondary Processing-ConversionSome of the conversion processes are shown below

DELAYED COKING

The heated charge(typically residuumfrom atmosphericdistillation towers) istransferred to largecoke drums whichprovide the longresidence time neededto allow the crackingreactions to proceed tocompletion.

FLUID CATALYTIC CRACKING

oil is crackedin thepresence of a finelydividedcatalyst which ismaintainedin an

aerated orfluidizedstate by the

oil vapors.

HYDROCRACKING

Hydrocracking is a

two-stage processcombining catalyticcracking andhydrogenation,wherein heavierfeedstocks arecracked in thepresence of hydrogen to

produce moredesirable products.

A mild form of thermal cracking,significantly lowersthe viscosity of heavycrude-oil residuewithout affecting theboiling point range.

VISBREAKING



Secondary Processing- Reforming

Reforming is another process designed to increase the volume of gasoline that can beproduced from a barrel of crude oil. For example, Hydrocarbons in the Naptha (anotherpetroleum byproduct) stream have roughly the same number of carbon atoms as those ingasoline, but their structure is generally more complex. Reforming rearranges Napthahydrocarbons into Gasoline molecules

The finishing touches occur during the final treatment. To make gasoline, refinery technicians carefully combine a variety of streams from the processing units. Among thevariables that determine the blend are octane level, vapor pressure ratings and specialconsiderations, such as whether the gasoline will be used at high altitudes. Impuritieslike Sulfur are also removed to make Gasoline as clean as possible

Blending & Treatment



Power Station

Lubricating Oil

Bottled Gas

Petrol

Chemical Works

Tar(bitumen

) for

roads

Diesel Fuel

Jet Fuel

WaxFuel Oil

To Summarize every barrel of crude holdsremarkable potential. It provides the building

blocks for countless products we depend onevery day. You can see below that petroleum inits more refined form contribute heavily to themodern economy.

Dont be surprised to know that a barrel of crude oilafter refining will provide slightly more than 1 barrel

of petroleum products. This gain from processingthe crude oil is similar to what happens to popcorn,it gets bigger after it is popped.

If you are still wondering how much of what isproduced here is a general breakup of the quantity of petroleum products produced in a refinery. Howeverthe product mix can be changed as needed. Forexample, the same barrel can be processed to yieldmore heating oil in winter. However that would alsomean something else will be produced less.

Some More About Refinery

Other Products

Liquefied Petroleum Gas (LPG)

Heavy Fuel Oil

Jet Fuel

Diesel Fuel & Heating Oil

Gasoline

Source- http://www.eia.doe.gov/kids/energyfacts/sources/non-renewable/oil.html#How%20used



Some facts About Refinery

Topping CDUHydroskimming CDU + Reformer

Cracking CDU + Cracker

Coking CDU + Cracker + Coker

Types of refinery

Some of the refineries we may not have heard of

In IndiaHaldia Refinery (IOC) 116,000 bpdPanipat Refinery (IOC), 240,000 bpdDigboi Refinery(IOC), 13,000 bpdGujrat Refinery(IOC), 68,000 bpdBarauni Refinery (IOC), 116,000 bpdGuwahati Refinery (IOC), 20,000 bpd

Mathura Refinery (IOC), 156,000 bpdBongaigaon Refinery(BRPL), 48,000 bpdManali Refinery (CPCL), 185,000 bpdJamnagar Refinery (RIL), 660,000 bpdMumbai Refinery (HPCL), 107,000 bpdVizag Refinery (HPCL), 150,000 bpdMumbai Refinery (BPCL), 135,000 bpdKochi Refinery, 146,000 bpd

Numaligarh Refinery (NRL), 58,000 bpdMangalore Refinery (MRPL), 190,000 bpd

World's Largest RefineriesParaguana Refining, Venezuela - 940,000 bpdSK Corporation, South Korea - 817,000 bpdReliance I, India - 661,000 bpdGS Caltex, South Korea - 650,000 bpdExxon Mobil, Singapore - 605,000 bpdReliance II, India (proposed) - 580,000 bpd

Exxon Mobil, Baytown, USA - 557,000 bpdS-Oil, South Korea - 520,000 bpdHovensa LLC, Virgin Islands - 495,000 bpdExxon Mobil, Baton Rouge, USA - 493,500bpdShell Eastern, Singapore - 458,000 bpd

In all there are 19 refineries in India

BPD- Barrel Per Day



Some more About Refinery

Indias first oil refinery is Digboi Refinery.

Worlds first oil refinery was set up in Poland

Kerosene is also called as Paraffin Oil

Fuel used in a space shuttle is Liquid Oxygen

LPG is called as both Liquid Petroleum Gas Or Liquefied Petroleum Gas

Fuel used in an aircraft is Kerosene



ExerciseFind the best match of terms in column A & B

Jamnagar

Hydrocracking

LPG & Naptha

Digboi Refinery

Sulfur

Biggest refinery in India

Conversion Process

Petroleum byproducts

First refinery in India

Impurity

Answer A B

Impurity

Commercial Products

Petroleum byproducts

Biggest refinery in India

First refinery in India

Secondary Processing Commercial Products Conversion Process

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