Petroleum Refining · Petroleum Components • FULL CONVERSION REFINERY – Change Less Valuable Fractions Into Higher Value Transportation Fuels – Process Heavier, Cheaper Crude

Petroleum Refining

1Ford, Bacon & Davis, LLC

• Handbook Of Petroleum Refining Processes, Robert A. Meyers, ed.

• Petroleum Refining Technology and Economics, James H. Gary, et al.

Ford, Bacon & Davis, LLC 2

• INPUT: Process Multiple Crude Compositions At Minimum Cost

• OUTPUT: Produce Slate Of Products That Provide The Most Profit For Current Market Conditions

• CONVERSION: Utilize Processes That Upgrade Value Of Petroleum Components

• FULL CONVERSION REFINERY– Change Less Valuable Fractions Into Higher Value

Transportation Fuels– Process Heavier, Cheaper Crude Oil– Convert ~90% Of Crude Oil Into Fuels And Products



PETROLEUMREFINERY

Crude Oil

LPG

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil

Lube / Specialty Oil

Byproducts

Refinery Products

$$$

$$$

$$$

$

$

$$

$

$$

CokeSulfur


Molecular Weight Density

Higher

Lower


STABILIZER

ATMOSPHERICTOWER

VACUUMTOWER

CRUDE DISTILLATION

CRUDE

LPG & GAS

SR GASOLINE

NAPHTHA

MIDDLE DISTILLATES

HVY ATMOS GAS OIL

VACUUM GAS OIL(LVGO/HVGO)

DELAYEDCOKER

COKE

TREATING

AND

BLENDING

REFINERY FUEL GAS

LIQUID PETROLEUM GAS (LPG)

REGULAR GASOLINE

PREMIUM GASOLINE

CHEMICAL FEEDSTOCKS

JET FUEL / KEROSENE

DIESELS

HEATING OILS

LUBE OILS

GREASES

ASPHALTS

INDUSTRIAL FUELS

REFINERY FUEL OIL

FLUIDIZEDCATALYTICCRACKING

(FCCU)

LIGHT ENDS UNIT

NAPHTHAHYDRO

TREATINGREFORMING

REFORMATE

ISOMERIZATION

CONVERSION PRODUCT FINISHING

VACUUM TOWER BOTTOMS

SULFUR RECOVERY SULFUR

RICHAMINE

SOURWATER

LEANAMINE

SWEET WATER

HYDRO-CRACKING

(HCU)

COKER GAS OIL

DISTILLATEHYDRO

TREATING

DISTILLATES

ALKYLATIONALKYLATES

COKERNAPHTHA

COKER DISTILLATE

GAS OILHYDRO

TREATING(GOHT)

HYDROCRACKATE

HCU DIESEL

CAT LIGHT ENDS

CAT NAPHTHA

CAT LIGHT CYCLE OIL (LCO)


Crude Oil

LPG

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil


Byproducts

CrudeDistillation Conversion Product

Finishing

Byproduct Recovery


ProductFinishing

Crude Oil

LPG

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil


Byproducts

CrudeDistillation Conversion

Byproduct Recovery

Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals


CRUDE

GASOLINE

1 BARREL 1 BARREL

JET FUEL

DIESEL$60 / BBL (BRENT)

$87 / BBL

$90 / BBL

$92 / BBL


1 BARRELCRUDE

1.1 BARRELPRODUCT=

CrudeOil


• Crude Oil Is A Complex Mixture Of Hydrocarbons Generated By Nature

• Light Crudes Have Lower Boiling Point Components With More Value As Products

• Sweet Crudes Have Lower Sulfur Concentrations– Less Expensive Materials Of Construction– Less Sulfur Handling Requirements

• Light, Sweet Crudes Are Becoming More Scarce And More Expensive


• Heavier Crudes Have Higher Boiling Point Components With Less Value As Products

• Heavier Crudes Require More Refinery Process Steps To Convert To Lower Boiling Point Components Of Higher Value

• Sour Crudes Have Higher Sulfur Concentrations– More Expensive Materials Of Construction– More Sulfur Handling Requirements

• Heavy, Sour Crudes Are More Available And Less Expensive Than Light, Sweet Crudes


• Crude Assay Is Used To Define Specific Properties That Impact Refining

• Crude Oil Properties Include:– Boiling Point Curve– API Gravity– Sulfur Content– Nitrogen Content– Metals (Nickel/Vanadium)– Conradson Carbon Residue (CCR)– PONA Analysis

(Paraffins/Olefins/Naphthenes/Aromatics)– Viscosity Curve



0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95

Vol Percent

Tem

pera

ture

, F

Vacuum Column Cutpoint

Crude Column Cutpoint

• API Gravity Is A Measure Of Crude Oil Density

• Higher API Gravity = Lower Density

• Lower API Gravity = Higher Density

• Light Crudes Are Greater Than 40° API

• Medium Crudes Are 20° To 40° API

• Heavy Crudes Are Less Than 20° API



Light Sweet Crude Oil

Oso (Nigerian)

47.4°API

0.046 % Sulfur

Crude Oil

LPG

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil


Byproducts

7.05 %

35.24 %

24.46 %

14.74 %

81.49 %Total


Medium Sweet Crude Oil

Brent (North Sea)

38.5°API

0.43 % Sulfur

Crude Oil

LPG

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil


Byproducts

3.4 %

28.8 %

14.9 %

14.7 %

Total 61.8 %


“Medium” Sour Crude Oil

Maya (Mexico)

22.2°API

3.3 % Sulfur

Crude Oil

LPG

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil


Byproducts

1.1 %

15.6 %

11.4 %

12.7 %

Total 40.8 %


Heavy Sour Crude Oil

Merey (Venezuela)

16.0°API

2.28 % Sulfur

Crude Oil

LPG

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil


Byproducts

0.61 %

8.55 %

8.64 %

15.50 %

Total 33.30 %

CrudeDistillation



ProductFinishing

Crude Oil

LPG

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil


Byproducts

Conversion

Byproduct Recovery

Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

CrudeDistillation


Batch StillLate 1800’s

Continuous Bench StillEarly 1900’s


Pipe Continuous StillEarly 1900’s

Trumble Process


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

ProductFinishing

Crude Oil

LPG

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil


Byproducts

Conversion

Byproduct Recovery

PreheatAndDesalter

AtmosphericTower

VacuumTower

Light Ends

Naphtha

Distillate

Gas Oil

Residual

Off Gas

Straight-Run Naphtha

Straight-Run Kerosene

Straight-Run Diesel

AGO

ATB(Atmos Resid)

LVGO

HVGO

VTB

(Vac Resid)

Removes Salts And

Solids From Crude

Separates Lighter Crude

Components

Separates Heavier Crude

Components

Crude/VacCrude Unit Pipestill


Atmospheric Tower

VacuumTower


Lower Boiling Temperature

Lower Molecular Weight

Higher Boiling Temperature

Higher Molecular Weight



Conversion



Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

ProductFinishing

Crude Oil

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil


Byproducts

Conversion

Byproduct Recovery

Light Ends

Naphtha

Distillate

Gas Oil

Residual

Off Gas

SR Naphtha

SR Kero

SR Diesel

Vac Btms

LVGO

HVGO

AGO

CrudeDistillation

LPG


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

ProductFinishing

Crude Oil

LPG

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil


Byproducts


Byproduct Recovery

Light Ends

Naphtha

Distillate

Gas Oil

Residual

Off Gas

SR Naphtha

SR Kero

SR Diesel

DelayedCoker

Vac Btms

FCCULVGO

HVGO

Hydro-cracker

AGO

Alkylation


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

ProductFinishing

Byproduct RecoveryRiser

Reactor

Regenerator

Air

AGOLVGOHVGO

Other Gas Oil

Main Fractionator

Heavy Cat Naphtha (HCN)

FCC Wet Gas

Light Cycle Oil (LCO)

Clarified Slurry Oil (CSO)

Fractionator Overhead

(Decant Oil)


Reactor

Regenerator

Main Fractionator


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

ProductFinishing

Byproduct Recovery

FCC Wet Gas

Fractionator Overhead

Wet Gas Compressor

FCC Gas Plant(Unsat Gas Plant)(Cat Light Ends Unit)

FCC Dry GasFCC C3’sFCC C4’s

FCC C3’sP/P OlefinsC3 OlefinsRefinery Grade Propylene

FCC C4’sB/B OlefinsC4 OlefinsRefinery Butylenes

Light Cat Naphtha

(LCN)

Coker LPG


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

ProductFinishing

Byproduct Recovery

Feed Preparation

IsobutaneFCC C4’sFCC C3’sFCC C5’s

Reactors

Fractionation

Propane

N-Butane

Recycle Isobutane

Alkylate



DuPont STRATCO

Alkylates


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

ProductFinishing

Byproduct Recovery

HDS/HDNReactors

AGOCoker GO

HVGO/LVGO

Hydrogen

HydrocrkgReactors

Separators

Recycle Compressor

Fractionation

Fuel Gas

HCU LPG

Lt Naphtha

Hvy NaphthaHydrocracker Naphtha = Hydrocrackate

Lt Distillate

HCU Diesel

Unconverted Oil

Full Conversion


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

ProductFinishing

Byproduct Recovery

HDS/HDNReactors

AGOCoker GO

HVGO/LVGO

Hydrogen

HydrocrkgReactors

Separators

Recycle Compressor

Fractionation

Fuel Gas

HCU LPG

Lt Naphtha

Hvy Naphtha

Lt Distillate

HCU Diesel

Partial Conversion

FCC Feed

Hydrocracker Naphtha = Hydrocrackate



Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

ProductFinishing

Byproduct Recovery

Heater

Vacuum Btms

CokeDrums

Petroleum Coke

Main Fractionator

Coker Gas

Plant

Fuel Gas

Coker LPG

Coker Naphtha

Coker Distillate(Coker Diesel)

Coker Gas Oil

Recycle


Coke Drums

Derricks For Cutting Water

Coke Pit

Feed Heaters


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

Crude Oil

LPG

Chemical Feedstock

Gasoline

Jet Fuel / Kerosene

Diesel

Fuel Oil


Byproducts


Byproduct Recovery

Light Ends

Naphtha

Distillate

Gas Oil

Residual

Off Gas

SR Naphtha

SR Kero

SR Diesel

DelayedCoker

Vac Btms

FCCULVGO

HVGO

Hydro-cracker

AGO

Alkylation

Petroleum Coke

Coker Gas OilCoker DistillateCoker NaphthaCoker LPG

Clarified Slurry Oil

Light Cycle OilHvy Cat NaphthaLt Cat NaphthaFCC C4’sFCC C3’sFCC Feed

HCU DieselHvy HydrocrackateLt HydrocrackateHCU LPG

Isobutane

PropaneN-Butane

Alkylate

ProductFinishing


• Light Ends – Fuel Gas

• Naphtha – Gasoline

• Distillates – Kerosene, Jet Fuel, Diesel

• Gas Oils – Pre-/Post- Hydrotreating Before Converting to Gasoline (FCCU) Or Diesel (Hydrocracking)



Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

Byproduct Recovery

DelayedCoker

FCCU

Hydro-cracker

Alkylation

Crude Unit Off GasAlky Propane/n-ButaneHCU LPGFCC C3’sSR NaphthaAlkylateLt/Hvy HydrocrackateLt/Hvy Cat NaphthaCoker NaphthaSR KeroseneSR DieselHCU DieselLight Cycle OilCoker Distillate

Clarified Slurry OilPetroleum Coke

Absorber –Deethanizer

LPG

Lt Naphtha

Sponge Absorber

Lean Oil

Rich Oil

Amine

Absorber

Lean Amine Fuel Gas

Rich Amine

Debutanizer

Lt SR Naphtha

Depropanizer

PropaneDeisobutanizer

Isobutane

N-Butane

SaturateGas Plant

To Sales

To Alkylation

To Gasoline Blending Or Sales

To Refinery Heaters

To AmineRegeneration

From AmineRegeneration

From MultipleRefinery Sources


AtmosphericCrude Tower

Straight Run

Hydrocracker

Light Hydrocrackate

Heavy Hydrocrackate

FCCU

Light Cat

Heavy Cat

Naphtha

Critical GasolineSpecifications:

OctaneSulfur

Reid Vapor PressureDelayedCoker

Coker

Conversion

CrudeDistillation

HydrotreatersWildProduct

Finishing

Octane Sulfur RVP


SR Naphtha Low High High

Alkylate Very High None Low

Lt Hydrocrackate Medium Very Low High

Hvy Hydrocrackate Medium Very Low Low

Lt Cat Naphtha High Medium Medium

Hvy Cat Naphtha High High Low

Coker Naphtha Medium Very High High

Wild Naphtha Very Low Very High Very High


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

Byproduct Recovery

DelayedCoker

FCCU

Hydro-cracker

Alkylation



NaphthaHydrotreater

(NHT)

SR Naphtha

Coker Naphtha

Wild Naphtha

Hydrogen

Stabilizer

LPG

Naphtha

Splitter

Isomerization(Penex)

Hydrogen Fuel Gas

Isomerate

Reformer

Proprietary Reformer TrademarksPlatformer (UOP)Rheniformer (Chevron)Powerformer (ExxonMobil)

Hydrogen(Net Gas)LPG

Reformate

Stabilize – Reduce RVP

Hydrotreat – Remove Sulfur and Olefins

Split – Separate Light And Heavy SR

Reform – Boost Heavy SR Octane

Isomerize – Boost Light SR Octane

SR/Coker/Wild


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

Byproduct Recovery

DelayedCoker

FCCU

Hydro-cracker

Alkylation



NaphthaHydrotreater

(NHT)

SR Naphtha

Coker Naphtha

Wild Naphtha

Hydrogen

Stabilizer

LPG

Naphtha

Splitter

Merox /Merichem

Treater

Caustic Soda Light SR

Reformer

Proprietary Reformer TrademarksPlatformer (UOP)Rheniformer (Chevron)Powerformer (ExxonMobil)


Reformate






SR/Coker/Wild


Light Ends

Naphtha

Middle Distillates

Gas Oils

ResidualsDelayedCoker

FCCU

Hydro-cracker

Alkylation



NaphthaHydrotreater

(NHT)

SR Naphtha

Coker Naphtha

Wild Naphtha

Hydrogen

Stabilizer

LPG

Naphtha

Splitter

Isomerization(Penex)

Hydrogen Fuel Gas

Isomerate

Reformer


Reformate

Lt Hydrocrackate

GuardBed

Hvy Hydrocrackate






SR/Coker/Wild


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

Byproduct Recovery

DelayedCoker

FCCU

Hydro-cracker

Alkylation



SHUReactor

Lt Cat Naphtha

Hvy Cat Naphtha

Lt Coker Naphtha

Hydrogen

Naphtha Splitter

Fuel Gas

Lt LS Gasoline

HDSReactor

Hydrogen

Recycle Compressor

Stabilizer

Fuel Gas

Hvy LS Gasoline

Remove Diolefins (Gum-Formers)

Remove Mercaptans (Sulfur)

Split to Maximize Light Cat Naphtha Octane

Hydrotreat But Minimize Olefin Saturation

Stabilize To Decrease Gasoline RVP

Lt Cat/Hvy Cat/Lt Coker


Light Ends

Naphtha

Middle Distillates

Gas Oils

ResidualsByproduct RecoveryDelayedCoker

FCCU

Hydro-cracker

Alkylation



HDSReactors

SR Kerosene

SR Diesel

Coker Distillate

Lt Cycle Oil

Hydrogen

Recycle Compressor

Fractionation

Fuel Gas

Wild Naphtha

Kerosene

ULSD

Distillate Hydrotreater (DHT)


Light Ends

Naphtha

Middle Distillates

Gas Oils

Residuals

Byproduct Recovery

DelayedCoker

FCCU

Hydro-cracker

Alkylation



HDS/HDNReactors

AGO

LVGO

HVGO

Coker Gas Oil

Hydrogen

Recycle Compressor

Fractionation

Fuel Gas

Wild Naphtha

FCC Feed

Gas Oil Hydrotreater (GOHT)

Hydrotreating Gas Oil Before FCCU Avoids Hydrotreating Separate FCCU Products


ByproductRecovery



Amine Regeneration

Unit

Rich Amine

Lean Amine

Acid Gas

Sour Water Stripper

Sour Water

Acid Gas

SRU (Claus) UnitAir

Molten Sulfur

Tail Gas Treatment (Scot) Unit

Thermal

Oxidizer

Vent


Sulfur Sulfur Sulfur Sulfur

Tail Gas


US Patent No. 3,963,443 (06/15/76)


REACTIONPREHEATING

TAILGAS

FROMSRU

PROCESSGAS

QUENCHCOOLING

H2SABSORPTION

TREATEDTAILGASTO

ATMOS

REACTION(SO2

CONVERSION TO H2S)

SOLVENTREGENERATION

ACIDGASTO

SRU

LEANSOLVENT

RICHSOLVENT

INCINERATION/WASTEHEAT

RECOVERY

BFW HPSTEAMCONDHP

STEAM

• Petroleum Refinery Converts Crude Oil To Fuels and Chemical Feedstocks

• Molecules In Crude Oil Are Converted To High Value Products Through Refinery Conversion And Product Finishing Steps

• Removing Sulfur From Refinery Products Is Critical in Meeting Environmental Requirements (Tier 3 = 10 ppmw)


Petroleum Refining · Petroleum Components • FULL CONVERSION REFINERY – Change Less Valuable Fractions Into Higher Value Transportation Fuels – Process Heavier, Cheaper Crude

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