Kuwait University

College of Engineering & Petroleum

Chemical Engineering Department

ChE 472/572

Petroleum Refining Engineering

Supplementary Class Notes

Fall 2015/2016

Dr. Tareq A. Albahri

Copyrights 2001 2015

Table of contents
Front Matter Tables, conversion factors and abbreviations
Part 1
Chapter 1 - Introduction
Chapter 2 - Composition of Petroleum
Chapter 3 - Significance of lab tests in petroleum refining
Chapter 4 - Characterization & properties estimation of crude oil and petroleum products
Chapter 5 - Refinery Feeds and Products
Chapter 6 - Modern Refinery Layout
Part 2
Chapter 7 - Separation Processes (CDU, VRU)
Chapter 8 - Desulfurization Processes (HTU, ARDS, Isomax, Merox)
Chapter 9 - Conversion Processes (FCC, HCR)
Chapter 10 - Heavy Oil Processing / Residue Upgrading (Coker, H-Oil)
Chapter 11 - Finishing Processes (Reforming, Alkylation)
Chapter 12 - Supporting Processes (H2 Production, H2 Recovery, Sulfur)
Chapter 13 - Product Blending
Part 3
Chapter 14 - Optimization
Chapter 15 - Economics
Chapter 16 - Environmental
Chapter 17 Combustion
Chapter 18 Safety
Chapter 19 Future
Chapter 20 - Catalysis

Appendix A
Common Abbreviations Used in Petroleum Refining
API
ARD or ARDS
ASTM
ATK
Atm. Resid.
BPA
BPSD
BS&W
C3
C3=
CABP
Cat Cracker
CCR
CCR
CDU
CN
D
DHTU
DPK
EGO
EOR
FBP
FUP
GO
GPH
GPM
GPSA
HFO
H-Oil unit
HP
HP Diesel
HRI
HSD
HSR
IBP
IFP
IK
JGC
K
KDC
KHTU
KNG
KOC
KPC
LCR
LCR
LFO
LGO
LNG

American Petroleum Institute

Atmospheric Residue Desulfurization.
American Standards for Testing and Materials
Aviation Turbine Kerosene.
Atmospheric Residue
Bottom pump-around
Barrels per stream day
Bottom sediment and water
Propane
Propene
Cubic Average Boiling Point
Catalytic Cracker
Central Control Room.
Central Control Room.
Crude Distillation Unit.
Cetane Number
Diesel
Diesel Hydrotreating Unit.
Dual Purpose Kerosene (Illumination + Aviation)
Export Gas oil
End of run
Final Boiling Point
Future Upgrade Project
Gas oil
Gallons per hour
Gallons per minute
Gas Processors Sellers Association
Heavy fuel Oil
Heavy Oil Unit
High Pressure
High Pour Point Diesel
Hydrocarbon Research, Inc. (HRI
High speed diesel
Hydrogen Sulfide Removal
Initial Boiling Point
Institute Francais du Ptrole
Illuminating Kerosene
Japan Gas Corporation
Kerosene
Kuwait Drilling Company
Kerosene Hydrotreating Unit.
Kuwait Natural Gasoline
Kuwait Oil Company
Kuwait Petroleum Corporation
Local Control Room.
Local Control Room.
Light Fuel Oil
Light Gas Oil
Liquefied Natural gas
3

LP
LPG
LSFO
Lub Oil
MAA
MAB
MABP
MDO
MeABP
MOGAS
MON
MOR
MPA
MTBE
N
NGPSA
NHTU
NPSH
O/H
PBD
PCN
PON
PSA
RMP
RON
SCFH
SHU
SOR
SR
SRU
SRU
SW
SWT
TBP
TEL
TGT
TPA
UOP
VABP
VRU
WABP

Low Pressure
Liquefied petroleum gas
Low Sulfur Fuel Oil
Lubricating oil.
Mina Al-Ahmadi Refinery.
Mina Abdulla Refinery.
Molal average boiling point
Marine Diesel Oil
Mean average boiling point
Motor Gasoline
Motor Octane Number
Middle of run
Middle pump-around
Methyl Tertiary Butyl Ether
Naphtha
National Gas Processors Sellers Association
Naphtha Hydrotreating Unit.
Net positive suction head
Overhead
Barrels per day
Petrochemical Naphtha
Posted Octane number
Pressure Swing Adsorption Unit.
Refinery Modernization Project
research octane number
Standard cubic foot per hour
Shuaiba Refinery.
Start of run
Straight Run
Sulfur Recovery Unit
Sulfur Recovery Unit.
Sour Water
Sour Water Treating Unit
True Boiling Point
Tetra Ethyl Lead
Tail Gas Treating Unit
Top pump-around
Universal Oil Company
Volumetric average boiling point
Vaccum Rerun Unit.
Weight average boiling point

Appendix B
Conversion Factors
Length
1 in. = 25.4 mm
1 ft = 12 in.
= 304.8 mm
1 mi = 5280 ft
= 1.6093 km
Volume
1 ft = 1728 cu in.
= 7.4805 gal
= 28.317 liters
= 62.30 1b H2O@60F in air
= 62.38 1b H2O@60F in vacuum
1 gal = 231 in.
= 3785.41 milliliters
= 8.328 1b H2O @ 60F in air
= 8.338 1b H2O @ 60F in vacuum
1bbl

= 42 US Gal
= 5.6146 cu ft
= 349.8 lb H2O @60F in air

Weight
1 lb = 453.59 gm
Pressure
1 atm = 14.696 1b/in.
= 760 mmHg @ 0C
= 33.93 ft H2O @ 60F
2
1 kg/cm = 14.223343 psi (lb/in2)
1 lb/in. = 51.71 mm Hg @ 0C
= 27.70 in. H2O @ 60F
= 2.309 ft H2O @ 60F
= 0.13456 Kg/cm
= 1 psi
1 Kg/m = 7.432 psi
1 ft H2O @ 60F = 0.4332 lb/in.
Flow rate
1 bbl/day (BPD) = 1.75 gal/hr (GPH)
= 0.2339 ft/hr
5

= 0.02917 gal/min
1 GPM = BPD / 34.3
1 m/hr = 150.95 bbl/day
1 ft/sec = 448.8 gal/min (GPM)
1 lb mol/hr = 9108 ft/day @ 60F, 1atm
1 gal H2O/min @ 60F = 499.7 lb/hr in air

BPD

lb/hr
,
sp.gr. (14.59)

GPM

lb/hr
,
sp.gr. (500)

GPH

lb/hr
sp.gr. (8.33)

Energy
1 Btu = 778.2 ft. 1bf
1 Kwh = 3412 Btu
1 hp = 550 ft.1bf/sec
= 2544 Btu/hr
= 745.7 watts
Viscosity
1 cp = 0.000672 lbm/sec.ft
= 0.00002089 lbf.sec./ft
= 2.419 1bm/hr.ft
1 dyne/cm = 28,570 lbm/hr
Standard gravity
g = 32.174 ft/sec
= 4.17X10 8 ft/hr
Temperature
R = F + 459.67
K = C + 273.134
R = 1.8 K
F = 1.8 C + 32
multiply C with 2 , remove 10% , then add 32
Ideal gas volume
V = 379.49 ft/lb mol @ 60F, 1atm (14.696 psia)
= 22.414 liters @ 32F, 1atm (14.696 psia)

Gas constant
R = 1.986 Btu/lbmol.R
= 10.73 psi.ft/lbmol.R
= 555 mm Hg.ft/lbmol.R
Density
1 sp.gr.60/60F = 1 gm/cm3
= 8.34 lb/gal
= 62.3 lb/ft3
= 350 lb/bbl
= 1000 Kg/m3
Density of water @60F = 8.3372 lb/gal (weight in vacuum)
= 0.99902 g/cc (weight in vacuum)
Density of water @60F (g/cc) = 0.999015 (sp.gr.)@60/60F
API

H2 flow
H2 flow
H2 flow

141.5
131.5
(sp.gr.) @60 F/60 F

1 Nm3 35.31467 SCF

1 lb/hr 4554 SCFD
1 lb/hr 192 SCFH

1 kcal = 3.9657 Btu

1 ton water = 269 gal
1 ton = 2000 lb
1 metric ton = 2204.62 lb
1 long ton = 2240 lb
1 short ton = 2000 lb
1 m3/hr = 6333.3 GPD
1 kg/hr = 52.92 lb/d
1kJ = 0.94781712267 Btu
1 Kilograms = 0.26417 Gallons [US]
1 lb = 0.1198 US gal
1 m3 = 264.172 US gal
1 m3 = 6.29 bbl
1 L = 0.264172 US Gal
1 W = 3.412141633 Btu/hr
1 mole ideal gas = 379.482 SCF
1 BHP = 0.745699872 KW
1 gal MEA = 8.34 lb
BHP = 0.7457 KW
bbl/6.29 = kL
1 bbl oil = 159 liter
Oxygen: 1 m3 = 1141 kg = 1.141 tonns

APPENDIX - C
Useful Properties

Table 3.4: Properties of Hydrocarbons and common gases1

Heating Value
Compound
MW
60F, 1 atm (Btu/scf)
Net
Gross
Methane
16.043
909.4
1010.0
Ethane
30.070
1618.7
1769.6
Propane
44.097
2314.9
2516.1
i-Butane
58.123
3000.4
3251.9
n-Butane
58.123
3010.8
3262.3
i-Pentane
72.150
3699.0
4000.9
n-Pentane
72.150
3706.9
4008.9
n-Hexane
86.177
4403.8
4755.9
n-Heptane
100.204
5100.8
5502.5
n-Octane
114.231
5796.1
6248.9
n-Decane
142.285
7189.6
7742.9
Hydrogen sulfide
34.080
586.8
637.1
Nitrogen
28.013
Oxygen
31.999
Carbon Dioxide
44.010
Water
18.0153
Air
28.9625
1
th
Source GPSA Engineering Data Book, 10 ed., 1987.
Atomic weights; C = 12.011

H = 1.008

N = 14.0067

O = 15.9994

S = 32.06

Appendix - D

Table A6-1 Properties of Hydrocarbons and Common Gases. Source: GPSA Engineering Data Book, 10th Ed., 1987
Boiling Point Vapor Press
Critical
Liquid
o
Compound
Formula Mol Wt F (1 atm)
@ 100 F
Press
Temp.
Spec.
Psia
Psia
Degr F
Grav.
60/60 F
Methane
CH4
16.043
-258.73
(5000)a
666.4
-116.67
(0.3)a
Ethane
C2H6
30.070
-127.49
(800)a
706.5
89.92
0.35619c
Propane
C3H8
44.097
-43.75
188.64
616.0
206.06
0.50699c
Iso- Butane
C4H10
58.123
10.78
72.581
527.9
274.46
0.56287c
Normal Butane
C4H10
58.123
31.08
51.706
550.6
305.62
0.58401c
Iso- Pentane
C5H12
72.150
82.12
20.445
490.4
369.10
0.62470
Normal Pentane
C5H12
72.150
96.92
15.574
488.6
385.8
0.63112
n- Hexane
C6H14
86.177
155.72
4.960
436.9
453.6
0.66383
n- Heptane
C7H16 100.204
209.16
1.620
396.8
512.7
0.68820
n- Octane
C8H18 114.231
258.21
0.537
360.7
564.2
0.70696
n- Decane
C10H22 142.285
345.48
0.061
305.2
652.0
0.73421
Nitrogen
N2
28.013
-320.45
493.1
-232.51
0.80940d
Oxygen
O2
31.999
-297.33
731.4
-181.43
1.1421d
b
Carbon Dioxide
CO2
44.010
-109.26
1071
87.91
0.81802c
Hydrogen Sulfide
H2S
34.08
-76.50
394.59
1300
212.45
0.80144c
Water
H2O
18.0153
212.00
0.950
3198.8
705.16
1.00000d
Air
Mixture 28.9625
-317.8
546.9
-221.31
0.87476d

Volume
Ratio
Scf gas/
gal liq.
(59.135)a
37.476c
36.375c
30.639c
31.790c
27.393
27.674
24.371
21.729
19.580
16.326
91.413c
112.93c
58.807c
74.401c
175.62c
95.557c

Table A6-1 continued

Acentric Factor,

0.0104
0.0979
0.1522
0.1852
0.1995
0.2280
0.2514
0.2994
0.3494
0.3977
0.4898
0.0372
0.0216
0.2667
0.0948
0.3443
-

Flammability Limits,
vol% in Air Mixt.
Lower
Upper
5.0
15.0
2.9
13.0
2.0
9.5
1.8
8.5
1.5
9.0
1.3
8.0
1.4
8.3
1.1
7.7
1.0
7.0
0.8
6.5
0.7
5.4
4.3
45.5
-

Compound
Methane
Ethane
Propane
Iso- Butane
Normal Butane
Iso- Pentane
Normal Pentane
n- Hexane
n- Heptane
n- Octane
n- Decane
Nitrogen
Oxygen
Carbon Dioxide
Hydrogen
Sulfide
Water
Air
a. Above critical point, extrapolated or estimated.
b. Sublimation point.
c. At saturation pressure, 60oF.
d. At normal boiling point.
e. Gas at 60oF, liquid at normal boiling point.
f. At the triple point pressure.

Heating Value
60oF, 1 atm (Btu/ scf)
Net
Gross
909.4
1010.0
1618.7
1769.6
2314.9
2516.1
3000.4
3251.9
3010.8
3262.3
3699.0
4000.9
3706.9
4008.9
4403.8
4755.9
5100.8
5502.5
5796.1
6248.9
7189.6
7742.9
586.8
637.1
-

10

Freezing Point @ 1 atm

Degr F

Heat of Vapn @ 1 atm

Btu/lb

-296.44f
-297.04f
-305.73f
-255.28
-217.05
-255.82
-217.05
-139.58
-131.05
-70.18
-21.36
-346.00f
-361.82f
-69.83
-121.88f
32.00
-

219.45
211.14
183.01
157.23
165.93
147.12
153.57
143.94
136.00
129.52
119.65
85.59
91.59
246.47
235.63
970.18
88.20

Appendix - E

Properties of Hydrocarbons
Tb
(F)

Tc
(R)

Pc
(psia)

ppg
(lb/gal)
as
liquid

API
as
liquid

BPD/
(mol/hr)
as liquid

18.02

212

1165

3206

8.334

10

1.235

O2

32

-297

278

731

2.92

Nitrogen

N2

28.02

-320

227

478

2.92

Air
Carbon
monoxide
Carbon dioxide

Air

28.98

-318

239

547

CO

28.01

-313

242

514

2.92

CO2

44.01

-109

548

1072

3.71

Hydrogen sulfide

H2S

34.08

-77

H2

2.016

-423

Methane

C1

16.04

-259

1306
188(3
06
673

2.91

Hydrogen

672
60(7
4)
343

2.19

407

4.19

-4120

21

ethene

= C2

28.05

-155

510

742

3.44

211

4.66

-1090

18.1

ethane

C2

30.07

-128

550

708

3.42

213

5.03

-720

18.62

propene

= C3

42.08

-54

657

667

4.352

140

5.525

224

14.18

propane

C3

44.09

-44

666

617

4.233

147

5.953

189

14.7

1-butene

= nC4-1

56.1

21

755

583

5.013

104

6.395

62.4

13.03

2-butene

= nC4-2

56.1

36

771

600

5.229

97

6.131

48

12.64

i-butene

= iC4

56.1

20

752

580

5.004

104

6.407

63.7

13.04

i-butane

iC4

58.12

11

735

529

4.695

120

7.074

71.9

13.81

n-butane

nC4

58.12

31

765

551

4.872

111

6.817

51.5

13.5

pentene?

= C5

70.13

86

854

586

5.384

87.6

7.443

19.1

12.65

i-pentane

iC5

72.15

82

830

483

5.209

95

7.914

20.4

13.05

n-pentane

nC5

72.15

97

846

490

5.262

92.7

7.835

15.6

13.03

cyclopentane

CP

70.13

121

922

655

6.257

57.1

6.405

9.91

11.11

i-hexane

iC6

86.17

140

897

440

5.485

83.6

8.977

6.77

12.82

n-hexane

nC6

86.17

156

914

440

5.536

81.6

8.895

4.96

12.81

cyclohexane

CH

84.16

177

996

590

6.532

49.1

7.362

3.26

10.98

benzene

78.11

176

1013

714

7.375

28.5

6.052

3.22

9.73

toluene

92.13

231

1070

590

7.269

30.8

7.243

1.03

10.14

o-xylene

o-X

106.16

292

1138

530

7.377

28.4

8.223

0.26

10.28

m-xylene

m-X

106.16

282

1115

510

7.243

31.4

8.375

0.33

10.42

p-xylene

p-X

106.16

281

1113

500

7.218

32

8.404

0.34

10.45

ethylbenzene

EB

106.16

277

1116

540

7.268

30.8

8.347

0.37

10.36

n-heptane

nC7

100.2

209

973

397

5.738

74.1

9.978

1.62

12.71

n-octane

nC8

114.22

258

1025

362

5.893

68.7

11.076

0.54

12.67

n-nonane

nC9

128.25

303

1071

331

6.017

64.6

12.18

0.18

Formul
a

MW

Water

H2O

Oxygen

Name

105

P@
100 F
(psia)

Kw

1.1

12.66
PD462