University College of Engineering (A)

Kakinada

Dept. of Petroleum Engineering &

Petrochemical Engineering
III Year, I Sem., B. Tech. Petrochemical Engineering
Petroleum Refinery Engineering

Overview of Petroleum Refining

Presented by

Prof. K. V. Rao
Programme Director
Petroleum Courses
JNTUK

Agenda
Introduction
What is the Purpose of an Oil Refinery?
What Goes In/Out of the Refinery
How Do You Get from Crude Oil to
Products?

Separations
Chemical Reactions

cont...

Agenda - Cont.

How Do You Get from Crude Oil to

Products?

Separations
Chemical Reactions
Major Equipment
Minimizing Pollution

What do The Petrochemical/Chemical

Engineers Do?

Overview
THE PURPOSE OF AN OIL
REFINERY IS TO TRANSFORM
RELATIVELY LOW VALUE CRUDE
OIL INTO HIGH VALUE
PRODUCTS AS EFFICIENTLY,
PROFITABLY AND
ENVIRONMENTALLY FRIENDLY
WAY AS POSSIBLE

Overview - Cont.
The price and quality of crudes is constantly
changing. The price and specifications of the
products is constantly changing. Government
regulations add additional constraints. There is
not much differential between the price of crude
and products.

HOW DO I KEEP IN BUSINESS?

How Do I Keep In Business ?

I need to design and revamp the plant utilizing the

latest technology to be more efficient
I need to make the plant more flexible and
responsive
I need to operate (control) the plant in the most
efficient manner possible
I need to keep the equipment running all the time
I NEED PETROCHEMICAL/CHEMICAL
ENGINEERS!

OK, But...
WHAT GOES ON IN AN OIL
REFINERY?

VPeertyroSlceihmuepmliaifcneadl
Flowchart

C
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s
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Purifcations

WeOil CrOiudle Separations

THE REFINERY

PRuXr=ifcCahteiomnsicarelmRoevaectsiounlfsurandheavymetals

NGaatsural RX Ethylene RX Polyethylene(GladGaBasgSs)tove

PBrouptane&RX Polymers(7UPBotles) (BarbeqFuelGrils)
N(Ca5p-hCth10a) RRXX MoOrrgeaPnoiclyCmheermsical(sFotb(AaslpHirenlm,GaHeats,iorAliSsntperroay)
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KGaersoOiselnse(C&10+)
JDeietsFeuleFluels
HOiol,mLWaeubHxreicating
(CarbConokMaeterialSimilartoCoal) FSGruteealplhMaitekFinibgers
Asphalt Roads PotHoles (TenisRacquets)
Methan
e
Ethane

What Is Crude Oil?

Crude Oil is a liquid mixture of thousands
of organic chemicals found underground. It
is the result of organic matter decaying over
thousands of years; hence the name fossil
fuel
Crude oil is found all over the world and
varies tremendously in its density,
aromatics, sulfur, and metals content

Major Refinery Products

LPG (Propane/Butane)
GASOLINE (hundreds of blends)
KEROSENE
JET FUELS
DIESEL FUELS
HEATING OILS
GREASES
ASPHALTS
COKE (not the kind you drink )

Gasoline Specifications
Gasoline must meet many criteria which change with
the time of year and geographic location. Some
critical specifications are:
Vapor Pressure
Octane
Aromatics / Benzene Content
Sulfur Content
Gasolines are always a blend of a number of streams
in the refinery

Other Specifications
Other refinery products must meet other
specifications such as:
Cetane number
Density
Pour Point
Flash Point
Viscosity

So, How Do You Make Good

Stuff Out Of That Gooey Crude?

So, How Do You Make Good

Stuff Out Of That Gooey Crude?

So, How Do You Make Good

Stuff Out Of That Gooey Crude?
REACTIONS
&
SEPARATIONS

So, How Do You Make Good

Stuff Out Of That Gooey Crude?

Separate crude into fractions

Convert low octane components to higher octane
components
Convert the very heavy stuff to heavy oils
Convert heavy oils to gasoline,diesel,jet fuel
Remove sulfur/nitrogen through reaction
Blend intermediate streams together to meet
product specifications

SEPARATIONS

SEPARATIONS CRUDE FRACTIONATION

HUGE DISTILLATION COLUMNS

ATMOSPHERIC DISTILLATION
VACUUM DISTILLATION

TYPICAL SIZE: 150,000 BARRELS/DAY

750 DEGREES F

OTHER SEPARATIONS
FLASH
DISTILLATION
ABSORPTION
ADSORPTION
SETTLING (WATER/OIL)

REACTIONS

REACTIONS
Almost all the reactions in the refinery use
special catalysts that increase the rate and
selectivity of the reaction. This improves
efficiency and reduces unwanted
byproducts.

Reactions to Make Higher Octane

ISOMERIZATION
C-C-C-C-C-C --> C C
nC6
C-C-C-C
iC6
REFORMING
C-C-C-C-C-C-C --> C
nC7
C
C-CH3
C
C toluene
C

Reactions To Make Higher Octane

ALKYLATION
C
C
C=C-C + C-C-C --> C-C-C-C-C
C
propylene isobutane
isoheptane (2,2,dmp)

Reactions To Convert Heavy Oils

HYDROCRACKING
H2 + heavy oil --> gasoline + diesel
550 F

300 F

450 F

use boiling point to describe oils

CAT CRACKING
heavy oil --> gasoline + propylene, butane,
other light ends
550 F

300 F

Reactions To Convert Resid

Resid is the bottom of the barrel - the
material that is left in the bottom of the
crude/vacuum distillation towers
COKING
resid + heat --> coke + heavy oil
> 900 F
solid
550 F

Reactions To Remove Sulfur

HYDRODESULFURIZATION
2 R-SH + H2 --> 2 R + 2 H2S
mercaptan

hydrocarbon

SULFUR RECOVERY
convert H2S to elemental sulfur:
2 H2S + 2 O2 --> SO2 + S + 2 H2O
2 H2S + SO2 --> 3S + 2 H2O

MAJOR REFINERY EQUIPMENT

Vessels-Reactors, Separators, Storage Tanks
Pumps & Compressors
Furnaces
Heat Exchangers
Instruments (measure flow, temperature,
pressure, composition)
Control Systems

MINIMIZING POLLUTION
Operate Furnaces Efficiently
Waste Material Goes To The Flare Stack
Avoid Spills & Accidental Releases
Special Treatment of Sewer Water
Lots of Paper Work!

WHAT HAPPENS TO THE

BAD STUFF IN THE CRUDE?

Sulfur
converted to elemental sulfur
in high sulfur fuel oil
in coke

Heavy Metals (nickel, vanadium)

in high sulfur fuel oil and coke

Nitrogen (organic nitrogen)

most is converted to ammonia and neutralized
in high sulfur fuel oil and coke

WHAT ROLE DO
ENGINEERS PLAY IN THE
REFINERY?

What Role Do Petrochemical Engineers Play?

Operations Engineer
Maintenance Engineer
Control Systems Engineer
Design Engineer
Health/Safety/Environmental Engineer
Planning / Scheduling Engineer
Reliability Engineer
Plant Manager

Other Ways Petrochemical Engineers

Support The Refining Industry
Research & Development Engineers
Technical Sales Engineers
Engineering & Construction Engineers
Governmental Regulators
University Professors

Other Engineering Disciplines In

The Refinery
Mechanical Engineers - design &
maintenance of compressors, vessels
Electrical Engineers - electrical,
instrumentation, controls
Computer Scientists - main plant control &
information systems

Summary
Refineries are very complicated chemical
processing plants that use reactions and
separations to convert crude oil into
gasoline and other valuable products
Petrochemical/Chemical engineers play an
important role in keeping these plants
running safely and efficiently