Petroleum Refinery Engineering (16PL340)

Dr. Venkata Swamy Nalajala

Assistant Professor
Department of Chemical Engineering

Academic Year:2017-18
 Unit-I

• Introduction: Overall refinery operations &

Indian scenario.
• Refinery feed stocks: Crude oil classification-
Composition and properties-Composition of
petroleum crude suitable for asphalt/coke
manufacture – Evaluation of crude oils.

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 Outcomes

• On completion of this unit students will be

able to:
– Understand overall refinery operations
– Indian scenario of refineries
– Understand classification of crude oil
– Composition and properties of crude oil
– Evaluation of crude oils

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 Unit-I

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 Overall refinery flow
• The crude oil is heated in a furnace and
charged to an atmospheric distillation tower,
where it is separated into butanes and lighter
wet gas, unstabilized light naphtha, heavy
naphtha, kerosine, atmospheric gas oil, and
topped (reduced) crude (ARC).
• The topped crude is sent to the vacuum
distillation tower and separated into vacuum
gas oil stream and vacuum reduced crude
bottoms (residua, resid, or VRC).
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 Overall refinery flow
– The vacuum reduced crude bottoms (VRC) from the
vacuum tower is then thermally cracked in a
delayed coker to produce wet gas, coker gasoline,
coker gas oil, and coke.
– Without a coker, this heavy resid would be sold for
heavy fuel oil or (if
the crude oil is suitable) asphalt.
– Historically, these heavy bottoms have sold for
about 70 percent of the price of crude oil.

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 Overall refinery flow
• The atmospheric and vacuum crude unit gas oils and
coker gas oil are used
as feedstocks for the catalytic cracking or
hydrocracking units.
• These units crack the heavy molecules into lower
molecular weight compounds boiling in the gasoline
and distillate fuel ranges.
• The products from the hydrocracker are saturated.
• The unsaturated catalytic cracker products are
saturated and improved in quality
by hydrotreating or reforming.
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 Overall refinery flow
• The light naphtha streams from the crude tower,
coker and cracking units are sent to an isomerization
unit to convert straight-chain paraffins into isomers
that have higher octane numbers.
• The heavy naphtha streams from the crude tower,
coker, and cracking units
are fed to the catalytic reformer to improve their
octane numbers.
• The products from the catalytic reformer are blended
into regular and premium gasolines for sale.

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 Overall Refinery flow
– The wet gas streams from the crude unit, coker,
and cracking units are separated in the vapor
recovery section (gas plant) into fuel gas, liquefied
petroleum gas (LPG), unsaturated hydrocarbons
(propylene, butylenes, and pentenes), normal
butane, and isobutane.
– The fuel gas is burned as a fuel in refinery furnaces
and the normal butane is blended into gasoline or
LPG. The unsaturated hydrocarbons and isobutane
are sent to the alkylation unit for processing.

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 Overall Refinery flow
The alkylation unit uses either sulfuric or
hydrofluoric acid as catalyst to
react olefins with isobutane to form
isoparaffins boiling in the gasoline range
The product is called alkylate, and is a high-
octane product blended into premium
motor gasoline and aviation gasoline.

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 Overall Refinery flow
The middle distillates from the crude unit, coker, and
cracking units are blended into diesel and jet fuels
and furnace oils.
In some refineries, the heavy vacuum gas oil and
reduced crude from paraffinic or naphthenic base
crude oils are processed into lubricating oils.
After removing the asphaltenes in a propane
deasphalting unit, the reduced crude bottoms
is processed in a blocked operation with the vacuum
gas oils to produce lubeoil base stocks.

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 Overall refinery flow
• The vacuum gas oils and deasphalted stocks are first
solvent-extracted to remove the aromatic compounds
and then dewaxed to improve the pour point.
• They are then treated with special clays or high-
severity hydrotreating to improve their color and
stability before being blended into lubricating oils.
• Each refinery has its own unique processing scheme
which is determined by the process equipment
available, crude oil characteristics, operating costs,
and product demand.

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 Overall refinery flow

• The optimum flow pattern for any refinery is

dictated by economic considerations and no
two refineries are identical in their operations.

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