Introduction to Oil Refining

World’s Largest Refineries*

Crude Capacity
Company Location b/cd
1 Paraguana Refining Center Judibana, Falcon, Venezuela 940,000
2 SK Corporation Ulsan, South Korea 817,000
3 LG-Caltex Yosu, South Korea 633,600
4 ExxonMobil Refining Singapore Jurong/Pulau Ayer Chawan 568,500
5 Reliance Petroleum Ltd Jamnagar, India 540,000
6 Hovensa LLC Saint Croix, Virgin Islands 525,000
7 S-Oil Corp. Onsan, Korea 520,000
8 ExxonMobil Refining, USA Baytown, TX 516,500
9 ExxonMobil Refining USA Baton Rouge, LA 488,500
10 Sidanco Angarsk, Russia 440,700
11 Norsi Kstovo, Nizhny Novgorod, Russia 437,792
12 BP Amoco plc Texas City, TX 437,000
13 Kuwait National Petroleum Co Mina Al-Ahmadi, Kuwait 427,500
14 BP Amoco plc Whiting, IN 410,000
15 Shell Eastern Petroleum Pte Ltd Pulau Bukom, Singapore 405,000
16 National Iranian Oil Co Abadan, Iran 400,000
* Plants with 400,000 b/cd or more capacity
Source: Oil and Gas Journal
How the World’s Largest Refiners Rank
Rank (1-1-00) Rank (1-1-99) Company Crude Capacity, b/cd*
1 1 Royal Dutch/Shell 4,230,000
2 2 Exxon Corp. 3,646,000
3 7,16 BP Amoco plc 2,793,000
4 3 Petroleos de Venezuela SA 2,595,000
5 4 Sinopec 2,507,000
6 5 Mobil Corp. 2,117,000
7 6 Saudi Aramco 1,922,000
8 9 China National Petroleum Corp. 1,763,000
9 8 Petroleo Brasileiro SA 1,760,000
10 10 Petroleos Mexicanos 1,662,000
11 20, — TotalFina SA 1,587,000
12 12 National Iranian Oil Co. 1,474,000
13 13 Texaco Inc. 1,429,000
14 11 Chevron Corp. 1,418,000
15 23, — Repsol-YPF SA 1,145,000
16 14 Kuwait National Petroleum Co. 1,058,000
17 15 Agip Petroli SpA 1,030,000
18 — Nippon Mitsubishi Oil 998,000
19 17 Elf Aquitaine 956,000
20 18 Marathon Ashland Petroleum LLC 935,000
21 19 Pertamia 930,000
22 21 Tosco Corp 920,000
23 22 Bashneftekhimzavody 866,000
24 25 Conoco, Inc. 832,000
25 24 SK Corp. 817,000
* Includes partial interest in refineries not wholly owned by the company.
Source: Oil and Gas Journal
 Regional Look at Worldwide Refining Operations
Catalytic Catalytic
Crude Vacuum Catalytic Catalytic Hydro- Hydro-
No. of Distillation, Distillation, Cracking Reforming cracking refining
Region Refineries b/cd b/cd b/cd b/cd b/cd b/cd
Asia-Pacific 203 19,643,997 3,575,998 2,491,615 1,942,422 706,710 3,193,520
Western Europe 108 14,434,402 5,098,283 2,128,556 2,131,002 674,753 2,401,548
E. Europe & FSU 100 12,048,607 3,996,517 862,466 1,485,416 152,435 99,500
Middle East 45 5,952,940 1,955,370 290,900 584,384 572,050 470,964
Africa 46 3,044,152 470,067 390,804 417,018 107,885 127,694
North America 182 19,977,640 8,756,195 6,340,150 4,092,918 1,698,870 1,850,100
S. America & 72 6,448,058 2,848,724 1,254,802 400,060 107,600 416,810
Caribbean
Total Regions 756 81,549,796 26,701,154 13,759,293 11,053,220 4,020,303 8,560,136

Source: Oil and Gas Journal

 Companies with 200,000+B/CD Capacity
Located in the U.S.
Number of Crude Capacity
Rank Company Refineries b/cd
1 BP Amoco plc 7 1,418,600
2 Exxon Co. USA 4 1,175,500
3 Chevron USA Products Co. 6 969,000
4 Marathon Ashland Petroleum LLC 7 935,000
5 Mobil Oil Corp. 4 928,700
6 Tosco Refining Co. 5 920,000
7 Motiva Enterprises LLC 4 842,000
8 Equilon Enterprises LLC 5 739,550
9 Sunoco, Inc. 4 707,000
10 Citgo Petroleum Corp. 4 617,975
11 Koch Refining & Marketing 2 577,000
12 Valero Energy Corp. 5 564,300
13 Clark Refining & Marketing 4 534,000
14 Conoco, Inc. 4 531,600
15 Atlantic Richfield Co. 4 512,220
16 Ultramar Diamond Shamrock Corp. 5 417,500
17 Phillips Petroleum Co. 3 355,000
18 Williams Co. 2 350,000
19 Tesoro Petroleum Corp. 3 275,200
20 Coastal Refining & Marketing, Inc. 3 275,000
21 Lyondell-Citgo Refining LP 1 268,800
22 Fina Oil & Chemical Co. 2 237,000
23 Orion Refining Corp. 1 200,000
Total 89 14,350,945
Source: Oil and Gas Journal
 Companies with 200,000+B/CD Capacity
Located in Western Europe
Number of Crude Capacity
Rank Company Refineries b/cd
1 Exxon Corp. 9 1,656,540
2 Royal Dutch/Shell 12 1,507,632
3 TotalFina SA 7 1,333,335
4 BP Amoco plc 6 1,179,800
5 Agip Petroli SpA 7 1,008,200
6 Repsol YPF SA 5 790,000
7 Elf Aquitaine 5 762,430
8 Cia Espanola de Petroles 3 304,300
9 Petrogal EP 2 334,300
10 Seras SpA 1 285,000
11 Veba Oel/Huhr Oel 1 246,000
12 Isab SpA 1 235,000
13 Louis Dreyfus (Wilhelmshafen) 1 225,000
14 DEA Mineraloel AG 2 220,000
15 PCK Schwedt AG 1 210,000
16 OMV AG 1 208,600
17 Neste Oy 1 200,000
18 Statoil Mongstad 1 200,000
Total 67 10,969,837
Source: Oil and Gas Journal
 Companies with 200,000+B/CD Capacity
Located in Latin America
Number of Crude Capacity
Rank Company Refineries b/cd
1 Exxon Corp. 9 1,656,540
2 Royal Dutch/Shell 12 1,507,632
3 TotalFina SA 7 1,333,335
4 BP Amoco plc 6 1,179,800
5 Agip Petroli SpA 7 1,008,200
6 Repsol YPF SA 5 790,000
7 Elf Aquitaine 5 762,430
8 Cia Espanola de Petroles 3 304,300
9 Petrogal EP 2 334,300
10 Seras SpA 1 285,000
11 Veba Oel/Huhr Oel 1 246,000
12 Isab SpA 1 235,000
13 Louis Dreyfus (Wilhelmshafen) 1 225,000
14 DEA Mineraloel AG 2 220,000
15 PCK Schwedt AG 1 210,000
16 OMV AG 1 208,600
17 Neste Oy 1 200,000
18 Statoil Mongstad 1 200,000
Total 67 10,969,837
Source: Oil and Gas Journal
 Companies with 200,000+B/CD Capacity
Located in Asia Pacific
Number of Crude Capacity
Rank Company Refineries b/cd
1 Exxon Corp. 9 1,656,540
2 Royal Dutch/Shell 12 1,507,632
3 TotalFina SA 7 1,333,335
4 BP Amoco plc 6 1,179,800
5 Agip Petroli SpA 7 1,008,200
6 Repsol YPF SA 5 790,000
7 Elf Aquitaine 5 762,430
8 Cia Espanola de Petroles 3 304,300
9 Petrogal EP 2 334,300
10 Seras SpA 1 285,000
11 Veba Oel/Huhr Oel 1 246,000
12 Isab SpA 1 235,000
13 Louis Dreyfus (Wilhelmshafen) 1 225,000
14 DEA Mineraloel AG 2 220,000
15 PCK Schwedt AG 1 210,000
16 OMV AG 1 208,600
17 Neste Oy 1 200,000
18 Statoil Mongstad 1 200,000
Total 67 10,969,837
Source: Oil and Gas Journal
 Refinery Flow Overview
Crude Distillation TYPICAL PRODUCTS
GAS & LIQUIFIED PETROLEUM GAS (LPG) VAPOR REFINERY FUEL GAS
RECOVERY
STRAIGHT RUN GASOLINE LPG

REGULAR GASOLINE
NAPTHA HYDRO Reformate
REFORMING PREMIUM GASOLINE
High Octane Gasoline TREATING

SOLVENTS
MIDDLE DISTILLATE HYDRO
TREATING
Gasoline between AVIATION FUELS

TREATING AND BLENDIG

FCC/Hydrocracking FCC
GASOLINE
HEAVY GAS OIL HYDRO CAT DIESELS
Crude TREATING CRACKING
Oil VACUUM GAS OIL HEATING OILS

LUBE OILS
SOLVENT
EXTRACTION
GASOLINE & GREASES
LUBE HYDRO NAPHTHA
STOCKS CRACKING ASPHALTS

LUBE OILS INDUSTRIAL FUELS

PROPANE SOLVENT
DEASPHALTER DEWAXING WAXES REFINERY FUEL OILS
GASOLINE & NAPHTHA
VISBREAKER FUEL OIL
ASPHALT

DELAYED GASOLINE & NAPHTHA

COKER COKE
COKE
 Crude Distillation
 First major processing unit in the refinery
 Distillation - Breaking down the constituents
according to boiling point
 There are normally two steps involved:
Atmospheric Distillation and Vacuum Distillation

This is the process that uses the

most number of pumps in the refinery
 Pump application:
 Crude Charge  Gas Oil
 Reflux and Tops  Naphtha, Kerosene & Diesel
 Intermediate Reflux  Topped Crude
 Atmospheric Distillation Unit
CRUDE CHARGE GAS
WATER COMPRESSOR

HEATER
250OF REFLUX
DRUM

Intermediate REFLUX PUMP

Reflux Pump 150 - 200OF
GASOLINE
300 - 400OF STEAM
NAPHTHA
400 - 500 F
O

STEAM
GAS OIL
DESALTER 500 - 600OF
HEATER SIDE CUT
750OF ATMOSPHERIC STRIPPERS
TOWER TOPPED CRUDE
700OF TO VACUUM TOWER
 Vacuum Distillation Unit
TO VACUUM EJECTORS

WATER

EXCHANGER

TOPPED
CRUDE
EXCHANGER LIGHT GAS OIL

850OF
25-50
HEAVY GAS OIL
MM Hg Suction
750OF ASPHALT
HEATER
VACUUM FLASHER EXCHANGER
TOWER BOTTOMS
(FLASHER) PUMP
 Catalytic Cracking
 Refining process used for the manufacture of the
gasoline and petrochemical feedstocks from the
heavier portions of the heavier portion of the crude oil
 Cracking occurs at 25 to 35 psig
 Centrifugal single and multistage pumps for cold
and hot service
 Special attention to be paid to the slurry oil pump
 Utilize a special catalyst, crystalline alumina silicate to
promote the cracking of the heavy hydrocarbon
molecules into light ones
 Catalytic Cracking Unit
FLUE GAS TO
POWER RECOVERY WATER
FRACTIONATOR
REACTOR
REGENERATOR
25-35 psig
GAS TO
25-35 psig 1000OF ADSORBER
1200-1300OF
STEAM WET GAS
COMPRESSOR
SLURRY
1000OF SPENT
SETTLER GASOLINE
REGEN CATALYST
CATALYST
AIR LIGHT
FRESH FEED
GAS OIL

AIR
RISER BLOWER
(MIXER) HEAVY
RECYCLE
GAS OIL
SLURRY PUMP SLURRY PUMP
600-700OF 600-700OF

SLURRY
DECANT OIL
 Hydrocracking
 Another process for making gasoline out of
heavier feedstocks
 Able to crack those oils that are not easily cracked by
catalytic cracking
 Able to make distillates and light oils from
residual oils
 External supply of hydrogen + catalyst is required
 Cracking occurs at 1000 to 2000 psig
 Multistage barrel type centrifugal pumps designed to operate
at temperatures of 700-800OF and pressure above 200 psig
 Hydrocracker
H2 MAKE UP
COMPRESSOR TO FUEL GAS GAS
H2 RECYCLE
2000 PSIG RECYCLE COMPRESSOR FRACTIONATOR
600OF
NAPHTHA
H2 SEPARATED LOW PRESSURE
FROM LIQUID SEPARATOR
HIGH PRESSURE DIESEL
H2 SEPARATOR
800OF CATALYST
FURNACE FIXED BED
2000 PSIG 2nd STAGE
CRUDE 1st STAGE FURNACE FEED PUMP
REACTOR

COOLER 700-800OF
HYDRAULIC
1st STAGE TURBINES
FEED PUMP
H2 RECYCLE
H2 MAKE UP
COMPRESSOR

RECYCLE
COMPRESSOR
2nd STAGE FURNACE
REACTOR

COOLER
 Catalytic Reforming
 A process to produce high octane gasoline
without the addition of lead
 The final product is blended with the other gasoline produced
in the Cat Cracker and Hydro Cracker to meet the required
octane
 Hydrogen molecules are not broken up but simply rearranged
 Catalyst containing platinum
 Hydrogen atmosphere
 Small number of process pumps required
Mostly single stage overhung for medium temperature and
pressure
 Catalytic Reforming Unit
NET
HYDROGEN
TO H2 SYSTEM
New H2 produced
during reaction
H2 MAKE UP
COMPRESSOR
COOLER

H2 RECYCLE
High Octane
COMPRESSOR
Gasoline
Platinum
H2 & oil Catalyst REFLUX
heated together) PUMP
REACTOR REACTOR REACTOR
900OF 900OF 900OF
REBOILER
STEAM

HEATER HEATER HEATER

SEPARATOR STABILIZER
(Reheating to maintain temp.)
COOLER
EXCHANGER High Octane
NAPHTHA To Separate H2 Gasoline
COOLER
FEED PUMP
 Hydrotreating
 Process of removing undesirable elements
(e.g.: sulphur, nitrogen) from products and feedstocks
by reacting them with hydrogen
and catalyst: H2 + S = H2S
 Hydrotreaters are popular to meet the new environmental
standards.
 Major pump application is the feed pump.
 Pump type is usually a horizontally-split,

multi-split type.
 Pressure range is about 1200 psig.
 Hydrotreater
VENT GAS
COMPRESSOR
H2 MAKE UP H2 RECYCLE PROPANE & LIGHTER
COMPRESSOR COMPRESSOR WATER
H2 RECYCLE

H2S, NH3
stick to WATER
catalyst HYDRAULIC
TURBINE
REFLUX PUMP
REACTOR
700-800OF
REBOILER

EXCHANGER STEAM

STRIPPER
FEED HEATER HYDROGEN
PUMP
SEPARATOR
COOLER
DESULPHURIZED
PRODUCT
 Hydrogen Plant
FLUE GAS STEAM H2 COMPRESSOR
H2
REFORMER
FURNACE SHIFT
STEAM CONVERTER METHANATOR

FEED GAS WATER

STEAM

GAS COOLER WATER

CO2

WATER

CO2 ADSORBER REGENERATOR

CO2 REMOVAL PROCESS
Vertically Integrated Hydrocarbon Processing Plant
Polyester
Polyester Fabric
Fabric PVC
PVC
Products
Products Products
Products
Finished
Molding
Molding Textured/Twisted/Dyed
Textured/Twisted/Dyed Yarn
Yarn Spun
Spun Yarn
Yarn Molding
Molding Products

Polymer
Polymer Polymer
Polymer Linear
Linear Alkyl
Alkyl Fibres &
Fibre
Fibre Filament
Filament Yarn
Yarn Benzene
Benzene Fibre
Intermediate
Polyester
Polyester
Granulate
Granulate
Polyester
Polyester Resins
Resins PTA
PTA PX
PX N-Paraffins
N-Paraffins V
Polyvinyl
Polyvinyl
A
Polyethylene
Polyethylene Polypropylene
Polypropylene Chlorides
Chlorides L
MEG
MEG VCM
VCM
U
Polymers
E & Chemicals
EDC
EDC
EO
EO Oxygen
Oxygen
CC1212 Caustic
Caustic
A
Ethylene Methane Propylene Toulene Xylene
D
Fuel
Fuel Gas
Gas Ethylene Methane Propylene Toulene Xylene Benzene
Benzene Caustic
Caustic Unit
Unit D
FEEDSTOCK
FEEDSTOCK CRACKER
CRACKER Salt
Salt E
D
Natural
Natural LPG Naphtha Gasoline Kerosene Diesel Sulphur Fuel
Refining
Gas
Gas LPG Naphtha Gasoline Kerosene Diesel Sulphur Fuel Oil
Oil

OIL
OIL REFINERY
REFINERY Oil & Gas
OIL
OIL && GAS
GAS EXPLORATION
EXPLORATION && PRODUCTION
PRODUCTION
 Fibres and Petrochemicals Complex
Process Block Diagram
MNP
Kerosene N-Paraffin LAB
LAB LAB

Benzene

Naphtha Para
Para Xylene
Xylene PTA
PTA PTA

Acetic Acid

MEG

Central Utilities
DG
DG Polymer
PSF
PSF PFY Chips Polymer
Chips
Chips
STG
STG
PFY
BOILER
BOILER PSF
 Petrochemicals and Polymers Complex
Process Block Diagram

Acetic Acid
PTA
PTA
PX
MEG
MEG PET POY PET/POY
NH3 EOD
EOD
MEG
MEG EO
Ethylene EG
EDC VCM
Naphtha PVC PVC
NGL HDPE HDPE/
Central Utilities LLDPE
Water C2 PE
PE
HRSG Cracker PP
PP PP
Gas C3
GT/STG
GT/STG CC44 + Heavier C4 + Heavier
C4 Polymers
Power
Caustic/ VCM PVC PVC
Salt Caustic/
EDC
EDC Plant
Plant
Caustic Soda
Process Pump (ANSI)
Process Pump (ANSI)
Double Row Angular Contact Ball Bearings
SKF 3200, 3300, 5200, and 5300 Series
 30O Contact Angle
 High Load Capacity
 High Speed Rating
 Normal and CB Clearance
 Steel Cage
 Conrad (A Suffix) and Filling Slot
(E Suffix) Designs
 Seals (RS1 Suffix) and
Shields (Z Suffix)
 Snap Rings (NR Suffix)
Double Row Angular Contact Ball Bearings
SKF DR 2000 Series
 40O Contact Angle
 Optimized Ball Complement
 High Load Capacity
 High Speed Rating
 CB Clearance Standard
 Dimensionally Interchangeable
with 3300/5300 Series
 Machined Brass Cage
Heavy Duty Process Pump (API)
Heavy Duty Process Pump (API)
Single Row Angular Contact Ball Bearings
SKF 7200 and 7300 Series
Back-to-Back
 40O Contact Angle
 Universally Matchable
 High Load Capacity
 High Speed Rating
 CB Clearance Standard
 Cage Options Face-to-Face
 Machined Brass (M)

 Pressed Brass (Y)

 Pressed Steel (J)
 Polymer (P)
Single Row Angular Contact Ball Bearings
MRC Pumpac 8000 Series
 Matched Set of 40O and 15O Contact
Angle Bearings 15O
40O
 Machined Brass Cage
 High Load Capacity Thrust Load
 High Speed Rating Direction
 Insensitive to Skidding
 Should Only be Used When the
Axial Load is Predominantly in One
Direction
 Chevron to be Oriented in the
Direction of Load
 Questions on an Oil Refinery
 What is the size of the plant in terms of crude oil
processing?
 What kind of processes are employed: atmospheric
distillation, vacuum distillation, cat reforming, cat
cracking, hydro cracking, hydro treatment?
 What products are made: gasoline, fuel oil, lube oil,
petrochemical feed stock?
 Are downstream petrochemical plants part of the refinery?
 How many pumps, electric motors, blowers, compressors,
fans, etc. are used?
 Oil Refinery Bearing Sales Potential
 1000 barrels/day yield a total bearing potential of USD
300-500 depending on maintenance practices
 50% of the total bearing potential is for pump bearings
 100 pumps yield a total bearing potential of
USD 800-1200
 MTBF is 1.5 to 7 years depending on maintenance
practices
 Potential for mechanical seals is 4 to 6 times that of
bearings
 Annual Total Maintenance Costs
As a % of Plant Replacement Value

6.00

5.00

% 4.00

3.00

2.00

1.00

0.00 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47

Plant Number

Data Supplied By Reliability Technologies©