EN4003 – oil engineering

TE09/10-REFINING BASICS

S. QUESNEL

26/10 & 02/11/17

Investigation – expo downstream
• 30th of november EXPO
• 5 groups of 3 students – 1 group of 4 students*
• 1 group = 1 topic downstream
• 1 report (mini 15 pages) / 8 points
• 1 exposition (15-20 mins) / (5 ind + 5 group) points
• 1 peer evaluation (auto and team evaluation) / 2 points
• Topics :
- biofuels ETBE production unit - biodiesel production
- electric network in refineries - steam vapor in refineries
- hydrogen in refineries - isomerisation unit
- catalytic reforming unit and gas plant (separation of LPG)

* students who were not part of 4 group students for expo

UPstream
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
 Investigation – expo
• Identify the context…

• Identify the consumption / production / demand Peru y

latin america …

• Identify and understand the equipment and process or

network ?...

• Describe how it works ? The main parameters and

standards applicables….

• Identify an impact environmental or safety ….

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

Glossary
https://jpcruzan.files.wordpress.com/2010/02/glosarioingles-espanol.pdf

Gasoline = gasolina

Diesel = gasoleo o diesel

Vaccum = a vacio

Lead = plomo

Catalyst = catalizador

Process = tratamiento

Feed = carga

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

 BBL?
safetysystems.valves.pentair.com

Refineries in Peru ?
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
 BBL?
safetysystems.valves.pentair.com

Refinerias en Peru ?
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
 OBJECTIVES

1. Know the structure of a refinery

2. Identify the different units of production

3. Understand the general schema of a refinery

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

 CONTENTS
0. Refinery Conchan 30´
1. General schema 30’
2. Distillation – GPL - gasoline 20’
3. Gasoline - Kerosene 30‘

02/11/17
Quizz PA4 : midstream – hydraulics - refinery 1 30´
4. Diesels 30’
5. Fuels - asfalts 30’
6. Case study Peru 60´

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

Power – energy of pumps
Pb(kW) brake power (kW)

Pb(kW) = q ρ g h / (Eff *3.6 106)

Ph(kW) hydraulic power (kW)

Ph(kW) = q ρ g h / (3.6 106)

q = flow capacity (m3/h)

ρ = density of fluid (kg/m3)
g = gravity (9.81 m/s2)
h = differential head (m)
The hydraulic Horse Power Ph(hp) :
Ph(hp) = Ph(kW) / 0.746
Pump input or Brake HorsePower (BHP) : potencia mecanica al eje de la
bomba.
Pump output or hydraulic or Water HorsePower (WHP) : potencia que puede
26/10 & 02/11/2017 proveer la bomba alTE09/10
liquido–refining rev 1 - S.Q
0. Conchan refinery
PETROPERU - Postulación al
Reconocimiento a la Gestión de Proyectos
de del medio Socio-Ambiental de Refinería
Conchán a través de la sustitución de la
Matriz Energética de Hornos y Calderos –
CIP - 2013

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

0. Conchan refinery

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

0. Conchan refinery

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

0. Conchan refinery

PETROPERU - Postulación al Reconocimiento a la Gestión de Proyectos

de del medio Socio-Ambiental de Refinería Conchán a través de la
sustitución de la Matriz Energética de Hornos y Calderos – CIP - 2013
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
0. Conchan refinery
• 1961
• National and imported Crude oil (Ecuador / Colombia) *
• Maritime Boat until 75.000 DWT
• Crude Distillation Unit 15,500 barrils per day
• gasolines for motors, solvents, diésel 2, diesel B5,
industrial fuels & asfalts
• Storage 2, 051,354 barrils of líquid hydrocarbons
* 2015

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

 http://sisbib.unmsm.edu.pe/bibvirtualdata/Tesis/Ingenie/matos_sp/T_completo%20.PDF

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

0. Conchan refinery
PETROPERU - Postulación al Reconocimiento a la Gestión de
Proyectos de del medio Socio-Ambiental de Refinería Conchán a
través de la sustitución de la Matriz Energética de Hornos y
Calderos – CIP - 2013

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

0. Conchan refinery

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
0. Conchan refinery
PETROPERU - Postulación al Reconocimiento a la Gestión de Proyectos
de del medio Socio-Ambiental de Refinería Conchán a través de la
sustitución de la Matriz Energética de Hornos y Calderos – CIP - 2013

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
 • REFINERIA
CONCHAN 40
ANOS
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
1. Refining overview
• Organisation

• Crude oil
• Comercial products
• Units of production

• Supply chain

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

1.1 Organisation
• 24H/24H – 365D/365 – 600 people Talara

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

1.1 Organisation
• Director
• Human ressources : pay and benefits, formation, work
contract,administration, legal
• Control of budget, commercial, accounts, purchase
• Quality – Safety – Environment - laboratory
• Operations : operators, equipments, explotation
• Technical : follow up of the units, projects studies,
optimisation
• Maintenance : reparation, test and control of the
equipments, projects, construction, inspection
• Planification, supply chain, storage

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

1.2 Crude oil-> products

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

1.3 Units of production
• Purchase of the crude oil (trading)
• Supply chain and storage of the crude oil

• Crude oil distillation to separate the subproducts

• Processing of the subproducts (ex:desulfuration)

• Blending the products to make comercial products

• Quality control
• Storage and supply chain of the comercial products

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

1.4 Units of production

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

1.5 Quizz
UNIT PRODUCTS

• HDT • Kerosene

• HDS
• Gasoline
• Reforming

• Merox • Diesel

• Amines
• GPL

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

2. Distillation – products GPL
• Desalting
• Pre heat train
• Distillation tower

• Processing of the naftas – extraction of LPG - desulfuration

• Separation of butane, propane,…
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
2.1 Pre heating
• Objetive : heat up the crude oil for desalting and fractioning

• Heat exchangers : Shell and tubes – TEMA

• Energy optimisation using warms streams to heat cols streams

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

2.2 Desalter
• Crude oil = hidrocarbons + salts + water + sediments
• Corrosion risk in the top of the tower od distillation
• Separation = decantation and electrostatic effect
Crude oil
desalted

Crude
oilsalty
Water Sediments
wash slugs

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

2.3 Atmosferic distillation

Destilacion
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q Destilacion 2
2.4. Naftas - GPL - gasoline

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

2.5. GPL - processing
In order to respect the comercial specifications:
• Washing gases to eliminate componentes S, H2S
• Separation of butane, propane : fractionning

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

QUIZZ : gasoline / LPG
• Gasohol ?

• Specifications of gasoline ?

• Specifications of diesel ?

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

 3.1. Gasoline
Nafta from distillation tower (Tfinal eb 200°C) requires processing:
• HiDroTreatment (H2) to eliminate N, S of the gasoline
• Splitter to separate lighters hidrocarbons (volatily)
• Reforming to improve the octane number

• Isomerisation to produce isomerate (good octane number)

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

3.2 Gasoline
Base to produce fuels for vehicules :
• Gasoline 84
• Gasoline 90
• Gasoline 95
• Gasoline 97

Main specifications :
• Vapor pressure < 11 Psi
• Final ebullition temperature < 220°C
• Concentration of lead (plomo) < 0.013 g/L
• Sulfur total < 0.2% (50 ppm 201?)
• Concentration of alcoholes componentes
Source : nafta from Unit of Distillation Primary
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
3.3 Kerosene (jet fuel)
Base to produce combustible for planes :
• Turbo A1 : comercial planes
• Turbo JP-5 : militar planes

Main specifications for Turbo A-1 :

• Freez point(cristalisation) < -46°C
• Final point of ebullition < 300°C
• Flash point > 38°C
• Concentration of sulfur < 0.3%

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

3.4 Turbo for planes
• Process Merox to reduce the concentration of sulfur
components
• Sweetening with catalyst

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

Quizz : storage
• Kerosene

• Gasoline

• Butane

• Propane

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

Quizz
UNIT PRODUCTS

• HDT • Kerosene

• HDS
• Gasoline
• Reforming

• Merox • Diesel

• Amines
• GPL

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

4. Diesels or distillates or gasoils
•

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

4.1 Diesels
Base to produce combustibles for car / trucks :
• Diesel B2
• Diesel B5 (Biodiésel B% aceites vegetales o grasas animales)

Main specifications :
• Kinematic viscosity 40°C : 1.7 – 4.1 cSt
• Final point of ebullition < 360°C
• Pour point (punto de escurrimiento) > 4°C
• Concentration of sulfur components (wt) < 50ppm

Sources : Unidad de Destilación Primaria or Crude Distillation Unit

Unidad de Destilación a Vacío or Vacuum Distillation Unit
Craqueo Catalítico en lecho Fluido or Fluid Catalytic
Cracking
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
4.1 Diesels

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

4.2 UDP - UDV
Diesels from UDP :
• Atmosferic Diesels
• GOA : Automotive GasOil

Diesels from UDV :

• GOLV : Vacuum Light GasOil
• GOPV : Vacuum Heavy GasOil

UDV :
• Fractionnate at reduce pressure to separate the heavy products
from Atmosferic Distillation (Atmosferic Residue)
• Produce Vacuum Diesels (GOLV/GOLPV) and Vacuum Residue (RV)
• Produce bases for asfalts, lubes
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
4.2 UDVacuum

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

4.2 UDVacuum

ChemEngineering
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
4.2 UDV

Source:Fawley oil refinery

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

4.2 UDV

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

4.3 Desulfuration of diesels
To comply with the specifications of sulfur concentration (50ppm),
an HydroDeSulfuration (HDS) unit of diesels is required :
• High Pressure (30-50 bar g) and temperature (350°C)
• Catalyst y hydrogene for the chemical reaction

It extracts the sulfur by combination with Hydrogene in order to

produce H2S (toxic gas) which requires treatment.
Unity associated to treat gas H2S : Unity Claus (production of sulfur)

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

4.3 Desulfuration of diesels

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

4.4 FCC
Conversion process of the heavy and long molecules to shorter and
lighters which will be used as bases for gasolines and diesels :
• feed : heavy diesel, or Atmosferic Residue,
• products : propane, butane, propylene, Light Cut Oil (Diesel form
FCC), butane, butene, Naphta Cracking (NFCC)

Complex process with circulation of catalyst and a fractionning section

(splitter) of the reaction products.

S H U : Hydrotreatment of nafta from FCC

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
4.4 FCC

Honeywell UOP
500
550°C
700-
750°C

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

4.4 FCC

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

4.5 FCC videos

3D video

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

5. Fuels – asfalts - lubes
Process to produce heavy comercial products from crude oil :
• Asfalts from Vacuum Residue (RV)
• The vacuum residue could produce fuels after a visbreaking
process
• The fuels (petróleos industriales) are used in the industry for
boilers and furnaces.
• Bases to make mineral oils, lubes (lubricantes)

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

5.1 Fuels
Different categories of fuels (petróleos industriales) :
• Petróleo industrial 4/5/6
• Petróleo industrial 500

Main specifications principales (fuel 6 / fuel 500):

• Kinematic viscosity at 50°C : 81 – 640 cSt / 641-1060 cSt
• Quantity of wáter and sediments < 2% vol
• Flash point > 60°C / 65°C
• Sulfur concentration (wt) < 3.5%

Source : Unidad de Destilación a Vacío (UDV o VDU)

Visbreaking de RV
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
5.2 Visbreaking

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

5.3 Lubes
Different applications for lubes :
• Vehicules
• Industry (rotating equipment)

Main specifications :
• Kinematic viscosity
• Pour point
• Compatibility with materiales

Sources : Unidad de Destilación a Vacío (UDV o VDU)

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

5.3 Lubes
Aromatics

Heavy Mineral oils

AROMATIC
Diesels
EXTRACTION

Light
Medium DEWAXING
Heavy

FINAL FINAL
ADDITIVES
Vacuum Residue
PARAFINS
WAX
Asfalts
LUBRICANTS

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

5.4 Asfalts - bitumens
Diferents types :
• Solid Asfalts -> require heating
• Liquid Asfalts -> diluted with a solvent without heating

Main specification :
• Kinematic viscosity
• Penetration

Sources : Unidad de Destilación a Vacío (UDV o VDU)

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

5.5 Asfalts - process

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

Conclusions

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

• cuarto poder talara 12 minutes

• TALARA general 10mins

• Talara dentro 15mins – global

• how is working a refinery 3mins

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

 6.2 Case study – Peru
• 2 groups Talara / 2 groups Pampilla

• Identify the process units

on the diagramas before and after MODERNISATION

• Identify the feed and final products of the new or

modified units ?

• Search The total cost of the project

• Search examples of modification or new equipment

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

6.2 Case study Pampilla : before

Source: http://www.minam.gob.pe/calidadambiental/wp-
content/uploads/sites/22/2014/06/Taller-MINAM-Jun-2014-Final-
26/10 & 02/11/2017 REPSOL.pdf TE09/10 –refining rev 1 - S.Q
6.2 Case study Pampilla : after

Source: http://www.minam.gob.pe/calidadambiental/wp-
content/uploads/sites/22/2014/06/Taller-MINAM-Jun-2014-Final-
26/10 & 02/11/2017 REPSOL.pdf TE09/10 –refining rev 1 - S.Q
6.2 Case study Talara : before

Source : http://www.minem.gob.pe/minem/archivos/file/DGGAE/ARCHIVOS/estudios/EIAS%20-
%20hidrocarburos/EIA/PETROLEOS_PERU/3.0%20Descripci%C3%B3n%20del%20Proyecto.pdf
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
 6.2 Case study Talara : after

Source : http://www.minem.gob.pe/minem/archivos/file/DGGAE/ARCHIVOS/estudios/EIAS%20-
%20hidrocarburos/EIA/PETROLEOS_PERU/3.0%20Descripci%C3%B3n%20del%20Proyecto.pdf

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q

 6.2 Case study Talara : after

Source : https://www.petroperu.com.pe/pmrt/wp-content/uploads/2017/04/Informe-
Proyecto-Modernizacion-Refineria-Talara.pdf
26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q
Fuentes : http://www.petroperu.com.pe/pmrt/infografias/
 Ressources
https://www.petroperu.com.pe/pmrt/
www.perupetro.com.pe

La industria de los hidrocarburos líquidos en el Perú: 20 años de aporte al desarrollo

país, Organismo Supervisor de la Inversión en Energía y Minería, Osinergmin, 2015

http://www.minam.gob.pe/calidadambiental/wp-
content/uploads/sites/22/2014/06/Taller-MINAM-Jun-2014-Final-REPSOL.pdf

Osinergmin - Organismo Supervisor de la Inversión en Energía y Minería

www.osinergmin.gob.pe/

J P Wauquier, El Refino Del Petróleo: Petróleo Crudo, Productos Petrolíferos, Esquemas

de Fabricación, Technip -> library UTEC *

Robert A. Meyers, Handbook of Petroleum Refining Processes, Third Edition

McGraw-Hill Education, 2004 -> Access engineering
Don W. Green, Perry's Chemical Engineers' Handbook, Eighth Edition, McGraw-Hill,2008,
-> Access engineering
Surinder Parkash, Petroleum Fuels Manufacturing Handbook,The McGraw-Hill, 2010

26/10 & 02/11/2017 TE09/10 –refining rev 1 - S.Q