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Introduction
Impurities in crude oil
Pretreatment of crude oil
Crude desalting
Crude distillation unit (CDU)
Vacuum distillation unit (VDU)
Introduction
• The petroleum refining process is the separation of
different hydrocarbons present in the crude oil into
useful fractions and the conversion of some of the
hydrocarbons into products having higher quality
performance.
• Refinery gases.
• Liquefied petroleum gas (LPG)
• Gasoline or naphtha (light / heavy)
• Kerosene, lamp oil jet fuel
• Diesel oil and domestic heating oils
• Heavy Industrial fuels
Secondary Distillation (Vacuum Distillation)
• Field separation.
• Desalting at plant site.
Process for Improvement of Properties
Hydroprocessing
• Hydrocracking
• Hydrotreating
• Catalytic cracking
• Catalytic reforming
• Isomerization
• Alkylation
• Polymerisation
Conversion Processes
• Thermal processes
• Visbreaking
• Delayed Coking
Catalytic Processes
• Catalytic cracking
• Hydrocracking
• Steam reforming
• Hydroconversion
Finishing Processes
• Hydrotreatment hydrogenation
• Sweetening
Environmental Protection Processes
• Acid gas processing
• Stack gas processing
• Waste water treatment processing
Process flow diagram of a simplified refinery unit
Flow diagram of a refinery facility for light oils (mainly gasoline,
kerosene, and distillates)
Figure 15. A Refinery facility
Evaluation of Crude Oil
• Calcium and magnesium chloride salts begin
to hydrolyse at 120oC releasing hydrogen
chloride gas which dissolves in water during
condensation in the crude oil distillation
column overhead or in the condenser causing
corrosion of materials at these locations.
CaCl2 H 2O 2HCl CaO
MgCl2 H 2O 2HCl MgO
Pretreatment of Crude Oil
• This separation process takes place on site
where crude oil is dug out.
s
E is the electric field, d is the drop diameter and
s is the distance between the drop centres and
K is a constant.
Desalting Process
• Settling: According to Stokes’ law, the settling
rate of the water droplets after coalescence is:
Settling rate
k H2O oil d 2
oil
A more severe thermal cracking of heavy gas oil can be used to produce
LPG and ethylene and light and middle distillates from heavy gas oil. A
highly aromatic byproduct from thermal cracking is called ethylene tar.
Ethylene is an important petrochemical feedstock, while ethylene tar can
be used as feedstock to produce carbon blacks. Catalytic cracking is
more frequently used for conversion of heavy gas oil to gasoline.
Conversion of Heavy Gas Oil
Conversion of Heavy Gas Oil
LONG RESIDUE
And WHERE do we get it from ?
102
Crude Distillation Units
+
• High Vacuum Unit
• Hydrogen Manufacturing Unit
• Hydrocracker Unit 103
Figure 15. A Refinery facility
Hydrocracker Overview
Stea Hydrogen
m
LPG GAS
Waxy Distilate
Short
Naphtha
Residue
Gas OIl
105
Hydrogen Manufacturing Unit
Catalyst
R
(Increase rate of reactions)
E
A Reactions
High Temp. C produce
T Hydrogen
O
R and
High press. Steam consume
heat
Plat Gas & Butane
HMU
106
HMU Reactions
CO + H2O = CO2 + H2
H
C
O + H2O
= C
O + H
O
C H H
H H2O H
CO H
H H2O H
C C H
H
H H + HO
H2O 2
= CO
+ H H
H
C H CO
H CO H
H H
H
H H
H
C
H H + H2O
= CO
+ H
H
H
H H
110
High Vacuum Unit
• The feed for the Unit is From CD1 , CD2 and Residue
tankage
• Under a vacuum of 20 mbar the light ends in the
long residue separate and pass up the column
• The light gases from the top of the column sent to
the furnace as a sour gas.
• Two further streams lower down the column go to
the Hydrocracker as Waxy Distillate
• The Short Residue from the bottom of the column is
pumped to Visbreaker Unit (VBU) as feed
111
Steam
Gas
20 mbar Vacuum
drawn by ejectors Gas to the Furnaces
20 mbar
Waxy
Distilate
Vacuum
Column Waxy Distilate
Waxy Distillate to
the Hydrocracker
Furnace
Long
Residue Short Residue to the
Visbreaker Unit Short Residue
VBU High Vacuum Unit HVU
112
•High Vacuum Unit
•Hydrogen Manufacturing Unit
•Hydrocracker Unit
113
Hydrogen Manufacturing Unit
114
Hydrogen Manufacturing Unit
• The Hydrogen is produced in the Reforming furnace
by reacting Hydrocarbons with Steam over a catalyst
• The unit produces 300 tonnes per day of high purity
Hydrogen for use in the Hydrocracker
• A by product of this reaction is Carbon Monoxide
( CO) and Carbon Dioxide CO2
• In a further stage to the process the CO reacts with
water to produce CO2 and Hydrogen
• The CO2 is separated from the Hydrogen and vented
to the atmosphere
115
270 gas burners Chemical reaction takes
place in the Reformer tubes
Feed Gas
Natural Gas
Free Gas from the
reformer unit.
Steam
H C C C C C C C H
H H H H H H H
H H
H H H H
Naphthenic C C
H C C
H
C C
H H H C C H
C C
H Aromatics C C
H
H H H H
118
Example of a Hydrocracking Reaction
Heptane
H H H H H H H
H C C C C C C C H
H H H H H H H
119
Example of a Hydrocracking Reaction
H H H H H H H
H C C C C C C C H
H H H H H H H
120
Example of a Hydrocracking Reaction
H H H H H H H
H C C C C H H C C C H
H H H H H H H
= Butane = Propane
121
Hydrocracking
Promotes Reaction
Catalyst
125 barg
High Pressure
370°C - 420°C
High Temp.
ADSORBS
Heavy Metals,
Bed 2 Nickel & Vanadium
Waxy Dist
HGO CONVERTS
Bed 3
Sulphur S + H2 = H2S
Nitrogen N + H3 = NH3
Oxygen O + H2 = H2O
Bed 4
Hydrogen
From HMU
To Reactor 2
Reactor 1 demetaling and Sulphur removal 124
Hydrodesulphurisation
Sulphur Contaminated
H H H H H H H
H C C C C C C C S
H H H H H H H
125
Hydrodesulphurisation
H H H H H H H
H C C C C C C C S
H H H H H H H
126
Hydrodesulphurisation
Hydrocarbon Molecule
H H H H H H H
H C C C C C C C H
H H H H H H H
H2S
S
( Hydrogen Sulphide )
H
127
Hydrocracking
Exothermic
Reactions
Cool H2
Quench
to control
Hydrogen reactions
C12 - C36
C3 & C4’s
C5 - C11’s
C12 - C14’s
C14 - C20’s 128
Distillation Section Gas C3 to C4
Naphtha C5 to C11
Distillation separates
fractions of oil because
of their different boiling points
C3 & C4’s
C5 - C11’s
C12 - C14’s
C14 - C20’s
VBU T-8144
Short Residue HFO
10800 t/d 5000 t/d
131
Scheme of petroleum refining
processes