Petroleum Refinery - Overview, Process Description

Overview of Processing in
Petroleum Refinery
Teuku Muhammad Adhe Haikal
Wednesday, 1st November 2023
Overview of Processing in Petroleum Refineries
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Oil & Gas Industry
UPSTREAM DOWNSTREAM
JACK UP RIG FIX PLATFORM

CRUDE DISTILLATION UNIT
Disclaimer:
These images are from
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awareness
ONSHORE WELL
MOPU
CATALYTIC REFORMING UNIT
ONSHORE PROCESSING FACILITY
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Crude Oil Overview
Crude Oil Composition Evaluation of Crude Oil and

Petroleum fuels
Hydrocarbon 1. Boiling Range
1) Paraffin (Saturated hydrocarbons/alkanes), CnH2n+2
2) Olefin (Unsaturated hydrocarbons/alkenes), CnH2n 2. True boiling point
3) Naphthene (Cycloalkanes), CnH2n 3. UOP Characterization Factor
4) Aromatic hydrocarbons, CnH2n-6 (KUOP)
4. ASTM Distillations
Contaminants
5. API Gravity and Specific
1) Salts
2) Metal Gravity
3) Sand, Mineral Matter and Water 6. Flash Point
4) Sulphur Compounds 7. Reid Vapor Pressure
8. Octane Number
Characterization of Crude Oil 9. Pour Point
1. Paraffin-base Crudes 10. BS&W
2. Mixed-base Crudes 11. Cetane Number
3. Naphthene-base Crudes
4. Aromatic Crudes API = (141.5/Specific Gravity) - 131.5
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Sulphur Compound
Structure Formula of Paraffin,
Olefin, Naphthene, Aromatic
Isomer
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Typical Products
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Classification of Refining Processes
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Classification of Refining Processes
o Separation processes
o Finishing processes
Memanfaatkan perbedaan sifat fisik
Melibatkan hydrotreating untuk
komponen minyak mentah untuk
menghilangkan heteroatom (S, N, dan
memisahkan kelompok senyawa
logam) dan pencampuran produk untuk
hidrokarbon atau kontaminan anorganik.
menghasilkan bahan bakar dan bahan
(misalnya distilasi, dewaxing, dan de-
dengan spesifikasi yang diinginkan dan
asphalting)
sesuai dengan peraturan lingkungan
o Conversion processes
dan pemerintah.
Menyebabkan perubahan kimia pada
o Supporting processes
komposisi hidrokarbon minyak mentah.
Menyediakan recovery heteroatom atau
Misalnya, proses FCC (Fluid Catalytic
senyawa heteroatom yang dihilangkan,
Cracking) memutus ikatan kimia pada
produksi hidrogen yang diperlukan
alkana rantai panjang untuk menghasilkan
untuk proses konversi dan
alkana rantai pendek untuk produksi
hidrotreating, dan sistem pengolahan
bensin dari fraksi minyak gas dengan titik
air limbah.
didih lebih tinggi.
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Separation: Crude Distillation Unit (CDU)
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Conversion & Finishing
Gas H2 Gas H2
Light Isomerate
Hidrotreater Isomerization
Naphta
Gas H2 Gas H2
Heavy Reformate
Hidrotreater Catalytic
Naphta Reformer Gas H2
Gasoline Bleending System

Hydrocracked
Cracker
Gasoline
Hydro
Heavy Vacuum Gas
Diesel Oil
Gas Oil
i-Butane Alkylate
Alkylation
Gas Butenes
Atmospheric Pentenes
Gas Oil Gas H2 Gas H2
Cracking (FCC)
Fluid Catalytic
Naphta
FCC Feed Hydrotreater
Hidrotreater FCC
Light Vacuum Gasoline
Gas Oil FCC Gas Oil
Distillation
Fuel Oil
Vacuum
Atmospheric
Bottoms
Heavy Vacuum
Gas Oil
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Finishing & Supporting
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Flow Diagram Integrating the Four Types of Processes in a Petroleum Refinery
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CDU Plant (Typical)
Overview
Used 85,000 BPD Crude Oil Refining Unit
(Atmospheric and Vacuum Distillation)
built in 1975. This complete crude unit
produces naphtha, distillate, asphalt and
off gas.
Major Equipment
o Atmospheric Column
o Vacuum Column
o Flash Drum
o Desalter
o Fuel Gas Furnace
o Seal Drum
o Condenser
o Heat exchanger
o Super Pumps (up to 1500 HP)
o Compressor
Image source: www.phxequip.com
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CDU Plant (Typical)
Fuel Gas Furnace Atmospheric Column

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Typical CDU Flowchart
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CDU Products and Gap

Analysis of Product Gap
Table 1. Typical Product of CDU
Table 3. Analysis of Product Gap
No. Product Cut Range (˚C)
1 Overhead product < 30 Performance Test
No ASTM Distillation Data, oCelsius
2 Naphtha 30 - 150
1 2 3
3 Kerosene 150 - 250
4 Diesel 250 - 370 1 Light Naphta 95 % 69 74 77
Atmospheric 2 Heavy Naphta 5 % 105 106 100
5 370 >
Residue 3 Heavy Naphta 95 % 165 164 149
Table 2. Common Gap Product of CDU 4 Kerosene 5 % 193 193 191
No. Product Separation Gap (˚C) 5 Kerosene 95 % 265 265 245
Straight Run Naphtha 6 gap: Heavy- Light Naphta 36 ?? ??
1
and Kerosene 11
7 gap:Kero- Heavy Naphta 28 ?? ??
2 Kerosene and Diesel 5.6
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Crude Oil Desalting Process

Desalt Crude
Desalter
Crude Oil
Dilution Water
Waste to disposal
Sketch of Desalter
Three Dimensional Model of Crude Oil Desalter
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VDU (Vacuum Distillation Unit)

off gas
Steam
Kerosene Naphta
Gas
Steam
LVGO
Diesel
Steam HVGO
Fired Atmospheric
Gas Oil
Crude Oil
Heater Crude Oil

Desalter Slow Wax
Distillation
Steam Tower
Fired
Heater
Flow Diagram for Typical CDU & VDU Residue
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Hydrotreating
Hydrotreating is an efficient method to remove
several compounds, including:
o Sulfur is the most critical compound to
remove. It is present in nearly all crude oil
feedstocks as sulfur mercaptans, sulfides,
disulfides, polysulfides, and thiophenes.
o Nitrogen is typically treated with hydrogen
gas and transformed into ammonia gas.
o Oxygen is reacted with hydrogen and
eliminated as water. Most oxygen in
distillation cuts is not present as oxygen gas,
but bonded to hydrocarbons.
o Olefins are volatile and unstable, and they
are not desirable in fuels. Olefins are
transformed into stable paraffinic
hydrocarbons.
o Metals are removed because they can
deposit on catalysts and in engines.
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Hydro-treating Process
Process Objective:
Untuk menghilangkan kontaminan
(belerang, nitrogen, logam) dan
olefin jenuh serta aromatik untuk
menghasilkan produk yang stabil
Primary Process Technique:
o Hidrogenasi terjadi dalam fixed
catalyst layer untuk
meningkatkan rasio H/C dan
menghilangkan sulfur, nitrogen,
dan logam.
o Selama hydrotreating, crude oil
cuts direaksikan secara selektif
dengan hidrogen serta adanya
Simplified Secondary Processing
katalis pada suhu yang relatif
tinggi dan tekanan sedang
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Common Hydrotreating Reactions
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Hydrotreating Process for Naphtha
o Light naphtha (C4-C6), boiling point range 30 - 90 oC

o Heavy naphtha (C6-C12), boiling point range 90 – 200 °C
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Hydrotreating Process for Diesel Oil
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Catalytic Reforming Process

Process Objective:
To convert low-octane naphtha into a
high-octane reformate for gasoline
blending and/or to provide aromatics
(benzene, toluene, and xylene) for
petrochemical plants. Reforming also
produces high purity hydrogen for
hydrotreating processes.
Process Technique:
Reforming reactions occur in chloride
promoted fixed catalyst beds; or
continuous catalyst regeneration (CCR)
beds where the catalyst is transferred
from one stage to another, through a
catalyst regenerator and back again.
Feed & Product of Catalytic Reforming
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Chemical Reactions in Catalytic Reforming

Desired Reaction:
 Dehydrogenation of Naphthenes
 Isomerization of Naphthenes and Paraffins
 Dehydrocyclization of Paraffins
Chemical
Reactions in
Catalitic
Reforming
Undesired Reaction:
Hydrocracking
 Dehydrogenation of Naphthenes
R R
+ 3H2
 Isomerization of Naphthenes and Paraffins
R R' C
R-C-C-C-C R-C-C-C
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Chemical Reactions in Catalytic Reforming Unit

 Dehydrocyclization of Paraffins R'
+ nH2
R-C-C-C-C
 Hydrocracking R''
+ nH2
. C C
R-C-C-C + H2 RH + C-C-C
H
 Demethylation
R-C-C-C-C + H2 R-C-C-C-H + CH4
R R'
+ H2 + CH4
 Dealkylation Aromatic
R R''
+ H2 + R'''-H
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Catalyst Poison for Catalytic Reforming Unit

o Sulphur
Maximum Sulphur content in the feed naphtha is o Metal
0.5 ppm wt. The feed naphtha Sulphur content Due to irreversible reaction effect,
usually is maintained as 1.1 - 0.2 ppm to ensure the metal contamination on the
the stability and maximum catalyst selectivity. reforming catalyst is not allowed,
o Nitrogen so that the feed naphtha shall not
Maximum nitrogen content in the feed naphtha contain any metal at all.
is 0.5 ppm wt. The nitrogen content on feed o High Feed End Point
naphtha will form ammonium chloride deposit at Maximum naphtha end point
the catalyst surface. allowed as feed of catalytic
o Water reforming is 204 oC. For endpoint
Water content on recycle gas of 30 ppm mole higher than 204 oC, polycyclic
indicates excessive water, dissolved oxygen or aromatic concentration will
combined oxygen in catalytic reforming unit. increase significantly and also
Moisture content more than 30 ppm can cause result in higher coke laydown.
excessive hydrocracking and coke laydown. The
other impact is chloride that stripped from
catalyst to influence the H2O/Cl balance then
distract the desired reaction.
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CRU Flow Chart
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Continuous Catalytic Reforming (CCR)
Item Applications
1 Feed pump isolation valve
2 Automated reactor overhead regeneration
3 Automated reactor overhead purge
4 Manual standby reduction zone purge
5 Manual reactor bottoms unloading valve
6 Automated reactor bottoms unloading valve
7 Manual hydrogen loading to lock hopper #1
8 Manual hydrogen vent to lock hopper #1 & 2
9 Manual nitrogen purge for lock hopper #1 & 2
10 Manual catalyst for lift engager 1 & 2
11 Automated catalyst for lift engager 1 & 2
12 Manual air valve to regeneration cooler
13 Manual air valve to surge hopper
14 Automated fresh catalyst addition
15 Manual regen catalyst uploading from surge hopper
16 Manual regen catalyst uploading from surge hopper
17 Manual pressure balancing for lock hopper
18 Manual reactor reformate isolation valve
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Fluid Catalytic Cracking Process (FCC)
Fluid catalytic cracking process

Regenerator
o The fluid catalytic cracking process (FCC) for
Rather than introduce expensive fresh
conversion of straight run atmospheric gas oil, vacuum
catalyst to the process, the existing
gas oils, atmospheric residues, and heavy stocks
coke covered spent catalyst coming
recovered from other operations into high octane
from the reactor can be regenerated
gasoline, light fuel oils and olefin-rich light gases.
by removing the coke deposits using
o The key components of the FCC unit are the reactor,
high temperature air at around 600 -
the regenerator and the fractionator.
700 C.
Reactor
Fractionator
o Feed is heated and mixed with the catalyst; reaction
The fractionating column separates
starts even before the fluid reaches the reactor;
the light ends, gasoline, and fuel oils.
therefore, the residence time in the reactor vessel is
The remaining bottoms product is
very short.
termed cycle oil and is typically fed
o The prime role of the reactor is to function as a
back to the beginning of the process
catalyst separator removing spent (coked) catalyst and
where it is mixed with the fresh feed.
direct it to the regenerator with cracked products
moving on to the fractionator.
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Fluid Catalytic Cracking Process (FCC)
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Delayed coking unit

Upgrade residues to lighter hydrocarbon fractions using the Selective Yield Delayed Coking (SYDEC) process
Description: Operating conditions (typical ranges):

o Charge is fed directly to the fractionator (1) where it o Heater outlet temperature,900 – 950 ºF
combines with recycle and is pumped to the coker o Coke drum pressure, 15 – 100 psig
heater. o Recycle ratio, equiv. fresh feed 0 – 1.0
o The mixture is heated to coking temperature, causing o Increased coking temperature decreases
partial vaporization and mild cracking. The vapor-liquid coke production; increases liquid yield
mix enters a coke drum (2 or 3) for further cracking. and gas oil end point.
o Drum overhead enters the fractionator (1) to be o Increasing pressure and/or recycle ratio
separated into gas, naphtha, and light and heavy gas increases gas and coke make, decreases
oils. Gas and naphtha enter the vapor recovery unit liquid yield and gas oil end point.
(VRU)(4). Products: Gas, Naphtha, Gas oil, Coke
o There are at least two coking drums, one coking while Licensor: Foster Wheeler USA
the other is decoked using high-pressure water jets. Corp./UOP.
o The coking unit also includes a coke handling, coke
cutting, water recovery and blowdown system. Vent gas
from the blowdown system is recovered in the VRU.
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Delayed coking unit

Upgrade residues to lighter hydrocarbon fractions using the Selective Yield Delayed Coking (SYDEC) process
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Isomerization
Process Objective:
To convert low-octane n-
paraffins to high-octane iso-
paraffins.
Primary Process
Technique:
Isomerization occurs in a
chloride promoted fixed bed
reactor where n-paraffins are
converted to iso-paraffins.
The catalyst is sensitive to
incoming contaminants (sulfur
and water).
Schematic Flow Diagram of Isomerization

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Isomerization
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Hydrocracking Process
Description:
o Hydrocracking process uses well proven co-current downflow fixed bed
reactors with state – of – the – art reactor internals and catalysts.
o The process uses recycle hydrogen and can be configured in partial
conversion once-through feed mode or with recycle of partially
converted oil to obtain 100% conversion to diesel and lighter products.
o Zeolitic and amorphous hydrocracking catalysts have been proven in
several commercial hydrocrackers.
Operating conditions:
o Typical operating pressure and temperatures range from 55 to 170 bar
(800 to 2500 psig) and 340 to 420°C (645 to 780°F).
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Hydrocracking Process
Description:
o Hydrocracking process can be used
to convert straight run vacuum gas
oils and heavy cracked gasoils to
high quality “sulfur-free” naphtha,
kerosene, diesel, and FCC feed,
meeting current and future
regulatory requirements.
o Hydrocracking process can be
designed for high conversion to
produce high smoke point kerosine
and high cetane diesel.
o The process can also be designed
for lower conversion/upgrade
mode to produce low sulfur FCC
feed with the optimum hydrogen
uptake or high VI (>145) lube stock.
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Visbreaking Process
Description:
In a “coil” type operation, charge is fed to the
visbreaker heater (1) where it is heated to a
high temperature, causing partial
vaporization and mild cracking. The heater
outlet stream is quenched with gas oil or
fractionator bottoms to stop the cracking
reaction. The vapor-liquid mixture enters the
fractionator (2) to be separated into gas,
naphtha, gas oil and visbroken resid (tar).
The tar may also be vacuum flashed for
recovery of visbroken vacuum gas oil.
Operating conditions:
Heater outlet temperature, ºF 850 – 910
Quenched temperature, ºF 710 – 800
An increase in heater outlet temperature will

result in an increase in overall severity,
further viscosity reduction and an increase in
conversion.
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Alkylation
Process Objective:
To combine light olefins
(propylene and
butylene) with isobutane
to form a high octane
gasoline (alkylate).
Primary Process
Technique:
Alkylation occurs in the
presence of a highly
acidic catalyst
(hydroflouric acid or
sulfuric acid).
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Merox Treatment
Process Objective:
Merox is often used to
treat products such as
LPG, naphtha, gasoline,
kerosene, jet fuel and
heating oils.
Process Technique:
Merox is a process to
extract and/or convert
Mercaptan sulfur into less
objectionable disulfides.
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Merox Treatment
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Feed and Products

No Processing Unit Feed Product
1 Naphtha Hydrotreater straight run naphtha and sweet naphtha (max. Sulphur and N2 content of 0.5 ppm
cracked naphtha wt and max. metal content of 2 ppm wt).
2 Catalytic Reforming sweet naphta from Naphtha HOMC (High Octane Mogas Component, LPG, gas H2)
Unit Hydrotreater
3 Fluid Catalytic Cracking heavy gas oil gasoline and diesel
4 Delayed Coking hydrocarbon long chain Gas, LPG, gasoline (cracked naphtha), gas oil (cracked
diesel), and residue/coke
5 Isomerization low-octane n-paraffins high-octane iso-paraffins
6 Hydrocracking low value naphtha, middle distillates, and ultra-clean lube
gas oils base stocks
7 Visbreaking Process Vacuum Residue overhead tail gas, naphtha and bottom
8 Alkylation light olefins (propylene and high octane gasoline

butylene) and isobutene.
9 MEROX Treatment Hydrogen sulfide free feed Treated LPG, naphtha, gasoline, kerosene, jet fuel and
heating oils
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Supporting process: Sulfur Recovery Unit (SRU)
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Supporting process: Water Treatment
Typical CPI separator

Water Treatment System
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Reference
a. “Basic Principles and Calculations in Chemical Engineering”, David M. Himmelblau / James B. Riggs,
2004, 7th Ed., PRENTICE HALL Professional Technical Reference, New Jersey.
b. ”Fuel, Combustion and Furnaces”, Griswold, J., 1946, McGraw-Hill Book Company, Inc. , New York.
c. “Oil Refinery Processes” A Brief Overview, Colwell, R.E., 2009, Process Engineering Associates, LLC.
d. ”Petroleum Refinery Engineering”, Nelson, W.L., 1985, 4.ed., International Student Edition, McGraw-
Hill Book Company, Singapore.
e. “Teknologi Proses Kilang Minyak Bumi”, Buku Pintar Migas Indonesia, Adhi Budiarto.
f. “Petroleum Waste Treatment and Pollution Control”, 2017,Shahryar Jafarinejad.
g. Fahim, M., et al., “Fundamentals of Petroleum Refining,” Elsevier Science, Amsterdam, Netherlands
(2010).
h. U.S. Energy Information Administration, “EIA-820 Annual Refinery Report,” EIA, Washington, DC
(2021).
i. Rao, B., “Modern Petroleum Refining Processes, 6th Edition,” CBS Publishers and Distributors Private
Limited, New Delhi, India (2018).
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Thank You
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Overview of Processing in

Oil & Gas Industry

JACK UP RIG FIX PLATFORM

CATALYTIC REFORMING UNIT

ONSHORE PROCESSING FACILITY

Crude Oil Overview

Crude Oil Composition Evaluation of Crude Oil and

Classification of Refining Processes

Classification of Refining Processes

Separation: Crude Distillation Unit (CDU)

Conversion & Finishing

Gasoline Bleending System

Finishing & Supporting

Flow Diagram Integrating the Four Types of Processes in a Petroleum Refinery

CDU Plant (Typical)

CDU Plant (Typical)

Fuel Gas Furnace Atmospheric Column

Typical CDU Flowchart

CDU Products and Gap

Crude Oil Desalting Process

Three Dimensional Model of Crude Oil Desalter

VDU (Vacuum Distillation Unit)

Heater Crude Oil

Common Hydrotreating Reactions

Hydrotreating Process for Naphtha

o Light naphtha (C4-C6), boiling point range 30 - 90 oC

Hydrotreating Process for Diesel Oil

Catalytic Reforming Process

Feed & Product of Catalytic Reforming

Chemical Reactions in Catalytic Reforming

 Isomerization of Naphthenes and Paraffins

Chemical Reactions in Catalytic Reforming Unit

Catalyst Poison for Catalytic Reforming Unit

CRU Flow Chart

Continuous Catalytic Reforming (CCR)

Fluid Catalytic Cracking Process (FCC)

Fluid catalytic cracking process

Fluid Catalytic Cracking Process (FCC)

Delayed coking unit

Description: Operating conditions (typical ranges):

Delayed coking unit

Schematic Flow Diagram of Isomerization

An increase in heater outlet temperature will

Feed and Products

8 Alkylation light olefins (propylene and high octane gasoline

Supporting process: Sulfur Recovery Unit (SRU)

Supporting process: Water Treatment

Typical CPI separator

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