REFINERY BASICS

Scope
BASICS REFINERY OPERATIONS CONCEPTS

CHAPTERS
123BASICS OF CRUDE OIL PETROLEUM INDUSTRY CRUDE OIL REFINING

Chapter -1

BASICS OF CRUDE OIL

1. BASICS OF CRUDE OIL

Crude oil: Crude oil or Petroleum are complex mixtures containing many different hydrocarbon compounds that vary in appearance and composition from one oil field to another. Crude oils range in consistency from water to tar-like solids, and in color from clear to black.

1. BASICS OF CRUDE OIL

Classification: The petroleum industry generally classifies crude oil on the following basis Geographic location Crude oil Assay API Gravity Sulfur Content
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1. BASICS OF CRUDE OIL

GEOGRAPHIC LOCATIONS On the basis of geographic location it is produced in, crude oil is classified as West Texas, Qatar marine, Oman, Arabian light etc. CRUDE OIL ASSAY On the basis of Crude oil assays1 crude oil is classified as Paraffinic Naphthenic Aromatic Mixed-base
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1. BASICS OF CRUDE OIL

API GRAVITY On the basis of API Gravity2 crude oil is classified as The higher the API gravity, the lighter the crude. The lower the API gravity, the heavier the crude SULFUR CONTENT On the basis of sulfur content crude oil is classified as Sour crude: Crude that contains appreciable quantities of hydrogen
sulfide or other reactive sulfur compounds Sweet crude : Crude that contains small quantities of hydrogen sulfide or other reactive sulfur compounds
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1. BASICS OF CRUDE OIL

THINGS TO REMEBER oil assay is essentially the chemical evaluation of crude oil feedstocks by petroleum testing laboratories. Or simply detail test report of crude oil analysis.
2API

1Crude

Gravity

Deg. API = 141.5 - 131.5 Sp. Gr.

OR

Sp. Gr. =

141.5 API + 131.5

1. BASICS OF CRUDE OIL

THINGS TO REMEBER Density is a measure of the thickness of the material. Density = Mass/Volume
Different units are used for density i.e. Kg/m3, lb/ft3 etc. Specific Gravity is the ratio of the density of material and density of water. Sp. Gr. = Density of material/ Density of water BS & W (Base Sediments & water) The heavy material which collects in the bottom of storage tanks, usually composed of oil, water, and foreign matter.
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1. BASICS OF CRUDE OIL

Composition:
Elemental Composition by weight
ELEMENT Carbon Hydrogen Nitrogen Oxygen Sulfur RANGE 83% - 87% 10% - 14% 0.1% - 2.0% 0.1% - 1.5% 0.5% - 3.0%

Hydrocarbon Composition by weight

HYDROCAR. Paraffins Naphthenes Aromatics Asphaltics RNAGE 15% - 60% 30% - 60% 03% - 30% 06% - Remainder
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Chapter -2

PETROLEUM INDUSTRY

2. PETROLEUM INDUSTRY
Petroleum Industry:

The petroleum industry is divided into three major components Upstream Midstream Downstream

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2. PETROLEUM INDUSTRY
UPSTREAM The upstream oil sector is a term commonly used to refer to the search for and the recovery and production of crude oil and natural gas.
The upstream oil sector is also known as exploration & production (E&P) sector.

DOWNSTREAM The downstream oil sector is a term commonly used to refer to refining of crude oil, and the selling and distribution of natural gas and products derived from crude oil. Midstream operations are usually included in the downstream category.
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2. PETROLEUM INDUSTRY
OIL REFINERY An oil refinery is an industrial process plant where crude oil is processed and refined into more useful petroleum products, such as gasoline, diesel, fuel oil, asphalt base etc.
A refinery is composed of two groups of chemical engineering Unit Operations mean physical change. Fluid Flow, Distillation, Heat Transfer, Filtration, evaporation etc are some example. Unit Processes mean chemical change. Oxidation, Reduction, Hydrodesulphurization, Hydro-reforming etc are some example.

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2. PETROLEUM INDUSTRY
TYPES OF OIL REFINERY
ON THE BASIS OF END PRODUCT

Fuel Refinery Lube Refinery

ON THE BASIS OF NO. OF UNITS

Topping Refinery Hydro-skimming Refinery Cracking Refinery Coking Refinery

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FUEL REFINERY

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HYDROSKIMMING REFINERY

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Chapter -3

CRUDE OIL REFINING

3. CRUDE OIL REFINING

Crude Oil Refining: Hydro-skimming Refinery can be split into following units Crude Distillation Unit Merox Unit (Naphtha, Kerosene, LPG) Hydrodesulphurization Unit Reformer Unit

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3. CRUDE OIL REFINING

CRUDE DISTILLATION UNIT The processing scheme of Crude Distillation unit can be described as

Desalting Heat Treatment Fractionation

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3. CRUDE OIL REFINING

DESALTING Desalting/dehydration is a process in which water, inorganic salts,

suspended solids, and water-soluble trace metals are removed from crude oil. This is the first step in the refining process, to reduce corrosion, plugging, and fouling of equipment.

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3. CRUDE OIL REFINING

HEAT TREATMENT

At the refinery, the desalted crude feedstock is preheated using recovered process heat (Exchanger1 Trains). The feedstock then flows to a direct-fired crude charge heater.
FRACTIONATION/DISTILLATION

Distillation is a separation process in which a liquid is converted into vapor ad the vapor then converted into a liquid of desired purity by the application or removal of heat. Distilland Feed to distillation Distillate - Product of distillation
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3. CRUDE OIL REFINING

The first step in the refining process is the separation of crude oil into various fractions or straight-run cuts by distillation in atmospheric and vacuum towers. The main fractions or "cuts" obtained have specific boiling-point ranges

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3. CRUDE OIL REFINING

FRACTIONS OBTAINED Fractions obtained from the crude oil distillation
FRACTIONS Gas Light Naphtha Heavy Naphtha Kerosene Fuel Oil Gas Oil BOILING POINT RANGE(F) Below 90 90 to 200 170 to400 350 to 550 390 to 620 Above 500 NO. OF HYDROCARBON C1 to C5 C5 to C7 C6 to C12 C12 to C15 C15 to C18 C16

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3. CRUDE OIL REFINING

THINGS TO REMEMBER Mass Transfer: Following mechanical devices are used to transport matter Gases: Fans, Blowers and compressor Liquids: Pumps Solids: Conveyor belts Heat Transfer: Following are the mechanisms for heat transfer Conduction Convection Radiation

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3. CRUDE OIL REFINING

THINGS TO REMEMBER Pump is a mechanical device used to transfer liquids from one point to another by increasing the mechanical energy of the liquid. Basics types of pump Positive displacement pump Centrifugal pump Exchanger is a mechanical device which increase or decrease the temperature of process streams in a variety of operations. Basics types of exchanger Shell ad Tube exchanger U Tube exchanger

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