May 26, 2020

PETROLEUM REFINERY
OVERVIEW

ABHIJIT PAL
WELCOME

Welcome to IIChE Internship Program – Petroleum Refinery

Key objective:
• High level overview – Industry and Technology
• Focus – Fitment of the technology – how it affects the market demand, its value
proposition
Key Learnings Expected
• How technology meets market demand – no one size fits all
• Industry approach towards problem resolution - troubleshooting
• Where the industry is moving and why? What innovations will drive it?
Expectation Setting:
• No details chemistry/ catalysis/ Temperature/ Pressure discussion on technology
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AGENDA
Typical Crude Properties
Processing units
Refinery Configuration
Primary Processing
Secondary Processing
Gas and LPG
Gasoline Technologies
Diesel Technologies
Residue Processing
Ancillary Units
Renewables

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REFINING HISTORY
• Small oil industry in Ukhta in 1745 – Russia

• 1840-1850’s development of illuminating

and lubricating oil extraction from coal
and other hydrocarbons

• By 1859 34 US companies producing

kerosene
- Only a small fraction from Pennsylvania rock oil
- Dr. Gesner founds 5,000 gal/day refinery in NYC
- Similar refining industries in Britain on channel
coal and France on shale oil

• ~1860 first US “oil refinery” built in Titusville,

Pennsylvania using batch stills

• 1910’s first use of continuous distillation

• First Indian Refinery – 1901 – Digboi refinery

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REFINERY PURPOSE
US
USDemand
Demand vol.vol.%%
Naphtha
Naphtha 4646
Distillates
Distillates 3030
Fuel
FuelOil
Oil 44
Other
Other 2020

Asia
AsiaPacific
Pacific Arab
ArabLight
LightCrude
Crudevol.
vol.%%
Naphtha
Naphtha 2828 Naphtha
Naphtha 2020
Distillates
Distillates 3636 Distillates
Distillates 4040
Fuel
FuelOil
Oil 1414 Fuel
FuelOilOil 4040
Other
Other 2222
Crude assays do not necessarily match product demand
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REFINERY OVERVIEW

• Lube stocks
CRUDE COMPOSITION

A complex mixture containing thousands PRODUCTS

of different organic hydrocarbon molecules Fuel Gas ( C1/C2)

–83-87% Carbon LPG ( C3/4)

–11-15% Hydrogen Naphtha ( C5 to C10) ( 65C to 180C)

–1-6% Sulfur Kerosene range ( C8- C17) ( 150C/180C to

230/300 C)
- 0 to 0.2% Nitrogen
Diesel range ( C12 to C 20) ( 170C/230C –
•Paraffins – saturated chains
370C ) VGO ( C20+ ) ( 370 C to 565 C)
•Naphthenes – saturated rings
Vacuum Residue ( 565 C+ EP)
•Aromatics – unsaturated rings

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ASSAY (EXAMPLE)

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CARBON NUMBER RANGE

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CRUDE COMPOSITION AND PRODUCT SPEC

Arabian Light ( CRUDE) Typical Product

Specs

Gasoline Octane 40 > 95

Jet Freeze Pt., -37 C -50°°C
Kero. Sulfur, 0.3 wt% 0.1 wt-%
Distillate S, >1 wt% 50/10
ppm
Dist. Cloud Pt., >7 C -15°°C
F/O Pour Pt., 32 C 38°°C
F/O Sulfur, 2 to 3 wt% 0.5 wt-%

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REFINERY SCHEME OVERVIEW
REFINERY OF THE
FUTURE

FUELS TO
PETROCHEMICALS

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 THE REFINERY OF THE FUTURE
Crude Processing: Fuels to Petrochemicals Customer Needs

FUELS • Maximum transportation fuels

Today

(gasoline, diesel, and jet)

CRUDE PETROCHEMICALS
Industry Transformation

Refinery • Opportunistic petrochemicals

PCHEM FEEDSTOCK Petrochemical
Complex

• More stringent fuel specifications

Developing

FUELS • Less diesel, more jet fuel

• Product flexibility to meet market needs
CRUDE
PETROCHEMICALS • More petrochemicals: ideally at
75% olefins, 25% aromatics
Refining & Petrochemical Complex • Lower environmental footprint
• Higher capital efficiency
Long Term

• Zero-fuels
• Direct to petrochemicals through
CRUDE PETROCHEMICALS alternative routes
• Lower environmental footprint
Petrochemical Complex
• High capital efficiency
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UOP 8446E-13
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 REFINERY OF THE FUTURE –
A VIEW TO ZERO FUELS PRODUCTION
FG Ethylene (C2=)
n-Paraffins
Steam
Cracking
Gas C4
LPG
Plant C3
PDH Propylene (C3=)

Naphtha MaxEne Aromatics Bz

Platforming
Unit Complex pX

Crude Oil Detergents LAB

Kero Hydro-
DHT
cracking LPG
LCO

FG
Aromatics
Extraction
FCC
LPG
LPG
FG C4 = - C8 = Olefin
Cracking
Slurry Fuel Oil
Hydrocracker

Maximum Petrochemical Base Stocks; Fuels Eliminated

UOP 8525A-14
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SUMMARY
Configuration drives product value essentially independent of
crude type
- Improvement may plateau especially for good quality crudes

Crude type will strongly influence the level of complexity needed

for acceptable returns

Optimal configuration will depend strongly on:

• Crude basis and desired flexibility
• Crude and product price structure
• Capital efficiency and hurdle rates
• Product mix constraints

There is not one right answer. Once the business definition is

assessed, multiple configurations need to be evaluated in detail to
determine the best course
UOP 6044C-15
PROCESSING UNITS

Primary Secondary Product Residue

Processing Processing Processing Processing

Atmospheric Fluidized Gasoline

Distillation Catalytic
Cracking Distillate Ancillaries
Vacuum (Kerosene/ Hydrogen
Distillation Hydrocracking Diesel)
Sulfur Recovery
Amine/ Sour
Gas Treating Water Treating
concentration
Multiple Units – Ancillaries separate
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PRIMARY
PROCESSING

CDU/ VDU

FCCU

HCU

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CDU & VDU

CDU: VDU:
• To distill and separate valuable • To recover valuable gas oils from
distillates (naphtha, kerosene, diesel) reduced crude via vacuum distillation.
and atmospheric gas oil (AGO) from the
crude feedstock

Open Art Technology

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CDU/VDU-PROCESS PRINCIPLES

Desalt and dehydrate Heat the

Preheat the crude
the crude using crude/Reduce Crude
feed utilizing
electrostatic enhanced to the desired
recovered heat from
liquid/liquid separation temperature using
the product streams
(Desalter fired heaters

Utilize pumparound Flash the crude in the

Product draws are on
cooling loops to atmospheric
the top, sides, and
create internal liquid distillation/Vacuum
bottom
reflux column

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CDU VDU-TYPICAL YIELDS ( WT%)

Boiling Point Ranges

°F °C

< 30 <0 Gas & LPG ( 2%-3%)

Naphtha (Gasoline) ( 15% to 30%)

100-390 38-200
Kerosene (Jet Fuel) ( 9% to 15%)
390-540 200-300
Diesel ( 9% to 17%)
540-625 280-330
Atmospheric Gas Oil ( 9% to 15%)
625-700 330-370
Vacuum Gas Oil (10 % to 16%)
700-1000 370-540
Resid ( 6% to 30%)
1000+ 540+

Covers Entire Range

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CDU AND VDU

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WET GAS COMPRESSOR – SPONGE ABSORBER

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STRIPPER DEBUTANIZER

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