Fundamentals of Petroleum Refining

Copyright......Page 1
Preface......Page 2
Crude Distillation......Page 4
Solvent Extraction......Page 5
Alkylation......Page 6
Refinery Configuration......Page 7
Crude Assay and Quality......Page 9
References......Page 12
Reid Vapour Pressure Blending......Page 13
Chemical Solvents......Page 14
Olefins......Page 15
Aromatics......Page 16
Sulphur Compounds......Page 18
Hydrotreating......Page 19
Nitrogen Compounds......Page 20
Asphaltenes and Resins......Page 21
Products Composition......Page 22
Gasoline......Page 23
Membrane Separation\r......Page 308
Fuel Oil......Page 24
Tank Emissions......Page 427
True Boiling Point Distillation......Page 25
Coking and Decoking Operation......Page 137
Flare Relief System......Page 367
API Gravity......Page 26
Aniline Point......Page 27
Smoke Point......Page 28
Elemental Analysis......Page 29
Aromatic Carbon Content......Page 30
SARA Analysis......Page 31
References......Page 33
Introduction......Page 34
The Case Study......Page 35
Fractionation......Page 36
Conventional HDS......Page 304
Conversion between ASTM and TBP Distillation......Page 37
Pseudo-Components......Page 41
Breakup of TBP Curve into Pseudo-components......Page 42
Breakup of TBP Curve into Pseudo-components Using Generalized Form......Page 44
Calculation of Pseudo-components Specific Gravities......Page 48
Hydrogen Production......Page 49
Space Velocity......Page 290
Refractive Index......Page 50
Molecular Type Composition of Petroleum Fractions......Page 51
Pseudo-critical Constants and Acentric Factors......Page 53
Gas Dispersion......Page 54
Generalized Equation for Thermophysical Properties......Page 55
Calculation of Enthalpy of Petroleum Fractions......Page 56
Estimation of Properties Related to Phase Changes......Page 59
Yield Correlations for Flexicoking......Page 146
Vapour-liquid Equilibrium......Page 60
Calculating Properties Utilizing UNISIM Software......Page 65
Questions and Problems......Page 67
References......Page 68
Introduction......Page 69
Process Description......Page 70
Operation of Crude Distillation Units......Page 72
Overflash......Page 74
Overhead Temperature......Page 75
Crude Oil Desalting......Page 76
Atmospheric Residue Desulphurization\r......Page 166
Desalting Process......Page 77
Description of Desalter......Page 78
Desalter Operating Variables......Page 79
Vacuum Distillation......Page 80
Process Simulation of Reformer by Equilibrium Reactions\r......Page 105
Crude Assay Data......Page 82
Material Balance......Page 85
Design of Crude Distillation Units Using Process Simulators......Page 88
Questions and Problems......Page 92
References......Page 93
Reformer Feed Characterization......Page 94
Research Octane Number......Page 95
Isomerization......Page 97
Thermodynamics of Reforming Reactions......Page 98
FCC Configuration......Page 208
Semi-regenerative Fixed Bed Process\r......Page 101
Thermodynamics of Isomerization......Page 117
Isomerization Catalysts......Page 118
Isomerization Yields......Page 119
Questions and Problems......Page 231
References\r......Page 121
Coke Formation......Page 122
Thermodynamics of Coking of Light Hydrocarbons\r......Page 124
Visbreaking......Page 125
Fluid Catalytic Cracking......Page 353
Visbreaking Severity......Page 126
Factors Affecting Refinery Costs......Page 401
Prediction of Visbreaking Yields......Page 127
Coil Visbreaker......Page 130
Soaker Visbreaker......Page 131
Delayed Coking......Page 132
Ebullated Bed Process......Page 343
Worst Case Scenario......Page 360
Delayed Coking Variables......Page 135
Types of Coke and their Properties......Page 136
Delayed Coker Yield Prediction......Page 139
Process Simulation of Delayed Coking......Page 141
Fluid Coking......Page 143
Questions and Problems......Page 150
References......Page 448
Role of Hydrotreating......Page 152
Upgrading Options......Page 322
Chemistry of Hydrotreating......Page 154
Hydrotreating Catalysts......Page 156
Thermodynamics of Hydrotreating......Page 157
Reaction Kinetics......Page 161
Naphtha Hydrotreating......Page 163
Acid Strength......Page 270
Make-up Hydrogen......Page 169
Reaction Temperature......Page 271
Catalyst Activity......Page 170
Middle Distillate Hydrotreating Correlations......Page 174
Simulation of ARDS Unit......Page 175
Feeds and Products......Page 179
Solid Waste Monitoring......Page 368
Hydrocracking Catalysts......Page 181
Thermodynamics......Page 184
Hydrocracking Processes......Page 185
Process Configuration......Page 187
Hydrocracking Severity......Page 188
Catalytic Dewaxing......Page 189
Maximum ATK Correlations......Page 191
Simulation of Hydrocracking Units......Page 193
Question and Problems......Page 196
Role of FCC in the Refinery......Page 198
Feedstock and Products......Page 199
FCC Reactions......Page 201
Primary Reactions......Page 203
Secondary Reactions......Page 204
Thermodynamics of FCC Reactions......Page 205
FCC Catalyst......Page 207
Refinery Complexity......Page 404
Process Description......Page 209
Modes of Fluidisation in FCC unit......Page 211
Reactor Material Balance......Page 215
Reactor Heat Balance......Page 216
Regenerator Heat Balance......Page 217
Kinetic Model for FCC Reactor......Page 218
Concentration and Temperature Profiles in the Riser......Page 221
Simulation of FCC unit......Page 226
Catalytic Pyrolysis Process......Page 229
Petro-FCC......Page 230
References......Page 233
Introduction......Page 235
Flash Point Blending......Page 238
Pour Point Blending......Page 240
Cloud Point Blending......Page 242
Aniline Point Blending......Page 243
Smoke Point Blending......Page 244
Viscosity Blending......Page 245
Gasoline Octane Number Blending......Page 246
Linear Programming (LP) For Blending......Page 252
Questions and Problems......Page 257
References......Page 259
Alkylation Processes......Page 260
Sulphuric Acid Alkylation Process......Page 261
Hydrofluoric Acid Alkylation......Page 264
Thermal Cracking and Coking......Page 418
Fixed Cost......Page 265
Kinetics and Thermodynamics of Alkylation......Page 266
Olefin Type......Page 269
Claus Process......Page 388
Performance of Alkylation Process......Page 272
Material Balance Calculations Using Yield Factors......Page 274
Fugitive Emissions......Page 276
Questions and Problems......Page 279
References......Page 280
Hydrogen Requirements in Modern Refineries......Page 281
Capital Costs......Page 282
Steam Reforming Reactions......Page 284
Thermodynamics of Steam Reforming......Page 285
Reaction Pressure......Page 289
Selective Adsorption for Sulphur Removal\r......Page 306
Aquaconversion......Page 344
High-Temperature Shift Converter......Page 292
Amine Treating......Page 293
Methanation......Page 294
Pressure Swing Adsorption (PSA)......Page 295
Emission Monitoring......Page 296
References......Page 297
Specifications of Clean Fuels......Page 299
Deep Desulphurization......Page 301
Oxidation and Extraction for Desulphurization\r......Page 307
Production of Clean Fuels from Natural Gas and Coal\r......Page 309
Synthesis Gas Production......Page 311
Production of Clean Fuels from Biological Sources (Biofuels)\r......Page 313
Bio-diesel......Page 315
Bio-Fuel from Flash Pyrolysis......Page 317
Gasification Routes......Page 318
Questions and Problems......Page 319
References......Page 320
Introduction......Page 321
Solvent Deasphalting\r......Page 323
Correlations for Solvent Deasphalting......Page 328
Gasification......Page 329
Residue-fluidized Catalytic Cracking......Page 334
Hydroprocessing......Page 338
Moving Bed Process......Page 340
Questions and Problems......Page 349
References......Page 350
Crude Oil Distillation......Page 352
Accidents and Loss Prevention Measures......Page 354
Risk Management and Risk Assessment......Page 355
Fire and Explosions......Page 358
Fault Tree Analysis......Page 361
HAZOP Case Study......Page 363
Safety Considerations in Plant Layout......Page 365
Safe Operation Systems......Page 366
Noise in Refinery......Page 369
Questions and Problems......Page 370
References......Page 371
Absorption of Acid Gases......Page 372
Crude Distillation......Page 374
Carbonate Process......Page 383
Physical Solvents......Page 384
Selexol Process......Page 385
Morphysorb Process......Page 386
Membrane Absorption......Page 387
Mercaptans Removal......Page 392
Gasoline MEROX......Page 394
Question and Problems......Page 395
References......Page 396
Refining Capacity......Page 398
Refining Costs......Page 399
Variable Cost......Page 400
Refining Margins......Page 403
Cash Flow Diagram......Page 405
Time Value of Money......Page 406
Inflation......Page 408
Profitability and Project Evaluation......Page 409
Case Study: Refinery Economic Evaluation......Page 411
Global Trends......Page 413
Questions and Problems......Page 414
References\r......Page 416
Desalter......Page 417
Fluid Catalytic Cracking (FCC)......Page 419
Asphalt Production, Solvent Extraction and Dewaxing......Page 420
Gas Waste......Page 421
Emission Estimation......Page 422
Stack and Flare Emissions......Page 425
Treatment and Control......Page 433
NOx Emission Treatment......Page 434
CO Emission Treatment......Page 435
Particulate Emission Control......Page 436
Emission Estimation......Page 439
Point Source Discharge......Page 440
Treatment and Control......Page 442
Secondary Treatment......Page 443
Tertiary Treatment Operations......Page 444
Solid Waste......Page 446
Questions and Problems......Page 447
Introduction......Page 450
Definition of Terms......Page 458
Process Simulator (UNISIM) Manual......Page 464
Reference......Page 472
References......Page 473
Notation......Page 475
C......Page 481
F......Page 482
N......Page 483
W......Page 484