Refining Fundamentals
Michael D. Morris
September 2007
Outline
Crude Oil Supply & Demand
Composition of Crude
Products from a modern refinery
Petroleum refining objectives
Process Overview
Refinery flowsheet Alkylation
Crude Distillation Reforming
Coking Hydroprocessing
Catalytic Cracking Sulfur Recovery
Proved Oil Reserves – End of 2006
BP Statistical Review of World Energy -2007
Major Crude Oil Consuming Areas
BP Statistical Review of World Energy -2007
Crude is Like Wine ......
Really Bad Wine.....
Sulfur Cadmium
Nitrogen Selenium
Nickel Arsenic
Vanadium Organic Acids
What’s in Crude Oil ?
Products Made from Crude Oil
Transportation Fuels Chemical Feedstocks
Gasolines C2/C3/C4 - olefins
Diesel fuels Olefins…polyethylene,
polypropylene
Commercial Fuels
Aromatics -polyesthers,
Fuel oils polystyrene
Heating oils
Jet fuels Specialty Products
Propane
Coke……...coal substitute
Butane
Asphalt…..road paving
Lubricants Sulfur…….fertilizer, roads
Motor Oils Waxes…….candles, sealants
Greases
White Oils/petrolatums
Why Crude Needs Processing
Petroleum Refining Objectives
Adjust the fuel yields to match the market
Increase gasoline
Decrease kerosene, gas oil, and resid
Remove contaminants & catalyst poisons
Sulfur
Nitrogen
Heavy metals
Improve fuel quality and meet specifications
Octane (gasoline)
Cetane (diesel)
Flow characteristics (especially jet!)
Gasoline Specifications
Federal and State regulations
Reid vapor pressure
Octane (R+M)/2
No Tetraethyl Lead
Aromatics (Benzene)
Oxygenates
Olefins
Sulfur
Customer Satisfaction/Preference
Octane (R+M)/2
Reid vapor pressure
Volatility - Gasoline distillation curve
Additives - Anti-oxidants, detergents
Typical Fuels Refinery Configuration
Fuel Gas
Alkylation
Separation
Reforming Gasoline
Crude
Hydro-
treating
Diesel
Catalytic
Cracking
Sulfur
Sulfur
Recovery
Coking Coke
Asphalt
Step One – Crude Oil Distillation
Fuel Gas
Alkylation
Separation
Reforming Gasoline
Crude
Hydro-
treating
Diesel
Catalytic
Cracking
Sulfur
Sulfur
Recovery
Coking Coke
Asphalt
Crude Oil Distillation
Pipestill Fractions
Pipestill Stream Dispositions
Fuel Gas
Alkylation
Separation
Reforming Gasoline
Crude
Hydro-
treating
Diesel
Catalytic
Cracking
Sulfur
Sulfur
Recovery
Coking Coke
Asphalt
Atmospheric Distillation Tower
Vacuum Distillation Tower
Compressor Applications – Crude Units
Liquid Ring Vacuum Pumps
0 psig suction pressure
20-40 psig discharge pressure
<100 o F
Wet, Corrosive, Hydrogen sulfide
Low but variable flow
Variable molecular weight
Oxygen contamination
Coking – The Bottom of the Barrel
Fuel Gas
Alkylation
Separation
Reforming Gasoline
Crude
Hydro-
treating
Diesel
Catalytic
Cracking
Sulfur
Sulfur
Recovery
Coking Coke
Asphalt
Petroleum Coking Process
Light Ends
Naphtha
Coke
Drums Raw Diesel
Gas Oil
Resid
Feed
Fractionator
Furnace Heavy
Gas Oil
Recycle
Petroleum Coking Process
Petroleum Coking Process
Petroleum Coking Product
Compressor Applications – Cokers
Variable Speed Centrifugal Compressors
10-20 psig suction pressure
40-120 psig discharge pressure
Highly variable flow - cyclic
Wet, corrosive, reactive
H2S - Highly Toxic
100 – 200 o F
Variable molecular wt.
Fluidized Catalytic Cracking
Fuel Gas
Alkylation
Separation
Reforming Gasoline
Crude
Hydro-
treating
Diesel
Catalytic
Cracking
Sulfur
Sulfur
Recovery
Coking Coke
Asphalt
Fluid Catalytic Cracking
Hydrocarbon to
Fractionation
FCCU Reactor
Flue Gas to
Energy
Recovery
Reactor Stripping
Section
Regenerator
1000+ F
Reactor Riser
Air
Feed
Catalyst Deactivation
Electron micrograph of carbon
deposit on catalyst surface
Fluid Catalytic Cracker
Compressor Applications – Fluid Catalytic Crackers
Turbo Expanders
Combustion gases nitrogen +CO2
25-35 psig inlet pressure
Atmospheric discharge pressure
High flow, variable but gradual
Wet, but above dew point
1200 -1250 o F inlet temperature
Abrasive particulates
Constant Speed Variable Speed
Centrifugal Compressors Centrifugal Compressors
Air Blowers 15-30 psig suction pressure
30-50 psig discharge 80-120 psig discharge pressure
Gradual changes in flow
Gradual changes in flow
Gradual changes in MW
High volume Wet, reactive gases
Multiple machines 100 -150 o F
Alkylation Process
Fuel Gas
Alkylation
Separation
Reforming Gasoline
Crude
Hydro-
treating
Diesel
Catalytic
Cracking
Sulfur
Sulfur
Recovery
Coking Coke
Asphalt
Alkylation Process – Sulfuric Acid
Isobutane Recycle Critical Variables
Temperature
Acid and Olefin
Caustic concentration
Treater
Reactor
Feed
Olefin +
Isobutane
De-isobutaniser
Acid
Settler
Fresh Acid Spent Acid Alkylate Product
Alkylation Reaction
Butylene
Isobutane
Double Bond
Catalytic cracking produces unmarketable light
olefins which must be reassembled with
isobutane into gasoline components
Olefin Alkylation
Tri-methylpentane
Result
Highly branched,
high octane
gasoline blending
component
Typical Sulfuric Acid Alkylation Unit
Compressor Applications – Sulfuric Acid Alkylation
Variable Speed
Centrifugal Compressors
Propane + butane refrigeration
refrigeration
5-10 psig suction pressure
50-70 psig discharge press.
Limited flow variability
Wet, highly corrosive, reactive
40-50 o F suction temperature
Low molecular wt. variability
Typical Fuels Refinery Configuration
Fuel Gas
Alkylation
Separation
Reforming Gasoline
Crude
Hydro-
treating
Diesel
Catalytic
Cracking
Sulfur
Sulfur
Recovery
Coking Coke
Asphalt
Catalytic Naphtha Reforming - Cyclic
Reformer Reactors Hydrogen
Light Ends
Separator
Naphtha Feed
65 Octane
De-butanizer
Furnaces
Reformate
Catalytic Naphtha Reforming - Cyclic
Reformer Reactors Hydrogen
Flue Gas
Light Ends
Air
Regeneration
Furnace
Separator
Naphtha Feed
65 Octane
De-butanizer
Furnaces
Reformate
Catalytic Naphtha Reforming - Cyclic
Hydrogen
Reformer Reactors
Light Ends
Air
Regeneration
Furnace
Separator
Naphtha Feed
65 Octane
De-butanizer
Furnaces
Reformate
“Ultraformer” Design Reformer
Compressor Applications – Naphtha Reforming
Variable Speed Centrifugal Centrifugal or Reciprocating
Compressors Compressors
Recycle Gas Compressor Regeneration Gas Compressor
80-100 psig suction pressure
160-180 psig suction pressure
150-250 psig discharge pressure
320-380 psig discharge Highly variable flow - cyclic
pressure
High nitrogen content
Highly variable flow - cyclic 100-200 o F
High hydrogen content
Low level chlorides
100 -140 o F
Variable molecular wt.
Combustion Air Compressor
Regeneration Gas Compressor – Compressor type Application Specific
Atmospheric suction pressure
50-250 psig discharge pressure
Variable flow demand – multiple services
Hydrotreating
Fuel Gas
Alkylation
Separation
Reforming Gasoline
Crude
Hydro-
treating
Diesel
Catalytic
Cracking
Sulfur
Sulfur
Recovery
Coking Coke
Asphalt
Hydrotreating Process
Fuel Gas
Compressor
Naphtha
Separator
Feed
Furnace Heat
Desulfurized
Product
Typical Desulfurization Units
Compressor Applications – Hydrotreating
Reciprocating Compressors
Make-up gas service
High compression ratio 4 - 18
300-3000 psig discharge press.
Limited flow variability
High hydrogen concentration
0
Suction temperatures < 150 F
Centrifugal Compressors
Recycle gas service
Low compression ratio
Low temperature100-200 0 F
Limited flow variability
High hydrogen concentration
0
Suction temperatures < 150 F
Sulfur Recovery Process
Fuel Gas
Alkylation
Separation
Reforming Gasoline
Crude
Hydro-
treating
Diesel
Catalytic
Cracking
Sulfur
Sulfur
Recovery
Coking Coke
Asphalt
Sulfur Recovery - Claus Process
Sulfur Recovery - Claus Process
Compressor Applications – Sulfur Recovery Units
Centrifugal or Positive Displacement Compressors
Combustion air
Atmospheric suction pressure
< 25 psig discharge pressure
Low flow variability - dependent on plant turndown
Refining Process Overview
Separation (getting started)
Crude Distillation
Boiling Range Adjustment (matching the market)
Delayed Coking
Catalytic Cracking
Alkylation
Heteroatom Removal
Catalytic Hydrotreating
Fuel quality improvement
Catalytic Reforming
Refining Industry Business Context
• A margin business, subject to cyclicality
• Capital intensive, combined with high cash costs
• High entry/exit barriers
• Politically sensitive/state-owned companies
• Long lead times on investment
• Mainly commodity products and very competitive
• Mature industry in most regions
