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PROCESS IN A
PETROLEUM
REFINERY
The isomerization process has importance in the present
refining field due to limitations on gasoline benzene,
aromatics, and olefin contents. The isomerization process
improve the octane number of light naphtha fractions and
also reduces benzene content by saturation of the benzene
fraction by converting it into cyclobenzene.
A Detailed study
NAME-YADAV RITIK
RANJAN
ROLL-CH14B090
INDEX
PETROLEUM
REFINING PROCESS AND TECHNOLOGY INVOLVED
IMPROVEMENT IN QUALITY OF CRUDE OIL
HYDROTREATING
REDUCING SULPHUR CONTENT
OCTANE NUMBERS
RON
MON
AKI
ISOMERIZATION IN PETROLEUM REFINING
HISTORY
ISOMERIZATION REACTION CONDITIONS
PROCESS USED FOR ISOMERIZATION
VAPOUR PHASE PROCESS
BUTAMER PROCESS
Mechanism
Process variable
Flow diagram
BENSAT PROCESS
Flow diagram
PENEX PROCESS
Mechanism
Flow diagram
O-T ZEOLITIC ISOMERIZATION PROCESS:
Mechanism
RECENT DEVELOPMENTS IN ISOMERIZATION
ENGINEERING CHALLENGES
ENVIRONMENTAL CHALLENGES
BIOREFINERY
HEALTH AND SAFETY ASPECTS
Safety
Health
REFRENCES
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PETROLEUM
consist of complex mixture of organic hydrocarbon molecule
83-87% Carbon
11-15% Hydrogen
1-6% Sulphur
A petroleum refinery is a setup for manufacturing different types of petroleum
products from crude oil. Refining is the processing of one complex mixture of
hydrocarbons into different other types of complex mixtures of hydrocarbons. Some
refined petroleum products are Gasolines
Kerosene
Asphalt
Lubricating oil
Diesel
REFINING PROCESS TECHNOLOGY
Process operation
Coking
Thermal process
Catalytic cracking
Catalytic reforming
Hydrocracking
Hydrotreating
Alkylation
Isomerization
Technology
delayed coking ,Fluid coking
Thermal coking
Fluid cracking
Semigenerative , cycle ,continuous generation
Distillate, upgrading residual
Desulfurization, post hydro treating of FCC
Sulfuric acid, hydrofluoric acid
C4 feed, C5 feed, C5 and C6 feed
Refining process
The crude oil is charged into an atmospheric distillation tower, where it is separated
into light gas at the top of distillation tower and reduced crude at bottoms . The
reduced crude is feeded to the vacuum distillation unit and separated into vacuum
gas oil stream and vacuum reduced crude bottoms. The reduced crude bottoms from
the vacuum distillation unit is thermally cracked in a coker to produce coke. The
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atmospheric and vacuum crude gas oils and coker gas oil are then feeded to fluid
catalytic cracking or hydrocracking units where heavy molecules are converted into
lower molecular weight compounds. The hydrocracked products are saturated
whereas catalytic cracker products are unsaturated and they need improvements in
quality by various methods.
FLOWCHART
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IMPROVEMENT IN QUALITY
HYDRO TREATINGThe main objective of hydro treating is to eliminate or remove contaminants from
crude like sulphur , nitrogen, and some metals and to saturate olefins and aromatics
to produce further finished product.
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OCTANE NUMBER
.
Iso-octane
Heptane
Octane number of any fuel is equivalent to octane number of the mixture containing
iso-octane and heptane. Octane number of fuel can be increased by increasing
carbon chain branching.
In the isomerization process, straight carbon chain are converted into more branched
carbon chain and hence octane number can be increased by isomerization process.
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Some isomerization may occur during the cracking process ,which results in
increased octane number.
Octane number can also be increased by adding some additive like tetraethyl lead
which act as octane booster by providing carbanion to increase the branching of
carbon chain.
Research Octane Number (RON)
The most popular type of octane rating used all over the world is the Research
Octane Number (RON). RON is measured by operating the fuel in a test engine
with a various compressions ratios under maintained circumstances, and
comparing the outcomes with those for mixtures of iso-octane and n-heptane.
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Isk
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Removal of sulphur content from feed and hydrogen are dried in fixed beds
of solid for proper mixing
The mixed feed is heated and passes through a hydrogenation reactor to
convert olefins to paraffin and saturate benzene to cyclohexane.
The hydrogenation discharge is then cooled and passes by a isomerization
reactor
The final discharge is then cooled and separated isomerate product used
gasoline blending
Butamer process
BenSat process
Penex process
O-T zeolitic isomerization process:
butane is converted into its isoparaffin , isobutane. Normal butane and hydrogen
chloride are recovered for recycling While isobutane is withdrawn from the reactor .
BUTAMER PROCESS
pt
CH3 - CH2 - CH = CH2 + H2
the above reaction is reversible under butamer process conditions and equilibrium is
to the left side.
Second carbocation is more stable than first because of inductive effect of three
methyl group
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Finally by hydrogenation
Iso-butane
PROCESS VARIABLES:-
FLOW DIAGRAM
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BenSat PROCESS:
The BenSat process is used to treat C5-C6 feedstocks with high benzene
contents. All the benzene is converted to cyclohexane upon a fixed bed of catalyst
Process conditions are moderate, and only a slight excess of hydrogen is needed.
Heat of reaction associated with benzene conversion is high ,which is managed
carefully to control temperature rise in the reactor. But this result in decrease of
octane number. Octane number of benzene is greater than cyclohexane. So BenSat
product need further processing in a isomerization unit in process like UOP penex
process.
FLOW DIAGRAM
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Light naphtha is feeded in any of the two dryer. These dryer are installed with
molecular sieves, to remove water to avoid deactivation of catalyst. After mixing with
small amount of hydrogen the feed enters a charge heater before entering the
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reactors. In this two reactors are there which operate in series. The rector effluent is
cooled before entering the product stabilizer. The purpose of stabilizer is to separate
any dissolved hydrogen, HCl and cracked gases (C1, C2, and C3s) from the
isomerate .The scrubber is used to remove HCL formed from organic chloride which
is added to enhance catalyst activity. The stabilized isomerized liquid product from
the bottom of the stabilizer then passes to gasoline blending.
An efficient recycle process is obtained by combining the Penex process with UOPs
Molex process, Which have molecular sieves to separate the stabilized product from
bottom into high octane isoparaffin and low octane normal paraffin stream. The low
octane normal paraffin is again charged into penex unit.
feed
penex
molex
Hence by formation of the carbonium ion the olefin is removed and equilibrium is
mantained. The above carbocation goes skeletal isomerization via cycloalkyl
intermidiate:
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The strong acidity of isomerization catalyst provide sufficient driving force for the
reaction given below. Furthur the carbocation loss a proton to form isoolefin.
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MECHANISM
Carbonium ions and isoparaffins are produced from normal paraffins by a
combination of hydride-ion. In the adsorbed state, skeletal rearrangement reactions
occur for stabilization of intermidiate. Alternatively, while the normal pentane is in the
carbonium ion state (nP+ or iP+), it may loose a proton to form an olefin, which can
be hydrogenated to form a isoparaffin.
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The modified isomerization process for PC-raffinate has been modified based on the
effects of water or moisture content and heptane fraction content. The fractionator is
used to regulate the content of heptane fraction and the water stripper to remove the
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water or moisture were outfitted to this process. The chemical properties of the
reactant for the isomerization reaction is controlled precisely by changing these
services.Commercial operation has been carried out under the process as the
isomerization activity constant (16.5%) and the isomerization activity and can be
regulated by changing the temperature for the reaction.
ENGINEERING CHALLENGES
ENVIRONMENTAL CHALLENGES
THE BIOREFINERY
The use of fossils fuels at current rate will create serious matter in future and cause
irreversible changes in our environment. Biomass is a renewable energy resource
which is more eco-friendly than other fuels like petroleum ,crude, coal. Any fuel
derived from biomass is known as biofuel. Advantages of this types of over others
are they are biodegradable and so cause less harm to environment. The easiest
and the common procedure to extract energy from biomass is combustion.
Biorefinery is the process that integrates biomass conversion techniques and
equipments to produce fuel power and chemicals from biomass.
There are many sources for biomass like sugar cane , soybeans ,algae and these
Biomass are already tested and implemented for some specific purposes in some
countries. Plants can be used for diverse feedstock for chemicals. Plant biomass can
be used to produce synthesis gas(syn gas).
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All the process involved in isomerization are closed, Although the potential risk for
fire exists from loose or leak contact at source of ignition such as the heater.This
types of equipment should be inspected frequently. Temperature and pressure of
the compressor should be monitored carefully, otherwise slight changes from the
maximum limit may cause explosion.
Safety:
If the feed is not fully dried and desulfurized, then there is possibility of acid
formation leading to catalyst poisoning and metal corrosion due to organic chlorides
used in reactors. Water or steam should not be enter in th areas where hydrogen
chloride (HCl) is present or formed. Precautions are required to prevent HCl from
entering sewers and drains channels which further cause water pollution and leads
to various health issues for humans as well as animal.
Health:
to hydrogen gas, HCl and to dust particles when solid catalyst is used industries.
Safe work trainings and sutaible personal protective kit should be provided to
prevent exposures to chemicals and other harmful things such as heat and noise,
during process.
REFRENCES
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http://www.byco.com.pk/index.php?
option=com_content&view=article&id=172&Itemid=190
https://www3.kfupm.edu.sa/catsymp/docs/18%20symppsium
%20papers/15%20cosmo.pdf
http://www.csgnetwork.com/octaneratecalc.html
https://en.wikipedia.org/wiki/Octane_rating
http://nptel.ac.in/courses/103102022/23
http://inside.mines.edu/~jjechura/Refining/09_Gasoline_Upgrading.pdf
https://books.google.co.in/books?
id=mU2eCgAAQBAJ&pg=PA237&dq=isomerization+process+in+petroleum+refini
ng&hl=en&sa=X&ved=0ahUKEwiM6t_C3dTLAhUEc44KHcQrCgAQ6AEIKTAB#v
=onepage&q=isomerization%20process%20in%20petroleum%20refining&f=true
http://www.google.co.in/patents/US2935546
d.yimg.com/kq/groups/3862917/709231331/name/Butamer.pdf
http://www.eoearth.org/view/article/153278/
http://www.processengr.com/ppt_presentations/oil_refinery_processes.pdf
BOOKS
The refinery of the future ,James .G.Speight
Petroleum refining process , James .G.Speight and Baki Ozum.
Thank you
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