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The process of oil refining involves five major processes which are briefly described:
SEPARATION PROCESSES
CONVERSION PROCESSES
ASSOCIATED OPERATIONS
Include processes used to break down
large longer chain molecules into smaller
ones by heating using catalysts. change
the size and/or structure of hydrocarbon • Cracking (thermal and catalytic)
molecules. These processes include: • Reforming
Decomposition (dividing) by thermal and • Alkylation
catalytic cracking; • Polymerization
Unification (combining) through • Isomerization
alkylation and polymerization; and • Coking
Alteration (rearranging) with • Visbreaking
isomerization and catalytic reforming.
INDUSTRIAL PROCESSES IN THE PETROLEUM REFINING INDUSTRY
TREATING PROCESSES
ASSOCIATED OPERATIONS
Petroleum-treating processes are used
to separate the undesirable • Hydrodesulfurization
components and impurities such as • Hydrotreating
sulfur, nitrogen and heavy metals from • Chemical sweetening
the products. • Acid gas removal
• Deasphalting
INDUSTRIAL PROCESSES IN THE PETROLEUM REFINING INDUSTRY
BLENDING/COMBINATION PROCESSES
ASSOCIATED OPERATIONS
AUXILIARY PROCESSES
ASSOCIATED OPERATIONS
Middle Distillates
Hydrotreating Middle Distillates Solvents
Lube oils
Lube-Base Solvent Lube Oil
Stocks Extraction and Waxes Greases
Dewaxing
Gasoline, Naphtha and
Middle distillates Asphalts
Vacuum Fuel Oil
Visbreaker Industrial fuels
Distillation Asphalt
REFINING TECHNOLOGY 10
Desalting/dehydration
Crude oil often contains water, inorganic salts, suspended solids, and water
‐soluble trace metals.
• First step in the refining process is to remove these contaminants so as to
reduce corrosion, plugging, and fouling of equipment and to prevent poisoning
catalysts in processing units.
• The two most typical methods of crude ‐oil desalting are chemical and
electrostatic separation, and both use hot water as the extraction agent.
• In chemical desalting, water and chemical surfactant (demulsifiers) are added
to the crude, which is heated so that salts and other impurities dissolve or attach
to the water, then held in a tank to settle out.
• Electrical desalting is the application of high ‐voltage electrostatic charges to
concentrate suspended water globules in the bottom of the settling tank.
Surfactants are added only when the crude has a large amount of suspended
solids.
• A third (and rare) process filters hot crude using diatomaceous earth.
Desalting process
The crude oil feedstock is heated to 65‐180°C to reduce viscosity and surface
tension for easier mixing and separation of the water. The temperature is
limited by the vapor pressure of the crude‐oil feedstock.
In both methods other chemicals may be added. Ammonia is often used to
reduce corrosion. Caustic or acid may be added to adjust the pH of the water
wash.
The oil/water mixture is homogenously emulsified in the emulsifying device.
The emulsifying device (as a valve) is used to emulsify the dilution water
injected upstream in the oil. The emulsification is important for contact
between the salty production water contained in the oil and the wash water.
Then the emulsion enters the Desalters where it separates into two phases by
electrostatic coalescence.
The electrostatic coalescence is induced by the polarization effect resulting
from an external electric source. Polarization of water droplets pulls them out
from oil-water emulsion phase. Salt being dissolved in these water droplets, is
also separated along the way.
Crude Desalting (typical operating conditions)
oAPI Water Wash, Temp. oF (oC)
vol%
>40 3-4 240-260 (115-125)
30-40 4-7 260-280 (125-140)
<30 7-10 280-330 (140-150)
Crude Distillation Unit
Crude Desalting
Distillation columns are classified by the manner in which they are operated:
1. Batch, in which the feed to the column is introduced batch‐wise. That is,
the column is charged with a 'batch' and then the distillation process is
carried out. When the desired task is achieved, a next batch of feed is
introduced.
2. Continuous columns process a continuous feed stream. No interruptions
occur unless there is a problem with the column or surrounding process
units. They are capable of handling high throughputs and are the most
common of the two types.
Continuous distillation columns
Classified according to:
1. Nature of the feed that they are processing:
– binary column ‐ feed contains only two components;
– multi‐component column ‐ feed contains more than two components.
2. Number of product streams they have:
– multi‐product column ‐ column has more than two product streams.
3. Where extra feed exits when used to help with the separation:
– extractive distillation ‐ where the extra feed appears in the bottom
product stream;
– azeotropic distillation ‐ where the extra feed appears at the top product
stream.
4. Type of column internals:
– tray column ‐ trays of various designs used to hold up the liquid to provide
better contact between vapour and liquid;
– packed column ‐ packings are used to enhance vapour‐liquid contact.
Main Components of Distillation Columns
Another important reason for removing sulfur from the naphtha streams within a
petroleum refinery is that sulfur, even in extremely low concentrations, poisons the
noble metal catalysts (platinum and rhenium) in the catalytic reforming units that are
subsequently used to upgrade the octane rating of the naphtha streams.
The industrial hydrodesulfurization processes include facilities for the capture and
removal of the resulting hydrogen sulfide (H2S) gas. In petroleum refineries, the
hydrogen sulfide gas is then subsequently converted into byproduct elemental sulfur
or sulfuric acid (H2SO4).
The image below is a schematic depiction of the equipment and the process
flow streams in a typical refinery HDS unit.
Hydrodesulfurization Plant
The liquid feed (at the bottom left in the diagram) is pumped up to the
required elevated pressure and is joined by a stream of hydrogen-rich recycle
gas. The resulting liquid-gas mixture is preheated by flowing through a heat
exchanger. The preheated feed then flows through a fired heater where the
feed mixture is totally vaporized and heated to the required elevated
temperature before entering the reactor and flowing through a fixed-bed of
catalyst where the hydrodesulfurization reaction takes place.
The hot reaction products are partially cooled by flowing through the heat
exchanger where the reactor feed was preheated and then flows through a
water-cooled heat exchanger before it flows through the pressure controller
(PC) and undergoes a pressure reduction down to about 3 to 5 atmospheres.
The resulting mixture of liquid and gas enters the gas separator vessel at about
35 °C and 3 to 5 atmospheres of absolute pressure.
Most of the hydrogen-rich gas from the gas separator vessel is
recycle gas, which is routed through an amine contactor for removal
of the reaction product H2S that it contains. The H2S-free hydrogen-
rich gas is then recycled back for reuse in the reactor section. Any
excess gas from the gas separator vessel joins the sour gas from the
stripping of the reaction product liquid.
The liquid from the gas separator vessel is routed through a reboiled
stripper distillation tower. The bottoms product from the stripper is
the final desulfurized liquid product from hydrodesulfurization unit.
The overhead sour gas from the stripper contains hydrogen, methane,
ethane, hydrogen sulfide, propane, and, perhaps, some butane and
heavier components. That sour gas is sent to the refinery's central gas
processing plant for removal of the hydrogen sulfide in the refinery's
main amine gas treating unit and through a series of distillation towers
for recovery of propane, butane and pentane or heavier components.
The residual hydrogen, methane, ethane, and some propane is used as
refinery fuel gas. The hydrogen sulfide removed and recovered by the
amine gas treating unit is subsequently converted to elemental sulfur in
a Claus process unit or to sulfuric acid in a wet sulfuric acid process or
in the conventional Contact Process.