SORAN UNIVERSITY

FACULTY OF CHEMICAL ENGINEERING

Final Assessment of (Refinery)

Prepared by

Tolaz Yasin Ahemed

Supervised by

Prof. Dr. Ibtisam Kamal

Wed 18 jun 2020

Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
Table of Contents
ITEM 1 : ................................................................................................................................................... 3
1. Desalting ............................................................................................................................................ 3
2. Vacuum distillation ........................................................................................................................... 4
ITEM 2: .................................................................................................................................................... 5
ITEM 3: A.1. ............................................................................................................................................. 8
I. Reforming ...................................................................................................................................... 8
II. Catalytic cracking .......................................................................................................................... 9
1. fixed bed catalytic cracking ........................................................................................................... 9
2. fluid bed catalytic cracking (FCC) .............................................................................................. 10
3. moving-bed catalytic cracking ..................................................................................................... 11
III. Alkylation..................................................................................................................................... 12
IV. Coking .......................................................................................................................................... 13
ITEM 3 B : ............................................................................................................................................. 14
ITEM 4 : ................................................................................................................................................. 16
Desulfurization ............................................................................................................................. 16
Amine Sweetening ....................................................................................................................... 17
References .............................................................................................................................................. 20

2
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
ITEM 1 :

1. Desalting
Desalting
1. Feed Raw crude and fresh water
2. Product Desalted crude oil , effluent water
3. Objective The objective of desalting process is to remove chloride salts and solids and
metals and water and amines from the crude oil by water-washing. Depending
on the specified salt substance within the desalted crude oil, a one or two-step
process prepare can be connected. For refining purposes, a salt concentration
of maximum 1, 5 PTB (pound of salt measured as NaCl per thousand barrels)
is desired. By desalting, a considerable percentage of suspended solids (sand,
clay, or soil particles, or even particles product from corrosion of pipelines
and other upstream equipments) are removed.
4. Operation  Temperature
variable  Washing water ratio
 Washing water injection point
 Water level
 Demuslifier injection rate
 Type of washing water
 Pressure drop in mixing valve
5. Effect of the single stage desalter system should give a desalting efficiency >90%. With a
efficiency double stage desalter system a desalting efficiency >98% is expected.
process
6. Process design:

3
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
2. Vacuum distillation
Vacuum distillation
1. Feed Atmospheric residue , steam
2. Product Light vacuum gas oil , heavy vacuum gas oil , slop wax , vacuum
residues
3. Objective The objective of vacuum distillation is to separate the atmospheric
residue into several fractions, including light
Vacuum gas oil (LVGO) and heavy vacuum gas oil (HVGO).
4. Operation variable  To further distill the residual oil from the atmospheric
distillation column, the distillation must be performed at
absolute pressures as low as 10 to 50 mmHg so as to limit the
operating temperature to less than 350°C.
 Vacuum distillation is the reduced temperature requirement at
lower pressures.
 Vacuum distillation increases the relative volatility of the key
components.
5. Effect of the Distillation at reduced pressures is a widely used process in the
efficiency process chemical industry, specially used in extraction / purification of
essential oils, deodorisation of Vanaspati / Vegetable Oils and
purification & drying of chemicals.
 Use of lower process temperatures. Under vacuum, there is a
reduction in boiling points. Hence thermally sensitive
substances can be processed easily
 Shorter time of thermal exposure of the distillation.
 Increase in relative volatility
 Fractional distillation under vacuum leads to easier separation
of components of a mixture.
 Reduction of energy consumption by lowering of the boiling
point under vacuum.
 Change in position of the azeotropic point at reduced pressure.
This enables separation under reduced pressure / vacuum of
hard to separate materials.
 Oxidation losses of the feed stock are reduced under good
vacuum conditions.
 Change in position of the azeotropic point at reduced pressure.
This enables separation under reduced pressure / vacuum of
hard to separate materials.

4
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
6. Process design:

ITEM 2:

5
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020

6
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020

7
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
ITEM 3: A.1.

I. Reforming
Reforming
1. Feed Naphtha C7-C10
2. Product High octane gasoline called reformate C5+
3. Catalyst Platinum / rhenium
4. Objective Increase the volume of gasoline
5. Operation Heat, pressure , and a catalyst and Controlling the temperature and (increasing
variable octane number causes to less producing reformate) and we can say (more
reformate causes to less octane number )
6. Description Rearranges naphtha hydrocarbon into gasolines.
process

8
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
II. Catalytic cracking
Cracking processes break down heavier hydrocarbon molecules (high boiling point oils) into lighter
products such as gasoline and diesel.

 The four types of catalytic cracking processes are fixed bed catalytic cracking, fluid bed
catalytic cracking (FCC), moving-bed catalytic cracking, and Thermofor catalytic cracking
(TCC).

1. fixed bed catalytic cracking

fixed bed catalytic cracking
1. Feed Heavy oil
2. Product Heavy gas , stabilized gasoline
3. Catalyst small lumps or pellets
4. Objective yields the following sum of branched chain unsaturated fragrant hydrocarbon.
5. Operation Temperature : 4250-4500 C
variable Pressure : 1.5 kg/cm2
6. Description In this method vapours of heavy oil is treated in the presence of catalyst due
process which a better yield of petrol is obtained. heavy oil is vapourised by heating in
an electrical heater. Then the vapours are passed over a series of trays
containing catalyst.

9
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
2. fluid bed catalytic cracking (FCC)
fluid bed catalytic cracking (FCC)
1. Feed gas oil
2. Product lighter hydrocarbon , gasoline , light gas oil , heavy gas oil , clarified slurry
oil.
3. Catalyst Zeolite
4. Objective The objective of a Fluid Catalytic Cracking Unit (FCCU) in the Refinery and
Petrochemical Company is to convert high molecular weight gas oils into
more valuable hydrocarbon products in a pure, safe, cost .
5. Operation In addition to the feedstock and catalyst, FCC product yields and qualities are
variable determined by a large number of operating variables, which may be divided
into independent and dependent variables. The major independent variables
are those that can be controlled directly and include:
1. Reactor Temperature, 2. Recycle Rate, 3. Feed Pre-heat Temperature, and
4. Space Velocity.
The dependent variables include:
1. catalyst circulation rate, 2. Regenerator temperature, 3. Regenerator air rate
and 4. Conversion .
Several operating variables are interrelated, e.g. when reactor temperature is
increased at constant feed and preheat temperature conditions the following
changes are observed: increased catalyst/oil ratio, increased conversion,
increased regenerator temperature, increased C3, C4, gas and de-butanized
gasoline and decreased LCO yield.
6. Description The Fluid Catalytic Cracking Unit (FCCU) receives multiple feeds consisting
process of high boiling components from several other refinery units and cracks these
streams into lighter and more valuable components.

10
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
3. moving-bed catalytic cracking
moving-bed catalytic cracking
1. Feed gas oil
2. Product distillate , oil , clarified oil , recycle gas , wet gas , naphtha
3. Catalyst small lumps or pellets
4. Objective Petroleum refining process for cracking (breaking) of long hydrocarbon
molecules by use of heat, pressure, and a granular cracking catalyst that is
continuously cycled between the reactor vessel and the catalyst regenerator.
5. Operation Temperature : 4250-4500 C
variable Pressure : 1.5 kg/cm2
6. Description Continuous catalytic cracking in moving bed frameworks is broadly utilized in
process petroleum refining to diminish the bubbling run of moderately nonvolatile
petroleum divisions, such as gas oil, subsequently creating tall quality gasoline
and fuel oil.

4. Thermofor catalytic cracking (TCC).

Thermafor (too alluded to as “thermofor” in a few sources) Splitting Handle was presented for way
better integration of thermochemistry (endothermic breaking and exothermic catalyst recovery) by
presenting a moving-bed setup, instead of a fixed-bed, -utilized in this prepare were engineered
alumina/silica dots that have more homogeneous and reliable properties (e.g., movement) than the
common minerals. Catalysts particles and the nourish are presented from the beat of the reactor and the
catalyst particles move descending with gravity as the breaking responses take put on the catalyst
surfaces. Steam is infused from the foot of the reactor to carry the splitting items to the fractionator for
recuperation. As the particles move down the reactor, they are deactivated by coke build-up on
dynamic destinations.

11
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
III. Alkylation
Alkylation
1. Feed fresh isobutane , butylene , propylene , amylene
2. Product Alkylate
3. Catalyst sulfuric acid , Hydrofluoric acid , solid acid , ionic liquids
4. Objective The unit 's aim is to react in the reaction section with an olefin feed
containing isebutane in the presence of the HF acting as a catalyst to
generate alkylate. .. In The fractionation section alkylate is separated by
distillation from excess isobutene and acid catalyst
5. Operation The reaction thermodynamics and kinetics are favored at low temperatures.
variable Sulfuric acid alkylation units are operated at 5–10 °C (40–50 F) and 1 to 10
atmospheres. Above 10 °C, oxidation and side reactions are promoted, and
the deteriorate-alkylate yield and quality while acid consumption increases.
In general, refiners will preferentially feed is butylene, because this yields
the highest quality alkylate (octane and vapor pressure). Also, butylene has
a lower-valued alternative use than propylene.
6. Description alkylation unit is one of the change forms utilized in petroleum refineries. It
process is utilized to change over isobutane and low-molecular-weight alkenes into
alkylate, a tall octane gasoline component. The method happens within the
nearness of an corrosive such as sulfuric corrosive or hydrofluoric
corrosive as catalyst

12
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
IV. Coking
Delayed coking Continuous coking
1. Feed Coke from atmospheric or vacuum Coke from atmospheric or
distiller vacuum distiller
2. Product gas, naphtha, and gas oils. heavier Larger coke particles as
hydrocarbons produced in the product
fractionator are recycled through the and a other coke treated as
furnace. recycle
back into the feed
3. Catalyst
5. Operation high temperatures (900°-950° F at low Higher temperature and a
variable pressure (25-30)=2 bar higher pressure of 50 psi
6. Description In delayed coking the heated charge Contact coking is a moving
process (typically residuum from atmospheric bed process where thermal
distillation towers) is transferred to cracking occurs by heating
large distiller coke drums which provide transferred from hot recycled
the long residence time needed to allow coke particles to a feedstock in
the cracking reactions to proceed to reactor
completion.

Flow diagram of delayed coking flow diagram of continuous coking

13
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
ITEM 3 B :

14
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020

15
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
ITEM 4 :

Sulfur compounds are chemical compounds that contain the chemical component sulfur. This chapter
talks about the gas chromatography division of hydrogen sulfide, carbonyl sulfide, sulfur dioxide, and
methyl mercaptan.

 Q/ Why removing sulfur compounds?

Ans/ Crude oil containing high sulfur substance increments the bubbling run additionally contaminates
the environment, so some time recently refining the crude oil sulfur must be re moved by diverse
desulfurization methods

 Q/ What is the effect of sulfur compounds contents on crude oil price?

Ans/ the costs of refining and the availability of refineries able to produce high value products can be
important. Crudes with high sulfur content are more corrosive and require more expensive process
mitigation measures. Sulfur and sulfur compounds are undesirable impurities for the environment and
may pose health and safety hazards. For these reason, limits on the sulfur content of hydrocarbon
products are set by national and international standard specifications.

 Q/ What are the most harmful sulfur compounds?

Ans/ H2SO4

Sulfuric acid is a clear, colorless, oily liquid that is very corrosive. An odor threshold of sulfuric acid in
air has been reported to be 1 milligram per cubic meter of air (mg/m3). If you are exposed to
concentrated sulfuric acid in air, your nose will be irritated and it may seem like sulfuric acid has a
pungent odor. When concentrated sulfuric acid is mixed with water, the solution gets very hot.
Concentrated sulfuric acid can catch fire or explode when it comes into contact with many chemicals
including acetone, alcohols, and some finely divided metals. When heated it emits highly toxic fumes,
which include sulfur trioxide. It is also called sulphine acid, battery acid, and hydrogen sulfate. More
sulfuric acid is produced in the United States than any other chemical. It is used in the manufacture of
fertilizers, explosives, other acids, and glue; in the purification of petroleum; in the pickling of metal;
and in lead-acid batteries (the type commonly used in motor vehicles). Sulfuric acid can be found in the
air as small droplets or it can be attached to other small particles in the air.

 Desulfurization
Definition of Desulfurization :

Desulfurization is the process of using hydrogen gas to reduce the sulfur content in hydrocarbons thus
reducing the emissions of sulfur oxides which are responsible for acid rain. Countries across the globe
have increasingly strict regulations in place to limit the sulfur content in fuels.

16
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
Types of Desulfurization

1. oxidative desulfurization
2. extractive desulfurization
3. biodesulfurization
4. hydrodesulfurization
5. desulfurization through alkylation
6. Chlorinolysis based desulfurization
7. Supercritical water based desulfurization

 Amine Sweetening
Amine gas treating ,also known as amine scrubbing , gas sweetening and acid gas removal ,refers to
a group of processes that use aqueous solution of various alkylamines (commonly referred to
simple as amines) to remove hydrogen sulfide (H2S) and carbon dioxide (CO2) from gases .it is a
common unit process used in refineries ,and is also used in petrochemical plants , nature gas
processing plant and other industries .

1. Types of amine which are used in gas treating:

 Diethanolamine (DEA)
 Monoethanolamine (MEA)
 Methyldiethanolamine (MDEA)
 Diisopropanolamine (DIPA)
 Aminoethoxyethanol (Diglycolamine) (DGA)

The most commonly used amine in industry plant are the alkanolamine DEA, MEA, and MDEA.
these amine are also used in many oil refinery to remove sour gas from liquid hydrocarbon such as
liquefied petroleum gas (LPG)

2. Process Flow:

Amine systems tend to be located in a central plant to service the entire sour gas production for a
field. A typical amine sweetening process is shown in the following diagram.

17
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020

Natural gas engineering hand book, Dr. Boyun guo & Dr.Ali Ghalmbour, university of louisiana at
Lafayette,© 2005 by gulf publishing company, Houston

3. Operation variable of amine:

Feed enters Absorber at conditions of (32.23 Ԩ, 69.96 bar, 10000 kg/hr) from the bottom of the column
and the amine (DEA) enter at the top of the column. Amine absorbs co2 from the feed gas. The sweet
feed gas exit from the top of column and the rich amine exit from the bottom .

4. Effect on the efficiency

Lower amine temperature provides a significant reduction in solvent circulation rate, steam
consumption rate, pumping duty and dehydration unit load while posing no risk of hydrocarbon
condensation or hydrate formation. Also, higher amine strength is best suited for the unit under
study, as it results in potential savings of operating costs without increasing the risks of corrosion
and fouling. there has been emphasis on improving amine gas sweetening plant efficiency due to
the increased exploitation of highly sour gas fields. This triggers the development of several
optimization techniques to maintain the profitability of gas plants. Schemes involving operational
changes alone are most preferred, due to the simplicity and flexibility in restoring plant operations
and for the low retrofitting costs attached to them.

5. Economic aspect
Processes using mixed amines such as MDEA/DGA and MDEA/DEA prove more economically viable
with a 50% reduction in capital costs and 20% and 48% savings on the stripping cost and the annual
power needed for the solvent circulation respectively. Therefore, the prospect of shutting down the
potassium carbonate section and retrofitting the DEA section to MDEA/DEA or MDEA/DGA appears
very promising, allowing ADGAS to decrease operating costs and possibly increase capacity.

18
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020
6. Benefits of Amine Units
 Reduces CO2 and H2S levels to the required specifications
 Modular, skid-mounted systems
 Reduced manufacturing and commissioning times
 Standardized and proven designs
 New equipment only
 Guaranteed performance
 Lower installation and removal costs
 Built in liquid containment to reduce environmental hazards

7. Reasons for Sweetening:

 Safety and Environmental Protection
 Product Specification (see above)
 Corrosion Prevention
 Improved Heating Values

gas is supplied to the sweetening system from the inlet separator and the condensate stabilizer. Sour
products recovered in this process are further processed in a sulphur recovery unit (SRU) If the volume
is low enough (less than 1 tonne of sulphur per day in the inlet gas), the gases are incinerated and
released to atmosphere as CO2 and SO2.

8. Rich Amine:
The amine picks up H2S and CO2 in the contactor tower.

9. Lean Amine:
 A lean amine stream from the bottom of the reboiler (or bottom of the tower) is pumped
back to the contactor.
 The lean amine is often passed through a charcoal filtration system to remove entrained
solids
 If anti-foam additives are added to the system, the charcoal filters will remove them, so they
should be taken off-line during addition.
 The lean amine must be cooled to approximately 6o C warmer than the inlet gas.

19
Name: Tolaz Yasin Ahmed
Wed 18 Jun 2020

References

1. Vafajoo L, Ganjian K, Fattahi M. Influence of key parameters on crude oil desalting: An

experimental and theoretical study. J Petrol Sci Engin. 2012;90-91:107-111. DOI:
10.1016/j.petrol.2012.04.022
2. Gary J, Handwerck G (eds.). Petroleum Refining: Technology and Economics. 4th edn. Marcel
Dekker, Inc. New York. USA; 2001. p. 49. ISBN: 0-8247-0482-7
3. Fahim M, Alsahhaf T, Elkilani A. Crude Distillation. In: Fahim M, Alsahhaf T, Elkila‐ ni A,
Fundamentals of Petroleum Refining. 1st edn. Elsevier B.V. Oxford. UK; 2010. p. 77. DOI:
10.1016/B978-0-444-52785-1.00004-8
4. Arnold K, Stewart M. Choosing a Process. In: Surface Production Operations. Vol‐ ume 1.
Design of Oil Handling Systems and Facilities. 1st edn. Elsevier. B.V. Massachu‐ setts. USA;
2007. p.30. DOI: 10.1016/B978-088415821-9/50011-7
5. Kang W, Xu B, Wang Y, Li Y, Shan X, An F, Liu J. Stability mechanism of w/o crude oil
emulsion stabilized by polymer and surfactant. Colloids Surfaces A: Physicochem Engin Asp.
2011;384:555-560. DOI:10.1016/j.colsurfa.2011.05.017
6. Ramalho J, Lechuga FC, Lucas EF, Effect of the structure of commercial poly(ethyl‐ ene
oxide-bpropylene oxide) demulsifier bases on the demulsification of water-incrude oil
emulsions: elucidation of the demulsification mechanism. Quím Nova. 2010;33:1664-1670.
DOI: 10.1590/S0100-40422010000800009
7. Pereira JC, Phenomena of Rupture and Inversion Emulsions: Physicochemical and Kinetic
Aspects [Thesis]. Mérida: University of Los Andes; 2009: 11-12, 33, 11, 25-26, 46-47, 64, 46-
47, 61-63, 46-47, 77-81.
8. Applied process design for chemical and petrochemica1 plants,Ernest e. Ludwig. volume 2,
thirdedition by gulf professional publishing
9. Natural gas engineering hand book, Dr. Boyun guo & Dr.Ali Ghalmbour, university of
Louisiana at Lafayette,© 2005 by gulf publishing company, Houston.
10. Cryogenic engineering second edition,Thomas m. Flynn,Cryoco, inc.louisville, colorado, u.s.a.
© 2005 by marcel dekker

20