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Chemical Engineering Production Process
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Chemical Engineering Production Process

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@SmittenGradient

Questions and Answers

What is the first main step in the production process?

  • Preparation of porous silica gel (correct)
  • Dehydration at T > 400 °C
  • Addition of aluminum salt
  • Stripping and regeneration

    • Silanol groups are considered acidic in nature.

    False

    What type of acid sites are formed during dehydration at high temperatures?

    Lewis acidic sites

    Zeolites are synthesized by mixing Na2SiO3 and NaAlO2 in a specific ____ range.

    <p>pH</p> Signup and view all the answers

    Match the properties of zeolite catalysts with their descriptions:

    <p>Higher Selectivity = Towards C5-C10 gasolines Higher H Transfer Activity = Compared to hydrocarbon chain breakage High Reaction Rate = Due to the concentration of reactants Cavity Size Variation = Affected by R group of ammonium salt</p> Signup and view all the answers

    What happens to zeolite catalysts in the presence of steam during the stripping and regeneration step?

    <p>Sintering occurs</p> Signup and view all the answers

    Zeolite catalysts have low reaction rates due to the high concentration of reactants within pores.

    <p>False</p> Signup and view all the answers

    What do quaternary ammonium salts do in zeolite cavities?

    <p>They stick within the cavities to determine structure and size.</p> Signup and view all the answers

    Silica hydrogel contains silanol groups at the ____.

    <p>surface</p> Signup and view all the answers

    Which product is produced at the highest rate during fluid coking?

    <p>Gasoil</p> Signup and view all the answers

    NOVEL COKE is produced by cracking inside the reactor.

    <p>True</p> Signup and view all the answers

    What substance undergoes partial combustion in the burner?

    <p>Coke</p> Signup and view all the answers

    What is the primary purpose of hydrotreating?

    <p>To remove sulfur compounds</p> Signup and view all the answers

    The addition of a gasifier in flexicoking makes the process more _____ by converting about 90% of the feed into liquids and gas.

    <p>flexible</p> Signup and view all the answers

    Organometallic compounds do not affect catalyst activity.

    <p>False</p> Signup and view all the answers

    What is the pressure range typically used during hydrotreating?

    <p>5-20 atm</p> Signup and view all the answers

    Match the following products with their respective yields in delayed coking:

    <p>Gas ≤ C4 = 7.5 Gasoline = 17 Gasoil = 53.5 Coke = 22</p> Signup and view all the answers

    The process of removing hydrogen sulfide by washing is known as ______.

    <p>amine washing</p> Signup and view all the answers

    What is the purpose of the cyclone in the coking process?

    <p>To remove carbonaceous particles</p> Signup and view all the answers

    Match the catalyst type to its primary reaction:

    <p>Co-Mo = Desulfurization Ni-Mo = Heavy metal removal Ni-W = Hydrogenation of olefins Pt = Catalyst poisoning</p> Signup and view all the answers

    Which of the following is NOT a compound targeted for removal during hydrotreating?

    <p>Carbon dioxide</p> Signup and view all the answers

    The presence of sulfur decreases SO2 emissions during catalyst regeneration.

    <p>False</p> Signup and view all the answers

    What common issue can nitrogen cause during the catalyst process?

    <p>Ammonia generation</p> Signup and view all the answers

    V is known to cause ______ which negatively affects catalyst performance.

    <p>sintering</p> Signup and view all the answers

    What is one of the functions of the Claus process?

    <p>Transform H2S into sulfur</p> Signup and view all the answers

    What is the primary purpose of hydrotreating?

    <p>To remove heteroatoms and saturate C-C bonds</p> Signup and view all the answers

    Hydrocracking typically results in a lower conversion rate compared to hydrotreating.

    <p>False</p> Signup and view all the answers

    What catalyst is used in hydrotreating processes and is sensitive to sulfur?

    <p>Pt catalyst</p> Signup and view all the answers

    The process by which heavy crude oils require additional treatments is known as __________.

    <p>residue conversion</p> Signup and view all the answers

    Match the following processes with their main characteristics:

    <p>Hydrotreating = Minimal conversion, fewer products Hydrocracking = Higher yield of fuel products Residue conversion = Recovers a large amount of the residue H2S removal = Uses steam to remove hydrogen sulfide from hydrocarbons</p> Signup and view all the answers

    Which process is more appropriate for producing diesel rather than gasoline?

    <p>Hydrocracking</p> Signup and view all the answers

    All petroleum products are considered high-value products.

    <p>False</p> Signup and view all the answers

    What are the characteristics of the residue used in petroleum processing?

    <p>Heavy, dirty, low value, hydrogen deficient</p> Signup and view all the answers

    In the petrochemical industry, processes transform low-value raw materials into high-value products through __________.

    <p>conversion processes</p> Signup and view all the answers

    What is a common feature of both hydrotreating and hydrocracking?

    <p>Both processes are forms of hydroprocessing</p> Signup and view all the answers

    What is used to cut petroleum coke from the drum?

    <p>High pressure water</p> Signup and view all the answers

    The vapours exit the column from the bottom and return to the fractionator.

    <p>False</p> Signup and view all the answers

    What is the temperature range of the scorching coke in the fluidized bed reactor?

    <p>500-550 °C</p> Signup and view all the answers

    The _____ is recovered and sent to other refinery units for gasoline production.

    <p>Naphtha</p> Signup and view all the answers

    Match the types of gas oil with their processing purpose:

    <p>Light Coker Gas Oil = Processed into diesel and other products Heavy Coker Gas Oil = Processed into diesel and other products</p> Signup and view all the answers

    What happens to the water separated from coke in the coke pit?

    <p>It is reused in the cutting water system</p> Signup and view all the answers

    A fluidized bed reactor uses a coke furnace-burner unit to maintain motion.

    <p>True</p> Signup and view all the answers

    What is the primary use of petroleum coke?

    <p>Fuel in power plants</p> Signup and view all the answers

    The OFFLINE DRUM is ______, ______, and ______ before the drum is opened to the atmosphere.

    <p>steamed, vented, cooled</p> Signup and view all the answers

    What process occurs when the feed meets the scorching coke?

    <p>Cracking</p> Signup and view all the answers

    Study Notes

    Production Process

    • The production process involves three main steps: preparation of porous silica gel, addition of aluminum salt, and dehydration at temperatures exceeding 400 °C.
    • The preparation stage creates spherical particles of silica hydrogel with silanol groups on the surface.
    • Aluminum salts, specifically Al(OH)3·3H2O, react with silanol groups to impart a negative charge on Al3+, balanced by hydrated cations on the silica surface.
    • Dehydration converts Brønsted acidic sites to Lewis acidic sites, enhancing catalytic activity.
    • Catalysts derived from this process exhibit low thermal stability and are prone to sintering, especially in steam environments during stripping and regeneration.

    Zeolite Catalysts

    • Zeolites are natural crystalline catalysts made of sodium alumino-silicates with a porous 3D structure.
    • Synthesized by mixing Na2SiO3 and NaAlO2 under specific pH conditions, zeolite crystallization is promoted through heating of the precipitate.
    • The size of zeolite cavities can be altered by varying the R group of quaternary ammonium salts included during the synthesis.
    • Zeolite catalysts show high selectivity for C5-C10 gasolines and are more active in hydrogen transfer than in hydrocarbon chain cleavage.
    • Hydrocarbon cleavage halts at higher molecular weights due to the transformation of hydride ions to carbocations and subsequent olefin hydrogenation.
    • Issues with zeolite catalysts include coke formation and potential reversible catalyst inhibition.

    Effects of Compounds on Catalysts

    • Sulfur increases SO2 emissions during catalyst regeneration, which can be managed through amine washing or the Claus process.
    • Nitrogen can generate ammonia, which neutralizes acidic catalyst sites, while oxygen and arsenic can poison Pt catalysts.
    • Organometallic compounds convert to heavy metals that can deactivate catalysts, with vanadium specifically causing sintering.
    • Sodium and potassium irreversibly neutralize zeolites' acidic sites.

    Hydrotreating

    • A high-pressure hydrotreating process (5-20 atm) using Co-Mo, Ni-Mo, or Ni-W catalysts is effective for removing sulfur and other heteroatoms before cracking processes.
    • This method helps desulfurize gasoils for diesel fuels and fuel oil, minimizing catalyst deactivation during catalytic cracking.
    • Hydrotreating serves to reduce coke formation from olefins and ammonia while also removing oxygen, nitrogen, and arsenic to protect Pt catalysts.

    Hydrocracking

    • Hydrocracking involves severe hydroprocessing to remove heteroatoms and saturate carbon-carbon bonds.
    • It results in higher yields of fuel products compared to mild hydrotreating.
    • The conversion rate in hydrocracking is notably higher than in mild processes, making products more suitable for diesel rather than gasoline.

    Petroleum Products

    • The petrochemical industry transforms low-value raw materials into high-value products, often with a higher H/C ratio.
    • Residue conversion processes address the treatment of heavy crude oils, recovering valuable products and reducing waste.
    • Heavy residue is characterized as high molecular weight, carbon-rich, and low-value, leading to the recovery of fuel gas and LPG and the production of petroleum coke, which can be used as fuel in power plants.

    Fluidized Bed Coking

    • The fluidized bed coking process integrates a coke reactor with a furnace-burner unit, using steam to maintain coke motion and facilitate cracking at high temperatures (500-550 °C).
    • The process generates various product yields, with more gasoil and less gasoline compared to delayed coking.
    • A portion of produced coke is collected while combustion gases are removed for carbonaceous particle separation.

    Flexicoking

    • Flexicoking includes a gasifier to enhance flexibility, converting around 90% of feed into liquids and gases and allowing excess coke to be gasified for energy or chemical production.

    Asphaltenes Extraction

    • Asphaltenes, the heaviest petroleum components, contain impurities and are solid at room temperature.
    • Removing asphaltenes increases gasoil yield during cracking processes and allows for their use as fuels in cement production and asphalt manufacturing.
    • The deasphalting process involves solvent recovery of non-asphaltene materials from both atmospheric and vacuum residues.

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    Description

    Explore the three main steps involved in the production process of porous silica gel. This quiz covers the preparation, addition of aluminum salt, and dehydration processes that lead to the formation of silica hydrogel particles with silanol groups. Test your knowledge on this essential chemical engineering topic.

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