Lecture 7: Processes In Oil Refinery (Catalystic) - Introduction to ChE

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Kazakh-British Technical University

Murat Yerlanovich Jumagaziyev

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chemical engineering oil refinery processes petroleum

Summary

This lecture covers the processes in an oil refinery, including catalytic processes, reactions, hydrocracking, and reforming. It discusses the role of chemical engineers in maintaining and optimizing these plants, and some supporting disciplines involved in engineering oil refineries.

Full Transcript

Murat Yerlanovich LECTURE 7: Jumagaziyev PROCESSES IN OIL Institute of Chemical Sciences, office 114 REFINERY (CATALYTIC) m.dzhumagaziyev@kb tu.kz PROCESSES IN THE OIL REFINERY Thermal Processes Catalytic...

Murat Yerlanovich LECTURE 7: Jumagaziyev PROCESSES IN OIL Institute of Chemical Sciences, office 114 REFINERY (CATALYTIC) m.dzhumagaziyev@kb tu.kz PROCESSES IN THE OIL REFINERY Thermal Processes Catalytic Processes Delayed Coking Hydrotreating Catalytic Cracking Visbreaking Hydrocracking Catalytic Reforming Thermal Alkylatio Pyrolysis n Cracking REACTIONS Almost all the reactions in the refinery use special catalysts that increase the rate and selectivity of the reaction. This improves efficiency and Reactions to Make Higher Octane ISOMERIZATION REFORMING REACTIONS TO MAKE HIGHER OCTANE ALKYLATION REACTIONS TO CONVERT HEAVY OILS HYDROCRACKING H2 + heavy oil --> gasoline + diesel 550o F (280-290 C) 300o F (150 C) o o 450o F (230-240 C) o use boiling point to describe oils CAT CRACKING heavy oil --> gasoline + propylene, butane, REACTIONS TO REMOVE SULFUR HYDRODESULFURIZATION 2 R-SH + H2 --> 2 R +2 H2S mercaptan hydrocarbon SULFUR RECOVERY convert H2S to elemental sulfur: 2 H2S + 2 O2 --> SO2 + S + 2 H2O 2 H2S + SO2 --> 3S + 2 H2O WHAT HAPPENS TO THE BAD STUFF IN THE CRUDE? Sulfur – converted to elemental sulfur – in high sulfur fuel oil – in coke Heavy Metals (nickel, vanadium) – in high sulfur fuel oil and coke Nitrogen (organic nitrogen) – most is converted to ammonia and neutralized – in high sulfur fuel oil and coke HYDROTREATING Hydrogenation is a class of chemical reactions in which the net result is the addition of hydrogen (H). Hydrogenolysis is a type of hydrogenation and results in the cleavage of the C-X chemical bond, where C is a carbon atom and X is a sulfur, nitrogen (N) or oxygen (O) atom. The net result of a hydrogenolysis reaction is the formation of C-H and H-X chemical bonds. Thus, hydrodesulfurization is a hydrogenolysis reaction. Using ethanethiol (C2H5SH), a sulfur compound present in some petroleum products, as an example, the hydrodesulfurization reaction can be simply expressed as Ethanethiol + Hydrogen → Ethane + Hydrogen TYPICAL HYDROTREATING HYDROCRACKING  Hydrocracking is the conversion of higher boiling point petroleum fractions to gasoline and jet fuels in the presence of a catalyst  Hydrocracking process was commercially developed in 1927 by I. G. Farben (in Germany) for conversion of lignite to gasoline  Esso, and Chevron applied this process later in USA  Due to the importance of this process, it has been heavily researched and modified in petroleum industry WHY HYDROCRACKING?  The increasing demand for gasoline and jet fuel compared to diesel fuel and home heating oils was a dominant factors in the development of hydrocracking process  Hydrogen as a byproduct of catalytic reforming process was available in large amounts and relatively cheap  Environmental concerns about sulfur and aromatic compounds were other factors in fast growth of hydrocracking in recent years HYDROCRACKING REACTIONS  Cracking and hydrogenation are complementary as shown below HYDROCRACKIN G REACTIONS Aromatics which are difficult to process in FCC are converted to useful products in Hydrocrackers. HYDROCRACKING REACTIONS  Cracking provides olefins for hydrogenation and Hydrogenation provides heat for cracking  The overall reaction provides an excess of heat as hydrogenation produces much larger heat than the heat required for cracking operation  Therefore the process is exothermic and quenching is achieved by injecting cold hydrogen into the reactor and apply other means of heat transfer, e.g. intermediate heat exchanger  Isomerization is another type of reaction, which occurs in hydrocracking HYDROCRACKING CATALYTIC REFORMING CATALYTIC REFORMING CATREF (CATALYTIC REFORMING) WHAT ROLE DO ENGINEERS PLAY IN THE REFINERY? WHAT ROLE DO CHEMICAL ENGINEERS PLAY? Operations Engineer Maintenance Engineer Control Systems Engineer Design Engineer Health/Safety/Environmental Engineer Planning / Scheduling Engineer Reliability Engineer Plant Manager OTHER WAYS CHEMICAL ENGINEERS SUPPORT THE REFINING INDUSTRY Research & Development Engineers Technical Sales Engineers Engineering & Construction Engineers Governmental Regulators (EPA) University Professors OTHER ENGINEERING DISCIPLINES IN THE REFINERY Mechanical Engineers - design & maintenance of compressors, vessels … Electrical Engineers - electrical, instrumentation, controls Computer Scientists - main plant control & information systems SUMMARY Refineries are very complicated chemical processing plants that use reactions and separations to convert crude oil into gasoline and other valuable products Chemical engineers play an important role in keeping these plants running safely and efficiently

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