Jones D.S.J., Pujado P.R. Handbook of Petroleum Processing

Springer, 2006. — 1353 p. — ISBN-10 1402028199.This Handbook describes and discusses the features that make up the petroleum refining industry. It begins with a description of the crude oils and their nature. It continues with the saleable products from the refining processes, with a review of the modern day environmental impact.An introduction to crude oil and its processingThe composition and characteristics of crude oil
The crude oil assay
Other basic definitions and correlations
Predicting product qualities
Basic processes
The processes common to most energy refineries
Processes not so common to energy refineries
The non-energy refineriesPetroleum products and a refinery configurationPetroleum products
A discussion on the motive fuels of gasoline and diesel
A refinery process configuration developmentThe atmospheric and vacuum crude distillation unitsThe atmospheric crude distillation unit
Process description
The development of the material balance for the atmospheric crude distillation unit
The design characteristics of an atmospheric crude distillation fractionating tower
The fractionator overhead system
The side streams and intermediate reflux sections
Calculating the main tower dimensions
The crude feed preheat exchanger system design
An example in the design of an atmospheric crude oil distillation tower
The vacuum crude distillation unit
Process description
The vacuum crude distillation unit’s flash zone
The tower overhead ejector system
Calculating flash zone conditions in a vacuum unit
Draw-off temperatures
Determine pumparound and internal flows for vacuum towers
Calculate tower loading in the packed section of vacuum towersThe distillation of the ‘Light Ends’ from crude oilA process description of a ‘light ends’ unit
Developing the material balance for light end units
Calculating the operating conditions in light end towers
Calculating the number of trays in light end towers
Condenser and reboiler duties
Tower loading and sizing
Checks for light end tower operation and performanceCatalytic reformingFeedstocks
Catalysts
Process flow schemes
Advantages of CCR Platforming
Catalysts and suppliersFluid catalytic cracking (FCC)Fluidization
Process control
Reaction chemistry and mechanisms
Gas oil cracking technology features
Cracking for light olefins and aromatics
NomenclatureAppendix Commercially available FCC catalysts and additivesDistillate hydrocrackingBrief history
Flow schemes
Chemistry
Catalysts
Catalyst manufacturing
Catalyst loading and activation
Catalyst deactivation and regeneration
Design and operation of hydrocracking reactors
Hydrocracking process variables
Hydrocracker licensors and catalyst manufacturersHydrotreatingBrief history
Flow schemes
Chemistry
Catalysts
Catalyst manufacturing
Catalyst loading and activation
Catalyst deactivation and regeneration
Design and operation of hydrotreating reactors
Hydrotreating process variables
Hydrotreaters licensors and catalyst manufacturersGasoline componentsMotor fuel alkylationHistory
Process chemistry
HF alkylation process flow description
Sulfuric acid alkylation
Stratco effluent refrigerated alkylation process
Alkylate properties
Recent developmentsCatalytic olefin condensationHistory
Catalytic condensation process
Catalytic condensation process for gasoline production
Hydrogenated versus nonhydrogenated polymer gasolines from the catalytic condensation process
Selective and nonselective gasoline production with the catalytic condensation process
Catalytic condensation process as a source of diesel fuels
Petrochemical operations
Dimersol process
Other dimerization or oligomerization processes
Recent developments
Catalytic olefin condensation with the InAlk process
Catalyst suppliersIsomerization technologies for the upgrading of light naphtha and refinery light endsProcess chemistry of paraffin isomerization
Primary reaction pathways
Isomerization catalysts
I-80 catalyst development and applications
LPI-100 catalyst development and applications
New isomerization process technologies
Isomerization process economics
Other applicationsRefinery gas treating processesThe process development and description
Common processes
Other gas treating processes
Calculating the amine circulation rate
Calculating the number of theoretical trays in an amine contactor
Calculating absorber tray size and design
Calculating the heat transfer area for the lean/rich amine exchanger
The stripper design and performance
Removing degradation impurities from MEA
The process design of an amine gas treating unitUpgrading the ‘Bottom of the Barrel’The thermal cracking processes
Deep oil’ fluid catalytic cracking
Residuum hydrocrackingAppendix Sizing a thermal cracker heater/reactorThe non-energy refineriesThe lube oil refinery
Lube oil properties
A description of major processes in lube oil refining
Asphalt production
The petrochemical refinery
The production of aromatics
Process discussion
Sizing a bitumen oxidizerSupport systems common to most refineriesControl systems
Definitions
Reflux drums
The control valve
Offsite systems
Storage facilities
Atmospheric storage
Pressure storage
Heated storage tanks
Calculating heat loss and heater size for a tank
Product blending facilities
Road and rail loading facilities
Jetty and dock facilities
Jetty size, access, and location
Waste disposal facilities
The flare
Effluent water treating facilities
Other treating processes
Utility Systems
Brief descriptions of typical utility systems
Steam and condensate systems
Fuel systems
Water systems
The hot lime process
The ion exchange processes
Compressed air system
Safety systems
Determination of risk
Definitions
Types of pressure relief valves
Capacity
Sizing of required orifice areas
Sizing for flashing liquids
Sizing for gas or vapor on low-pressure subsonic flow
Example calculation for sizing a tank heater
Example calculation for sizing a relief value
Control valve sizingEnvironmental control and engineering in petroleum refiningAqueous wastes
Pollutants in aqueous waste streams
Treating refinery aqueous wastes
Oxidation of sulfides to thiosulfates
Oxidation of mercaptans
Oxidation of sulfide to sulfate
Oil–water separation
The API oil–water separator
Storm surge ponds
Other refinery water effluent treatment processesEmission to the atmosphere
Features of the Clean Air Act
The major effects of air pollution and the most
common pollutants
Monitoring atmospheric emission
Reducing and controlling the atmospheric pollution in
refinery products
Controlling emission pollution from the refining
processes
Noise pollution
Noise problems and typical in-plant/community noise standards
Fundamentals of acoustics and noise control
Coping with noise in the design phase
A typical community/in-plant noise program
Partial pressures of HS and NH over aqueous solutions of HS and NH
Example of the design of a sour water stripper with no reflux
Example design of an API separatorRefinery safety measures and handling of hazardous materialsHandling of hazardous materials
Anhydrous hydrofluoric acid
The amines used in gas treating
Caustic soda
Furfural
Hydrogen sulfide, HS
Methyl ethyl ketone, MEK
Fire prevention and fire fighting
The design specification
Fire prevention with respect to equipment design
and operation
The fire main
Fire foam and foam systems
Class B fire foams
Class A fire foamsQuality control of products in petroleum refiningSpecifications for some common finished products
The LPG products
The gasolines
The kerosenes
Aviation turbine gasoline (ATG) and jet fuels
The gas oils
The fuel oil products
The lube oils
The asphalts
Petroleum coke
Sulfur
The description of some of the more common tests
Specific gravity (D1298)
ASTM distillations (D86, D156)
Flash point test method (D93)
Pour point and cloud point (D97)
Kinematic viscosity (D446)
Reid vapor pressure (D323)
Weathering test for the volatility of LPG (D1837)
Smoke point of kerosenes and aviation turbine fuels (D1322)
Conradson carbon residue of petroleum products (D189)
Bromine number of petroleum distillates (D1159)
Sulfur content by lamp method (D1266)
Octane number research and motorEconomics — Refinery planning, economics, and handing new projectsRefinery operation planning
Running plans
Developing the running planBasis for assessing requirements
The results
The refinery operating program
Process evaluation and economic analysis
Study approach
Building process configurations and the screening study
Example calculation
Investment costs for the new facilities
Preparing more accurate cost data
Summary data sheets
Capital cost estimates
Discounted cash flow and economic analysis
Results
Using linear programs to optimize process
configurations
Executing an approved project
Developing the duty specification
The project team
Primary activities of the project team
Developing the operating manual and plant commissioning
Process guarantees and the guarantee test runRefinery plan inadequacies report
Crude oil inventory schedule
Product inventory and schedule
Outline operating schedule
Detailed operating program and schedule
Typical weekly program
Typical factors used in capacity factored estimates
Example of a process specification
Example of a process guaranteeEconomic analysisAnalysis at one point in time
Cost of production
Reporting parametersBackground for economic calculations
Progressions
Loan repayments (mortgage formula)
Average rate of interestProcess equipment in petroleum refiningVessels
Fractionators, trays, and packings
Drums and drum design
Specifying pressure vessels
Pumps
Pump selection
Selection characteristics
Capacity range
Evaluating pump performance
Specifying a centrifugal pump
The mechanical specification
The process specification
Compiling the pump calculation sheet
Centrifugal pump seals
Pump drivers and utilities
Reacceleration requirement
The principle of the turbine driver
The performance of the steam turbine
Compressors
Calculating horsepower of centrifugal compressors
Centrifugal compressor surge control, performance curves and seals
Specifying a centrifugal compressor
Calculating reciprocating compressor horsepower
Reciprocating compressor controls and inter-cooling
Specifying a reciprocating compressor
Compressor drivers, utilities, and ancillary equipment
Heat exchangers
General design considerations
Choice of tube side versus shell side
Estimating shell and tube surface area and pressure drop
Air coolers and condensers
Condensers
Reboilers
Fired heaters
Codes and standards
Thermal rating
Heater efficiency
Burners
Refractories, stacks, and stack emissions
Specifying a fired heaterLMTD correction factors
Heat of combustion of fuel oils
Heat of combustion of fuel gasses
Values for coefficient C
Some common heat transfer coefficients
Standard exchanger tube sheet dataA dictionary of terms and expressions

AppendicesExamples of working flow sheets
General data
Friction loss for viscous liquids
Resistance of valves and fittings
Viscosity versus temperature
Specific gravity versus temperature
Relationship between specific gravity and API degrees
Flow pressure drop for gas streams
Relationship of chords, diameters, and areas
A selection of crude oil assays
Conversion factors
An example of an exercise using linear programming
Linear programming aids decisions on refinery configurations