Republic of the Philippines

Batangas State University

Alangilan, Batangas City

Chevron Pascagoula Refinery

Physical Chemistry

Group 1
Abog, Joshua Jophet Allen S.
Adia, Karla Mariel E.
Ramirez, Felipa A.
Romey, Ray Francisdeo C.

Engr. Melanie P. Adante

March 2014
 CHAPTER I
Introduction
It is amazing how a yellow to gold substance from deep within the Earth,
known as petroleum, becomes fuel, plastics, rubbers, tires and many more.
Basically, petroleum is composed of various and enormous chains of
hydrocarbon of various molecular weights and other liquid compounds. This raw
material is converted into useful products through a refinery.
A refinery is a production facility composed of complex units used in
separating different components of petroleum. It consists of different types of
units that have distinct operations for different types of products. The main goal
of refining petroleum is to take the undesirable components and upgrade them
into useful products. To achieve better quality of the product, more complex
processes are done that result to higher cost of production.

Company Profile
The root was an 1879 oil discovery at Pico Canyon, north of Los Angeles,
which led to the formation of the Pacific Coast Oil Co. That company later
became Standard Oil Co. of California and, subsequently, Chevron. They took on
the name Chevron when they acquired Gulf Oil Corporation in 1984, which nearly
doubled the worldwide proved crude oil and natural gas reserves. The merger
with Gulf was then the largest in U.S. history.

Another major branch of the family tree is The Texas Fuel Company,
formed in Beaumont, Texas, in 1901. It later became known as The Texas
Company and, eventually, Texaco. In 2001, the two companies merged. The
acquisition of Unocal Corporation in 2005 strengthened Chevron's position as an
energy industry leader, increasing the crude oil and natural gas assets around
the world.

The founder and chairman of Standard Oil was John D. Rockefeller.

Presently, the chairman and CEO of Chevron Corporation is John S. Watson.
Our diverse and highly skilled global workforce consists of approximately 61,900
employees, including more than 3,600 service station employees. In 2012,
Chevron's average net production was 2.61 million barrels of oil-equivalent per
day. About 75 percent of that production occurred outside the United States.
Chevron had a global refining capacity of 1.95 million barrels of oil per day at the
end of 2012.

Since the operation in 1963, the Pascagoula refinery has grown to be the
corporation's largest U.S. refinery and one of the top ten petroleum refineries in
the United States.

Location
The Pascagoula Refinery is located on Industrial Road (Mississippi
Highway 611), just off U.S. Highway 90, situated east of the City of Pascagoula
in an unincorporated area of Jackson County.
The facilities are located in the Bayou Casotte Industrial Park that covers
over 3,000 acres next to the Mississippi Sound. About two-thirds of the acreage
is wetlands and forestlands that are home to many species of wildlife indigenous
to the Gulf Coast since only a portion of the property is developed.

Fig. 1 Aerial Shot of Chevron Pascagoula Refinery

 CHAPTER II

Process

The four basic steps in the refining process at Chevron Pascagoula are
distillation, cracking, treating and reforming. These processes occur in the main
operating areas Crude/Aromatics, Cracking I, RDS/Coker, Cracking II, and at
the Sulfur Recovery Unit.

Fig. 2.1. Pascagoula Refinery Process Flow

1. Distillation
Oil is pumped through pipes in hot furnaces and separating light
hydrocarbon molecules from heavy ones in downstream distillation towers the
tall, narrow columns that give refineries their distinctive skylines.
The Pascagoula Refinery's refining process begins when crude oil is
distilled in two large Crude Units that have three distillation columns, one that
operates at near atmospheric pressure, and two others that operate at less than
atmospheric pressure, i.e., a vacuum.
During this process, the lightest materials, like propane and butane,
vaporize and rise to the top of the first atmospheric column. Medium weight
materials, including gasoline, jet and diesel fuels, condense in the middle. Heavy
materials, called gas oils, condense in the lower portion of the atmospheric
column. The heaviest tar-like material, called residuum, is referred to as the
"bottom of the barrel" because it never really rises.
The distillation process occurs on the separation units. These units take an
incoming stream and separate it into different components. No chemical
reactions occur in these units.

Fig. 2.2. Desalting Unit

 Desalter: Ions in the crude oil will corrode the pipes in the refinery and may
deactivate the catalysts. It is important to remove these salts from the crude
before any other processes are started. This involves forcing water into the
crude oil feed stream. This pulls out the salts and prevents corrosion.

Atmospheric Distillation: This is performed at atmospheric pressures. The

outputs of the distillation unit include light ends, kerosene, diesel, heavy gas oil,
and atmospheric residue.

Figure 2.3. Atmospheric Distillation

In some cases, distillation columns are operated at less than atmospheric

pressure (vacuum) to lower the temperature at which a hydrocarbon mixture
boils. This "vacuum distillation unit" (VDU) reduces the chance of thermal
decomposition (cracking) due to overheating the mixture.

Vacuum Distillation: This unit distils the atmospheric residue and

produces light vacuum gas oil, heavy vacuum gas oil, and vacuum residue.
The distillation occurs because the pressure inside of the unit is decreased
 to nearly zero, allowing the components of the atmospheric residue to boil at
a lower temperature.

Fig 2.4. Vacuum Distillation

Light Ends Unit: The light ends unit consists of many different
fractionators that separate the different components of the light ends fraction
from atmospheric distillation. The separated components consist of methane
and ethane, which are used for fuel to heat operations throughout the
refinery; propane and butane, which are mixed and compressed to be sold
as Liquid Petroleum Gas (LPG); light straight run (lsr) naphtha (C5 and
C6), which is used in gasoline pools; and heavy straight run (hsr) naphtha,
which is used as a feed stock for the catalytic reformer.
 Fig. 2.5. Light Ends Units

Deasphalter: This unit takes the vacuum residue and pulls out all of the
heavy particles leaving heavy gas oil that can be further refined or used as
fuel oil, and asphalt, which is used in paving.

Fig 2.6. Deasphalter

 Dewaxer: This unit precipitates long n-paraffins out of heavy vacuum gas
oil creating lubricating oils that will withstand low temperatures without
solidifying.

Fig 2.7. Dewaxer

The Pascagoula Refinery added a new low-pressure vacuum column to
the Crude I Unit and converted the RDS/Coker's VDU into a second vacuum
column for the Crude II Unit as part of the 2003 Clean Fuels Project. These and
other distillation upgrades improved gas oil recovery and decreased residuum
volume.
Refinery operators precisely control the temperatures in the distillation
columns using the most up-to-date computer control systems which are designed
with pipes to withdraw the various types of products where they condense.
Products from the top, middle and bottom of the column travel through these
pipes to different plants for further refining.

2. Cracking
 At the Pascagoula Refinery, they convert middle distillate, gas oil and residuum
into primarily gasoline, jet and diesel fuels by using a series of processing plants
that literally "crack" large, heavy molecules into smaller, lighter ones.
Heat and catalysts are used to convert the heavier oils to lighter products using
three "cracking" methods:
1. fluid catalytic cracking (FCC)
2. hydrocracking (Isomax)
3. coking (or thermal-cracking)

1. The Fluid Catalytic Cracker (FCC) uses high temperature and catalyst to crack
86,000 barrels (3.6 million gallons) each day of heavy gas oil mostly into
gasoline. Hydrocracking uses catalysts to react gas oil and hydrogen under high
pressure and high temperature to make both jet fuel and gasoline.
Also, about 58,000 barrels (2.4 million gallons) of lighter gas oil is
converted daily in two Isomax Units, using this hydrocracking process.

The refinery blend most of the products from the FCC and the Isomaxes directly
into transportation fuels, i.e., gasoline, diesel and jet fuel. We burn the lightest
molecules as fuel for the refinery's furnaces, thus conserving natural gas and
minimizing waste.
In the Delayed Coking Unit (Coker), 98,000 barrels a day of low-value residuum
is converted (using the coking, or thermal-cracking process) to high-value light
products, producing petroleum coke as a by-product. The large residuum
molecules are cracked into smaller molecules when the residuum is held in a
coke drum at a high temperature for a period of time. Only solid coke remains
and must be drilled from the coke drums.
Modifications to the refinery during its 2003 Clean Fuels Project increased
residuum volume going to the Coker Unit. The project increased coke handling
capacity and replaced the 150 metric-ton coke drums with new 300 metric-ton
drums to handle the increased residuum volume.
The Coker typically produces more than 6,000 tons a day of petroleum coke,
which is sold for use as fuel or in cement manufacturing.
The cracking processes takes place on the conversion units. These units
change the composition of input streams through chemical reactions. In the
reactors, a low grade product is converted into a higher grade product.

Catalytic Cracker: This unit transforms heavy gas oil into light
distillates, such as gasoline and LPG, as well as light cycle oil. The unit
utilizes a catalyst to take long chain hydrocarbons and break (crack) them
into shorter, more valuable hydrocarbons.
Fig. 2.8. Catalytic Cracker
 Hydrocracker: This unit performs the same operation as the catalytic
cracker, but uses hydrogen gas instead of a catalyst to break long
hydrocarbon chains into shorter ones. Also, the feedstock is light vacuum
gas oil and the products are light and middle distillates.

Fig 2.9. Hydrocracker

Thermal Cracker: This unit uses heat to break larger molecules into smaller
ones, but is rarely used today.
Visbreaker: This unit employs a mild version of thermal cracking to convert
vacuum residue into light and middle distillates, fuel oil, and coke or heavy gas
oil into slightly lighter fuel oil.
 Fig 2.10 Visbreaker

Alkylater: This unit converts short olefins (ethylene, propylene, and

butenes) and isobutane chains into branched C7 and C8 chains via strong
acids and heat.

Fig. 2.11. Alkylater

 Delayed Coker: This unit uses a very severe version of thermal
cracking to convert vacuum residue into light and middle distillates, as well
as coke.

Fig. 2.12. Delayed Coker

Combining
While the cracking processes break most of the gas oil into gasoline and
jet fuel, they also break off some pieces that are lighter than gasoline. Since
Pascagoula Refinery's primary focus is on making transportation fuels, they
recombine 14,800 barrels (622,000 gallons) each day of lighter components in
two Alkylation Units. This process takes the small molecules and recombines
them in the presence of sulfuric acid catalyst to convert them into high octane
gasoline.
3. Treating (Removing Impurities)
The products from the Crude Units and the feeds to other units contain
some natural impurities, such as sulfur and nitrogen. Using a process called
hydrotreating (a milder version of hydrocracking), these impurities are removed
to reduce air pollution when our fuels are used.
Because about 80 percent of the crude oil processed by the Pascagoula
Refinery is heavier oils that are high in sulfur and nitrogen, various treating units
throughout the refinery work to remove these impurities.
In the RDS Unit's six 1,000-ton reactors, sulfur and nitrogen are removed
from FCC feed stream. The sulfur is converted to hydrogen sulfide and sent to
the Sulfur Unit where it is converted into elemental sulfur. Nitrogen is transformed
into ammonia which is removed from the process by water-washing. Later, the
water is treated to recover the ammonia as a pure product for use in the
production of fertilizer.
The RDS's Unit main product, low sulfur vacuum gas oil, is fed to the FCC
(fluid catalytic cracker) Unit which then cracks it into high value products such as
gasoline and diesel.

Fig. 2.13. Hydrotreater

 Hydrotreater: Most crude oils today have a high sulfur content. Sulfur
is a strong pollutant and must be removed to meet emission standards.
Also, sulfur can deactivate catalysts in further refining units. Sulfur is
removed by pumping hydrogen gas into any stream. The hydrogen reacts
with a molecule and extracts the sulfur to produce hydrogen sulfide.

4. Reforming
Octane rating is a key measurement of how well a gasoline performs in an
automobile engine. Much of the gasoline that comes from the Crude Units or
from the Cracking Units does not have enough octane to burn well in cars.
The gasoline process streams in the refinery that have a fairly low octane
rating are sent to a Reforming Unit where their octane levels are boosted. These
reforming units employ precious-metal catalysts - platinum and rhenium and
thereby get the name "rheniformers." In the reforming process, hydrocarbon
molecules are "reformed" into high octane gasoline components. For example,
methyl cyclohexane is reformed into toluene.

The reforming process actually removes hydrogen from low-octane

gasoline. The hydrogen is used throughout the refinery in various cracking
(hydrocracking) and treating (hydrotreating) units.
The refinery operates three catalytic reformers, where we rearrange and
change 71,000 barrels (about 3 million gallons) of gasoline per day to give it the
high octane cars need.
 Catalytic Reformer: This unit takes HSR naphtha and unsaturates the
hydrocarbons to produce aromatic rings and other various olefins. These
aromatic rings and olefins are used in premium gasolines because of their
high octane numbers.

Fig 2.14. Reforming

Product testing

Blending
A final and critical step is the blending of the refined products. Gasoline,
for example, is blended from treated components made in several processing
units. Blending and Shipping Area operators precisely combine these to ensure
that the blend has the right octane level, vapor pressure rating and other
important specifications. All products are blended in a similar fashion.

Quality Control
The refinerys modernly-equipped Laboratory, chemists and technicians
conduct quality assurance tests on all finished products, including checking
gasoline for proper octane rating. Techron Chevrons patented performance
booster, is added to gasoline at the companys marketing terminals, one of which
is located at the Pascagoula Refinery.
 CHAPTER III

Products

Upon estimation, Chevron's Pascagoula Refinery processes 330,000

barrels (13.9 million gallons) of crude oil a day. Imagine the size of a football field
covered to a depth of 40 feet equivalent to that amount.
Due to its efficient operations and complex capabilities to treat less
expensive sour, heavy crude oil, the Pascagoula Refinery's total conversion of
crude oil to light products is about 85 percent, a significantly high conversion rate
for low-grade crude oil.
Chevron's Pascagoula Refinery is primarily a fuel refinery, in that they
mainly manufacture:
Motor Gasoline - about 130,000 barrels per day (BPD)
Jet Fuel - 50,000 BPD
Diesel Fuel - 68,000 BPD
Fuel Oils such as bunker fuel, Liquefied Petroleum Gas (LPG), aviation
gasoline, petroleum coke and sulfur
The refinerys specialty products include:
Paraxylene - a compound used as a feed stock in the textile and plastics
industries;
Benzene and ethylbenzene - used in the manufacture of a wide range of
products, including automobile tires, sporting goods, nylon, and pharmaceuticals
Propylene - used in the manufacture of plastics
 CHAPTER IV

Market and Transportation

Product Marketing
Products manufactured are marketed throughout the Southeastern United
States, and in Central and South America. A network of product pipelines,
coastal ships, railroad, and tank trucks carries finished products to regional
distribution center. In turn, these centers supply products to wholesale
consumers and industrial customers in the South and Southeast.
Pascagoula Marketing Terminal
Most of the area wholesale customers receive their products at a
marketing terminal located at the Pascagoula Refinery. It is at the terminal where
Techron, the patented fuel additive, is added to all Chevron and Texaco
gasolines marketed locally.
At the terminal, tank trucks load motor gasoline and low-sulfur diesel for
delivery to wholesale customers including area independently owned Chevron
Food Mart stations and Texaco stations and jet fuel for delivery to customers that
include area airports.
The Global Marketing Division of Chevron Corporation operates the
terminal. The refinery is operated by the Global Manufacturing Division of
Chevron Corporation.

Terminals Vapor Recovery Unit

The refinery takes care to protect air quality at the local gasoline stations.
Vapors are produced in the underground storage tanks when gasoline is
delivered to our stations. During product delivery, the vapors produced in the
underground storage tanks are pushed back into the tanker delivery truck and
stored there. When the truck tank loads new product at the refinery's Marketing
Terminal, the tank is connected to a Vapor Recovery Unit that employs the latest
technology to recover the vapors. The recovery unit actually condenses much of
the vapor to liquid, thus protecting air quality and recovering gasoline product.

LPG Terminal
Area customers load propane at a separate LPG (Liquefied Petroleum
Gas) truck terminal. The LPG is marketed by Chevron's LPG Supply and Trading
International Marketing Team.

Crude Oil Transportation & Storage

Transporting Products
About 65 percent of the products leave the refinery by way of marine
shipments and 30 percent via a pipeline that runs from the refinery to Collins,
Mississippi, where it connects with two major pipeline systems. The remaining 5
percent of the products is shipped by truck and railroad.

Marine Tankers, Pipelines

Most of the crude oil processed at the Chevron Pascagoula Refinery
comes from foreign sources and arrives by marine tanker.
The crude oil is transported to the refinery wharf by 800 feet-long marine tankers
managed by the Chevron Shipping Company.
Berths for crude oil marine tankers are situated along the refinerys marine
terminal, which is located on Bayou Casotte adjacent to the Port of Pascagoulas
marine facilities.
At the marine terminal, the cargo of crude oil is discharged through
pipelines to storage tanks in the refinery. The marine terminal also has berths to
load refined products. About 65 percent of all refinery products leave the refinery
via ship or barge. Wharf operators receive ships from such places as Mexico and
South America.
The refinery also takes care to protect air quality at our marine terminal. In
1999, Chevron installed a Marine Vapor Recovery (MVR) system at the marine
terminal to control vapors of volatile organic compounds (VOCs) that are
generated during cargo loading. The MVR system complies with the Clean Air
Acts regulations for control of VOC emissions from tank vessels that carry oil
and chemicals in bulk.

Crude Oil Storage

Tanks, some with capacities of more than 390,000 barrels (16 million
gallons), store the crude oil, as well as intermediate stocks (partially refined),
finished products and chemicals.
The refinerys 200 tanks have containment areas designed to hold their
capacities in the event of a tank rupture. The system also diverts rainwater runoff
from this area to the refinerys effluent treating facilities to protect local waters.
 Chapter V

Health Safety and Environment

Protecting the earths natural resources is as important to the refinery as

providing the energy sources so essential to improving our quality of life. The
refinerys goal is to be recognized and admired everywhere for having a record of
environmental excellence.
Chevrons values, business strategies and field operations reflect the
highest possible environmental standards, which are built on a long history of
going beyond local requirements to protect people and the environment.
At Chevron's Pascagoula Refinery, the employees have a special
appreciation for the environmental uniqueness of the Gulf Coast because its
where people live and raise families. They believe that the best way to prevent
environmental problems is with pollution prevention and source control and to
train personnel in all operational, safety and environmental aspects of refining.
The Refinery has about 40 employees working full-time in the Safety,
Environmental & Health Group, and Refinery employees is taught about
environmental regulations and the importance of being alert to any problem.
The refinerys environmental policies stress open dialogue with
community, and encourage comments and questions from neighbours in Jackson
County and throughout the Gulf Coast area.

Maintaining Clean Water

Protecting the Water
Chevron Pascagoula refinery is the only oil refinery on the Mississippi Gulf
Coast. The refinery takes great care to be a responsible industrial neighbour. Any
water used in the refining process is collected and undergoes extensive
treatment and is in compliance with all local, state, and federal regulatory
requirements.
Water Treatment and Testing
Water used in Chevron Pascagoula Refinery's processes undergoes
extensive treatment before being discharged from our Outfall Canal to the
Mississippi Sound. In 2009, the Pascagoula Refinery completed construction of a
new Effluent Treatment Plant. This state-of-the-art facility has demonstrated
superior efficiency in removing water contaminants.
Water treatment begins at the Oil-Water Separators, where oil is removed
from process water and recycled back into the refinery for processing. Process
water is then routed through the robust treatment system, including activated
sludge units (bio-reactors) where microorganisms feed on contaminants in the
water. The water is tested to ensure it meets or exceeds parameters established
by Mississippi Department of Environmental Quality and the Environmental
Protection Agency.
More than 300 samples are collected and analyzed weekly to help operate
the Effluent Treatment Plant. These results are used in conjunction with
numerous online analyzers to continuously monitor and maximize treatment.
Alert points notify Chevron personnel to take action before abnormal conditions
can negatively affect water quality. This extensive analysis ensures all treated
water meets environmental requirements and will not harm marine life.
Water from other refinery processes is recovered, treated, and reused,
thus reducing the amount of water the refinery draws from the Pascagoula River.

Stormwater & Groundwater

The refinery's stormwater system provides treatment of stormwater that
falls within our process units. This collected stormwater is routed through pipes
and tanks, rather than through earthen ditches, to the Effluent Treatment Plant.
Stormwater discharged from the Refinery's permitted outfalls is inspected or
sampled prior to being discharged, meeting the Mississippi Department of
Environmental Quality water permit requirements.
To ensure groundwater protection, 14 wells located around the refinery
are routinely monitored and report the results to the Mississippi Department of
Environmental Quality. Drinking water from wells is also routinely monitored and
reported the findings to the Mississippi Department of Health.

Protecting Nature
Reducing Environmental Impact to Air, Water & Land
The Chevron Pascagoula Refinery employs effective measures to reduce
emissions. These efforts include leak detection and repair, adding secondary
seals to many tanks, and continuing to upgrade pollution-control equipment and
technology. Additionally, process changes that reduce severity of operating
conditions, like temperature and pressure, also contribute to emissions
reductions.

Reducing Chemical Emissions

Refinery emissions of SARA or TRI chemicals have decreased 14%
since 2010 (baseline year). After adjusting for the Refinery Production Index,
emissions decreased 15% from 2010. These numbers show the success of the
refinery's continuing effort to reduce toxic emissions. Emissions continue to
decline despite the fact that the U.S. Environmental Protection Agency's (EPA)
list of reportable SARA chemicals in 2009 is twice as large as the original
baseline list in 1988 and the fact that the refinery today is more complex than in
1988. NOx and SO2 emissions at Pascagoula have decreased by 62% since
2005. This has been achieved as part of an ongoing effort which includes
installation of a state of the art Flare Gas Recovery system, additional tail gas
units for Sulfur Recovery plants, and installation of pollution controls on existing
furnaces, and replacing outdated steam boilers with new equipment with better
emissions controls.

Reducing Waste
The refinery continues to employ new technology and procedures that
reduce waste generation or recover waste and transform it into useful products.
The refinery reduce waste by decreasing waste sources, recycling, using less
hazardous materials, and treating waste inside the refinery.
In September 2009, the Pascagoula Refinery attained a significant
environmental milestone. The refinery achieved the U.S. Environmental
Protection Agencys designation of "Corrective Action Remedy Construction
Complete with Controls," known as the CA550. This designation is the
culmination of more than 24 years of work investigating and installing technically
sound and innovative means of controlling and cleaning waste on refinery
property. The refinery has spent more than $44 million on corrective action work
of this kind since 1998.

Reducing Hazardous Waste

Since 2010 (baseline year), the refinery has decreased the annual
generation of hazardous waste by 11%. This decline has occurred even though
the refinery continues to grow and become more complex.

Recycling Activities
Approximately 1.4 million barrels of oil is recovered from refinery process
water each year and recycled back into our units to be converted to sale-able
products.
Process by-product gas is treated to remove 99.96 percent of its H 2S and
used as fuel gas, reducing natural gas purchases by approximately 39 billion
standard cubic feet per year.
Approximately 157 billion gallons per year of cooling water is recirculated
through the refinery.
Approximately 1.7 billion gallons per year of condensate recovered from
the refinery steam system is reused as boiler feed water.
Approximately 200 million gallons per year of sour process water are
treated to recover approximately 12,000 tons ammonia and 275,000 tons of
sulfur. Both chemicals are sold to fertilizer manufacturers. Most of the water is re-
used in refinery processes to remove salts.
 CO2, a byproduct of manufacturing H2 from natural gas, is used in the
effluent system for pH control, minimizing the need for purchased chemicals.
2,059 tons of spent catalyst was recycled in 2011 through metallurgical
smelters to recover the metals for reuse in the steel and copper industry.
5,686 tons of scrap metal was recycled during 2011.
Approximately 104,551 barrels of oily solids material was recycled into the
refinery process and not sent off site during 2011.
87,155 tons of spent acid was sent from the refinery for recycling during
2011.
435,215 pounds of paper products were recycled during 2011.

Conserving Natural Resources

Saving Water
Chevron Pascagoula uses water to produce steam and to keep the
Refinery product streams and equipment cool, similar to the cooling system in
cars.
Cooling the water in large wooden cooling towers and re-circulating it
minimizes the amount of fresh water needed. The water falls in droplets from the
top to the bottom of the cooling tower. Large fans pull air from the bottom to the
top.
The falling water cools when it encounters the rising air and forms
billowing clouds of steam. These plumes of white clouds, which can be seen from
miles away, are not smoke. Rather, they consist of condensed water vapor that is
formed during the cooling process. The clouds behave like fog, dissipate quickly,
and do not harm the environment.
The Refinerys water re-circulation rate for cooling systems is about 400
million gallons per day. Steam condensate recovery and recycle are about 7
million gallons per day.
Water Source
All the water used in the Refinerys processes is supplied by the Jackson
County Industrial Water System, which draws from the Pascagoula River and not
from groundwater resources.
The water is pumped from the river through dual pipelines to the Bayou
Casotte treating facility where clarification, filtration, and pH adjustments are
done. Treated water is transported by pipeline to the Refinery and other Bayou
Casotte area industrial users.
To replenish evaporative and consumed water losses, the Refinery uses
about 16 million gallons of water per day from the Jackson County Industrial
Water System, which is operated by the Jackson County Port Authority.

Saving Energy
The refinerys Utilities Area and Mississippi Power Company co-
generating plant, located adjacent to the Refinery, supply the required utilities for
Chevron Pascagoula Refinerys continuous operation.
The refinerys Utilities Area supplies some electrical power and most
steam requirements, as well as all the compressed air, fuel gas, fire water,
process water, drinking water, nitrogen, and both high and low pressure boiler
feed water.
Mississippi Power Companys co-generating facility provides 85 percent of
the Refinerys electricity needs and about 60 percent of the steam requirements.
The co-generating units waste heat recovery boilers generate and supply steam
to the refinery at 600 pounds per square inch and 650F.

Oil-To-Oil Heat Exchangers

In order to process the crude oil, many of the refinerys process units
require heat. In an effort to maximize energy efficiency, heat is recovered from
hot product streams leaving the refinerys process units by oil-to-oil heat
exchanger equipment.
 This heat is transferred into the cold feed streams coming into the process
units, which reduces the amount of fuel gas required for process heating.
Since recovering heat energy minimizes the fuel burned, it also helps keep
the environment clean. Saving energy has a direct effect on profitability by
reducing our operating costs.

Insulation
Covering the refinerys equipment and piping with insulation prevents heat
from escaping into the atmosphere. Insulation not only saves energy (and
reduces operating costs) it also provides safety protection to the employees by
covering the hot equipment and piping.

Vapor Recovery
Loading Displaces Vapors
During loading of bulk liquid tankers or barges, the liquid introduced
displaces vapors from previous cargoes that still exist in the tank and those
vapors generated by the current cargo loading. The vapors of certain cargoes
contain volatile organic compounds (VOCs) that include hydrocarbons,
oxygenated hydrocarbons, and organic compounds containing nitrogen or sulfur.

Chevron MVR System meets federal requirements

The Clean Air Act of 1990 requires the control of VOC emissions, and the
Marine Vapor Recovery units at the refinerys marine facility meet Coast Guard
(Title 33, Code of Federal Regulations, Part 154) and Clean Air Act (Title 40,
Code of Federal Regulations, Part 61 and 63) requirements.
The Pascagoula Refinerys Marine Vapor Recovery (MVR) system
includes two units that serve Berths 2-5 and a separate unit at Berth 6, which is
located a good distance away from Berths 2-5.
Units "A" and "B"; each with 35,000 barrels liquid loading per hour vapor recovery
capacity; combined vapor recovery capacity 70,000 barrels per hour of liquid
loading.
 Recovers vapors from VOC emissions containing vapor pressure of 1.5 psi or
greater.
The process uses Lean Oil Absorption. While a regulated product is being
loaded, vapors are recovered from the marine vessels by a header system. This
header carries the vapors, either by pressure from loading or pulled by vapor
boosters that provide a slight vacuum on the header. The vapors are routed
through a chilled absorber, entrained in the Lean Oil, then passed through a
series of exchangers, and then into a stripper column where the VOCs are
stripped out by heat and held in a holding drum. The recovered VOCs are then
pumped in to a crude transfer line for reprocessing.

Marketing Terminal Vapor Recovery Unit

As a tank truck drops (delivers) new product into the underground storage
tank at Chevron stations, the vapors created during the drop are pushed back
into the tank truck and stored there.
As the tank truck loads new product at the Marketing Terminal using a
"bottom loading" method, the product being loaded into the bottom of the tank
pushes the collected vapors into a vapor recovery hose connected to the
recovery system. The Adsorb/Absorb vapor recovery unit condenses the vapors,
recovering about 2 gallons of gasoline per 1000 gallons loaded product.

Protecting Wetlands & Forestlands

Since about two-thirds of Chevrons 3,000-acre property in Jackson
County is wetlands and forestlands, the refinery is home to nearly all species of
wildlife indigenous to the Gulf Coast. Take a look at this list of some of
our Refinery Residents, or animals that call the refinery home.
The coexistence of the deer, raccoons, foxes, waterfowl and fish with the
refinery operations is a tremendous source of pride for Chevron and its
employees. This sense of pride provides additional incentive for employees to
take special care in following environmental regulations when operating our
plants and when replacing (or mitigating) wildlife habitats impacted by plant
expansions.
 There were four successful wetland mitigation sites the refinery
constructed to replace those used in plant expansions. The sites are often
included in refinery tours, and the North Mitigation Area is showcased by the
Mississippi State Coastal Research & Extension Center as an exemplary
constructed inter-tidal saltwater marsh.

North Mitigation Area (Saltwater marsh)

When Chevron expanded refinery operations in the early 1980s,
construction of about 25 acres of salt marsh wetlands to replace (or mitigate)
property used for the expansion started. Pine flatwood uplands were excavated,
and a centrally located tidal creek was built and connected to the tidal waters of
the Bangs Lake estuary. The site includes a low marsh zone dominated by
Smooth Cordgrass, a mid-marsh zone dominated by Needle Rush, and a high
marsh salt panne zone. Some of the fish, shellfish, mammals, and birds that live
in or visit the area are white shrimp, blue crabs, mullet, flounder, marsh rabbit,
raccoon, muskrat, mink, clapper rail, great blue heron, great egret, red-winged
blackbird, red-tailed hawk, northern harrier hawk, willet, and hooded merganser.
The North Mitigation Area was the site of a Corps of Engineers-funded
study conducted from 1992-1995 by Mississippi State Universitys Coastal
Research & Extension Center that compared a constructed marshland to a
natural habitat. Calling the refinerys mitigation project a success, the studys
1995 report said the constructed areas numbers and types of fish, shellfish, birds
and plants are comparable to those of a natural estuarine saltwater marsh.
South Mitigation Area (Freshwater marsh)
Also in the mid-1980s as part of the mitigation for the Pascagoula
Residuum Conversion Project, 15 acres of pine wood flatlands were flooded to
create a freshwater marsh. Over time the rising water table in the flooded section
killed the pine trees, which greatly reduced the overhead canopy. Plant
community characteristics that resulted from this change in canopy cover and
hydrology now closely duplicate the flora found in freshwater marshes. Some
examples of the animals and birds that now seasonally visit or live in this area
are alligators, otters, raccoons, nutria, red fox, marsh rabbits, snowy egrets,
reddish egrets, glossy ibis, green herons, great blue herons, scarlet tanagers,
mottled ducks, and fresh water turtles.

North Woods Mitigation Area (Bottom-land hardwood swamp)

Site alterations in drainage on 26 acres of mixed pine and hardwood forest
in 1993 have converted this area into a partially inundated (flooded) open
canopy/bottom-land hardwood swamp. The site was created as mitigation for the
refinerys Aromax Project. Dikes were constructed along the lower borders of this
area to trap periodic run-off from rain events. Additionally, several ponds and a
canal were built and stocked with bass and bluegill to enhance the areas
wetland performance. Since 1993 the canopy layer has been shifting from a
dominant slash pine canopy, to a mixed hardwood open canopy composed
primarily of water oak, cypress, red maple, and black gum. The mixed under-
story is composed of ferns, sedges, rushes, and grasses. Some of the wildlife
that live or visit at this site are alligators, white-tailed deer, otters, snapping
turtles, great horned owls, wood ducks, ospreys, pileated woodpeckers, belted
kingfishers, bald eagles, leopard frogs, raccoons, tri-colored herons, and great
egrets.

Out-fall Canal Mitigation Area (Shoreline beach restoration)

In 1994 a fixed weir was installed across the mouth of the refinerys Out-
fall canal to meet certain requirements of the Clean Water Act. (The Out-fall
canal is the effluent waterway that transports the Refinerys treated wastewater
to its discharge point in the Mississippi Sound.) As mitigation for the project, a
breakwater was built to restore and to protect rapidly eroding shoreline on the
western side of the weir, at the edge of the Mississippi Sound. As a result of the
breakwater, approximately 800 feet of inter-tidal marsh/low dune shoreline has
been protected from erosion, and 52,000 square feet of shallow bay bottom has
been converted to inter-tidal marsh. Protected openings in the breakwater allow
access to the marsh area by fish and shellfish during high tide events and
promote the accumulation of sediments to replace those lost by erosion.
Examples of some of the animals and birds that seasonally visit or live in this
area are white and brown pelicans, snowy egrets, ospreys, black-necked stilts,
blue crabs, oysters, raccoons, great blue herons, great egrets, marsh rabbits,
sea-side sparrow, and cormorants.

Rhodes Lake Mitigation Area (Partnership with International Paper)

In addition to the above on-site mitigation areas we have also partnered
with International Paper in a wetlands restoration project at the Rhodes Lake
Mitigation Area in Moss Point. This 915-acre site is owned by International Paper
and the wetland quality has been adversely affected by historical uses and tidal
action from tropical systems like Hurricane Katrina. In 2008 we partnered with
International Paper to fund the restoration of this ecosystem to a riverine and
bottomland hardwood forest ecosystem in exchange for future mitigation credits
at our refinery. This project is currently in progress and is expected to be
completed in 2018.

Health and Safety

Pascagoula Refinery employees, as well as the community, are interested
in ensuring the plant operates safely and efficiently. Chevron provides a safe
work place and safe products that exceed current governmental regulations. Our
safety policy not only stresses commitment to employee health, but also
emphasizes promotion of activities that provide a safe and protected workplace
for employees, contract workers, visitors and our neighbors.

Flares
Oil refining is a dynamic process. Temperatures, pressures and other
processing conditions are carefully controlled to make the specified amount of
products. Equipment breakdown, power outage or other upsets may cause the
pressure in the plant to rise. To control the pressure, valves automatically open,
safely diverting the material to a "relief system." Here the excess hydrocarbons
are burned in smokeless flares, forming primarily water and carbon dioxide. The
flares prevent hydrocarbon vapors from escaping into the atmosphere.

Training
Refinery personnel receive extensive safety training in their specific duties
before they begin their jobs, and they receive refresher training at regular
intervals. The Chevron Pascagoula Refinery has an entire organization, the
Learning & Development Group, whose experienced employees focus on training
and safety assurance. Its Process Safety Management (PSM) group has
responsibility for the Refinerys proactive processes designed to prevent the
release of hazardous chemicals, particularly into areas where exposure to
employees and others may be possible.

Emergency Response Team

The refinery's on-site fire department (Plant Protection Group) is equipped
with state-of-the-art response equipment and staffed by 14 full-time professional
(OSHA-approved) fire fighters who conduct regular training for the refinery's
Emergency Response Team (ERT).
Recognized industry-wide for its excellence, the ERT is made up of
approximately 80 employee volunteers who each year undergo 150 hours of
specialized training that qualifies them to effectively respond to any and all types
of industrial emergency situations. Training areas include - industrial fire fighting
(hydrocarbon, chemical and structural fires); high angle and confined space
rescue; hazardous materials release or leak response; and emergency vehicular
operations training. Additionally, the ERT's Medical First Responders and
nationally certified Emergency Medical Technicians respond to medical
emergencies.

Emergency Response Plans

While Chevron Pascagoula maintains an exemplary safety record, we
have multiple emergency response plans in place to effectively respond to any
plant emergency. In the event of an incident, Plant Protection's highly trained
Emergency Response Team is immediately dispatched to the scene, and
refinery-wide multi-discipline emergency response groups establish an Incident
Command Center to manage a comprehensive response. Incident Command
personnel notify all area government agencies, and a trained Public Affairs Team
provides up-to-date information to the media, Refinery employees, and
community inquirers. In the event that the incident is of concern to the public,
Incident Command personnel work with the Jackson County Emergency
Communications District to notify the community, and Public Affairs Team
personnel dispatch alerts to all area media outlets. The response teams keep the
community and media updated throughout the incident.

Community Emergency Planning

Chevron Pascagoula emergency response personnel fill key leadership
positions on Jackson County's Local Emergency Planning Committee (LEPC), a
network of representatives from the county's public and private sectors who work
to plan and coordinate all types of emergency response in the county, including
those involving hazardous material, training and community awareness. The
group is made up of representatives from 40 public safety, health, emergency
services agencies, and local industries. All municipal and county fire, police and
civil defense agencies in Jackson County have representatives on the LEPC.

LEPC participating industries, including the Pascagoula Refinery, worked

with the Jackson County Civil Defense Director to establish a countywide
emergency notification system. The Pascagoula Refinery provided $7,775 to the
county Emergency Office for the Emergency Warning Evacuation System which
was launched in spring 2003.

Safety and Management

Chevron's commitment to Operational Excellence and maintaining an
incident and injury free workplace is aided by the use of the Loss Prevention
System (LPS). Used in concert with other comprehensive safety programs in
place at the refinery, LPS is a proven behavior-based system designed to help
prevent and resolve unplanned safety or business related losses.

Fig 5. Loss Prevention Self-Assessment

By focusing on behavior-based tools and management techniques,

employees identify the risks of an injury or incident before it occurs and then
implement the proper changes or improvements so that the task can be
performed safely and efficiently.
As a result of these comprehensive safety management programs, the
Refinery continues to experience world-class safety performance.

Oil Spill Prevention & Preparedness

The refinery also maintains an extensively trained Pascagoula Oil Spill
Response Team and regularly conducts oil spill drills. If oil were to spill in the
water, the on-staff teams would respond immediately, deploying floating oil
booms to contain the spill. Oil recovered from a spill would be pumped into a
storage tank for recycling.
As part of the refinerys oil spill preparedness, members of Pascagoula Oil
Spill Response Team designed and had constructed a one-of-a-kind wildlife
rehabilitation unit the first fully-equipped oiled wildlife rehab unit in the world
that can be transported by air.
 Built by Featherlite to rigorous specifications, the trailer is 108 inches in
height, the maximum height commercial air carriers can accommodate. On the
ground, the trailer can be pulled by a standard truck (one or two ton) with the
proper hitch.
The 38-by-8 foot trailer contains all the specialized equipment required to
evaluate, clean and rehabilitate oiled wildlife. It is also equipped with the
laboratory facilities required by a veterinarian during the response and
rehabilitation period.

Spill & Air Protection

At the marine terminal, the cargo of crude oil is discharged through
pipelines to storage tanks in the refinery. The marine terminal also has eight
berths to load refined products. About 70 percent of all refinery products leave
the refinery via ship or barge. Wharf operators receive ships from such places as
Mexico and South America.
We also take care to protect air quality at our marine terminal. In 1999,
Chevron installed a Marine Vapor Recovery (MVR) system at the marine terminal
to control vapors of volatile organic compounds (VOCs) that are generated
during cargo loading.
The MVR system complies with the Clean Air Acts regulations for control
of VOC emissions from tank vessels that carry oil and chemicals in bulk.

Health and Wellness Program

Safe operations are also impacted by Chevrons focus on enhancing and
preserving the health and well-being of our employees, retirees, and their
families. By providing a comprehensive Health & Wellness Program, Chevron
believes that striving to keep employees healthy impacts not only their health
risks, but promotes a safe and productive workforce.
An integrated approach between an interdisciplinary staff of health
professionals is provided to insure that employees physical and mental needs
are addressed. This includes an on-site Medical Clinic, the Health Quest
Employee Wellness Program, and one of the most comprehensive health care
packages in the industry. The approach is to provide employees with a needs-
based health promotion program to assist in reducing injuries and illnesses.
Employees are offered to access first aid medical treatment, assessment of and
counseling in health risks and dealing with a broad range of personal, family, and
work-related concerns or problems, reducing stress and shift work issues. Also
included in this program is an on-site Chevron owned and operated fitness
center. This comprehensive Health & Wellness Program supports Chevron's
strategic intent to be the industry leader in safety and health performance."

Fitness for Duty

Employees want to work in an environment that is safe. The Refinery has
implemented a fitness for duty process to ensure that employees can safety
perform the essential physical, psychological and cognitive requirements of their
job without risk to self, others or the environment and are not impaired by drugs,
alcohol or disabling medical conditions.

Generalization
A refinery is a complex chemical plant that utilizes several different
techniques to take a very rough feedstock, crude oil, and converts it into
desirable products. Oil companies invest large sums of capital into these
refineries in hopes of making a large profit. This has only been a simple
overview and further instruction will be needed to completely understand all
aspects of a petroleum refinery. Processing petroleum undergoes complex units
to become profitable products. Each employee must avoid any inaccuracy to
ensure the safety of the people and the environment.