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OPERATIONS
NAME : CHUDERSEN NANA SEAKARAN
ID NO. : 1103161001
COURSE : CHEMICAL PROCESS INDUSTRIES
LECTURER : PROF. DR. SOUNDARAJAN
INTRODUCTION:
HOW IS PETROLUEM (CRUDE OIL) FORMED?
• The oil and gas that formed in the source rock deep within the
Earth moved upward through tiny, connected pore spaces in the
rocks.
2.Sulphur content
• Typically less than 0.5% sulphur content : SWEET
• Typically greater than 1.5% sulphur content : SOUR
THE EXPLORATION & PRODUCTION (E&P)
PROCESS OF PETROLEUM
EXPLORATION (METHODS)
SURFACE GEOLOGICAL
GEOPHYSICAL METHODS
METHODS
• Presence of volatile hydrocarbons near
the surface is an indication of oil Extensive :
formation at some distance beneath. • Seismic survey measures shock wave
• How to detect : patterns and characterizes strata.
• Sensitive gas chromatography used to • Air surveys from 250-300kph low flying
detect as low as 1×10-4 vol % conc. planes with magnetometer for magnetic
• Microbiological flora of the survey and scintillation counter for
hydrocarbon oxidizing type in water radioactivity survey.
wells is usually evidence of hydrocarbon Intensive :
deposits. • Sonic and ultrasonic probing during core
• Radioactive isotopic exchange of carbon sampling to measure porosity
with rock deposits gives lower C-14 • Neutron reflecting measurements with
assay where gaseous hydrocarbons are scintillation detector which increase in the
seeping (leaking). vicinity of hydrocarbons
PRODUCTION (METHODS)
DRILLING YIELDS
2. Intermediate refineries
• Produces motor fuel, distillate fuels and residuals. Typical of
European refineries where petrol demand is low relative to
heating fuels.
DESIGN OF REFINERY
1. Independent unit operation
• Until 1950, all refineries were built with holding capacities between
units so that any unit could be operated, shut down, and
reconditioned independently.
2. Integrated operation
• The integrated refinery can be built with 20-30% investment
savings; it is designed with little hold-up capacity between units
since refinery maintenance requirements can be reliably scheduled.
REFINERY PROCESSES
Separation
Conversion
Treatment
3. Treatment
• Treatment involves both chemical reactions and physical separation, such as
dissolving, absorption or precipitation, using a variety and combination of
processes.
• Sweetening compounds and acids are used to desulphurize crude oil before
processing, and to treat products during and after processing.
REFINERY PROCESSES
4. Formulating and Blending
• The process of mixing and combining hydrocarbon fractions, additives and
other components to produce finished products with specific desired
performance properties.
• As oil is being fed into the CDU, the crude is heated to a temperature between
100 and 137°C. This allows harmful salts to be removed at the desalter. The now
desalted crude continues through the system into the heater where it is further
heated to a temperature of over 350°C.
• Next, it is fed into the atmospheric column where the vapours and liquids separate.
Residues are stripped out at the bottom of the column. The products (naphtha,
kerosene, diesel and gas oil) are taken from the side of the column and moved
through the refinery for further processing.
CLOUD AND POUR POINTS
• Cloud point : The temperature at which the first cloudy appearance
of the petroleum product occurs when it is cooled.
• Both pour and cloud points are important properties of the product
streams as far as heavier products are concerned.
THERMAL CRACKER
• Thermal cracker involves a chemical cracking process followed by the
separation using physical principles (boiling point differences) to yield
the desired products.
• Thermal cracking yields naphtha + gas, gas oil and thermal cracked
residue.
• In some petroleum refinery configurations, thermal cracking process is
replaced with delayed coking process to yield coke as one of the
petroleum refinery products.
• Operating conditions : Temperature : 450 – 500°C
Pressure : 2-3 bar
HYDROTREATING
• Hydrotreating is applied extensively in petroleum refinery to remove
sulphur as well as other undesirable compounds.
• The unit is one of the most important units of the modern refinery.
• Heavy naphtha which does not have high octane number is subjected
to reforming in the reformer unit to obtain reformate product (with
high octane number), light ends and reformer gas (hydrogen).
• Liquid petroleum products which come in contact with the skin can
cause irritation and some can be absorbed through the skin.
• Air pollution
Oil refineries cause smog and air pollution. Air is polluted by up to 100 pollutants
emitted from the stacks and leaking equipment at refineries.
• Land pollution
Land is polluted by the large amount of harmful waste from refineries which
needs to be dumped. SO2 mixes easily in water, including moisture in the air to
form an acid. Acid rain and early morning dew causes much damage to metals,
stones, and the environment.
• Water pollution
Water is polluted by the fallout from air pollution and by refineries discharging
chemical pollutants into waterways. Accidental oil spills also pollute the
groundwater and open waterways.