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- The process of crude oil refining
- Chemical plant
- Oil & Gas Filtration and Separation Solutions
- Manufacturing locations
- Oil and Gas
- Equipment critical analysis: The need for an effective maintenance program
- Pumps and packages for the oil and gas industries
- Oilfield Equipment and Services
- Pumps and packages for the oil and gas industries
The process of crude oil refiningVIDEO ON THE TOPIC: Refinery Crude Oil Distillation Process Complete Full HD
An oil refinery or petroleum refinery is an industrial process plant where crude oil is transformed and refined into more useful products such as petroleum naphtha , gasoline , diesel fuel , asphalt base , heating oil , kerosene , liquefied petroleum gas , jet fuel and fuel oils. Oil refineries are typically large, sprawling industrial complexes with extensive piping running throughout, carrying streams of fluids between large chemical processing units, such as distillation columns.
In many ways, oil refineries use much of the technology, and can be thought of, as types of chemical plants. The crude oil feedstock has typically been processed by an oil production plant. There is usually an oil depot at or near an oil refinery for the storage of incoming crude oil feedstock as well as bulk liquid products.
Petroleum refineries are very large industrial complexes that involve many different processing units and auxiliary facilities such as utility units and storage tanks. Each refinery has its own unique arrangement and combination of refining processes largely determined by the refinery location, desired products and economic considerations. An oil refinery is considered an essential part of the downstream side of the petroleum industry.
Some modern petroleum refineries process as much as , to , barrels , to , cubic meters of crude oil per day. According to the Oil and Gas Journal in the world a total of refineries were operated on the 31 December for a total capacity of Jamnagar Refinery is the largest oil refinery, since 25 December , with a processing capacity of 1. Located in Gujarat , India, it is owned by Reliance Industries. The Chinese were among the first civilizations to refine oil.
In the 9th century, oil fields were exploited in the area around modern Baku , Azerbaijan. Through Islamic Spain , distillation became available in Western Europe by the 12th century. In the Northern Song Dynasty — , a workshop called the "Fierce Oil Workshop", was established in the city of Kaifeng to produce refined oil for the Song military as a weapon. The troops would then fill iron cans with refined oil and throw them toward the enemy troops, causing a fire — effectively the world's first " fire bomb ".
The workshop was one of the world's earliest oil refining factories where thousands of people worked to produce Chinese oil powered weaponry.
Prior to the nineteenth century, petroleum was known and utilized in various fashions in Babylon , Egypt , China , Philippines , Rome and Azerbaijan. However, the modern history of the petroleum industry is said to have begun in when Abraham Gessner of Nova Scotia , Canada devised a process to produce kerosene from coal. In the early twentieth century, the introduction of the internal combustion engine and its use in automobiles created a market for gasoline that was the impetus for fairly rapid growth of the petroleum industry.
The early finds of petroleum like those in Ontario and Pennsylvania were soon outstripped by large oil "booms" in Oklahoma , Texas and California. Another close contender for the title of hosting the world's oldest oil refinery is Salzbergen in Lower Saxony , Germany.
Salzbergen's refinery was opened in At one point, the refinery in Ras Tanura , Saudi Arabia owned by Saudi Aramco was claimed to be the largest oil refinery in the world. For most of the 20th century, the largest refinery was the Abadan Refinery in Iran. This refinery suffered extensive damage during the Iran—Iraq War. Prior to World War II in the early s, most petroleum refineries in the United States consisted simply of crude oil distillation units often referred to as atmospheric crude oil distillation units.
Some refineries also had vacuum distillation units as well as thermal cracking units such as visbreakers viscosity breakers, units to lower the viscosity of the oil. All of the many other refining processes discussed below were developed during the war or within a few years after the war. They became commercially available within 5 to 10 years after the war ended and the worldwide petroleum industry experienced very rapid growth.
The driving force for that growth in technology and in the number and size of refineries worldwide was the growing demand for automotive gasoline and aircraft fuel.
In the United States, for various complex economic and political reasons, the construction of new refineries came to a virtual stop in about the s. The size of oil refining market in was valued over USD 6 trillion in and is set to witness a consumption of over million barrels per day MBPD by Oil refining market will witness an appreciable growth because of rapid industrialization and economic transformation. Changing demographics, growing population and improvement in living standards across developing nations are some of factors positively influencing the industry landscape.
In the 19th century, refineries in the U. There was no market for the more volatile fraction, including gasoline, which was considered waste and was often dumped directly into the nearest river. The invention of the automobile shifted the demand to gasoline and diesel, which remain the primary refined products today. Today, national and state legislation require refineries to meet stringent air and water cleanliness standards. In fact, oil companies in the U. In the earliest data provided , the United States operated refineries with a combined capacity of In , there were operable U.
Indeed, in order to reduce operating costs and depreciation, refining is operated in fewer sites but of bigger capacity. In through , as revenue streams in the oil business dried up and profitability of oil refineries fell due to lower demand for product and high reserves of supply preceding the economic recession , oil companies began to close or sell the less profitable refineries. Raw or unprocessed crude oil is not generally useful in industrial applications, although "light, sweet" low viscosity, low sulfur crude oil has been used directly as a burner fuel to produce steam for the propulsion of seagoing vessels.
The lighter elements, however, form explosive vapors in the fuel tanks and are therefore hazardous, especially in warships. Instead, the hundreds of different hydrocarbon molecules in crude oil are separated in a refinery into components that can be used as fuels , lubricants , and feedstocks in petrochemical processes that manufacture such products as plastics , detergents , solvents , elastomers , and fibers such as nylon and polyesters.
Petroleum fossil fuels are burned in internal combustion engines to provide power for ships , automobiles , aircraft engines , lawn mowers , dirt bikes , and other machines. Different boiling points allow the hydrocarbons to be separated by distillation. Since the lighter liquid products are in great demand for use in internal combustion engines, a modern refinery will convert heavy hydrocarbons and lighter gaseous elements into these higher value products. Oil can be used in a variety of ways because it contains hydrocarbons of varying molecular masses , forms and lengths such as paraffins , aromatics , naphthenes or cycloalkanes , alkenes , dienes , and alkynes.
While the molecules in crude oil include different atoms such as sulfur and nitrogen, the hydrocarbons are the most common form of molecules, which are molecules of varying lengths and complexity made of hydrogen and carbon atoms , and a small number of oxygen atoms.
The differences in the structure of these molecules account for their varying physical and chemical properties , and it is this variety that makes crude oil useful in a broad range of several applications. Once separated and purified of any contaminants and impurities, the fuel or lubricant can be sold without further processing. Smaller molecules such as isobutane and propylene or butylenes can be recombined to meet specific octane requirements by processes such as alkylation , or more commonly, dimerization.
The octane grade of gasoline can also be improved by catalytic reforming , which involves removing hydrogen from hydrocarbons producing compounds with higher octane ratings such as aromatics. Intermediate products such as gasoils can even be reprocessed to break a heavy, long-chained oil into a lighter short-chained one, by various forms of cracking such as fluid catalytic cracking , thermal cracking , and hydrocracking.
The final step in gasoline production is the blending of fuels with different octane ratings, vapor pressures , and other properties to meet product specifications. Another method for reprocessing and upgrading these intermediate products residual oils uses a devolatilization [ permanent dead link ] process to separate usable oil from the waste asphaltene material.
Oil refineries are large scale plants, processing about a hundred thousand to several hundred thousand barrels of crude oil a day.
Because of the high capacity, many of the units operate continuously , as opposed to processing in batches , at steady state or nearly steady state for months to years.
The high capacity also makes process optimization and advanced process control very desirable. Petroleum products are materials derived from crude oil petroleum as it is processed in oil refineries.
The majority of petroleum is converted to petroleum products, which includes several classes of fuels. Oil refineries also produce various intermediate products such as hydrogen , light hydrocarbons, reformate and pyrolysis gasoline.
These are not usually transported but instead are blended or processed further on-site. Chemical plants are thus often adjacent to oil refineries or a number of further chemical processes are integrated into it.
For example, light hydrocarbons are steam-cracked in an ethylene plant, and the produced ethylene is polymerized to produce polyethene. Because technical reasons and environment protection demand a very low sulfur content in all but the heaviest products, it is transformed to hydrogen sulfide via catalytic hydrodesulfurization and removed from the product stream via amine gas treating.
Using the Claus process , hydrogen sulfide is afterwards transformed to elementary sulfur to be sold to the chemical industry. The rather large heat energy freed by this process is directly used in the other parts of the refinery. Often an electrical power plant is combined into the whole refinery process to take up the excess heat.
According to the composition of the crude oil and depending on the demands of the market, refineries can produce different shares of petroleum products. The largest share of oil products is used as "energy carriers", i.
These fuels include or can be blended to give gasoline, jet fuel , diesel fuel , heating oil , and heavier fuel oils. Heavier less volatile fractions can also be used to produce asphalt , tar , paraffin wax , lubricating and other heavy oils. Refineries also produce other chemicals , some of which are used in chemical processes to produce plastics and other useful materials. Since petroleum often contains a few percent sulfur -containing molecules, elemental sulfur is also often produced as a petroleum product.
Carbon , in the form of petroleum coke , and hydrogen may also be produced as petroleum products. The hydrogen produced is often used as an intermediate product for other oil refinery processes such as hydrocracking and hydrodesulfurization. Petroleum products are usually grouped into four categories: light distillates LPG, gasoline, naphtha , middle distillates kerosene, jet fuel, diesel , heavy distillates and residuum heavy fuel oil, lubricating oils, wax, asphalt.
These require blending various feedstocks, mixing appropriate additives, providing short term storage, and preparation for bulk loading to trucks, barges, product ships, and railcars. This classification is based on the way crude oil is distilled and separated into fractions. Over 6, items are made from petroleum waste by-products including: fertilizer , floor coverings , perfume , insecticide , petroleum jelly , soap , vitamin capsules. See link to partial list of by-products listed by Ranken Energy .
Sample of Crude oil petroleum. Cylinders of Liquified petroleum gas. Pile of asphalt -covered aggregate for formation into asphalt concrete. The image below is a schematic flow diagram of a typical oil refinery  that depicts the various unit processes and the flow of intermediate product streams that occurs between the inlet crude oil feedstock and the final end products.
The diagram depicts only one of the literally hundreds of different oil refinery configurations. The diagram also does not include any of the usual refinery facilities providing utilities such as steam, cooling water, and electric power as well as storage tanks for crude oil feedstock and for intermediate products and end products.
There are many process configurations other than that depicted above. For example, the vacuum distillation unit may also produce fractions that can be refined into end products such as: spindle oil used in the textile industry, light machinery oil, motor oil, and various waxes.
The crude oil distillation unit CDU is the first processing unit in virtually all petroleum refineries. The CDU distills the incoming crude oil into various fractions of different boiling ranges, each of which are then processed further in the other refinery processing units. The CDU is often referred to as the atmospheric distillation unit because it operates at slightly above atmospheric pressure. Below is a schematic flow diagram of a typical crude oil distillation unit.
The incoming crude oil is preheated by exchanging heat with some of the hot, distilled fractions and other streams.
Browse terms related to these fuel groups: alternative fuels coal electricity natural gas nuclear petroleum renewable. Examples include butane C 4 H 10 and butylene C 4 H 8. Used in Keene's cement, in pigments, as a paper filler, and as a drying agent. Used in the sulfite process for the manufacture of wood pulp.
As oil and gas get harder and more expensive to process the industry is under pressure to squeeze the most value out of them while searching for viable alternatives. Our solutions are designed to handle all feedstocks and still ensure easy, reliable, stable and profitable hydrocracking and hydrotreating. Superior process designs, performance catalysts and proprietary equipment ensure significantly longer cycle length while increasing yield and plant availability, reducing energy consumption and CO 2 emissions. Our portfolio also includes a full range of solutions for emissions management and the efficient and reliable production of high quality hydrogen, ensuring our customers benefit from all potential synergies with minimum environmental impact. Solutions for all feedstocks for reliable and profitable hydrotreating and hydrocracking. Explore the processes we work with in this industry Chemical processing. Producing ammonia at the lowest cost per ton is a challenge many industries face every day.
Oil & Gas Filtration and Separation Solutions
By Riaz Khan, Ammeran B. Oil and gas operators are now being driven to now operate beyond their originally conceived design life and field life. Asset life extension ALE beyond these thresholds presents unique safety and business risk challenges for the oil and gas industry. With aging equipment and facilities, operators face increasing challenges in maintaining equipment reliability and integrity as well as operational safety.SEE VIDEO BY TOPIC: Petroleum Process Units & Products.
The upstream part of the oil and gas business is comprised of production facilities. These facilities are where hydrocarbons are first recovered in the process. Pall filtration and separation solutions increase oil recovery rates, help maximize output and efficiently dispose of produced water. Transportation of produced fluids, gas processing, and LNG production is what comprises the midstream segment. The complex system of pipelines, compressor stations and access points move product to endpoints. Separation of oil, gas and water and the removal of solid contaminants is essential prior to pipeline transportation. Oil and gas refining process rely on the purity of feed streams for efficient process reactions. Removal of fluid and particulate contaminants from feed streams and fluid recirculation processes is essential for improving refining efficiency.
Zyfra AI. About Industries Products Services Contacts. Optimize your production process using cutting edge technology.
A chemical plant is an industrial process plant that manufactures or otherwise processes chemicals , usually on a large scale. Other kinds of plants, such as polymer, pharmaceutical, food, and some beverage production facilities, power plants , oil refineries or other refineries , natural gas processing and biochemical plants, water and wastewater treatment, and pollution control equipment use many technologies that have similarities to chemical plant technology such as fluid systems and chemical reactor systems. Some would consider an oil refinery or a pharmaceutical or polymer manufacturer to be effectively a chemical plant. Petrochemical plants plants using chemicals from petroleum as a raw material or feedstock are usually located adjacent to an oil refinery to minimize transportation costs for the feedstocks produced by the refinery. Speciality chemical  and fine chemical plants are usually much smaller and not as sensitive to location. Tools have been developed for converting a base project cost from one geographic location to another. Chemical plants use chemical processes , which are detailed industrial-scale methods, to transform feedstock chemicals into products. The same chemical process can be used at more than one chemical plant, with possibly differently scaled capacities at each plant. Also, a chemical plant at a site may be constructed to utilize more than one chemical process, for instance to produce multiple products. A chemical plant commonly has usually large vessels or sections called units or lines that are interconnected by piping or other material-moving equipment which can carry streams of material. Such material streams can include fluids gas or liquid carried in piping or sometimes solids or mixtures such as slurries.
Oil and Gas
Platform types for underwater drilling. Crude oils and natural gases are mixtures of hydrocarbon molecules organic compounds of carbon and hydrogen atoms containing from 1 to 60 carbon atoms. The properties of these hydrocarbons depend on the number and arrangement of the carbon and hydrogen atoms in their molecules. The basic hydrocarbon molecule is 1 carbon atom linked with 4 hydrogen atoms methane. All other variations of petroleum hydrocarbons evolve from this molecule.
Equipment critical analysis: The need for an effective maintenance program
The Industrial Solutions business area at thyssenkrupp is a leading partner for the engineering, construction, and service of industrial plants and systems. In addition to chemical, coke, refinery, cement, and other industrial plants, our portfolio also includes mining, and ore processing and port handling equipment, along with corresponding services. In collaboration with our customers, we develop top-quality solutions and deliver efficiency, reliability, and sustainability over the entire life cycle. Around 11, employees at over 60 locations form a global network with a technology portfolio that guarantees maximum productivity and cost-efficiency. We design and build complete coke plants of various types for the production of coke from different grades of coal. Whether horizontal chamber kilns, heat recovery or byproduct systems — thanks to our know-how and innovative processes our coke plants meet the latest environmental standards and reliably produce high-quality coke for internal use or for sale. Our materials handling capabilities range from individual machines to the design and construction of complete handling facilities for port terminals and stockyards.
Pumps and packages for the oil and gas industries
Oilfield Equipment and Services
An oil refinery or petroleum refinery is an industrial process plant where crude oil is transformed and refined into more useful products such as petroleum naphtha , gasoline , diesel fuel , asphalt base , heating oil , kerosene , liquefied petroleum gas , jet fuel and fuel oils. Oil refineries are typically large, sprawling industrial complexes with extensive piping running throughout, carrying streams of fluids between large chemical processing units, such as distillation columns. In many ways, oil refineries use much of the technology, and can be thought of, as types of chemical plants. The crude oil feedstock has typically been processed by an oil production plant.
Pumps and packages for the oil and gas industries
Shell chemicals companies have a global manufacturing base, with some assets operated by Shell chemicals companies, some by other Shell Group companies, and others by joint ventures. A portion of the CO2 generated by the upgrading facility is captured and stored sub-surface. Monoethylene glycol is primarily sold to customers in North America for use in making products such as polyester fibers, plastic drinking bottles, adhesives and inks. The site is highly integrated from the bitumen upgrading units, through the oil products refining units and finally, the chemicals products units.
Oil refineries and large petrochemical plants contain thousands of pieces of process and utilities equipment that are subject to wear, erosion, deterioration, aging, etc. Imagine being a maintenance engineer and receiving 50 work orders during an overhaul with a limited budget, time, labor, spare parts, tools, machines, etc. How does that engineer prioritize the work? An important daily challenge at all hydrocarbon processing plants is equipment failure, which can have many causes and consequences.