Petroleum Refining Designs and Applications

640 Pages·2018·24.767 MB·English

by  Coker, A. Kayode

Petroleum Refining Design and
Applications Handbook
Scrivener Publishing
100 Cummings Center, Suite 541J
Beverly, MA 01915-6106
Publishers at Scrivener
Martin Scrivener ([email protected])
Phillip Carmical ([email protected])
Petroleum Refining Design and
Applications Handbook
Volume 1
A. Kayode Coker
This edition first published 2018 by John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, USA and Scrivener
Publishing LLC, 100 Cummings Center, Suite 541J, Beverly, MA 01915, USA
© 2018 Scrivener Publishing LLC
For more information about Scrivener publications please visit www.scrivenerpublishing.com.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form
or by any means, electronic, mechanical, photocopying, recording, or otherwise, except as permitted by law. Advice on
how to obtain permission to reuse material from this title is available at http://www.wiley.com/go/permissions.
Wiley Global Headquarters
111 River Street, Hoboken, NJ 07030, USA
For details of our global editorial offices, customer services, and more information about Wiley products visit us at
www.wiley.com.
Limit of Liability/Disclaimer of Warranty
While the publisher and authors have used their best efforts in preparing this work, they make no representations or
warranties with respect to the accuracy or completeness of the contents of this work and specifically disclaim all warranties,
including without limitation any implied warranties of merchantability or fitness for a particular purpose. No warranty may
be created or extended by sales representatives, written sales materials, or promotional statements for this work. The fact
that an organization, website, or product is referred to in this work as a citation and/or potential source of further informa-
tion does not mean that the publisher and authors endorse the information or services the organization, website, or product
may provide or recommendations it may make. This work is sold with the understanding that the publisher is not engaged
in rendering professional services. The advice and strategies contained herein may not be suitable for your situation. You
should consult with a specialist where appropriate. Neither the publisher nor authors shall be liable for any loss of profit or
any other commercial damages, including but not limited to special, incidental, consequential, or other damages. Further,
readers should be aware that websites listed in this work may have changed or disappeared between when this work was
written and when it is read.
Library of Congress Cataloging-in-Publication Data
ISBN 978-1-118-23369-6
Cover design by Kris Hackerott
Cover Image: Refinery Illustration, Seamartini | Dreamstime.com
Set in size of 11pt and Minion Pro by Exeter Premedia Services Private Ltd., Chennai, India
Printed in the USA
10 9 8 7 6 5 4 3 2 1
To my wife, Victoria O. Coker for her forbearance and fortitude.
Love and Thanks
To the spiritual guides and invisible helpers in Creation without which this project
cannot be accomplished.
Sincere and deepest gratitude
To all personnel working in petroleum refineries and petrochemical industries world
wide and endeavoring to make their facilities safe.
“God wills that His Laws working in Creation should be quite familiar to man, so that
he can adjust himself accordingly, and with their help can complete and fulfil his course
through the world more easily and without ignorantly going astray.”
Abd-ru-shin
(In the Light of Truth)
The Laws of Creation
The Law of the Attraction of Homogeneous Species
The Law of Gravitation
The Law of Reciprocal Action
“What is Truth?”
Pilate (John 18, 38)
“Only the truth is simple.”
Sebastian Haffner
“Woe to the people to whom the truth is no longer sacred!”
Friedrich Christoph Schlosser
“Truth does not conform to us, dear son but we have to conform with it.”
Matthias Claudius
“Nothing will give safety except truth. Nothing will give peace except the serious search for truth.”
Blaise Pascal
“Truth is the summit of being: justice is the application of it to affairs”
Ralph Waldo Emerson
“The ideals which have lighted my way, and time after time have given me new courage to face
cheerfully, have been Kindness, Beauty and Truth”
Albert Einstein
“It irritates people that the truth is so simple”.
Johann Wolfgang von Goethe
“Truth is the Eternal - Unchangeable! Which never changes in its form, but is as it has been
eternally and will ever remain, as it is now. Which can therefore never be subjected to any
development either, because it has been perfect from the very beginning. Truth is real, it is ‘being’!
Only being is true life. The entire Universe is “supported” by this Truth!”
Abd-ru-shin
Truth
To honor God in all things and to perform everything solely to the glory of God
Abd-ru-shin
(In The Light of Truth)
Awake!
Keep the heart of your thoughts pure, by so doing you will bring peace and be happy.
Love thy neighbour, which means honour him as such!
There in lies the adamantine command: You must never consciously harm him, either in his body
or in his soul, either in his earthly possessions or in his reputation!
He who does not keep this commandment and acts otherwise, serves not God but the darkness, to
which he gives himself as a tool!
Honour be to God Who only sows Love! Love also in The Law of the destruction of the darkness!
Abd-ru-shin
(In the Light of Truth)
Love & Gratitude
Crystal Images © Office Masaru Emoto, LLC
Contents
Preface xix
Acknowledgments xxi
About the Author xxiii
1 Introduction 1
References 6
2 Composition of Crude Oils and Petroleum Products 7
2.1 Hydrocarbons 8
2.1.1 Alkynes Series 12
2.2 Aromatic Hydrocarbons 14
2.3 Heteroatomic Organic Compounds 15
2.3.1 Non-Hydrocarbons 15
2.3.2 Sulfur Compounds 18
2.4 Thiols 18
2.5 Oxygen Compounds 20
2.6 Nitrogen Compounds 22
2.7 Resins and Asphaltenes 23
2.8 Salts 24
2.9 Carbon Dioxide 24
2.10 Metallic Compounds 24
2.11 Products Composition 25
2.11.1 Liquefied Petroleum Gas (LPG) (C and C ) 26
3 4
2.11.2 Gasoline (C to C ) 26
5 11
2.11.3 Condensate (C , C and C >) 27
4 5 6
2.11.4 Gas Fuel Oils (C to C ) 27
12 19
2.11.5 Kerosene 27
2.11.6 Diesel Fuel 28
2.11.7 Fuel Oils # 4, 5, and 6 28
2.11.8 Residual Fuel Oil 28
2.11.9 Natural Gas 29
References 30
3 Characterization of Petroleum and Petroleum Fractions 31
3.1 Introduction 31
3.1.1 Crude Oil Properties 32
3.1.2 Gravity, API 32
3.1.3 Boiling Point Range 33
3.1.4 Characterization Factor 33
3.1.5 The Universal Oil Product Characterization factor, K 34
UOP
3.1.6 Carbon Residue, wt% 34
3.1.7 Nitrogen Content, wt% 36
3.1.8 Sulfur Content, wt% 36
ix
x Contents
3.1.9 Total Acid Number (TAN) 36
3.1.10 Salt Content, pounds/1000 barrels 36
3.1.11 Metals, parts/million (ppm) by weight 36
3.1.12 Pour Point (oF or °C) 36
3.2 Crude Oil Assay Data 37
3.2.1 Whole crude oil average properties 37
3.2.2 Fractional properties 37
3.3 Crude Cutting Analysis 37
3.4 Crude Oil Blending 37
3.5 Laboratory Testing of Crude Oils 46
3.5.1 True Boiling Point (TBP) Curve 46
3.5.2 ASTM D86 Distillation 46
3.5.3 Boiling Points 47
3.5.4 Conversion Between ASTM and TBP Distillation 49
3.5.5 Petroleum Pseudo-Components 54
3.5.6 Pseudo-Component Normal Boiling Points 55
3.5.7 ASTM D1160 Distillation 55
3.5.8 Determination of ASTM IBP, 10%, 20–90% Points of Blend 55
3.5.9 ASTM 10–90% Points 56
3.5.10 Initial Boiling Point Determination 56
3.5.11 ASTM End Point of Blend 56
3.5.12 Flash Point 56
3.5.13 Flash Point, °F, as a Function of Average Boiling Point 57
3.5.14 Smoke Point of Kerosenes 57
3.5.15 Luminometer Number 57
3.5.16 Reid Vapor Pressure (RVP) 57
3.5.17 Vapor Pressure of Narrow Hydrocarbon Cuts 58
3.6 Octanes 58
3.7 Cetanes 58
3.7.1 Cetane Index 59
3.8 Diesel Index 59
3.9 Determination of the Lower Heating Value of Petroleum Fractions 59
3.10 Aniline Point Blending 60
3.11 Correlation Index (CI) 60
3.12 Chromatographically Simulated Distillations 61
References 62
4 Thermodynamic Properties of Petroleum and Petroleum Fractions 63
4.1 K-Factor Hydrocarbon Equilibrium Charts 64
4.2 Non-Ideal Systems 72
4.3 Vapor Pressure 74
4.3.1 Vapor Pressure Determination using the Clausius-Clapeyron and the Antoine Equations 75
4.4 Viscosity 80
4.4.1 Conversion to Saybolt Universal Viscosity 80
4.4.2 Conversion to Saybolt Furol Viscosity 82
4.4.3 Equivalents of Kinematic (cSt), Saybolt Universal (SUS), and Dynamic viscosity 82
4.4.4 Viscosity of Liquid Hydrocarbons 83
4.4.5 Gas Viscosity 84
4.5 Refractive Index 87
4.6 Liquid Density 89
4.6.1 Gas Density 89
Contents xi
4.7 Molecular Weight 90
4.8 Molecular Type Composition 90
4.9 Critical Temperature, T 96
c
4.10 Critical Pressure, P 97
c
4.11 Pseudo-Critical Constants and Acentric Factors 98
4.12 Enthalpy of Petroleum Fractions 99
4.13 Compressibility Z Factor of Natural Gases 100
4.14 Simulation Thermodynamic Software Programs 105
References 110
5 Process Descriptions of Refinery Processes 111
5.1 Introduction 111
5.2 Refinery and Distillation Processes 115
5.3 Process Description of the Crude Distillation Unit 120
5.3.1 Crude Oil Desalting 121
5.3.2 Types of Salts in Crude Oil 122
5.3.3 Desalting Process 122
5.3.4 Pumparound Heat Removal 127
5.3.5 Tower Pressure Drop and Flooding 130
5.3.6 Carbon Steel Trays 130
5.3.7 Rectifying Section of the Main Column 130
5.3.8 Side Stripping Columns 130
5.3.9 Crude Column Overhead 130
5.3.10 General Properties of Petroleum Fractions 130
5.4 Process Variables in the Design of Crude Distillation Column 132
5.4.1 Process Design of a Crude Distillation Column 133
5.5 Process Simulation 134
5.5.1 Overall Check of Simulation 135
5.5.2 Other Aspects of Design 136
5.5.3 Relationship between Actual Trays and Theoretical Trays 137
5.6 Process Description of Light Arabian Crude Using UniSim® Simulation Software [12] 138
5.6.1 Column Conventions 141
5.6.2 Performance Specifications Definition 142
5.6.3 Cut Points 142
5.6.4 Degree of Separation 142
5.6.5 Overflash 142
5.6.6 Column Pressure 143
5.6.7 Overhead Temperature 143
5.6.8 Bottom Stripping 144
5.6.9 Side Stream Stripper 144
5.6.10 Reflux 144
5.7 Troubleshooting Actual Columns 144
5.8 Health, Safety and Environment Considerations 145
References 148
6 Thermal Cracking Processes 149
6.1 Process Description 152
6.2 Steam Jet Ejector 152
6.3 Pressure Survey in a Vacuum Column 154
6.4 Simulation of Vacuum Distillation Unit 156