The document provides information about various processes at an oil refinery. It discusses desalting crude oil to remove salt. It then describes the main distillation units like atmospheric distillation and vacuum distillation that separate crude oil into different hydrocarbon fractions. Other process units mentioned include hydrotreating to remove contaminants, catalytic reforming to increase octane of naphtha, fluid catalytic cracking to convert heavy fractions to lighter products, and hydrocracking to break larger molecules.

1. GROUP B
Oil Refinery

2. Group Members
Name Reg No
Kifayat Ali 17-ME-047
Umair Hayat 17-ME-112
Shawaiz Summer 17-ME-028
Faizan Amjad
Ahmad Khan
Abdul Moeed
17-ME-104
17-ME-051
17-ME-098

3. Oil Refinery

4. Desalting
 It is a process unit in an oil refinery that removes salt
from the crude oil
 PTB (pounds of salt per thousand barrels of crude oil)
 Salts: Calcium, Sodium and Magnesium Chlorides,
sand, drilling mud, polymer, corrosion byproduct.
 High temperature Hydrolysis Hydrochloric acid

5. 3D view of Desalter

6. Benefits of Crude Oil Desalting
 Increase crude throughput
 Less plugging, scaling, coking of heat exchanger and
furnace tubes
 Less corrosion in exchanger, fractionators, pipelines,
etc.
 Better corrosion control in CDU overhead
 Less erosion by solids in control valves, exchanger,
furnace, pumps
 Saving of oil from slops from waste oil

7. Atmospheric crude distillation unit
 Purpose: separation of LPG, naphtha, kerosene,
hydrocarbon diesel and fuel oil.
 Desalting Tube
 The temperature is highest at the bottom and lowest is at
the top
 Hydrocarbon naphtha 120 °C–130 °C
 Kerosene 140 °C–270 °C
 Diesel 280 °C–300 °C
 (RCO)reduced crude oil 340 °C–350 °C

8. Flow Diagram Of Atmospheric Distillation

9. Vacuum distillation
 The process in which pressure above the liquid
mixture to be distilled is reduced to less than
its vapor pressure.
 Temperatures above 370 to 380 °C :
 Will undergo thermal cracking and form petroleum coke at temperatures above that, hydrocarbons boil
above that temperature.
 Absolute pressures as low as 10 to 40 torr

10. Vacuum distillation unit:
 Process objective:
To recover valuable gas oils from reduced crude via
vacuum distillation.
 Primary process techniques:
Reduce the hydrocarbon partial pressure via vacuum
and stripping steam.

11. Process steps:
 Heat the reduced crude to the desired temperature
using fired heaters.
 Flash the reduced crude in the vacuum distillation
column.
 Utilize pump around cooling loops to create internal
liquid reflux .
 Product draws are top, sides, and bottom.

12. Schematic diagram:

13. Hydrotreating:
 Process objective:
To remove contaminants (sulfur, nitrogen, metals)
and saturate olefins and aromatics to produce a
clean product for further processing or finished
product sales.

14. Primary process techniques:
 Hydrogenation occurs in a fixed catalyst bed to
improve H/C ratios and to remove sulfur, nitrogen,
and metals.

15. Process steps:
 Feed is preheated using the reactor effluent.
 Hydrogen is combined with the feed and heated to
the desired hydrotreating temperature using a fired
heater.
 Feed and hydrogen pass downward in a
hydrogenation reactor packed with various types of
catalyst depending upon reactions desired.
 Reactor effluent is cooled and enter the high
pressure separator which separates the liquid
hydrocarbon from the hydrogen/hydrogen
sulfide/ammonia gas.

16.  Acid gases are absorbed from the hydrogen in the
amine absorber.
 Hydrogen, minus purges, is recycled with make-up
hydrogen.
 Further separation of LPG gases occurs in the low
pressure separator prior to sending the
hydrocarbon liquids to fractionation.

17. Schematic diagram:

18. Naphtha Hydrotreater:
 Primary objective is to remove sulfur contaminant
for downstream processes; typically < 1wppm.

19. Distillate hydrotreater:
 Sulfur removal from kerosene for home heating.
 Convert kerosene to jet via mild aromatic saturation.
 Remove sulfur from diesel for clean fuels.
 Ultra-low sulfur diesel requirements are leading to
major unit revamps.

20. Catalytic reformer:
 Process objective:
To convert low-octane naphtha into a high-octane
reformate for gasoline blending and/or to provide
aromatics (benzene, toluene, and xylene) for
petrochemical plants. Reforming also produces high
purity hydrogen for hydrotreating processes.

21. Primary process techniques:
 Reforming reactions occur in chloride promoted
fixed catalyst beds; or continuous catalyst
regeneration (CCR) beds where the catalyst is
transferred from one stage to another, through a
catalyst regenerator and back again. Desired
reactions include: dehydrogenation of naphthenes to
form aromatics; isomerization of naphthenes;
dehydrocyclization of paraffins to form aromatics;
and isomerization of paraffins. Hydrocracking of
paraffins is undesirable due to increased light-ends
make.

22. Process steps:
a) Naphtha feed and recycle hydrogen are mixed,
heated and sent through successive reactor beds.
b) Each pass requires heat input to drive the
reactions.
c) Final pass effluent is separated with the hydrogen
being recycled or purged for hydrotreating.
d) Reformate product can be further processed to
separate aromatic components or be used for
gasoline blending.

23. Schematic diagram:

24. Fluid Catalytic Cracker:
 Process objectives:
To convert low value gas oils to valuable products
such as naphtha, diesel and slurry oil.
 Primary process technique:
catalytic cracking increases H/C ratio by carbon
rejection in a continuous process.

25.  Process steps:
a) Gas oil feed is dispersed into the bottom of the riser
using steam.
b) Thermal cracking occurs on the surface of the catalyst.
c) Disengaging drum separates spent catalyst from
product vapors.
d) Steam strips residue hydrocarbons from spent
catalyst.
e) Air burns away the carbon film from the catalyst in
either a “partial-burn” or “full-burn” mode of operation.
f) Regenerated catalyst enters bottom of riser-reactor.

26. Schematic Diagram:

27. Hydro-cracking
 Hydrocracking is a catalytic process assisted by the
presence of added hydrogen gas.
 Used to break the larger C-C bonds into shorter.
 Product of this cracking are saturated
hydrocarbons.
 Normally facilitated by the bifunctional catalysts.
 Breaking of hydrocarbon chain and as well as
addition of hydrogen to aromatics and olefins to
produce naphthalene and alkanes.

28. Products and uses of hydrocracking
 Products of hydrocking are jet fuels, diesels,
LPG, low sulphur naphtha.
 Fluid cracking is used in USA for gasoline.
 Hydrogen cracking is used because it reduces
tar formation, reduces impurities, prevent
build up of coke on catalyst.
 By using hydrogen we can produce high
octane number fuel.

29. Visbreaking
 Visbreaking is a process in which quantity of residual
oils is reduced from oil during distillation and to
increase the quantity of valuable products.
 Requires temperature to thermally crack oil in a
furnance.
 Reduces viscosity of residual oil and is a non catalytic
process.

30. Technology involved and fuel stability in
visbreaking
 Coil and soaker visbreaking.
 Coil visbreaking involves burning of oil in furnance.
 In soaker visbreaking oil is heated in a drum next to
furnace.
 Soaker visbreaking is more advantageous than
coil visbreaking because it requires lesser fuel.

31. Fuel stability
 Fuel stability means the ability of fuel oil to
produce sediments when stored.
 Residue introduced in visbreaking process contains
asphaltanes , resins , aromatic compounds,
parafinnic hydrocarbons.
 Viscosity blending is a major process in
visbreaking
 Visbreaking preferentially cracks aliphatic
compounds of low density and high viscosity.

32. Alkylation:
 Process objective:
To combine light olefins (propylene and butylene)
with isobutane to form a high octane gasoline
(alkylate).
 Primary process technique:
Alkylation occurs in the presence of a highly acidic
catalyst (hydroflouric acid or sulfuric acid).

33. Process steps:
 Olefins from FCC are combined with IsoButane and
fed to the HF Reactor where alkylation occurs.
 Acid settler separates the free HF from the
hydrocarbons and recycles the acid back to the
reactor.
 A portion of the HF is regenerated to remove acid
oils formed by feed contaminants or hydrocarbon
polymerization.
 Hydrocarbons from settler go to the DeIsobutanizer
for fractionating the propane and isobutane from the
n-butane and alkylate.

34.  Propane is then fractionated from the isobutane;
propane as a product and the isobutane to be
recycled to the reactor.
 N-Butane and alkylate are deflourinated in a bed of
solid adsorbent and fractionated as separate
products.

35. Schematic diagram:

36. Delayed coking process:
 Process objective:
To convert low value resid to valuable products
(naphtha and diesel) and coker gas oil.
 Primary Process Technique:
Thermocracking increases H/C ratio by carbon
rejection in a semi-batch process.

37. Process steps:
 Preheat resid feed and provide primary condensing
of coke drum vapors by introducing the feed to the
bottom of the main fractionator.
 Heat the coke drum feed by fired heaters.
 Flash superheated feed in a large coke drum where
the coke remains and vapors leave the top and goes
back to the fractionator.
 Off-line coke drum is drilled and the petroleum coke
is removed via hydrojetting.

38. Schematic diagram:

39. Fluidic Coking Process:
• Process Objective:
To convert low value resid to valuable products
(naphtha and diesel) and coker gas oil.
• Primary Process Technique:
Thermocracking increases H/C ratio by carbon
rejection in a continuous process.

40. Process steps:
 Preheat resid feed, scrub coke particles, and provide
primary condensing of reactor vapors by introducing the
feed to the scrubber.
 Resid is atomized into a fluid coke bed and
thermocracking occurs on the particle surface.
 Coke particles leaving the reactor are steam stripped to
remove remaining liquid hydrocarbons.
 Substoichiometric air is introduced to burner to burn
some of the coke and provide the necessary heat for the
reactor.
 Reactor vapors leave the scrubber and go to the
fractionator.

41. Schematic diagram:

42. Dimerization
 A dimer is an oligomer consisting of two
structurally similar monomers
 Dimerization unit converts olefins(Alkenes) into
higher-octane gasoline blending components.

43. Formation of Hi-Octane
 Butenes formed after merox treatment can be
dimerized into isooctene which may subsequently be
hydrogenated to form isooctane. Isooctane is also
known as Hi-Octane, which can be used in cars and
aviation Industry

44. Storage
Crude oil
 Pressurized storage tanks
 Stainless Steel
 High Carbon Steel
 Great Efficiency
 Gas storage
• Pressure Regulators
• Thermally Insulated
• Leak Detection Sensors
• Over flow Vents

45. video

46. Isomerization
 In chemistry isomerization is the process by which
one molecule is transformed into another molecule
which has exactly the same atoms, but the atoms
have a different arrangement e.g. A-B-C → B-A-C
 Normal pentane into higher-octane branched
molecules

47. Isomerization

48. Thank You