Crude oil refining equipment
Supervised by :Dr.Ihsan Habib
Prepared by:Mhmoud Mohmed
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INTRODUCTION
Definition of crude oil
Crude oil: heavy, high-density black liquid that tends to brown or green,
flammable. It is sometimes used on the surface of the earth in the form of oil pools,
which the ancients knew in its raw form and used in some life uses such as lighting,
construction and ship painting. It was also used in the treatment of certain diseases. In
some simple industries, crude oil is an important source of energy, Vehicles and
.chemical products
Of Crude Oil Composition
Crude oil consists of a complex mixture of hydrocarbons and other organic
compounds, whose composition varies greatly from one type to another. Organic
compounds, as is known, consist of carbon and hydrogen, and other elements such as
oxygen, nitrogen and sulfur. Oil also contains traces of certain mineral elements, And
nickel. Methane CH4, ethane C2H6, bromine, C3H8, and C4H10 are a high
.proportion of petroleum-forming hydrocarbons
Composition by weight
Element Percent range
Carbon to 87% 83
Hydrogen to 14% 10
Nitrogen to 2% 0.1
Oxygen to 1.5% 0.05
Sulfur to 6.0% 0.05
Metals 0.1% <
Origin OfCrude Oil
Scientists differed on the origin of petroleum, some of them believe that the inorganic
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material is represented in carbon and its compounds are the origin, and some of them
believe that the origin of petroleum is the living organism composed of organic
.matter. These are some theories of crude oil formation
Biogenic theory
Many geologists believe that the origin of petroleum, as well as coal and natural gas,
are the remains of ancient organisms from small marine plants and animals. The
remains of these organisms were deposited in large quantities in low areas of the
oceans and covered with layers of mud. Under the influence of pressure, heat and
time factor, The organisms have undergone many transformations and vital
.interactions to produce oil
Alternative theory
Many scientists believe that the origin of the oil is not the organism, but its origin is
the carbon element and some inorganic carbon compounds such as calcium carbide,
for example CaC2 where the element carbon and its compounds, which were filling
the earth out of time, chemical changes resulted in this huge mixture of hydrocarbons
and the rest of the organic compounds Petroleum component. It is believed that the
:beginning was an interaction of this kind
CaC2 + 2H2O = C2H2 + Ca(OH)2
Oil Refining
Crude oil is not useful, and to benefit from it, it is treated by a series of processes.
These processes are called (oil refining), which produces a group of useful products.
:Oil refining usually takes place in the following stages
First: Primary treatment: It includes the disposal of water and salts associated with
oil, which is an important step ahead of the refining process because the presence of
water and salts in the refinery causes serious problems, including the rise of pressure
.in the tower because of evaporation of water, and salt causes corrosion
Second: distillation process, which is the main and important process that takes place
.in huge towers, and the separation of oil into its components
:Third: Improving specifications
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After obtaining derivatives, it is not marketed directly because it is in fact not usable
so far, and to be usable, some improvements have to be made to be suitable for the
required use If we took the example of naphtha directly from the distillery and put in
a car, the engine will work Abnormal noise, not to mention the engine noise, even if
kerosene was used directly as a jet fuel for the plane crash to contain untreated
kerosene on waxy material frozen in the air delivery pipes at low temperatures in the
.air High
Therefore, some operations must be done to make the derivative ready for use, which
is known as "improving specifications". The produced naphtha is processed in special
units for desulfurization, chain cracking and octane lifting. To operate the car engine in
.a quiet and smooth
Kerosene used in airplanes as fuel is known as the process of removing candles, which
are long-chain vehicles that can easily freeze inside the engine's jet tubes, causing
them to fall. These compounds are removed to reduce the freezing of fuel. Thus, for
the rest of the derivatives, the processes of improving specifications are appropriate for
.the purpose in which they will be used
After briefly identifying the crude oil and its components and the processes that are
carried out by it to separate the impurities and improve the specifications. We will start
by identifying parts of the refining unit (oven, refrigeration tower, heat exchangers,
controllers, and other parts). We will then discuss the flow of materials within the
.refining unit and explain the production lines of each product
Explanation of some parts of the refining unit
First: The Oven Heater H-241
Is a large metal structure designed to contain the heat resulting from the combustion
process of fuel and oxygen inside the combustion chamber of the furnace The heat
generated by combustion is transmitted to the material in direct radiation from the
flame as well as from the heat reflected from the walls of the furnace and called
Radiation Zone. In addition, another area between the radiation zone and the oven
chimney is called the Convection Zone. This area takes heat from the hot gases rising
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up to the furnace, which is generated by fuel combustion. In general, this Fire Box is
padded from inside with a fireproof shell that reduces heat loss. Hangers are installed
on walls or ceiling to absorb heat directly from burners. Figure {1} and figure {2} are
shown. The parts of the furnace in the light refining units where the heat is obtained
in the radiation area by a number of torches (10) in controlled amounts of air and
fuel. The heat of the combustion process is transmitted by the radiation to the oil
material running in the files placed on the walls of the furnace and out of the network
of other files in the higher area is the load area, which in turn acquires heat from hot
gases out of the radiation area, which exit from this area to the atmosphere by the
chimney Stack is controlled by its temperature and temperature by the gate (Dumper)
installed in the middle of the chimney and the light weight of these gases relative to
.the weight of the air heading up to get out of the oven through the chimney
)furnace(
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Second: Fractionating Tower
The refining tower is a vertical multi-point pot that is used in refining crude oil and is
the main nerve of the process. The refining tower is one of the physical ways to
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separate hydrocarbon hydrocarbons by means of the densities teams because they
contain trays for evaporation and condensation. So that the light picks are pulled from
the top and the heavy ones are pulled from the bottom of the tower. There are two
types of distillation towers, the first distillation towers and the second distillation
.towers
The refinery tower used in Samawah Refinery units is the first type (air distillation
tower). The tower contains 29 Chinese and each tray contains a number of valve
valves made of stainless steel to resist corrosion inside the tower. The tower has a
number of clouds where the materials (and boiling points) are grouped into pockets to
pull out of the tower. To maintain the thermal balance inside the tower, the gas oil is
cooled after cooling it to 65C to Chinese No. 8 and the naphtha after cooling to 60C
to the top of the tower above the trays. In the top of the tower there are two PSV
safety valves used to protect the tower. The valves are opened if the pressure inside
the tower reaches 40 ° C. psi. The tower pressure is controlled by discharging the
gases into the Flare system via the control PCV- 403. Crude oil enters the tower from
the flash zone where the oil at this stage is a mixture of liquids and vapors that
evaporate the vapors to the top to condense while the liquids drop down. As shown in
.Figure( 3)
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Third: Heat Exchangers
E-211-A,B&C
E-211-A, B & C is one of the most important exchanges in the refining unit and is
used to heat crude oil before entering the furnace as well as to cool the produced
black oil. Crude oil enters from the bottom of the E-211-C swap by the Shell Side and
.emerges from the top of the swap E-211-A
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While the black oil enters from the top of the swap E-211-A side of the Tube Side
.and emerges from the swap E-211-C
E-215
The E-215 is used to raise the temperature of crude oil and reduce the temperature of
black oil after leaving the tower to reduce corrosion in the pumps of black oil 314-A,
B P - The temperature of black oil outside the swap is controlled by For use in
.heating the white oil in the boiler to improve its specification
E-216
The E-216 is the first phase of the heating of crude oil as it enters the temperature of
the atmosphere and rises to a temperature of ( 30oC) alternating with gas oil from the
.bottom of the tower
E-213
The E-213 boiler is used to heat the white oil in the deflection tower using the heat of
the black oil outside of the E-215 swap to improve the specifications of the white oil.
White oil enters the bottom of the kettle from the side of the side tube while the black
.oil enters the top of the boiler from the side of the shell
Fourth: Controlling Control Valves
Control devices are used to maintain operational conditions of pressure, temperature,
flow and level. This is done by controlling the valves from the control room. There
are two types of controllers that open when the Air To Close is stopped and the
second is closed when the Air To Open is closed to maintain the equipment of the
.refining unit. Here are some types of controls used in the unit
FCV-101: Used to control the capacity of the refining unit by controlling the flow of
.crude oil from the exchangers and inside to the furnace
.FCV-112: Used to control the production of white oil
.FCV-114: Used to control heavy naphtha production
.FCV-118: Used to control light naphtha production
.LCV-302: Used to control the level of black oil inside the refining tower
.LCV-303: Used to control the level of white oil inside the tower deflection
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LCV-304: Used to control the level of gas oil inside the tower deflection.
ILC-305: Used to get rid of the amount of water collected inside the Naphtha pool by
.varying the densities
.TCV-202: Used to control the temperature of the crude oil outside of the furnace
.TCV-203: Used to control the top tower temperature
TCV-204: Used to control the Chinese temperature No. 8.
.TCV-205: Used to control the temperature of the naphtha pool pot
PCV-403: is used to control the pressure of the naphtha pool and thus control the
pressure of the refining unit by discharging the non-condensing gases into the Flare
.system or the furnace fuel system
Type Of Valves
Gate valve-1
Globe Valve-2
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Ball valve-3
: Check Valve-4
Plug Valve-5
butterfly valve-6
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chock valve-7
:There are also many types of valves used for different purposes such as
Safety valve
Regulator valve
Relief valve
Refinery unit product
:First: Naphtha
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One of the main oil refining products is distilled at a temperature between 65-
200 ° C. Its molecules consist of a number of carbon atoms ranging from 6-12
:atoms of carbon. The naphtha is divided into two parts
A-Light Naphtha: In this type of hydrocarbons with long chains open and used
for the production of gasoline in the first place and used in the production of
.olefins (ethylene, propylene) in second place
B-Heavy Naphtha: Naphtha is dominated by heavy hydrocarbons Used in the
production of aromatic compounds and are later separated into benzene, toluene
and other compounds as well as can be used in the manufacture of some
.petroleum solvents
:Second: Kerosene White oil
a liquid that is circulating between 150-300 ° C and contains paraffin hydrocarbons
with a range of between 11-18 atoms. Used as fuel for heating, lighting, heating
.and other uses
:Third: Gas Oil
It is produced from distillation, thermal cracking and cracking by auxiliary agents and
dripping at (275-400 ° C). It is a brown color containing hydrocarbons with
carbon atoms in the range of 15-20 carbon atoms . It is important to convert it into
gasoline (gasoline) by thermal cracking process, as well as fuel for diesel engines,
.heat generation in homes, factories and electricity generation
:Fourth: Fuel Oil
A distillate residue of crude oil with high asphalt content, which means that it contains
metal materials and may contain ionic compounds such as sodium, calcium, iron
and nickel. Fuel oil is used to obtain steam used in ships and vapors or as fuel in
large marine diesel engines as well as in electric power stations (as in the
SamawatDesalat plant) to generate electricity or as furnace fuel in cement plants
.or undergo vacuum distillation for lubricating oils, Asphalt
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Product Quantities And Qualities
Light Naphtha
Yield 15.4 %
Rate 10.2 m3/hr
TBP IBP-130°C
API 67.4
Total Sulfur 0.013 %
Kerosene
Yield 17 %
Rate 11.3 m3/hr
TBP 150-240°C
Flash Point 37.8° C
API 48.4
Total Sulfur 0.15
Diesel Oil
Yield 12 %
Rate 7.9 m3/hr
TBP 240-305
Flash Point 65.6° C
API 37.6
Total Sulfur 1.1
Fuel Oil
Yield 50.5
Rate 33.4 m3/hr
TBP 305+
Flash Point 65.6
API 17.8
Total Sulfur 3.2
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:Tests of petroleum products
DA-130N : direct measure of density of fluid-1
AVP-30D:for measuring the vapor pressure of products by water bath-2
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measuring the kinematics viscosity by standard method (ASTM D – 4451P 71)-3
ADA-500 SERIES (auto distillation analyzer)-4
pac (optiflash) : auto measuring the flash point of kerosene – 200 -5
pensky- martens closed tester IP 34 (for RC) -6
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STANHOPE-SETA: measure the salt content in crude oil-7
: Types of the controllers used in the distillation unit
FCV-101: used to control the capacity of the unit by control the flow of crude oil -1
from exchangers and inlet of the furnace
FCV-112: used to control the kerosene-2
FCV – 114: used to control heavy naptha-3
FCV-118: used to control the light naptha -4
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LCV-302: used to control the RC -5
inside the column
LCV-303: used to control the -6
kerosene inside the column
LCV-304: used to control the gas oil in-7
the column
TCI-202: used to control the -8
temperature of crude oil out from
furnace
TCI-204: used to control the -9
temperature on top of the column
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