Petroleum Refining
Fourth year
Chemical Engineering Department /College of Engineering/Al-Qadissiya
University
Husham Al.Tameemi 2015-2016
Chapter one: Introduction Petroleum Refining
REFERENCES
TEXT BOOK:
Nelson, W. L. "Petroleum Refinery Engineering", Tata
McGraw Hill Publishing Company Limited, Fourth
Edition, 1958.
HAND BOOK:
James H. Gary & Glenn E. Handwerk "Petroleum
Refining, Technology & Economics", 4th ed., Marcel
Dekker, Inc., 2001.
B.K. Bhaskara Rao, “Modern Petroleum Refining
Processes” Edn. 3, Oxford & IBH Publishing Company
Pvt. Ltd. New Delhi.
Antos, G.J. "Fundamentals of Petroleum Refining"1st
edition, 2010 The Boulevard, Langford Lane, Kidlington,
Oxford OX5 1GB, UK.
James G. Speight, "The Chemistry and Technologyof
Petroleum",5th Eddition,2014CRC press.
Fundamentals_of_Petroleum_Refining, First
Edition,2010.
Internet Sites.
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Chapter one: Introduction Petroleum Refining
PETROLEUM REFINING SYLLABUS
Curriculum:
1. Introdution 23. Properties and needs
2. Crude oils and their 24. Production techniques
chemical composition 25. Removal of asphalt by
3. Physical and chemical solvents
characteristics of crude oil and 26. Extraction by furfural
its products 27. Dewaxing
4. Evaluation of crude oil 28. Production of different
5. Preparation of crude oil types of fuels and oil products
for refining 29. Gas oil
6. Crude oil refining 30. Solvents
7. Thermal processes 31. Car and aero plane gasoline
8. Cracking 32. Jet fuel
9. Coking 33. Kerosene
10. Steam cracking 34. Diesel
11. Catalytic processes in oil 35. Asphalt
refineries 36. Wax
12. Catalytic cracking 34. Environmental Aspects in
13. Hydro cracking Refining Process.
14. Desulphurization by
hydrogen Practical:
15. Reforming 37. Density
16. Isomerization 38. Flash point
17. Polymerization 39. Viscosity
18. Steam reforming 40. Aniline point
19. Conventional chemical 41. Sulfur content
treatment of refinery products 42. Water content
20. Treatment with sulfuric 43. Carbon content
acid 44. Salt content
21. Treatment with earth
22. Lubricating oils
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Chapter one: Introduction Petroleum Refining
Introduction
Crude oil or (petroleum) is becoming increasingly important in the world, day after
day and exceed uses and derive strategic importance of crude oil from two facts:
1. It is being a source of energy.
2. It is being the basic raw material for the chemical industry and the branches of
various petrochemical. Exhorts crude oil good position between the different energy
sources for the following reasons:
1. Contain many products can be separated from each other by refining and represent
a variety of sources in fuel use and production assistant lubrication oils products and
asphalt and petroleum solvents, as some of its derivatives important materials in
Petrochemical industries.
2. The presence of natural gas with crude oil under the surface of the earth.
3. It can be transferred to long distances easily.
4. Low cost of production, transportation and refining.
َخ إٌفظ اٌخب١ّ٘ رٕجغ أٚ ٗرزؼذ اسزؼّبالرٚ َٛ٠ ِب ثؼذٛ٠ ٌُ اٌؼبٟخ إٌفظ اٌخبَ ف١ّ٘رضداد أ
:ٓ١مز١خ ِٓ زم١د١االسزشار
.ٔٗ ِصذس ٌٍطبلخٛ و.1
سط إٌفظ٠ .خ اٌّخزٍفخ٠ٚب١ّ١وٚاٌجزشٚ خ٠ّٚب١ع اٌصٕبػبد اٌىٚٗ ٌفش١ٔٗ ِبدح خبَ أسبسٛ و.2
: خ١ٌٓ ِصبدس اٌطبلخ اٌّخزٍفخ ٌألسجبة اٌزب١ضح ث١ّاٌخبَ ثّىبٔٗ ِز
رّثً ِصبدسٚ ش٠ك اٌزىش٠ب ػٓ طشٙب ػٓ ثؼضٍّٙىٓ فص٠ ذح٠ ِٕزدبد ػذٍٝ ػٞٛسز٠ .1
جبد٠اٌّزٚ اإلسفٍذٚ ذ١٠د اٌزضٛ٠إٔزبج ِٕزدبد ِسبػذٖ وضٚ دٛلٌٛ اسزؼّبي اٟػخ فِٕٛز
. خ٠ٚب١ّ١وٚ اٌصٕبػبد اٌجزشّٟخ فِٙ ادِٛ ٗ رشىً ثؼط ِشزمبرٚ , خ١ٌٚاٌجزش
. ِغ إٌفظ اٌخبَ رسذ سطر األسضٟؼ١د اٌغبص اٌطجٛخٚ .2
.ذح١ ِسبفبد ثؼٌٌٝٗ ٔمٍٗ إٛٙس.3
. ٖش٠رىشٚ ٍٗٔمٚ ٗ أخفبض وٍفخ أٔزبخ.3
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Chapter one: Introduction Petroleum Refining
Petroleum (Crude Oil) النفط الخام
Introduction:
Petroleum is perhaps the most important substance consumed in modern society. It
provides not only raw materials for the ubiquitous plastics and other products but also
fuel for energy, industry, heating, and transportation.
Fig.(1) Crude Oil Uses
Fig.(2) Different Types of Sources Energy
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Chapter one: Introduction Petroleum Refining
Fig. (3) Global Crude Oil consumption
Origin of Petroleum (Crude Oil) َأصً إٌفظ اٌخب
The word petroleum, derived from the Latin petra and oleum, literally means rock
oil and refers to hydrocarbons that occur widely in the sedimentary rocks in the form
of gases, liquids, semisolids, or solids. From a chemical standpoint, petroleum is an
extremely complex mixture of hydrocarbon compounds, usually with minor amounts
of nitrogen-, oxygen-, and sulfur-containing compounds, as well as trace amounts of
metal-containing compounds
There are two theories on the origin of carbon fuels: the abiogenic theory and the
biogenic theory (Kenney et al., 2001, 2002). The two theories have been intensely
debated since the 1860s, shortly after the discovery of widespread occurrence of
petroleum.
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Chapter one: Introduction Petroleum Refining
Abiogenic Origin النظرٌة الغٌر عضوٌة
There have been several attempts at formulating theories that describe the detail of the
origin of petroleum, of which the early postulates started with inorganic substances as
source material. For example, in 1866, Berthelot considered acetylene the basic
material and crude oil constituents were produced from acetylene. Initially, inorganic
carbides were formed by the action of alkali metals on carbonates after which
acetylene was produced by the reaction of the carbides with water.
ًٍخ ِث١ذاد اٌثم١ ِٓ اٌىشثٚاد اٌّشؼخ أٌّٛثبْ ثفؼً ا١ٌّ اٌٝشخغ إ٠ يٚؼزمذ أْ أصً اٌجزش٠
خ١ٌش اٌسشاسح اٌؼب١ رٕزح ثزأثٟ اٌز، ٗ١ٕ١ٍاد اسزِٛ ْٛ رىٚ ض ِغ اٌّبء١ إٌّغٚذ ا٠ذ اٌسذ١وبسث
.اصٛ اٌخٚ ت١ٕخ اٌزشو٠ٔبد ِزجبٛوشثٚذس١٘ ِٓ ظ١ٍ خٚح أ٠ِض
Biogenic Origin )خ٠ٛخ (اٌؼض١بئ١خ األز٠إٌظش
Petroleum is a naturally occurring hydrocarbon mixture but hydrocarbons that are
synthesized by living organisms usually account for less than 20% of the petroleum
(Hunt, 1996). The remainder of the hydrocarbons in petroleum is produced by a
variety of processes that converts other organic material to hydrocarbons as part of the
maturation processes generally referred to as diagenesis, catagenesis, and
metagenesis. These three processes are a combination of bacteriological action and
low-temperature reactions that convert the source material into petroleum. During
these processes, migration of the liquid products from the source sediment to the
reservoir rock may also occur.
Most geologists view crude oil and natural gas as the products of compression and
heating of ancient vegetation over geologic timescales. According to this theory, it is
formed from the decayed remains of prehistoric marine animals and terrestrial plants.
Over many centuries this organic matter, mixed with mud, was buried under thick
sedimentary layers of material. The resulting high levels of heat and pressure cause
the remains to metamorphose, first into a waxy material known as kerogen and then
into liquid and gaseous hydrocarbons in a process known as catagenesis. These then
migrate through adjacent rock layers until they become trapped underground in
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Chapter one: Introduction Petroleum Refining
porous rocks called reservoirs, forming an oilfield, from which the liquid can be
extracted by drilling and pumping.
ًخ ثفؼ١ إٌجبرٚ خ١ٔاٛ١اد اٌسٌّٛدخ رسًٍ ا١ْ ٔزٛي لذ رىٚؼزمذ اٌجؼط أْ اٌجزش٠ اٌجؼط األخش
ْٛخ رى٠شٙخ اٌّد٠أبد اٌجشٛ١خ ِٓ اٌس١ٕ٘ب اٌذ٠ ٌٍجمبٟش االئزالف١ اٌزمطٚ خ١ائٛ٘ب اٌال٠اٌجىزش
.اصٛ اٌخٚ ت١ٕخ اٌزشو٠ٔبد ِزجبٛوشثٚذس١٘ ِٓ ْٛ رزىٟائً اٌزٛظ ِٓ اٌس١ٍخ
Fig.(4) Biogenic Origin of crude oil
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Chapter one: Introduction Petroleum Refining
Fig. (5)Method of exploration and production of crude oil
Petroleum Refining (Petroleum Purification):
Petroleum refining plays an important role in our lives. Most transportation
vehicles are powered by refined products such as gasoline, diesel, aviation turbine
kerosene (ATK) and fuel oil. The recent price rise of crude oil from $50 to $150 per
bbl over the last 2 years has affected the refining industry in three ways: First is an
increased search for fuel products from non-fossil sources such as biodiesel and
alcohols from vegetable sources, Second is the development of better methods to
process tar sand, coal gasification and synthesis of fuels by Fischer–Tropsch (FT)
technology and Third is the initiation of long-term plans to look for renewable energy
sources. However, crude oil prices are still a cheap source for transportation
fuels and petrochemicals.
petroleum refining is the separation of petroleum into fractions and the
subsequent treating of these fractions to yield marketable products. In fact, a refinery
is essentially a group of manufacturing plants that vary in number with the variety of
products produced (Figure7). Refinery processes must be selected and products
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Chapter one: Introduction Petroleum Refining
manufactured to give a balanced operation in which petroleum is converted into a
variety of products in amounts that are in accord with the demand for each. For
example, the manufacture of products from the lower-boiling portion of petroleum
automatically produces a certain amount of higher-boiling components. If the latter
cannot be sold as, say, heavy fuel oil, these products will accumulate until refinery
storage facilities are full. To prevent the occurrence of such a situation, the refinery
must be flexible and be able to change operations as needed. This usually means more
processes: thermal processes to change an excess of heavy fuel oil into more gasoline
with coke as the residual product, or a vacuum distillation process to separate the
heavy oil into lubricating oil stocks and asphalt.
Fig.(6)Simplified form illustrates the process of converting crude oil into
products
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Chapter one: Introduction Petroleum Refining
Fig.(7) the process of converting crude oil into petroleum
Products in details
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Chapter one: Introduction Petroleum Refining
History of World Refineries:
-Old human was used of oil to prehistoric times, where used by the Sumerians and
Babylonians in Mesopotamia and raised the oil has been found in other places in the
world and in the eastern Mediterranean Sea and the Dead sea was known asphalt lake,
which dates back to the term asphalt.
-The discovery of oil due to the presence of petroleum reservoirs close to the surface
of the earth, which was liberated them vapors and erupt into flames, which was called
(fire timeless) and serve them were some of the doctrines of Zoroastrianism.
-In 1859, Drake was drilled in the state of Pennsylvania in the United States the first
well in search of oil at a depth of 21.11 meters, and petrol is found in general at
different depths ranging between 20-20 thousand meters.
-The first refinery was built in 1860 in the United States a cost of $ 15000.
- historically the first distillation of Petroleum took place in Russia in 1735 AD.
ٚ ْٛ٠ِشٛث اسزؼٍّٗ اٌس١خ ز٠س ِب لجً اٌزبسٛ ػصٌٝي إٚشخغ اسزخذاَ اإلٔسبْ ٌٍجزش٠
ٟ فٚ ٌُ اٌؼبٟ فٜ أِبوٓ أخشٟي فٚخذ أثبس اٌجزشٚ لذٚ ٓ٠ اٌشافذٞادٚ ْٟ فٛ١ٍاٌجبث
دٛؼ٠ ٞ اٌزٚ شح اإلسفٍذ١ؼشف ثجس٠ ْ وبٚ ذ١ٌّسظ وبٌجسش اٛط اٌّز١ششق اٌجسش األث
. ب١ٌب ِصطٍر اإلسفٍذ اٌشبئغ زبٙ١ٌإ
ٟاٌزٚ جٗ ِٓ سطر األسض٠خ لش١ٌٚدػبد ثزشٛد ِسزٛخٚ ٌٝي إٚشخغ اوزشبف اٌجزش٠
) ٗ١ٌشاْ االص١ٌٕ ( اٝ وبٔذ رذػٟشاْ اٌز١ٌٕب اٙ١ رٕذٌغ فٚ ثخشح٢ب إِٙ وبٔذ رزسشس
. خ١وبٔذ رؼجذ٘ب ثؼط اٌّزا٘ت اٌضسادشزٚ
بد اٌّزسذح٠الٌٛ اٟب ف١ٔخ ثٕسٍفب٠الٚ ٟ ) فDrake (ه٠ َ زفش دس1581 َ ػبٟ ف
ٖسٛي– ثصٚخذ اٌجزشٛ٠ٚ ، ِزش21.11 ػّكٍٝي ػٚي ثئش ثسثب ػٓ اٌجزشٚخ أ١ى٠األِش
. أٌف ِزش22 - 22 ٓ١ذ ثٚ أػّبق ِخزٍفخ رزشاٍٝػبِٗ ػ
18222$ ٗخ ثىٍف١ى٠بد اٌّزسذح األِش٠الٌٛ اٟ َ ف1582 َ رُ ثٕبءٖ ػبٝي ِصفٚ أ
.َ 1338 َب ػب١سٚ سٟي خشد فٚش ٌٍجزش١ٗ رمط١ٍّي ػٚب أ١خ٠ اٌّسدً ربس
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Chapter one: Introduction Petroleum Refining
التقطٌر المستمر ()Batch Distillation
-المصافً األولٌة كانت تستخدم نظام التقطٌر ( على شكل وجبات).
-فً بداٌات عام 0681م تم استخدام نظام التقطٌر المستمر ،و قد استمر تطوٌر طرق
اإلنتاج المستمر وقد سجل بصوره واسعة استخدام وحدات اإلنتاج المستمر عام 0101م.
-حالٌا و حدات اإلنتاج المستخدمة جمٌعها تعمل بطرٌقه التقطٌر المستمر .
التكسٌر الحراري ( ) Thermal Cracking
ٌ -قصد بالتكسٌر الحراري فً مجال تكنولوجٌه البترول استخدام الحرارة وحدها أو مع وجود
عوامل مساعده معٌنه لتغٌر مكونات البترول و آسر األواصر للحصول على مكونات جدٌدة
لهل أوزان جزٌئٌه أوطأ من الخامات.
-أول تسجٌل لعملٌه التكسٌر الحراري عام 0680م
التقطٌر التجزٌئً () Fractionation
ٌ -قصد بها عملٌه فصل المزٌج السائل إلى عدد من النواتج لها مدى غلٌان ضٌق.
-فً المصافً األولٌة كانت عملٌه الفصل تتم بعدد من عملٌات التقطٌر المتعاقبة .
-الحقا حدث تطوٌر فً طرٌقه اإلنتاج حٌث استخدمت أبراج تقطٌر تعمل وفٌها ٌتم استخدام
عملٌه التكثٌف الجزئً ( ) Partial Condensationباستخدام المكثفات لتكثٌف خلٌط
البخار بدرجات حرارة مختلفة.
العملٌات الكٌمٌاوٌة ( )Chemical Processing
-عام 0111م تم تطوٌر طرٌقه الهدرجة وهً عبارة عن عملٌه تكسٌر حراري فً ضغوط
عالٌة بوجود الهٌدروجٌن .
-عام 0121هودري استخدم العامل المساعد فً هذه الطرٌقة ( سٌلٌكات األلمنٌوم .) 1
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Chapter one: Introduction Petroleum Refining
Petroleum Refineries in Iraq (General View)
Current Companies of Refining:
1. North Refineries company: it represent largest company for petroleum refining
in Iraq:
A. Establishing Date: 1976
B. Current Capacity:402000 Bbl./day
C. No. of Refineries and other units:
Large Refineries: (Baggy Refinery)
North Refinery with capacity:170000 Bbl./day
Salahaldeen1 Refinery with capacity: 70000 Bbl./day
Salahaldeen2 Refinery with capacity:170000 Bbl./day
Oils Refinery with capacity:125000 ton/year for different types of
oils.
Factory production and mobilization of metal drums
1100Drum/h(200 lit.)
Factory production and mobilization of plastic cans
1250Can/h (5 lit.), 1000 Can/h(1 lit.)
Small Refineries
Kirkuk Refinery with capacity: 30000 Bbl./day
Asseeniay Refinery with capacity: 20000 Bbl./day
Alkisk Refinery with capacity: 10000 Bbl./day
Hadeethah Refinery with capacity:16000 Bbl./day
Algiarah Refinery with capacity: 16000 Bbl./day
D. The company produces various types of products such as unleaded gasoline,
jet fuel, kerosene, gas oil and black oil for export and various types of oils,
such as motor oil, gasoline and motor oil for diesel and oils Sewing
Machines and Transformers products, asphalt, sulfur, fuel gas and liquid
gas ... etc..
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Chapter one: Introduction Petroleum Refining
2. Midland Refineries Company: it represent oldest company for petroleum
refining in Iraq:
E. Establishing Date: 1953
F. Current Capacity:210000 Bbl./day
G. No. of Refineries and other units:
Large Refineries:
Adora Refinery with capacity:130000 Bbl./day
Adora Oils Refineries with capacity:121000 ton/year for different
types of oils.
Other units for nitrogen production (liquid and gas)
Small Refineries:
Asimawa Refinery with capacity: 30000 Bbl./day
Adiwania Refinery with capacity:20000 Bbl./day
Annajaf Refinery with capacity: 30000 Bbl./day
H. The company produces various types of products such as gasoline, jet fuel,
kerosene, gas oil and black oil for export and various types of oils, such as
motor oil, gasoline and motor oil for diesel and oils Machines and
Transformers products, asphalt, fuel gas and liquid gas ... etc..
3. South Refineries Company: it represent smallest company for petroleum
refining in Iraq:
I. Establishing Date: 1998
J. Current Capacity:100000 Bbl./day
K. No. of Refineries and other units:
Large Refineries:
Bassra Refinery with capacity: 70000 Bbl./day
Oils Refinery with capacity:125000 ton/year for different types of oils.
Small Refineries:
Thi Qar Refinery with capacity: 10000 Bbl./day
Misan Refinery with capacity:10000 Bbl./day
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Chapter one: Introduction Petroleum Refining
L. The company produces various types of products such as unleaded gasoline,
jet fuel, kerosene, gas oil and black oil for export and various types of oils,
such as motor oil, gasoline and motor oil for diesel.
Future Refineries:
Fig.(8) Future refineries in Iraq
Organization of Petroleum Exporting Countries
"OPEC" )ثهٚي (أٚي اٌّصذسح ٌٍجزشِٕٚظّخ اٌذ
An organization consisting of the world's major oil-exporting nations. The
Organization of Petroleum Exporting Countries (OPEC) was founded in 1960 to
coordinate the petroleum policies of its members, and to provide member states with
technical and economic aid. OPEC is a cartel that aims to manage the supply of oil in
an effort to set the price of oil on the world market, in order to avoid fluctuations that
might affect the economies of both producing and purchasing countries.
OPEC membership is open to any country that is a substantial exporter of oil and that
shares the ideals of the organization. As of 2011, OPEC had 12 member countries,
including founder members Iran, Iraq, Kuwait and Venezuela.
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Chapter one: Introduction Petroleum Refining
بسبد١ك اٌس١ ٌزٕس1182 َ اٌؼشاق ػبٟثه) فٚي (أٚي اٌّصذسح ٌٍجزشٚرأسسذ ِٕظّخ اٌذ
إٌّظّخٛ٘ ثهٚ أ.خ٠الزصبدٚ خ١ٕي األػضبء ثّسبػذاد فٚذ اٌذ٠ٚرضٚ ،بٙخ ألػضبئ١ٌٚاٌجزش
،خ١ٌّق اٌؼبٛ اٌسٌٟخ ٌضجظ أسؼبس إٌفظ فٚ ِسبٟض ِٓ إٌفظ فٚ إداسح اٌّؼشٌٝذف إٙ رٟاٌز
.خ١اٌششائٚ ي إٌّزدخٚ الزصبداد وً ِٓ اٌذٍٝ لذ رؤثش ػٟرٌه ٌزدٕت اٌزمٍجبد اٌزٚ
.ب ٌٍّٕظّخ١ٍ رشزشن ثبٌّثً اٌؼٟاٌزٚ ش ٌٍٕفظ١ ِصذس وجٟ٘ ٌخٚ دٞزخ أِبَ أٛثه ِفزٚخ أ٠ٛػض
اٌؼشاقٚ ْشا٠ُ أػضبء ِؤسس إٙ١ ثّٓ ف،اٌٛخ ػضٚ د12 ثهٚ وبْ أ،2211 َاػزجبسا ِٓ ػب
.ال٠ٚفٕضٚ ذ٠ٛاٌىٚ
Organization of Arab Petroleum Exporting Countries
"OAPEC"
)اثهٚي(اٚخ اٌّصذسح ٌٍجزش١ي اٌؼشثِٕٚظّخ اٌذ
OAPEC was established in 1968 by Kuwait, Libya and Saudi Arabia. Its other
members include: Algeria, Bahrain, Egypt, Iraq, Qatar, Syria, Tunisia and the United
Arab Emirates. Although they have several members in common, OAPEC is a
separate and distinct entity from OPEC (the Organization of the Petroleum Exporting
Countries), the 12-nation cartel that plays a pivotal part in determining global
petroleum prices.
An inter-governmental organization based in Kuwait that seeks to foster cooperation
among the 11 Arab oil-exporting nations that are its members, and develop their
petroleum industry.
ب١ج١ٌٚ ذ٠ٛ ِٓ لجً اٌى1185 َ ػبٟاثه) فٚي(اٚخ اٌّصذسح ٌٍجزش١ي اٌؼشثٚرأسسذ ِٕظّخ اٌذ
ٔسٛ ر،ب٠سٛ س، لطش، اٌؼشاق، ِصش،ٓ٠ اٌجسش، اٌدضائش:ٓ٠رشًّ أػضبء آخشٚ .خ٠دٛاٌسؼٚ
اثهٚ أ،اسُ اٌّشزشوخُٛ ػذح أػضبء ِٓ اٌمٙ٠ اٌشغُ ِٓ أْ ٌذٍٝ ػ.خ اٌّزسذح١اإلِبساد اٌؼشثٚ
ٟاٌزٚ ٌخٚ د12 إٌّظّخٚ ،)ي اٌّصذسح ٌٍٕفظٚثه (ِٕظّخ اٌذٚض ػٓ أ١ِّزٚ ًبْ ِسزم١ وٛ٘
.َق إٌفظ اٌخبٛ سٟب ف٠سٛسا ِسٚرٍؼت د
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Chapter one: Introduction Petroleum Refining
World's Largest Refineries
Name of Refinery Location Barrels per Day
Jamnagar Refinery Jamnagar, India 1,240,000
SK Energy Ulsan, South Korea 1,120,000
Paraguana Refinery Paraguana, Falcon,
940,000
(PDVSA)Complex Venezuela
GS Caltex Yeosu Refinery (GS
Yeos, South Korea 730,000
Caltex)
S-Oil Onsan Refinery (S-Oil) Ulsan, South Korea 670,000
ExxonMobil Singapore 605,000
(Motiva Port Arthur Refinery Port Arthur ,Texas,
600,250
Enterprises) USA
Baytown
Baytown, TX, USA 560,500
(ExxonMobil)Refinery
(Saudi Ras Tanura Refinery
Saudi Arabia 550,000
Aramco)
(Marathon Garyville Refinery
Garyville, LA, USA 522,000
Petroleum)
Baton Rouge Baton Rouge, LA,
502,500
(ExxonMobil)Refinery USA
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