Handbook of Petroleum Processing

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Format: Hardcover
Pub. Date: 2006-04-01
Publisher(s): Springer Verlag
List Price: $809.00

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Summary

This reference work targets researchers who have chosen a career in this complex but essential industry as well as people who are new in the industry and are looking for easy references to the work in which they are involved. This book is an essential addition to the libraries of universities which contain a chemical engineering faculty as well as to the libraries of engineering construction companies, and oil refineries.This Handbook describes and discusses the features that make up the petroleum refining industry. It begins with a description of the crude oils and their nature. It continues with the saleable products from the refining processes, with a review of the modern day environmental impact.There is a complete overview of the processes that make up the refinery with a brief history of the processes. It also describes design technique, operation, and, in the case of catalytic units, the chemistry of the reaction routes. These discussions are supported by calculation procedures and examples, sufficient to enable good input to modern computer simulation packages.The Handbook also covers off-sites and utilities, as well as environmental and safety aspects relevant to the industry.The chapter on refinery planning covers both operational planning and the decision making procedures for new or revamped processes.Finally, to complete Part 1 of the work, the major items of equipment used in the industry are reviewed. This chapter gives a detail of the equipment with examples of the process specifications for these items.Part 2 is in part a glossary and in part a dictionary of the terms and expressions used in Petroleum Refining. This part of the book also includes an appendix section with an item on much used data such as converging factors, selected crude oil assays and an example of optimising a refinery configuration using linear programming.

Author Biography

The editor S.Jones is a retired chemical engineer having spent 10 years in BP's Refinery, 4 years in BP Research and Development, 2 years in Esso's Refinery Development Dept, 18 years in Process Engineering with Fluor Corporation (Final position general manager-operations), 8 years as private engineering consultant in SA. Retired in 1992.The assistant editor P.R.Pujado was the Assistant Lecturer at the University of Manchester, Institute of Science and Technology, 1971-1972; Development Engineer (SA Cros), 1972-1975; Process Coordinator-Aromatics (UOP LLC), 1975-1980; Manager, Marketing Services-Petrochemicals (UOP LLC), 1980-1990; R&D Fellow-Olefins production and processing (UOP LLC), 1990-present.

Table of Contents

An introduction to crude oil and its processing
1(46)
The composition and characteristics of crude oil
1(5)
The crude oil assay
6(3)
Other basic definitions and correlations
9(9)
Predicting product qualities
18(9)
Basic processes
27(1)
The processes common to most energy refineries
28(9)
Processes not so common to energy refineries
37(3)
The non-energy refineries
40(5)
References
45(2)
Petroleum products and a refinery configuration
47(64)
Introduction
47(1)
Petroleum products
48(15)
A discussion on the motive fuels of gasoline and diesel
63(13)
A refinery process configuration development
76(33)
Conclusion
109(2)
The atmospheric and vacuum crude distillation units
111(78)
The atmospheric crude distillation unit
112(57)
Process description
112(3)
The development of the material balance for the atmospheric crude distillation unit
115(4)
The design characteristics of an atmospheric crude distillation fractionating tower
119(3)
The fractionator overhead system
122(6)
The side streams and intermediate reflux sections
128(9)
Calculating the main tower dimensions
137(5)
The crude feed preheat exchanger system design
142(4)
An example in the design of an atmospheric crude oil distillation tower
146(23)
The vacuum crude distillation unit
169(14)
Process description
169(2)
The vacuum crude distillation unit's flash zone
171(1)
The tower overhead ejector system
172(4)
Calculating flash zone conditions in a vacuum unit
176(1)
Draw-off temperatures
177(1)
Determine pumparound and internal flows for vacuum towers
178(1)
Calculate tower loading in the packed section of vacuum towers
179(4)
Appendix
183(6)
The distillation of the `Light Ends' from crude oil
189(28)
A process description of a `light ends' unit
189(2)
Developing the material balance for light end units
191(5)
Calculating the operating conditions in light end towers
196(3)
Calculating the number of trays in light end towers
199(4)
Condenser and reboiler duties
203(2)
Tower loading and sizing
205(9)
Checks for light end tower operation and performance
214(3)
Catalytic reforming
217(22)
Feedstocks
219(8)
Catalysts
227(5)
Process flow schemes
232(2)
Advantages of CCR Platforming
234(2)
Catalysts and suppliers
236(1)
References
237(2)
Fluid catalytic cracking (FCC)
239(48)
Fluidization
244(3)
Process control
247(1)
Reaction chemistry and mechanisms
248(2)
Gas oil cracking technology features
250(21)
Cracking for light olefins and aromatics
271(7)
Nomenclature
278(1)
References
279(3)
Appendix 6.1. Commercially available FCC catalysts and additives
282(5)
Distillate hydrocracking
287(34)
Brief history
287(1)
Flow schemes
288(4)
Chemistry
292(6)
Catalysts
298(2)
Catalyst manufacturing
300(5)
Catalyst loading and activation
305(1)
Catalyst deactivation and regeneration
306(2)
Design and operation of hydrocracking reactors
308(4)
Hydrocracking process variables
312(7)
Hydrocracker licensors and catalyst manufacturers
319(2)
Hydrotreating
321(34)
Brief history
322(1)
Flow schemes
323(4)
Chemistry
327(7)
Catalysts
334(3)
Catalyst manufacturing
337(3)
Catalyst loading and activation
340(2)
Catalyst deactivation and regeneration
342(2)
Design and operation of hydrotreating reactors
344(3)
Hydrotreating process variables
347(6)
Hydrotreaters licensors and catalyst manufacturers
353(2)
Gasoline components
355(128)
Motor fuel alkylation
355(17)
Introduction
355(1)
History
355(1)
Process chemistry
356(4)
HF alkylation process flow description
360(4)
Sulfuric acid alkylation
364(2)
Stratco effluent refrigerated alkylation process
366(4)
Alkylate properties
370(1)
Recent developments
370(1)
Conclusions
371(1)
References
371(1)
Catalytic olefin condensation
372(111)
Introduction
372(1)
History
373(1)
Catalytic condensation process
373(3)
Catalytic condensation process for gasoline production
376(3)
Hydrogenated versus nonhydrogenated polymer gasolines from the catalytic condensation process
379(4)
Selective and nonselective gasoline production with the catalytic condensation process
383(2)
Catalytic condensation process as a source of diesel fuels
385(1)
Petrochemical operations
386(3)
Dimersol process
389(94)
The non-energy refineries
483(38)
Introduction
483(1)
The lube oil refinery
483(11)
Lube oil properties
486(1)
A description of major processes in lube oil refining
487(7)
Asphalt production
494(14)
The petrochemical refinery
508(4)
The production of aromatics
508(3)
Process discussion
511(1)
Appendix 12.1 Sizing a bitumen oxidizer
512(9)
Support systems common to most refineries
521(90)
Control systems
521(12)
Definitions
522(1)
Reflux drums
523(5)
The control valve
528(5)
Offsite systems
533(54)
Storage facilities
533(1)
Atmospheric storage
534(2)
Pressure storage
536(1)
Heated storage tanks
537(1)
Calculating heat loss and heater size for a tank
538(4)
Product blending facilities
542(3)
Road and rail loading facilities
545(4)
Jetty and dock facilities
549(1)
Jetty size, access, and location
549(3)
Waste disposal facilities
552(7)
The flare
559(6)
Effluent water treating facilities
565(2)
Other treating processes
567(1)
Utility Systems
568(1)
Brief descriptions of typical utility systems
569(1)
Steam and condensate systems
569(1)
Fuel systems
570(5)
Water systems
575(6)
The ``hot lime'' process
581(1)
The ion exchange processes
581(4)
Compressed air system
585(2)
Safety systems
587(15)
Determination of risk
587(1)
Definitions
588(3)
Types of pressure relief valves
591(2)
Capacity
593(2)
Sizing of required orifice areas
595(5)
Sizing for flashing liquids
600(1)
Sizing for gas or vapor on low-pressure subsonic flow
600(2)
Appendix 13.1 Example calculation for sizing a tank heater
602(4)
Appendix 13.2 Example calculation for sizing a relief value
606(1)
Appendix 13.3 Control valve sizing
607(4)
Environmental control and engineering in petroleum refining
611(64)
Introduction
611(1)
Aqueous wastes
611(20)
Pollutants in aqueous waste streams
612(4)
Treating refinery aqueous wastes
616(5)
Oxidation of sulfides to thiosulfates
621(2)
Oxidation of mercaptans
623(1)
Oxidation of sulfide to sulfate
624(1)
Oil--water separation
624(1)
The API oil-water separator
625(3)
Storm surge ponds
628(1)
Other refinery water effluent treatment processes
629(1)
Reference
630(1)
Emission to the atmosphere
631(15)
Features of the Clean Air Act
631(3)
The major effects of air pollution and the most common pollutants
634(5)
Monitoring atmospheric emission
639(1)
Reducing and controlling the atmospheric pollution in refinery products
640(3)
Controlling emission pollution from the refining processes
643(3)
Noise pollution
646(11)
Noise problems and typical in-plant/community noise standards
646(1)
Fundamentals of acoustics and noise control
647(5)
Coping with noise in the design phase
652(1)
A typical community/in-plant noise program
653(4)
Appendix 14.1 Partial pressures of H2S and NH3 over aqueous solutions of H2S and NH3
657(10)
Appendix 14.2 Example of the design of a sour water stripper with no reflux
667(5)
Appendix 14.3 Example design of an API separator
672(3)
Refinery safety measures and handling of hazardous materials
675(30)
Introduction
675(1)
Handling of hazardous materials
675(21)
Anhydrous hydrofluoric acid
675(6)
The amines used in gas treating
681(2)
Caustic soda
683(4)
Furfural
687(3)
Hydrogen sulfide, H2S
690(3)
Methyl ethyl ketone, MEK
693(3)
Fire prevention and fire fighting
696(9)
The design specification
696(1)
Fire prevention with respect to equipment design and operation
697(4)
The fire main
701(1)
Fire foam and foam systems
701(2)
Class B fire foams
703(1)
Class A fire foams
704(1)
Quality control of products in petroleum refining
705(34)
Introduction
705(1)
Specifications for some common finished products
706(9)
The LPG products
706(1)
The gasolines
706(2)
The kerosenes
708(1)
Aviation turbine gasoline (ATG) and jet fuels
708(2)
The gas oils
710(2)
The fuel oil products
712(1)
The lube oils
713(1)
The asphalts
713(1)
Petroleum coke
714(1)
Sulfur
715(1)
The description of some of the more common tests
715(24)
Specific gravity (D1298)
715(1)
ASTM distillations (D86, D156)
716(2)
Flash point test method (D93)
718(1)
Pour point and cloud point (D97)
718(3)
Kinematic viscosity (D446)
721(2)
Reid vapor pressure (D323)
723(1)
Weathering test for the volatility of LPG (D1837)
724(2)
Smoke point of kerosenes and aviation turbine fuels (D1322)
726(5)
Conradson carbon residue of petroleum products (D189)
731(2)
Bromine number of petroleum distillates (D1159)
733(1)
Sulfur content by lamp method (D1266)
734(2)
Octane number research and motor
736(1)
Conclusion
737(2)
Economics---Refinery planning, economics, and handing new projects
739(112)
Refinery operation planning
739(1)
Running plans
740(3)
Developing the running plan
743(2)
Background
745(1)
Basis for assessing requirements
746(1)
The results
747(1)
The refinery operating program
748(4)
Process evaluation and economic analysis
752(1)
Study approach
752(4)
Building process configurations and the screening study
756(2)
Example calculation
758(4)
Investment costs for the new facilities
762(5)
Preparing more accurate cost data
767(4)
Summary data sheets
771(4)
Capital cost estimates
775(9)
Discounted cash flow and economic analysis
784(9)
Results
793(1)
Using linear programs to optimize process configurations
794(5)
Executing an approved project
799(1)
Developing the duty specification
799(7)
The project team
806(1)
Primary activities of the project team
807(15)
Developing the operating manual and plant commissioning
822(8)
Process guarantees and the guarantee test run
830(6)
Appendices
Refinery plan inadequacies report
836(1)
Crude oil inventory schedule
837(1)
Product inventory and schedule
838(1)
Outline operating schedule
839(1)
Detailed operating program and schedule
840(1)
Typical weekly program
841(1)
Typical factors used in capacity factored estimates
842(1)
Example of a process specification
842(2)
Example of a process guarantee
844(7)
Economic analysis
851(26)
Introduction
851(1)
Analysis at one point in time
852(7)
Cost of production
859(5)
Reporting parameters
864(5)
Appendices
Background for economic calculations
869(4)
Progressions
873(1)
Loan repayments (mortgage formula)
874(1)
Average rate of interest
875(2)
Process equipment in petroleum refining
877(194)
Introduction
877(1)
Vessels
877(47)
Fractionators, trays, and packings
878(30)
Drums and drum design
908(6)
Specifying pressure vessels
914(10)
Pumps
924(30)
Pump selection
928(1)
Selection characteristics
929(1)
Capacity range
929(5)
Evaluating pump performance
934(2)
Specifying a centrifugal pump
936(1)
The mechanical specification
937(1)
The process specification
938(1)
Compiling the pump calculation sheet
938(5)
Centrifugal pump seals
943(3)
Pump drivers and utilities
946(3)
Reacceleration requirement
949(1)
The principle of the turbine driver
950(1)
The performance of the steam turbine
951(3)
Compressors
954(45)
Calculating horsepower of centrifugal compressors
956(7)
Centrifugal compressor surge control, performance curves and seals
963(5)
Specifying a centrifugal compressor
968(7)
Calculating reciprocating compressor horsepower
975(4)
Reciprocating compressor controls and inter-cooling
979(3)
Specifying a reciprocating compressor
982(8)
Compressor drivers, utilities, and ancillary equipment
990(9)
Heat exchangers
999(41)
General design considerations
1002(3)
Choice of tube side versus shell side
1005(1)
Estimating shell and tube surface area and pressure drop
1006(10)
Air coolers and condensers
1016(9)
Condensers
1025(4)
Reboilers
1029(11)
Fired heaters
1040(26)
Codes and standards
1043(2)
Thermal rating
1045(2)
Heater efficiency
1047(4)
Burners
1051(2)
Refractories, stacks, and stack emissions
1053(5)
Specifying a fired heater
1058(8)
Appendices
LMTD correction factors
1066(1)
Heat of combustion of fuel oils
1067(1)
Heat of combustion of fuel gasses
1068(1)
Values for coefficient C
1069(1)
Some common heat transfer coefficients
1070(1)
Standard exchanger tube sheet data
1070(1)
A dictionary of terms and expressions
1071(214)
Appendices
1285(64)
Examples of working flow sheets
1285(5)
General data
1290(18)
Friction loss for viscous liquids
1291(9)
Resistance of valves and fittings
1300(1)
Viscosity versus temperature
1301(1)
Specific gravity versus temperature
1302(1)
Relationship between specific gravity and API degrees
1303(2)
Flow pressure drop for gas streams
1305(2)
Relationship of chords, diameters, and areas
1307(1)
A selection of crude oil assays
1308(22)
Conversion factors
1330(2)
An example of an exercise using linear programming
1332(17)
Linear programming aids decisions on refinery configurations
1333(16)
Alphabetic index 1349

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