CPI M2U1 PETROLEUM PETROCHEMICALS

petra, oleum

The word petroleum comes from the Latin ____, meaning “rock” and _____, meaning “oil.”

sweet

referring to oil as "_____" which means it contains relatively little sulfur

sour

“____," which means it contains substantial amounts of sulfur.

Petroleum

can be described as thick, flammable, yellow-to-black mixture of gaseous, liquid, and solid hydrocarbons that occurs naturally beneath the earth's surface

1859, Colonel Edwin Drake, Titusville Pennsylvania

In ____ - When _______ _____ _____ drilled the first successful oil well in Titusville, Pennsylvania

zooplankton, algae

A fossil fuel, petroleum is formed when large quantities of dead organisms, usually ___________ and _____,

Natural gas and crude oil

The two most common forms [of petroleum] are?

Secondary raw materials/ intermediates

are obtained from natural gas and crude oils through different processing schemes.

Coal, oil shale, tar sand

are complex carbonaceous raw materials and possible future energy and chemical sources. However, they must undergo lengthy and extensive processing before they yield fuels and chemicals similar to those produced from crude oils

Natural gas

A naturally occurring mixture of light hydrocarbons (alkanes) accompanied by some nonhydrocarbon compounds

80% methane (CH4), 7% ethane (C2H6), 6% propane (C3H8), 4% butane and isobutane (C4H10), and 3% pentanes (C5H12).

Typical composition of natl gas

Propane and butane

are usually liquefied under pressure and sold as liquefied petroleum gases (LPG).

Methane and ethane

Mixture of commercial natl gas

Natural gas

is found in deep underground rock formations or associated with other hydrocarbon reservoirs in coal beds and as methane clathrates

Petroleum

fossil fuel found in close proximity to and with natural gas.

Biogenic and thermogenic

Most natural gas was created over time by two mechanisms:

Biogenic gas

is created by methanogenic organisms in marshes, bogs, landfills, and shallow sediments.

Thermogenic gas

Deeper in the earth, at greater temperature and pressure, ___________ ___ is created from buried organic material.

Crude oil

often called "black gold" crude oil has ranging viscosity and can vary in color from black and yellow depending on its hydrocarbon composition.

Crude oil

It is typically obtained through drilling

Diagenesis

organic material combined with mud and was then heated to high temperatures from the pressure created by heavy layers of sediment.

Catagenesis

changes the chemical composition first into a waxy compound called kerogen and then, with increased heat, into a liquid through a process called

Alkanes, cycloalkanes, aromatics, asphaltenes

Hydrocardons found in petroleum crude oil

Ancient biomass

petroleum is derived from

Separation, Conversion, Purification

Petroleum Refining

Separation

The oil is separated into its constituents by distillation, and some of these components (such as the refinery gas) are further separated with chemical reactions and by using solvents.

Conversion

The various hydrocarbons are then chemically altered to make them more suitable for their intended purpose.

Purification

The hydrogen sulphide gas which was extracted from the refinery gas in separation process is converted to sulphur, which is sold in liquid form to fertilizer manufacturers.

Specific Processes are classified into:

Physical Separation Processes

Chemical Catalytic Conversion Processes

Thermal Chemical Conversion Processes

Physical Separation Processes:

Crude Oil Desalting

Crude Distillation

Vacuum Distillation

Solvent Deasphalting

Solvent Extraction

Solvent Dewaxing

Crude Oil Desalting

The crude oil contains salt (these chlorides except for NaCl). It is removed in the form of dissolved salt in tiny droplets of water which forms a water-in oil emulsion.

Crude distillation

This involves the removal of undesirable components like sulphur, nitrogen, and metal compounds, and limiting the aromatic contents.

Crude distillation unit

Vacuum distillation

is the reduced temperature requirement at lower pressures. It increases the relative volatility of the key components.

10- 50mmHg, 350C

Operating pressure and temperaturemof Vacuum distillation

Solvent Deasphalting

This is the only physical process where carbon is rejected from heavy petroleum fraction such as vacuum residue.

Propane

in liquid form is usually used to dissolve the whole oil, leaving asphaltene to precipitate.

Bright Stock

The deasphalted oil (DAO) has low sulphur and metal contents since these are removed with asphaltene. This oil is also called “______ _____” and is used as feedstock for lube oil plant.

Solvent extraction

In this process, lube oil stock is treated by a solvent, such as phenol and furfural, which can dissolve the aromatic components in one phase (extract) and the rest of the oil in another phase (raffinate).

Solvent Dewaxing

The raffinate is dissolved in a solvent (methyl ethyl ketone, MEK) and the solution is gradually chilled, during which high molecular weight paraffin (wax) is crystallized, and the remaining solution is filtered.

Lube oil

The extracted and dewaxed resulting oil is called

Catalytic Reforming

In this process a special catalyst is used to restructure naphtha fraction (C6-C10) into aromatics and isoparaffins.

platinum metal supported on silica or silica base alumina

Catalyst for catalytic reforming

Hydrotreating

This is one of the major processes for the cleaning of petroleum fractions from impurities such as sulphur, nitrogen, oxy-compounds, chloro-compounds, aromatics, waxes and metals using hydrogen.

cobalt and molybdenum oxides on alumina matrix,

Catalysts for hydrotreating

Catalytic Hydrocracking

For higher molecular weight fractions such as atmospheric residues (AR) and vacuum gas oils (VGOs), cracking in the presence of hydrogen is required to get light products.

Dual function catalyst for cat. hydrocracking

zeolite catalyst for the cracking function and rare earth metals supported on alumina for the hydrogenation functio

Kerosene, jet fuel, diesel, fuel oil

The main products of cat. hydrocracking

Catalytic Cracking or Fluid Catalytic Cracking (FCC)

is the main player for the production of gasoline.

Zeolite base

Catalyst for FCC

Vacuum Gas Oil (VGO) and gasoline

Main feed and product of FCC

Alkylation

the process in which isobutene reacts with olefins such as butylene to produce a gasoline range alkylate.

sulphuric acid or hydrofluoric acid.

Catalyst for alkylation

Isomerization

the process in which low octane number hydrocarbons (C4, C5, C6) are transformed to a branched product with the same carbon number. This process produces high octane number products.

Pt-zeolite base

Catalyst for isomerization

Chemical Conversion Process

Catalytic Reforming

Hydrotreating

Catalytic Hydrocracking

Catalytic Cracking

Alkylation

Isomerization

Thernal Chemical Conversion Process

Delayed Coking

Flexicoking

Visbreaking

Delayed Coking

This process is based on the thermal cracking vacuum residue by carbon rejection forming coke and lighter products such as gases, gasoline and gas oils.

The vacuum residue is heated in a furnace and flashed into large drums where coke is deposited on the walls of these drums, and the rest of the products are separated by distillation.

Flexicoking

In this thermal process, most of the coke is gasified into fuel gas using steam and air.

Gases. Gasoline and gas oils with very little coke

Flexicoking products

Visbreaking

This is a mild thermal cracking process used to break the highly viscosity and pour points of vacuum residue to the level which can be used in further downstream processes.

Coil visbreaking, soaker visbreaker

In this case, the residue is either broken in the furnace coil (____ ___________) or soaked in a reactor for a few minutes (_______ __________).

Gases, gasoline, gas oil, unconverted residue

Visbreaking Products

Ammonia

is a source of nitrogen in agricultural fertilizers and petroleum is used in its production.

Plastics

which include ethylene and propylene come from olefins (Alkenes). Alkenes are derivatives of petroleum.

Mineral oil and petrolatum

are used in many creams and topical pharmaceuticals.

Rubber

obtained from plants which is a natural elastomer and is used in making tires.

Dyes, synthetic detergents, and fabrics

contain petroleum distillates such as benzene, toluene, and xylene.

Lubricants

greases and adds viscosity are derivatives of petroleum.

Paraffin wax

a solid derivable from petroleum that consists of a mixture of hydrocarbon molecules.

Tar

used in preserving wooden vessels against rot, it is produced from petroleum.

Asphalt/bitumen

has primary use in road construction is a derivative of petroleum.

Transportation

Industrial Power

Heating and Lighting

Lubricants

Petrochemical Industry

Use of by-products

Six Main Uses of Petroleum

Air pollution hazards

Water pollution hazards

Soil pollution hazards

Oil spills

Acid rain

Environmental Impacts

Enviro