CPI LEC (M1 and M2-U1)

Introduction to CPI, Petroleum and Petrochemicals

What is the origin and meaning of the word petroleum?

Derived from Latin petra (rock) and oleum (oil).

Raw materials undergo chemical conversion during their processing into finished products, as well as the physical conversions common to industry in general.

Chemical Process Industries

Interdependent Principles Of Chemical Process Industries

1. Mass and Energy Balances

2. Thermodynamics and Kinetics

3. Unit Operations and Chemical Reactions

4. Instrumentation and control

5. Economics

This involves the burning of a fuel and oxidant to produce heat and/or work. (used in process heating)

Combustion

The process of heating a substance to a high temperature but below the melting or fusing point, causing loss of moisture, reduction or oxidation, and dissociation into simpler substances is known as

Calcination

The thermochemical decomposition of organic material at elevated temperatures without the participation of oxygen. It involves the simultaneous change of chemical composition and physical phase, and is irreversible. (used in the petroleum industry)

Cracking or Pyrolysis

a reaction in which hydrogen is detached from a molecule. The reaction is strongly endothermic, and therefore heat must be supplied to maintain the reaction temperature. (used in the manufacture of synthetic rubber)

Dehydrogenation

a chemical reaction or process which results in the formation of a chemical bond between a halogen atom and another atom. (used in the manufacture of organic chemicals)

Halogenation

a chemical reaction in which water is used to break down a compound; this is achieved by breaking a covalent bond in the compound by inserting a water molecule across the bond (used in the manufacture of organic chemicals)

Hydrolysis

a chemical reaction involving the addition of oxygen, the removal of hydrogen, or the removal of an electron from a substance. (used in the manufacture of organic chemicals)

Oxidation

a chemical reaction in which two or more molecules combine to form larger molecules that contain repeating structural units (used in the manufacture of plastics, elastomers and synthetic rubbers)

Polymerization

the complete transfer of one or more electrons to a molecular entity (also called "electronation"), and, more generally, the reverse of the processes described under oxidation (used in polymer catalyst manufacture)

Reduction

Give examples of physical conversions

Distillation, Filtration, Adsorption, Diffusion, Crystalization

This is a method of separating mixtures based on differences in volatilities of components in a boiling liquid mixture.

Distillation

the mechanical or physical operation which is used for the separation of solids from fluids (liquids or gases) by interposing a medium through which only the fluid can pass.

Filtration

the adhesion of atoms, ions, or molecules from a gas, liquid, or dissolved solid to a surface.

Adsorption

the spread of particles through random motion from regions of higher concentration to regions of lower concentration.

Diffusion

the (natural or artificial) process for the formation of solid crystals from a uniform solution. It is in general the last chemical purification step in the production of ingredients.

Crystallization

basic science on which chemical industries rest

Chemistry

the fraction of the raw material recovered as the main (desired) product

Yield

The goal of the chemical engineer is to have the conversion equal to the ___

yield

the fraction changed to something else (by – products)

Conversion

the study of reaction speeds

Kinetics

a study showing the origin the ultimate disposition of all materials used, is an essential first step in any processing study.

Material Balance

is widely used for providing useful data on all phases of technical reactions

Thermodynamics

• all mass is charged to the process and nothing is withdrawn until the operation is complete

• usually for small-scale processing

• more expensive

• tendency of producing non-uniform products

BATCH

• the input and output streams are flows that move continuously through the equipment

• large-scale processing

• less expensive

• uniformity of products may be maintained

CONTINUOUS

a set of boxes interconnected to one another by arrows to show the flow of steps involved in the conversion of raw materials into finished products.

FLOWCHARTS

• for the purpose of studying the process

• often show only material and energy flows and operating condition

Rough-block diagram (simple)

• for actual plant construction

• show such details as fire lines, instruments and control systems, air lines, drains, etc.

Complex-flow diagram

a specialist in current aspects of chemical process design

Process Engineer

Factors to consider in planning a plant

Pilot plant

Equipment

Corrosion

Materials of Construction

Automatic and instrument

a small-scale unit designed to allow experiments that obtain design data for larger plants and sometimes to produce significant quantities of a new product to permit user evaluation

Pilot plant

- for studying alternative raw materials

- should be constructed with equipment identical in material with that to be used by the commercial plant to ascertain the effects of corrosion

Pilot plant

should not be chosen simply to record process variables; their function is to assure consistent quality, usually by sensing, controlling, recording, and maintaining desired operating conditions.

Instruments

Instrument types

1. Indicating Instruments

2. Recording Instruments

3. Indicating/recording and controlling instruments

show results by mechanical movement of some type of device which is proportional to the quantity being measured (bourdon pressure gages)

Analog instruments

utilize a “transducer” and electronic circuitry to convert this signal to readable numerical figures which are displayed and/or recorded.

Digital devices

a device to convert the quantity being measured into some type of signal (usually electrical or pneumatic)

“transducer”

Engineers are distinguished from scientists by their ___ and ___

consciousness of costs and profits

Yields and conversions of the chemical process form the basis for the ___, which in turn are the foundation for cost determination.

material balances

It is frequently a major cost in chemical plants, but it is often possible to reduce it use by altering processing procedures.

Energy

Skilled operators contribute as much to a plant’s success as excellence in design. The chemical process industries have moved rapidly into labor – saving techniques

Labor

An experienced chemical engineer can closely estimate the cost of processing.

The single largest cost is usually raw material, with energy, labor, overhead, and depreciation all being significant.

Overall Cost

What are the Chemical Process Economics

Competing Processes

Material Balances

Energy

Labor

Overall Cost

What are the Market Evaluation

Purity and Uniformity of Product, Packaging, Sales and Customer Service

The physical condition of the products has a great influence on marketability

Purity and Uniformity of Product

are expensive and should be avoided whenever possible

Packaging and storing

These are able to instruct customers concerning the profitable use of their employer’s products. These form the major contact between buyer and seller.

Sales and customer service

proper location for a chemical plant is determined largely by:

Availability of raw materials, Energy, Transportation, Markets, Environmental constraints, Water supply, Availability of efficient labor, Cost of Land, Waste disposal facilities

Nothing is so destructive to a plant as ___.

fire

OSHA

Occupational Safety and Health Act

Under OSHA, there are three types of standards:

1. Initial standards

2. Emergency temporary standards

3. Permanent standards

issued to protect employees from serious danger from toxic or harmful substances or from new hazards

Emergency temporary standards

can be set only after formal proceedings where interested persons have a chance to submit their views and objections

Permanent standards

These have produced important savings in construction costs by revealing flaws not evident from the usual engineering drawings. Computer graphics are also proving helpful in plant design.

Three – dimensional scale models

Certain companies arrange for promising young engineers to spend time studying management. The combination of a B.S. in chemical engineering followed by an M.B.A. in business has been very popular as a springboard to middle management.

Management for Productivity and Creativity

A good place to do this is in the pilot plant, although modern electronic simulators are proving very valuable.

Training for Plant Procedures

This creates or utilizes the rapidly changing procedures, new raw materials, and new markets. Without it, a company would be left behind in the competitive progress of its industry.

Research

It is the adaptation of research ideas to the realities of production and industry.

Development

A form of intellectual property. It consists of a set of exclusive rights granted by a sovereign state to an inventor or their assignee for a limited period of time in exchange for the public disclosure of an invention.

Patents

provides the right to exclude others from making, using, selling, offering for sale, or importing the patented invention for the term of the patent, which is usually 20 years from the filing date

patent

Results and Benefits of Research

1. New and improved processes

2. Lower costs and lower prices of products

3. Services and products never before known

4. Change of rarities to common commercial supplies of practical usefulness

5. Adequate supply of materials previously obtained only as by – products

6. Freedom from domination by foreign control

7. Stabilization of business and industrial employment

8. Products of improved quality

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

petra; oleum

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

Petroleum

How is crude oil classified in the oil industry?

By origin location and by viscosity (light, intermediate, heavy).

What does 'sweet' crude mean?

Crude with relatively little sulfur.

What does 'sour' crude mean?

Crude with substantial sulfur.

Name some fractions petroleum can be separated into.

Natural gas, gasoline, naphtha, kerosene, fuel and lubricating oils, paraffin wax, asphalt.

When and by whom was the first successful oil well drilled?

1859 by Colonel Edwin Drake in Titusville, Pennsylvania.

What transformation occurred regarding gasoline in the 19th to early 20th century?

Gasoline became a major product as mobility increased; it was initially a byproduct of kerosene.

By 1920, approximately how many cars were in the U.S.?

About 23 million.

Why did gasoline engines become practically advantageous for vehicles?

Because battery-powered engines did not have sufficient range.

By the end of WWI, how many trucks and cars did Britain have?

56,000 trucks and 36,000 cars.

When were airplanes and tanks first used in warfare?

1918.

What change did Britain make to ships during WWI?

Converted coal-burning ships to oil-powered for speed and mobility.

In the 1940s, what percent of world oil did the U.S. produce?

65 percent.

What share of world oil production did the Middle East account for in the 1940s?

Less than 5 percent.

When were 'supergiant' oil fields discovered in Kuwait and Saudi Arabia?

1930s and 1940s.

Ford's ten-year plan to reduce dependence on Middle Eastern oil by domestic energy development (150 coal-fired plants, 200 nuclear plants, synfuel plants).

Project Independence

What happened to synfuels in the 1980s?

Oil glut led to abandonment of synfuels and some alternative energy initiatives.

A fossil fuel, petroleum is formed when large quantities of dead organisms, usually ___ and ___, are buried underneath sedimentary rock and subjected to both intense heat and pressure.

zooplankton; algae

What are the two basic raw materials for petrochemicals?

Natural gas and crude oil.

Light hydrocarbons like methane and ethane, or heavier like naphtha or gas oil.

intermediates in refining

Which other resources could be future energy sources?

Coal, oil shale, tar sands

A naturally occurring mixture of light hydrocarbons, main component is methane, accompanied by some non-hydrocarbon compounds..

natural gas

natural gas that is found in reservoirs containing no oil (dry wells)

Non-associated natural gas

is present in contact with and/or dissolved in crude oil and is coproduced with it

Associated gas

The principal component of most natural gases is ___.

methane

A typical sample of natural gas when it is collected at its source contains about

80% methane (CH4)

7% ethane (C2H6)

6% propane (C3H8)

4% butane and isobutane (C4H10), and

3% pentanes (C5H12).

What is the typical methane content in natural gas at the source?

About 80%.

Which gases are typically removed from natural gas before sale?

C3, C4, C5 hydrocarbons; LPG (propane and butanes) is liquefied and sold.

The commercial natural gas delivered to the customer is primarily a mixture of ___.

methane and ethane

liquefied petroleum gases (LPG) contain what?

propane and butanes

Where is natural gas found?

In deep underground rock formations, coal beds, and methane clathrates.

Most natural gas was created over time by two mechanisms which are?

biogenic and thermogenic

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

Biogenic

buried organic material formation of natural gas

thermogenic

A composite mixture of hydrocarbons (50-95% by weight) occurring naturally.

crude oil

often called "black gold"

crude oil