[Искра]

Handbook of Petroleum Processing / Справочник по нефтепереработке


Год: 2006
Автор: Jones D.S.J., Pujado P.R. / Джонс Д.С.Д., Пуджадо П.Р.
Жанр: Химическая промышленность
Издательство: Springer
ISBN: 978-1-4020-2820-5
Язык: Английский
Формат: PDF
Качество: Изначально компьютерное (eBook)
Количество страниц: 1356

Описание: В книге описаны основные принципы и методы нефтеперерабатывающей промышленности. The wheel, without doubt, was man’s greatest invention. However until the late 18th century and early 19th century the motivation and use of the wheel was limited either by muscle power, man or animal, or by energy naturally occurring fromwater flowand wind. The invention of the steam engine provided, for the first time, a motive power independent of muscle or the natural elements. This ignited the industrial revolution of the 19th century, with its feverish hunt for fossil fuels to generate the steam. It also initiated the development of the mass production of steel and other commodities.
Late in the 19th century came the invention of the internal combustion engine with its requirement for energy derived from crude oil. This, one can say, sparked the second industrial revolution, with the establishment of the industrial scene of today and its continuing development. The petroleum products from the crude oil used initially for the energy required by the internal combustion engine, have mushroomed to become the basis and source of some of our chemical, and pharmaceutical products.
The development of the crude oil refining industry and the internal combustion engine have influenced each other during the 20th century. Other factors have also contributed to accelerate the development of both. The major ones of these are the increasing awareness of environmental contamination, and the increasing demand for faster travel which led to the development of the aircraft industry with its need for higher quality petroleum fuels. The purpose of this introductory chapter is to describe and define some of the basic measures and parameters used in the petroleum refining industry. These set the stage for the detail examination of the industry as a whole and which are provided in subsequent chapters of this encyclopedia.

1. An introduction to crude oil and its processing 1
The composition and characteristics of crude oil 1
The crude oil assay 6
Other basic definitions and correlations 9
Predicting product qualities 18
Basic processes 27
The processes common to most energy refineries 28
Processes not so common to energy refineries 37
The non-energy refineries 40
References 45
2. Petroleum products and a refinery configuration 47
2.1 Introduction 47
2.2 Petroleum products 48
2.3 A discussion on the motive fuels of gasoline and diesel 63
2.4 A refinery process configuration development 76
Conclusion 109
3. The atmospheric and vacuum crude distillation units 111
3.1 The atmospheric crude distillation unit 112
Process description 112
The development of the material balance for the
atmospheric crude distillation unit 115
The design characteristics of an atmospheric crude
distillation fractionating tower 119
The fractionator overhead system 122
The side streams and intermediate reflux sections 128
Calculating the main tower dimensions 137
The crude feed preheat exchanger system design 142
An example in the design of an atmospheric crude oil
distillation tower 146
3.2 The vacuum crude distillation unit 169
Process description 169
The vacuum crude distillation unit’s flash zone 171
The tower overhead ejector system 172
Calculating flash zone conditions in a vacuum unit 176
Draw-off temperatures 177
Determine pumparound and internal flows for
vacuum towers 178
Calculate tower loading in the packed section of
vacuum towers 179
Appendix 183
4. The distillation of the ‘Light Ends’ from crude oil 189
A process description of a ‘light ends’ unit 189
Developing the material balance for light end units 191
Calculating the operating conditions in light end towers 196
Calculating the number of trays in light end towers 199
Condenser and reboiler duties 203
Tower loading and sizing 205
Checks for light end tower operation and performance 214
5. Catalytic reforming 217
Feedstocks 219
Catalysts 227
Process flow schemes 232
Advantages of CCR Platforming 234
Catalysts and suppliers 236
References 237
6. Fluid catalytic cracking (FCC) 239
Fluidization 244
Process control 247
Reaction chemistry and mechanisms 248
Gas oil cracking technology features 250
Cracking for light olefins and aromatics 271
Nomenclature 278
References 279
Appendix 6.1. Commercially available FCC catalysts
and additives 282
7. Distillate hydrocracking 287
Brief history 287
Flow schemes 288
Chemistry 292
Catalysts 298
Catalyst manufacturing 300
Catalyst loading and activation 305
Catalyst deactivation and regeneration 306
Design and operation of hydrocracking reactors 308
Hydrocracking process variables 312
Hydrocracker licensors and catalyst manufacturers 319
8. Hydrotreating 321
Brief history 322
Flow schemes 323
Chemistry 327
Catalysts 334
Catalyst manufacturing 337
Catalyst loading and activation 340
Catalyst deactivation and regeneration 342
Design and operation of hydrotreating reactors 344
Hydrotreating process variables 347
Hydrotreaters licensors and catalyst manufacturers 353
9. Gasoline components 355
9.1 Motor fuel alkylation 355
Introduction 355
History 355
Process chemistry 356
HF alkylation process flow description 360
Sulfuric acid alkylation 364
Stratco effluent refrigerated alkylation process 366
Alkylate properties 370
Recent developments 370
Conclusions 371
References 371
9.2 Catalytic olefin condensation 372
Introduction 372
History 373
Catalytic condensation process 373
Catalytic condensation process for gasoline production 376
Hydrogenated versus nonhydrogenated polymer
gasolines from the catalytic condensation process 379
Selective and nonselective gasoline production with the
catalytic condensation process 383
Catalytic condensation process as a source of
diesel fuels 385
Petrochemical operations 386
Dimersol process 389
Other dimerization or oligomerization processes 391
Recent developments 392
Catalytic olefin condensation with the InAlk process 393
Catalyst suppliers 398
Conclusions 398
References 399
9.3 Isomerization technologies for the upgrading of light
naphtha and refinery light ends 400
Introduction 400
Process chemistry of paraffin isomerization 401
Primary reaction pathways 403
Isomerization catalysts 404
I-80 catalyst development and applications 406
LPI-100 catalyst development and applications 409
New isomerization process technologies 410
Isomerization process economics 412
Other applications 415
Conclusions 415
References 416
Bibliography 416
10. Refinery gas treating processes 417
Introduction 417
The process development and description 417
Common processes 419
Other gas treating processes 423
Calculating the amine circulation rate 424
Calculating the number of theoretical trays in an amine
contactor 425
Calculating absorber tray size and design 428
Calculating the heat transfer area for the lean/rich amine
exchanger 428
The stripper design and performance 429
Removing degradation impurities from MEA 430
Appendix 10.1 The process design of an amine gas
treating unit 431
11. Upgrading the ‘Bottom of the Barrel’ 447
The thermal cracking processes 448
‘Deep oil’ fluid catalytic cracking 458
Residuum hydrocracking 469
Conclusion 472
Appendix 11.1 Sizing a thermal cracker heater/reactor 473
12. The non-energy refineries 483
Introduction 483
12.1 The lube oil refinery 483
Lube oil properties 486
A description of major processes in lube oil refining 487
12.2 Asphalt production 494
12.3 The petrochemical refinery 508
The production of aromatics 508
Process discussion 511
Appendix 12.1 Sizing a bitumen oxidizer 512
13. Support systems common to most refineries 521
13.1 Control systems 521
Definitions 522
Reflux drums 523
The control valve 528
13.2 Offsite systems 533
Storage facilities 533
Atmospheric storage 534
Pressure storage 536
Heated storage tanks 537
Calculating heat loss and heater size for a tank 538
Product blending facilities 542
Road and rail loading facilities 545
Jetty and dock facilities 549
Jetty size, access, and location 549
Waste disposal facilities 552
The flare 559
Effluent water treating facilities 565
Other treating processes 567
Utility Systems 568
Brief descriptions of typical utility systems 569
Steam and condensate systems 569
Fuel systems 570
Water systems 575
The “hot lime” process 581
The ion exchange processes 581
Compressed air system 585
13.3 Safety systems 587
Determination of risk 587
Definitions 588
Types of pressure relief valves 591
Capacity 593
Sizing of required orifice areas 595
Sizing for flashing liquids 600
Sizing for gas or vapor on low-pressure
subsonic flow 600
Appendix 13.1 Example calculation for sizing a tank heater 602
Appendix 13.2 Example calculation for sizing a relief value 606
Appendix 13.3 Control valve sizing 607
14. Environmental control and engineering in petroleum
refining 611
Introduction 611
14.1 Aqueous wastes 611
Pollutants in aqueous waste streams 612
Treating refinery aqueous wastes 616
Oxidation of sulfides to thiosulfates 621
Oxidation of mercaptans 623
Oxidation of sulfide to sulfate 624
Oil–water separation 624
The API oil–water separator 625
Storm surge ponds 628
Other refinery water effluent treatment processes 629
Reference 630
14.2 Emission to the atmosphere 631
Features of the Clean Air Act 631
The major effects of air pollution and the most
common pollutants 634
Monitoring atmospheric emission 639
Reducing and controlling the atmospheric pollution in
refinery products 640
Controlling emission pollution from the refining
processes 643
14.3 Noise pollution 646
Noise problems and typical in-plant/community noise
standards 646
Fundamentals of acoustics and noise control 647
Coping with noise in the design phase 652
A typical community/in-plant noise program 653
Appendix 14.1 Partial pressures of H2S and NH3 over
aqueous solutions of H2S and NH3 657
Appendix 14.2 Example of the design of a sour water
stripper with no reflux 667
Appendix 14.3 Example design of an API separator 672
15. Refinery safety measures and handling of hazardous
materials 675
Introduction 675
15.1 Handling of hazardous materials 675
Anhydrous hydrofluoric acid 675
The amines used in gas treating 681
Caustic soda 683
Furfural 687
Hydrogen sulfide, H2S 690
Methyl ethyl ketone, MEK 693
15.2 Fire prevention and fire fighting 696
The design specification 696
Fire prevention with respect to equipment design
and operation 697
The fire main 701
Fire foam and foam systems 701
Class B fire foams 703
Class A fire foams 704
16. Quality control of products in petroleum refining 705
Introduction 705
16.1 Specifications for some common finished products 706
The LPG products 706
The gasolines 706
The kerosenes 708
Aviation turbine gasoline (ATG) and jet fuels 708
The gas oils 710
The fuel oil products 712
The lube oils 713
The asphalts 713
Petroleum coke 714
Sulfur 715
16.2 The description of some of the more common tests 715
Specific gravity (D1298) 715
ASTM distillations (D86, D156) 716
Flash point test method (D93) 718
Pour point and cloud point (D97) 718
Kinematic viscosity (D446) 721
Reid vapor pressure (D323) 723
Weathering test for the volatility of LPG (D1837) 724
Smoke point of kerosenes and aviation turbine
fuels (D1322) 726
Conradson carbon residue of petroleum
products (D189) 731
Bromine number of petroleum distillates (D1159) 733
Sulfur content by lamp method (D1266) 734
Octane number research and motor 736
Conclusion 737
17.1. Economics—Refinery planning, economics, and handing
new projects 739
17.1.1 Refinery operation planning 739
Running plans 740
Developing the running plan 743
Background 745
Basis for assessing requirements 746
The results 747
The refinery operating program 748
17.1.2 Process evaluation and economic analysis 752
Study approach 752
Building process configurations and the
screening study 756
Example calculation 758
Investment costs for the new facilities 762
Preparing more accurate cost data 767
Summary data sheets 771
Capital cost estimates 775
Discounted cash flow and economic analysis 784
Results 793
Using linear programs to optimize process
configurations 794
Executing an approved project 799
Developing the duty specification 799
The project team 806
Primary activities of the project team 807
Developing the operating manual and plant
commissioning 822
Process guarantees and the guarantee test run 830
Appendices
17.1.1 Refinery plan inadequacies report 836
17.1.2 Crude oil inventory schedule 837
17.1.3 Product inventory and schedule 838
17.1.4 Outline operating schedule 839
17.1.5 Detailed operating program and schedule 840
17.1.6 Typical weekly program 841
17.1.7 Typical factors used in capacity factored
estimates 842
17.1.8 Example of a process specification 842
17.1.9 Example of a process guarantee 844
17.2. Economic analysis 851
Introduction 851
Analysis at one point in time 852
Cost of production 859
Reporting parameters 864
Appendices
17.2.1 Background for economic calculations 869
17.2.2 Progressions 873
17.2.3 Loan repayments (mortgage formula) 874
17.2.4 Average rate of interest 875
18. Process equipment in petroleum refining 877
Introduction 877
18.1 Vessels 877
Fractionators, trays, and packings 878
Drums and drum design 908
Specifying pressure vessels 914
18.2 Pumps 924
Pump selection 928
Selection characteristics 929
Capacity range 929
Evaluating pump performance 934
Specifying a centrifugal pump 936
The mechanical specification 937
The process specification 938
Compiling the pump calculation sheet 938
Centrifugal pump seals 943
Pump drivers and utilities 946
Reacceleration requirement 949
The principle of the turbine driver 950
The performance of the steam turbine 951
18.3 Compressors 954
Calculating horsepower of centrifugal compressors 956
Centrifugal compressor surge control, performance
curves and seals 963
Specifying a centrifugal compressor 968
Calculating reciprocating compressor horsepower 975
Reciprocating compressor controls and inter-cooling 979
Specifying a reciprocating compressor 982
Compressor drivers, utilities, and ancillary equipment 990
18.4 Heat exchangers 999
General design considerations 1002
Choice of tube side versus shell side 1005
Estimating shell and tube surface area and pressure
drop 1006
Air coolers and condensers 1016
Condensers 1025
Reboilers 1029
18.5 Fired heaters 1040
Codes and standards 1043
Thermal rating 1045
Heater efficiency 1047
Burners 1051
Refractories, stacks, and stack emissions 1053
Specifying a fired heater 1058
Appendices
18.1 LMTD correction factors 1066
18.2 Heat of combustion of fuel oils 1067
18.3 Heat of combustion of fuel gasses 1068
18.4 Values for coefficient C 1069
18.5 Some common heat transfer coefficients 1070
18.6 Standard exchanger tube sheet data 1070
19. A dictionary of terms and expressions 1071
Appendices 1285
A Examples of working flow sheets 1285
B General data 1290
B1 Friction loss for viscous liquids 1291
B2 Resistance of valves and fittings 1300
B3 Viscosity versus temperature 1301
B4 Specific gravity versus temperature 1302
B5 Relationship between specific gravity and API degrees 1303
B6 Flow pressure drop for gas streams 1305
B7 Relationship of chords, diameters, and areas 1307
C A selection of crude oil assays 1308
D Conversion factors 1330
E An example of an exercise using linear programming 1332
Linear programming aids decisions on refinery
configurations 1333
Alphabetic index 1349

Доп. информация:Опубликовано группой