Fundamentals of. Petroleum and Petrochemical. Engineering. University of Calcutta Calcutta, India. CRC Press. Taylor & Francis Group

Transcription

1 Fundamentals of Petroleum and Petrochemical Engineering Uttam Ray Chaudhuri University of Calcutta Calcutta, India CRC Press Taylor & Francis Group Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Croup, an Informa business

2 Preface Author Introduction xxiii xxv Chapter 1 Crude Petroleum Oil Composition of Crude Oil Hydrocarbon Groups Complex Hydrocarbons Non-Hydrocarbons or Hetero-Atomic Compounds Physical Properties of Crude Oil Origin of Hydrocarbons Exploration Techniques Gravimetric Method Magnetometric Method Seismic Survey Remote Sensing Method Geochemical Methods Stratigraphy Resource Estimation Effect of Pressure Connate Water Effect of Temperature Effect of Viscosity Oil Field Development Well Logging Oil Production Processes Crude Conditioning and Storage Transportation and Metering of Crude Oil Gas Hydrates Production Method Coal Bed Methane Questions Chapter 2 Petroleum Products and Test Methods Crude Oil Analysis API Gravity Characterisation Factor Bottom Sediment and Water 28 xi

3 xii 2.2 Domestic Fuels Liquified Petroleum Gas Kerosene Smoke Point FlashPoint Char Point and Bloom Distillation Test Sulfur Content and Corrosion Automotive Fuels Motor Spirit American Standard for Testing Material Distillation Octane Number Corrosion Reid Vapour Pressure Oxidation Stability Additives High Speed Diesel Cetane Number Diesel Index Sulfur Corrosion FlashPoint Flame Length Pour Point Viscosity Aviation Fuels Furnace Fuels Gaseous Fuels Liquid Fuels Lubricating Oils Viscosity Saybolt Method Redwood Method Brookfield Method Viscosity Index Cloud Point Pour Point Miscellaneous Products Jute Batching Oil Mineral Turpentine Oil Carbon Black Feed Stock Bitumen Petroleum Coke Wax 48 Questions 48

4 xiii Chapter 3 Processing Operations in a Petroleum Refinery Crude Oil Receiving Desalting of Crude Oil Distillation and Stripping Atmospheric Distillation Stabilisation Amine Absorption De-Ethaniser Meroxing and Caustic Wash Liquified Petroleum Gas Splitter Naphtha Redistillation Naphtha Pretreatment Naphtha Platinum Reforming (Platforming) Kerosene Hydrodesulfurisation Diesel Hydrodesulfurisation Vacuum Distillation Solvent Extraction Propane Deasphalting Solvent Dewaxing Hydrofinishing Catalytic Processes for Lube Oil Base Stock Manufacture Hydrocracking Mild Hydrocracking Hydrogen Generation Feed Desulfurisation Primary Reforming Secondary Reforming Shift Reactors Hydrogen Purification Fluid Catalytic Cracking Bitumen Blowing Vis-Breaking Coking 80 Questions Si Chapter 4 Lubricating Oil and Grease Components of Finished Lubricating Oils Automotive Oils Industrial Lubricants Bearing Lubricants Hydraulic Lubricants Compressor Lubricants Pump Lubricants Aviation Lubricants 87

5 xiv 4.5 Marine Lubricants Greases Lube Blending and Grease Manufacture Environmental Impact of Lubricants Reclamation of Used Lubricants Power Consumption in a Blending Tank 94 Questions 98 Chapter 5 Petrochemicals Defintions of Petrochemicals Feedstocks Intermediates Finished Products Naphtha Cracking Primary Fractionator or Stabiliser Hydrogen Separator Conversion Processes for Selected Petrochemicals Polyethylene Low Density Polyethylene High Density Polyethylene Linear Low Density Polyethylene Polypropylene Ill Polyethylene Terephthalate Ill Terephthalic Acid Ethylene Glycol Polyvinyl Chloride Polystyrene Polybutadiene Acrylonitrile Butadiene Styrene Styrene-Butadiene Rubber Poly Methyl Metha Acrylate Polytetrafluoroethylene Nylons Phenol Formaldehyde Urea Formaldehyde Melamine Formaldehyde Polyurethane Toluene Diisocyanate Silicone Petrochemical Complex Downstream Units Petrochemicals' Hub Processing of Plastic, Rubber, and Fibre Moulding of Plastics Extrusion Moulding 124

6 ' xv Blow Moulding Compression Moulding Thermal Moulding Injection Moulding Rubber Compounding 127 Questions 128 Chapter 6 Offsite Facilities, Power and Utilities Layout of Petroleum and Petrochemical Plants Processing Units Offsite Facilities Floating Roof Tank Fixed Roof Tank Pressure Vessels Horton Sphere Accessories Blending Operations Filling, Loading, and Despatch Operations Pipeline Transport Effluent Water Treatment Off Gas Treatment Internal Fuel Oil Circulation Power and Steam Generating Plant Cooling Tower Water Conditioning Plant 147 Questions 150 Chapter 7 Material and Energy Balances Measurement of Quantity of Crude Oil and Products Tank Dipping Volume Correction Density Correction Measurement of Gases in Closed Vessels Material Balance in a Plant Flow Meter Readings Fuel Consumption Steam Consumption Overall Material Balance Energy Balance in a Plant Heat Balance Energy Balance in a Heat Exchanger 164 Questions Energy Balance in a Furnace Energy Balance in a Distillation Column Overall Energy Balance

7 xvi Chapter 8 Heat Exchangers and Pipe-Still Furnaces Heat Exchangers Theory of Heat Exchange Heat Balance Rate of Heat Transfer Fouling Plate Type Heat Exchanger Extended Surface Exchanger Scraped Surface Exchanger Heat Exchanger Train Pipe-Still Furnace Pipe-Still Furnace Elements Heater Pipes or Tubes Refractories Burners Convection Zone Radiant Section Stack or Chimney Operation of a Furnace Draught in a Furnace Furnace Design by the Wilson, Lobo and Hottel Method Furnace Design by the Lobo and Evans Method 205 Questions 206 Chapter 9 Distillation and Stripping Processes of Distillation and Stripping Batch Distillation Boiling Point and Equilibrium Diagrams Theory of Distillation Continuous Distillation Top Reflux Drum Rectification Section Streams Leaving the Envelope under Study Streams Entering the Envelope under Study Reboiler Stripping Section Feed Plate or Flash Zone Evaluation of Fraction Vaporised (f) from the Quality of the Feed McCabe-Thiele Method Operating Line for the Feed Section or Feed Line Operating Line and Plates for the Stripping Section 218

8 xvii 9.7 Enthalpy Balance Method Reflux Drum Top Plate Reboiler Numerical Solution Types of Refluxes Internal Reflux Minimum Reflux Gap and Overlap Packie's Correlation 231 Question 234 Chapter 10 Extraction Extraction Principle Extraction Process Definition of Terms Related to Extraction Partition Coefficient Partial Solubility Solvent to Feed Ratio Solvent Recovery Separation of Phases Selectivity Solvent Power Critical Solution Temperature Phase Equilibrium in the Extraction Process Batch Extraction Continuous Extraction Computation of Number of Plates 240 Questions 248 Chapter 11 Reactor Calculations Reactors in Refineries and Petrochemical Plants Reaction Stoichiometry, Mechanism, and Pathways Rate of Reaction and Kinetic Equations Batch, Continuous Stirred Tank Reactor, and Plug Flow Reactor Concepts Naphtha Reformer Calculations Calculations for a Fluidised Catalytic Cracking Reactor 271 Chapter 12 Elements of Pipeline Transfer Facilities Pipes and Tubes Fittings and Supports Corrosion Protection 276

9 <v;jj 12.3 Crude Oil Transfer Lines Design Steps for Crude Pipes Economic Pipe Diameter Product Transfer Lines Gas Transfer Lines Pumps and Compressors Centrifugal Pumps Priming Specific Speed Positive Displacement Pumps Rotary Pumps Compressors Power Calculations for Pumping and Compression 290 Chapter 13 Instrumentation and Control in a Refinery Control Hardware Hardware Cables Control Loops The Process Piping and Instrumentation Diagram Control Software Distributed Control System The Control Room Crude Throughput Control Desalter Control Atmospheric Distillation Column Control Reflux Drum Pressure Control Reflux Drum Level Control Top Plate Temperature Draw Plate Temperature Overfiash Rate Flash Zone Pressure and Temperature Bottom Temperature Furnace Control Vacuum Distillation Control Reformer Unit Control Fluid Catalytic Cracking Unit Control Reactor Outlet Temperature Control Level Control of the Catalyst Bed in the Stripper Section of the Reactor Pressure Balance between the Reactor and the Regenerator Fail-Safe Devices Normal Running Conditions During Planned Shutdown 321

10 x'x During Accidents or Emergency Shutdown Power Plant Failure Standard Signals in Process Control 323 Chapter 14 Miscellaneous Startup Power Plant Startup Startup of a Crude Distillation Unit Starting a Naphtha Pretreatment Plant Starting a Naphtha Reforming Plant Starting a Fluid Catalytic Cracking Plant Shutdown Shutdown of a Crude Distillation Unit Shutdown of a Naphtha Pretreatment Unit Regeneration of the Catalyst Shutdown of a Naphtha Reforming Unit Regeneration of Reforming Catalyst Maintenance of Plant and Equipments Fire and Explosion Pyrophoric Iron Factories Act Safety Analysis 337 Chapter 15 Plant Management and Economics Cost of Equipment Capacity Ratio Method Purchased Price First Cost of the Equipment Depreciation Cost of a Plant Operating Cost Product Cost Profit and Product Price Taxes and Duties Breakeven Point, Payout Period, and Rate of Return Payout Period or Payback Period Rate of Return Linear Programming Material Audit Category of Materials Papers to Be Maintained Tank Dip Register Pass Out Vouchers Tank Dip Memos 353

11 XX Daily Stock Report Daily Pumping Record Daily Operation Record Material Audit of Capital Goods Energy Audit Electricity Audit Thermal Audit Steam Balance 368 Appendix Index