Preface... xii. 1. Refinery Distillation... 1

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1 Preface... xii Chapter Breakdown... xiii 1. Refinery Distillation... 1 Process Variables... 2 Process Design of a Crude Distillation Tower... 5 Characterization of Unit Fractionation General Properties of Petroleum Fractions Atmospheric Distillation Unit Vacuum Distillation Unit Crude Desalting Distillate Hydrotreating Naphtha Hydrodesulfurization Process Kerosene Hydrotreating Gas Oil Hydrodesulfurization Atmospheric Residuum Desulfurization Hydrocracking Processes Hydrocracking Reactions Process Configuration Process Flow Scheme Operating Conditions Catalyst Sulfiding and Unit Startup Shutdown Procedure vii

2 viii Catalyst Regeneration Mild Hydrocracking Residuum Hydrocracking Gasoline Manufacturing Processes Catalytic Reforming Fluid Catalytic Cracking Alkylation Isomerization of C 5 /C 6 Normal Paraffins Methyl Tertiary Butyl Ether Hydrogen Production and Recovery Natural Gas Desulfurization Steam Reforming Carbon Monoxide Conversion Carbon Dioxide Removal Methanation Pressure Swing Adsorption Route Partial Oxidation Process Hydrogen Recovery Residuum Processing Delayed Coking Visbreaking Solvent Deasphalting Bitumen Blowing Treating Processes General Principles FCCU Light Gasoline Jet Fuel (ATK) Sweetening

3 ix 8. Sulfur Recovery and Pollution Control Processes Sulfur Recovery from Acid Gas Claus Tail Gas Treatment Flue Gas Desulfurization Amine Treatment Refinery Water Systems Cooling Water System Sea Water Cooling System Cooling Towers Boiler Feedwater System Utility Water System Treatment of Oily Water Wet Slop Oil System Treatment of Sanitary Sewage Sour Water Treatment Refinery Off-site Facilities and Utility Systems Refinery Tankage Shipping Terminals and Sea Lines Refinery Tankage Estimation Product Blending System Refinery Flare System Refinery Steam System Refinery Fuel System Product Blending Gasoline Octane Blending ASTM Distillation Blending Viscosity Blending

4 x Pour Point Blending Flash Point Blending Reid Vapor Pressure Blending for Gasolines and Naphthas Aniline Point Blending Crude Oil Assays Refinery Stock Balancing Data for Model Building Calculation Procedure Refinery Material Balance Spreadsheet Program Refinery Linear Programming Modeling Overview Development of the Refinery LP Model The Structure of a Refinery LP Model Property Propagation to Other Tables Blending Specifications Stream Pooling (Recursion Process) Distributive Recursion Objective Function Optimization Step Solution Convergence Interpreting the Solution Report Writer Programs Delta-based Modeling Atmospheric Crude Distillation and VDU Modeling Single-product LP Blender Pricing Petroleum Products Netback and Formula Pricing for Crude Oil Pricing Petroleum Products and Intermediate Stocks

5 xi Assigned Crude Yields Definitive Operating Plan DOPs in Joint-ownership Refineries Fixed- and Balancing-grade Products Product Equivalencies Product Equivalency Determination Crude Oil Equivalency Equivalency of Slop Product Allocation Input Data Forecaster Changes Rules for Forecaster Changes Crude Oil Changes DOP Loss Adjustment Retrospective DOP Allocation of Balancing Grades Reverse Allocation Final Allocation Allocation LPs Process Unit Capacities Product Prices Summary of Primary Data Input for LPs Examination of LP Results Final Allocation Cycle Allocation Spreadsheet Program Product Allocation Problems Available Tankage Capacity Estimation of Total Available Capacity

6 xii Minimum and Maximum Inventory (LI and HI) Allocation of Tankage Capacity Ullage Ceding of Refinery Capacity Ceding of Tankage Capacity Shipping Inventory Forecasts Weekly Production Estimates Refinery Estimate Schedule Procedure Allocation of Deltas Inventory and Ullage Forcasting System (Joint Ownership Refineries) Refinery Operating Cost Allocation of Operating Cost System Costing Method Theoretical Sales Realization Valuation Method Cost Allocation for Actual Usage Unused Capacity Charge Appendix: Processing Agreement for Joint-ownership Refinery Index