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Refinery Basics

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Refinery Basics John Kulluk Ph.D. Torrance Fire Department & Robert Distaso PE 714/573-6253 Orange County Fire Authority Refining Means. . . 1. To reduce to a ... – PowerPoint PPT presentation

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Title: Refinery Basics


1
Refinery Basics
  • John Kulluk Ph.D.
  • Torrance Fire Department
  • Robert Distaso PE 714/573-6253
  • Orange County Fire Authority

2
Refining Means. . .
  • 1. To reduce to a pure state, to remove
    impurities
  • 2. To improve or perfect

3
Refinery Process Flow Chart
Sulfur
Gas Plant
Fuel Gas
Isom
Distilling
Splitter
Gasoline
Reformer
Jet Fuel
Hydrotreating
Distillate Fuel
Hydrotreating
Alky
CCU
Flasher
ResidualFuel
Visbreaker
Leffler, 1985
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Other Refinery Units
  • Steam Generation
  • Wastewater Treatment
  • Hydrogen Generation
  • Power Generation (e.g., cogen)
  • Air Separation Plant
  • Loading/Unloading - Railcar, Trucks, etc.
  • Storage (high pressure hydrocarbon, crude oil,
    intermediates)
  • Floating-Roof Tanks - 150 diameter is common
  • Spherical Tanks - 50 are common
  • Horton Spheroid (refrigerated)
  • Steam-Heated Tanks for Heavier Products
  • Self-Contained Firewater Supply
  • Firewater Pumps

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8
What is Crude Oil?
  • Mixture of organic carbon chain molecules
  • Impurities include sulfur and nitrogen compounds
  • Some metals and salts too

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Components such as . . .
  • Straight-Chain Hydrocarbons
  • Olefins
  • Cyclic H/C
  • Aromatics (Benzene, toluene, xylenes)
  • Mercaptans
  • Hydrogen Sulfide (H2S)
  • Greases
  • Propane
  • LPG

11
Other Hazardous Materials
  • Sulfur
  • Hydrofluoric Acid (HF)
  • Sulfuric Acid (H2SO4)
  • Ammonia (NH3)
  • Sodium Hypochlorite
  • Radioactive Materials
  • Chlorine
  • Amines
  • MEK
  • Sulfur Dioxide (SO2)
  • Heavy Metal Catalysts
  • Sour Water
  • Caustic (fresh/spent)
  • Alcohol
  • Asbestos

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Whats All this Stuff?
14
What Goes on at a Refinery. . .?
  • Separation of components by distillation, e.g.
  • Atmospheric
  • Vacuum
  • Hydrotreating (uses excess hydrogen)
  • Breaking apart molecules to make smaller ones,
    e.g.
  • catalytic cracking
  • hydrocracking
  • Joining molecules to make bigger ones, e.g.
  • Reforming - alkylation that lengthens the
    hydrocarbon chain
  • Reforming - cyclic that generates hydrogen

15
Physical Hazards
  • High Pressure/Temperature Steam
  • Oil/Gas-Fired Furnaces
  • Acoustic
  • High Voltage (4160V, 480V, 13.2 kV)
  • Falling Hazards
  • Confined Space Hazards
  • Cranes/Lifting Hazards
  • Hot Work Hazards
  • Acid Exposure
  • Toxic Vapors
  • Radiation
  • Flammability Hazards

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Common PPE Requirements
  • Hardhat
  • Hardsoled / Hardtoe Shoes
  • Safety Glasses with Side Protection
  • Safety Goggles or Faceshield
  • Fire-Resistant Clothing

18
Process Hazards
  • Emergency Flare
  • Atmospheric Pressure Relief
  • High Temperature (up to 2000oF)
  • Low Temperature (e.g., Brittle Fracture)
  • High Pressure (up to 3000 psig)
  • Low Pressure (e.g., vacuum)

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QUESTIONS ?
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