Thermal conversion processes such as thermal cracking, visbreaking, coking, and coke calcination are used to convert heavy hydrocarbon fractions into more valuable products. Thermal cracking involves heating heavy hydrocarbons to high temperatures to crack long molecules into shorter ones. Visbreaking is a mild thermal cracking that reduces the viscosity of heavy residues. Coking uses heat to crack heavy residues into lighter fractions and petroleum coke in large drums. Coke calcination further processes petroleum coke by removing volatiles in a rotary kiln to increase the carbon ratio for uses such as anodes.
The document discusses petroleum refining, cracking, and methods of producing synthetic petrol. It describes how crude oil is refined through separation, conversion, and treatment processes like distillation. Cracking breaks large hydrocarbon molecules into smaller, more useful molecules through thermal or catalytic cracking. Synthetic petrol can be produced via polymerization, Fischer-Tropsch synthesis from syngas, or Bergius process where coal is hydrogenated over a catalyst into liquid fuels.
Refineries process crude oil through distillation and other separation processes to produce fuels and other products. Crude oil is separated into components like gasoline, jet fuel, diesel, and residual fuel through units like atmospheric distillers, vacuum distillers, reformers, crackers, and hydrotreaters. Refineries also have utilities like hydrogen plants, sulfur recovery units, wastewater treatment, and power generation. Hazards in refineries include fires and explosions from flammable liquids and gases, exposure to toxic chemicals, and physical hazards from high pressures and temperatures.
Petroleum is a naturally occurring flammable liquid consisting of hydrocarbons found underground. It is extracted through oil drilling and refined into many consumer products through fractional distillation. Crude oil varies in composition but largely includes paraffins, naphthenes, and aromatics. Octane and cetane ratings indicate gasoline and diesel fuels' resistance to knocking during combustion in engines. Synthetic petrol can also be produced through processes like Fischer-Tropsch that use coal, steam, and catalysts to synthesize hydrocarbon fuels.
This document discusses various methods for cracking heavy oils and residues into lighter products. It describes hydrocracking, catalytic cracking, coking, and thermal cracking processes. It focuses on fluid catalytic cracking (FCC), explaining that FCC is the most common cracking process used in refineries. It converts heavy hydrocarbon fractions into more valuable gasoline, olefin gases, and other products. The FCC process involves cracking feedstock in the presence of a fluidized catalyst in a riser reactor, separating the cracked products, and regenerating the spent catalyst.
Visbreaking and delayed coking are processes used in oil refineries. Visbreaking uses heat to crack large hydrocarbon molecules and reduce viscosity, producing gas, naphtha, and distillates. It occurs in either coil or soaker units. Delayed coking thermally cracks residual oil in parallel furnaces and drums, producing coker gas oil and petroleum coke while maximizing distillates and minimizing coke yield. Problems include fouling, coke formation, and asphaltene precipitation, which can be addressed using high pressure heat exchangers.
A presentation on Petroleum for the
Course: B.Tech. Polymer Science in DU FYUP
Subject: Raw Materials,
Year - For Ist Year Students.
You may download this ppt to get a better idea about the contents and animation!
all process involve in petroleum to get final products from crude oil like LPG, petrol, diesel, jet fuel, kerosene,neptha, heavy neptha, coke and petroleum products
The document discusses petroleum refining, cracking, and methods of producing synthetic petrol. It describes how crude oil is refined through separation, conversion, and treatment processes like distillation. Cracking breaks large hydrocarbon molecules into smaller, more useful molecules through thermal or catalytic cracking. Synthetic petrol can be produced via polymerization, Fischer-Tropsch synthesis from syngas, or Bergius process where coal is hydrogenated over a catalyst into liquid fuels.
Refineries process crude oil through distillation and other separation processes to produce fuels and other products. Crude oil is separated into components like gasoline, jet fuel, diesel, and residual fuel through units like atmospheric distillers, vacuum distillers, reformers, crackers, and hydrotreaters. Refineries also have utilities like hydrogen plants, sulfur recovery units, wastewater treatment, and power generation. Hazards in refineries include fires and explosions from flammable liquids and gases, exposure to toxic chemicals, and physical hazards from high pressures and temperatures.
Petroleum is a naturally occurring flammable liquid consisting of hydrocarbons found underground. It is extracted through oil drilling and refined into many consumer products through fractional distillation. Crude oil varies in composition but largely includes paraffins, naphthenes, and aromatics. Octane and cetane ratings indicate gasoline and diesel fuels' resistance to knocking during combustion in engines. Synthetic petrol can also be produced through processes like Fischer-Tropsch that use coal, steam, and catalysts to synthesize hydrocarbon fuels.
This document discusses various methods for cracking heavy oils and residues into lighter products. It describes hydrocracking, catalytic cracking, coking, and thermal cracking processes. It focuses on fluid catalytic cracking (FCC), explaining that FCC is the most common cracking process used in refineries. It converts heavy hydrocarbon fractions into more valuable gasoline, olefin gases, and other products. The FCC process involves cracking feedstock in the presence of a fluidized catalyst in a riser reactor, separating the cracked products, and regenerating the spent catalyst.
Visbreaking and delayed coking are processes used in oil refineries. Visbreaking uses heat to crack large hydrocarbon molecules and reduce viscosity, producing gas, naphtha, and distillates. It occurs in either coil or soaker units. Delayed coking thermally cracks residual oil in parallel furnaces and drums, producing coker gas oil and petroleum coke while maximizing distillates and minimizing coke yield. Problems include fouling, coke formation, and asphaltene precipitation, which can be addressed using high pressure heat exchangers.
A presentation on Petroleum for the
Course: B.Tech. Polymer Science in DU FYUP
Subject: Raw Materials,
Year - For Ist Year Students.
You may download this ppt to get a better idea about the contents and animation!
all process involve in petroleum to get final products from crude oil like LPG, petrol, diesel, jet fuel, kerosene,neptha, heavy neptha, coke and petroleum products
COURSE LINK:
https://www.chemicalengineeringguy.com/courses/petrochemicals-an-overview/
Introduction:
The course is mainly about the petrochemical industry. Talks about several chemicals and their chemical routes in order to produce in mass scale the demands of the market.
Learn about:
Petorchemical Industry
Difference between Petroleum Refining vs. Petrochemical Industry
Paraffins, Olefins, Napthenes & Aromatics
Market insight (production, consumption, prices)
Two main Petrochemical Processes: Naphtha Steam Cracking and Fluid Catalytic Cracking
The most important grouping in petrochemical products
Petrochemical physical & chemical properties. Chemical structure, naming, uses, production, etc.
Basic Gases in the industry: Ammonia, Syngas, etc…
C1 Cuts: Methane, Formaldehyde, Methanol, Formic Acid, Urea, Chloromethanes etc…
C2 Cuts: Ethane, Acetylene, Ethylene, Ethylene Dichloride, Vinyl Chloride, Ethylene Oxide, Ethanolamines, Ethanol, Acetaldehyde, Acetic Acid, Ethylene Glycols (MEG, DEG, TEG)
C3 Cuts: Propane, Propylene, Propylene Oxide, Isopropanol, Acetone, Acrylonitrile, Propediene, Allyl chloride, Acrylic acid, Propionic Acid, Propionaldehyde, Propylene Glycol
C4 Cuts: Butanes, Butylenes, Butadiene, Butanols, MTBE (Methyl Tert Butyl Ethers)
C5 cuts: Isoprene, Pentanes, Piperylene, Cyclopentadiene, Dicyclopentadiene, Isoamyl, etc…
Aromatics: Benzene, Toluene, Xylenes (BTX), Cumene, Phenol, Ethyl Benzene, Styrene, Pthalic Anhydride, Nitrobenzene, Aniline, Benzoic Acid, Chlorobenzene, etc…
At the end of the course you will feel confident in how the petrochemical industry is established. You will know the most common petrochemicals as well as their distribution, production and importance in daily life. It will help in your future process simulations by knowing the common and economical chemical pathways.
This document discusses various systems for classifying crude oil and hydrocarbon resources. It describes classification based on chemical composition, including proportions of paraffins, naphthenes and aromatics. It also discusses physical property-based classification systems including API gravity, viscosity, density and pour point. Reservoir characterization aims to identify and quantify reservoir properties that control fluid distribution and migration in order to accurately describe the reservoir and optimize hydrocarbon recovery. Future resources are expected to come from unconventional reservoirs with low permeability.
This document discusses crude oil processing and the production of hydrocarbon intermediates. It describes how crude oil is distilled through atmospheric and vacuum distillation to produce simple fractions like naphtha, gas oil, and catalytic cracker gases. These refinery products undergo further processing through thermal cracking, catalytic cracking, and steam reforming to produce olefins, diolefins, and aromatics. Key processes mentioned include thermal cracking (steam cracking) to produce ethylene and catalytic reforming to produce BTX aromatics. Delayed coking is also summarized as a thermal cracking process used to upgrade heavy residues into lighter fractions.
Distillation is a key separation process used in petroleum refining to separate crude oil into its various components like gasoline, kerosene, and diesel. Crude oil is first desalted and dewatered before being fed to a distillation unit where it is heated and separated based on differences in boiling points into various hydrocarbon fractions. Further refining processes like reforming, cracking, and hydrotreating are used to convert heavier fractions into lighter, more valuable products like gasoline.
This document provides a brief overview of oil refinery processes, including historical events and descriptions of key unit operations like crude distillation, vacuum distillation, fluid/delayed coking, fluid catalytic cracking, alkylation, and hydrotreating. Process schematics and typical yields are shown for each unit operation.
Carbonization is the process of heating coal in the absence of air to produce coke. There are two types of carbonization: low temperature (500-700°C) which produces semi-coke and more liquid byproducts, and high temperature (>900°C) which produces denser coke and more gaseous byproducts. Coking coal undergoes carbonization to produce strong, porous coke for metallurgical purposes, while non-coking coal leaves a powdery residue and is not suitable for coke production.
Thermal cracking is a refinery process that breaks larger hydrocarbon molecules into smaller molecules like gasoline. The presentation discusses various aspects of thermal cracking including:
1. The necessity of cracking to produce more gasoline from heavier crude oil fractions.
2. The main types of cracking - thermal cracking and catalytic cracking. Thermal cracking uses high temperatures without a catalyst.
3. Key thermal cracking processes like Dubbs, pyrolysis, visbreaking, and coking which use different temperatures and pressures to produce different product yields.
4. The thermal cracking reactions of decomposition, hydrogenation, polymerization, and cyclization that alter the hydrocarbon molecules.
5. Commercial thermal cracking units and how they operate to continuously
Fluid coking is a continuous process that thermally converts heavy hydrocarbons like residue into lighter products using two fluidized bed vessels, a reactor and a burner. In the reactor, feedstock is cracked into vapor and coke deposits on circulating coke particles, which transfer heat to the reactor. Flexicoking integrates fluid coking with coke gasification to upgrade residues. It uses an air gasifier to burn coke for heat and a steam gasifier to produce syngas that can be further processed. Dual gasification flexicoking employs both gasifiers, with the air gasifier providing heat and the steam gasifier generating syngas for downstream use or hydrogen production.
This document provides information on fluid catalytic cracking (FCC), including:
1) FCC is a process that uses heat and a catalyst to break down large hydrocarbon molecules in vacuum gas oil into smaller molecules like gasoline and light olefins.
2) The catalyst, usually a zeolite, facilitates cracking reactions at lower temperatures and pressures than thermal cracking. During FCC, the catalyst is regenerated by burning off coke deposits.
3) FCC units typically produce gasoline, light olefins like ethylene and propylene, and LPG as products from cracking heavier hydrocarbon feeds.
This document summarizes the hydrodealkylation process for converting toluene to benzene using hydrogen gas. It discusses the raw materials of toluene and hydrogen, the chemical reaction where toluene and hydrogen produce benzene and methane, properties of benzene, a flow chart of the process, descriptions of process steps including reactor design and hydrogen issues, alternative processes, uses of benzene, and health hazards of benzene exposure.
This document discusses three methods of producing synthetic petrol: polymerization, Fischer–Tropsch process, and Bergius process. Polymerization involves combining smaller hydrocarbon molecules to form heavier molecules resembling gasoline. The Fischer–Tropsch process converts carbon monoxide and hydrogen into liquid hydrocarbons using a catalyst at high pressures and temperatures. The Bergius process directly converts coal to liquids by mixing coal with hydrogen gas and heating it in the presence of a catalyst.
The document discusses the alkylation process. It begins with an overview of the chemistry and components involved. It then describes the typical process which involves reacting olefins like propylene and butylene with iso-paraffins like isobutane in the presence of an acid catalyst to produce a high-octane gasoline blendstock called alkylate. The document concludes by noting that alkylation is an important process for meeting gasoline regulations given alkylate's low emissions profile.
basic building block processes in petrochemical technologyAfzal Zubair
Petrochemical processes involve basic building block processes for manufacturing intermediates and products. Key petrochemical processes include thermal cracking, catalytic cracking, and steam reforming which produce olefins, synthesis gas, and aromatic compounds from petroleum feedstocks like naphtha and gas oil. Thermal cracking uses steam to crack ethane, propane and heavier hydrocarbons to produce ethylene, propylene and other products. Catalytic reforming uses naphtha to produce BTX aromatic compounds. Steam reforming produces a mixture of carbon monoxide and hydrogen from hydrocarbon feeds. Polymerization then links monomer molecules into long chains or networks to form plastics, fibers and other polymer products.
The document discusses various thermal cracking and catalytic cracking processes used in the oil refining industry to break down heavy hydrocarbon molecules into lighter products such as gasoline. It describes processes such as steam cracking, catalytic cracking, hydrocracking, thermal cracking, visbreaking, and coking. It provides details on the operating conditions, reactions, equipment used, and products of each process. The goal of these cracking processes is to produce more valuable and widely used products from heavy oil fractions.
The aniline point test determines the lowest temperature at which equal volumes of aniline and an oil sample fully mix. A lower aniline point indicates a higher aromatic content in the oil sample. The test is suitable for transparent liquid samples with an initial boiling point above room temperature. The aniline point can be used to estimate properties like cetane number, diesel index, and aromatic content, which provide information about the oil sample's combustion quality and suitability for diesel fuel. Extracting the oil sample with furfuraldehyde can lower its aromatic content and thus increase the aniline point.
Thermal conversion processes include thermal cracking, visbreaking, coking, and coke calcination. Thermal cracking involves cracking large hydrocarbon molecules into smaller ones at high temperatures. Visbreaking is a mild thermal cracking process used to reduce the viscosity of residues and produce fuel oil, naphtha, and gas oil. Coking involves heating residues to very high temperatures to produce coke and lighter hydrocarbon products.
Petroleum lab experiment 02 - octane number and cetane numberSafeen Yaseen Ja'far
The document describes an experiment conducted by a group of chemical engineering students to determine the octane number of gasoline samples and the cetane number of diesel fuel samples. It includes the aim of the experiment, theoretical background on octane and cetane numbers, methodology, procedures, calculations, and a discussion section with answers to questions about fuel compositions and effects of adding compounds.
refining of crude oil by Arun kumar ranaBIET Jhansi
This document discusses the refining of crude oil. It begins by describing crude oil as a complex mixture of hydrocarbons found in the Earth's crust. The refining process separates crude oil into fractions using fractional distillation based on differences in boiling points. Major fractions include petroleum gas, naphtha, gasoline, kerosene, diesel, lubricating oil, and fuel oil. Further processing using thermal cracking and catalytic cracking converts heavier fractions into more valuable products like liquefied petroleum gas and gasoline. Refineries are upgraded in response to market demands and clean air regulations.
- The FCC unit uses a catalyst to crack heavy hydrocarbon fractions from the crude oil distillation unit into lighter, more valuable products like gasoline and olefin gases. This catalytic cracking process yields higher octane gasoline and more olefins than thermal cracking.
- The C3 separator separates butanes from the gas fraction, which are then used in isomerization and LPG production. The C2 separator further separates propane and lighter hydrocarbons from the stream.
- These separators allow refineries to separate and recover hydrocarbon fractions at different carbon numbers for downstream refining processes based on differences in density.
CRACKING ppt for chemical engineering studentssmmaker21
Cracking is a process that breaks down complex, heavy hydrocarbons like kerogen and heavy petroleum into lighter, more useful molecules like light hydrocarbons. There are two main types of cracking: thermal cracking uses high temperatures without a catalyst, while catalytic cracking uses lower temperatures with a catalyst. Cracking is necessary to produce important petrochemical feedstocks like ethylene and propylene that are in higher demand than heavier hydrocarbon fractions.
COURSE LINK:
https://www.chemicalengineeringguy.com/courses/petrochemicals-an-overview/
Introduction:
The course is mainly about the petrochemical industry. Talks about several chemicals and their chemical routes in order to produce in mass scale the demands of the market.
Learn about:
Petorchemical Industry
Difference between Petroleum Refining vs. Petrochemical Industry
Paraffins, Olefins, Napthenes & Aromatics
Market insight (production, consumption, prices)
Two main Petrochemical Processes: Naphtha Steam Cracking and Fluid Catalytic Cracking
The most important grouping in petrochemical products
Petrochemical physical & chemical properties. Chemical structure, naming, uses, production, etc.
Basic Gases in the industry: Ammonia, Syngas, etc…
C1 Cuts: Methane, Formaldehyde, Methanol, Formic Acid, Urea, Chloromethanes etc…
C2 Cuts: Ethane, Acetylene, Ethylene, Ethylene Dichloride, Vinyl Chloride, Ethylene Oxide, Ethanolamines, Ethanol, Acetaldehyde, Acetic Acid, Ethylene Glycols (MEG, DEG, TEG)
C3 Cuts: Propane, Propylene, Propylene Oxide, Isopropanol, Acetone, Acrylonitrile, Propediene, Allyl chloride, Acrylic acid, Propionic Acid, Propionaldehyde, Propylene Glycol
C4 Cuts: Butanes, Butylenes, Butadiene, Butanols, MTBE (Methyl Tert Butyl Ethers)
C5 cuts: Isoprene, Pentanes, Piperylene, Cyclopentadiene, Dicyclopentadiene, Isoamyl, etc…
Aromatics: Benzene, Toluene, Xylenes (BTX), Cumene, Phenol, Ethyl Benzene, Styrene, Pthalic Anhydride, Nitrobenzene, Aniline, Benzoic Acid, Chlorobenzene, etc…
At the end of the course you will feel confident in how the petrochemical industry is established. You will know the most common petrochemicals as well as their distribution, production and importance in daily life. It will help in your future process simulations by knowing the common and economical chemical pathways.
This document discusses various systems for classifying crude oil and hydrocarbon resources. It describes classification based on chemical composition, including proportions of paraffins, naphthenes and aromatics. It also discusses physical property-based classification systems including API gravity, viscosity, density and pour point. Reservoir characterization aims to identify and quantify reservoir properties that control fluid distribution and migration in order to accurately describe the reservoir and optimize hydrocarbon recovery. Future resources are expected to come from unconventional reservoirs with low permeability.
This document discusses crude oil processing and the production of hydrocarbon intermediates. It describes how crude oil is distilled through atmospheric and vacuum distillation to produce simple fractions like naphtha, gas oil, and catalytic cracker gases. These refinery products undergo further processing through thermal cracking, catalytic cracking, and steam reforming to produce olefins, diolefins, and aromatics. Key processes mentioned include thermal cracking (steam cracking) to produce ethylene and catalytic reforming to produce BTX aromatics. Delayed coking is also summarized as a thermal cracking process used to upgrade heavy residues into lighter fractions.
Distillation is a key separation process used in petroleum refining to separate crude oil into its various components like gasoline, kerosene, and diesel. Crude oil is first desalted and dewatered before being fed to a distillation unit where it is heated and separated based on differences in boiling points into various hydrocarbon fractions. Further refining processes like reforming, cracking, and hydrotreating are used to convert heavier fractions into lighter, more valuable products like gasoline.
This document provides a brief overview of oil refinery processes, including historical events and descriptions of key unit operations like crude distillation, vacuum distillation, fluid/delayed coking, fluid catalytic cracking, alkylation, and hydrotreating. Process schematics and typical yields are shown for each unit operation.
Carbonization is the process of heating coal in the absence of air to produce coke. There are two types of carbonization: low temperature (500-700°C) which produces semi-coke and more liquid byproducts, and high temperature (>900°C) which produces denser coke and more gaseous byproducts. Coking coal undergoes carbonization to produce strong, porous coke for metallurgical purposes, while non-coking coal leaves a powdery residue and is not suitable for coke production.
Thermal cracking is a refinery process that breaks larger hydrocarbon molecules into smaller molecules like gasoline. The presentation discusses various aspects of thermal cracking including:
1. The necessity of cracking to produce more gasoline from heavier crude oil fractions.
2. The main types of cracking - thermal cracking and catalytic cracking. Thermal cracking uses high temperatures without a catalyst.
3. Key thermal cracking processes like Dubbs, pyrolysis, visbreaking, and coking which use different temperatures and pressures to produce different product yields.
4. The thermal cracking reactions of decomposition, hydrogenation, polymerization, and cyclization that alter the hydrocarbon molecules.
5. Commercial thermal cracking units and how they operate to continuously
Fluid coking is a continuous process that thermally converts heavy hydrocarbons like residue into lighter products using two fluidized bed vessels, a reactor and a burner. In the reactor, feedstock is cracked into vapor and coke deposits on circulating coke particles, which transfer heat to the reactor. Flexicoking integrates fluid coking with coke gasification to upgrade residues. It uses an air gasifier to burn coke for heat and a steam gasifier to produce syngas that can be further processed. Dual gasification flexicoking employs both gasifiers, with the air gasifier providing heat and the steam gasifier generating syngas for downstream use or hydrogen production.
This document provides information on fluid catalytic cracking (FCC), including:
1) FCC is a process that uses heat and a catalyst to break down large hydrocarbon molecules in vacuum gas oil into smaller molecules like gasoline and light olefins.
2) The catalyst, usually a zeolite, facilitates cracking reactions at lower temperatures and pressures than thermal cracking. During FCC, the catalyst is regenerated by burning off coke deposits.
3) FCC units typically produce gasoline, light olefins like ethylene and propylene, and LPG as products from cracking heavier hydrocarbon feeds.
This document summarizes the hydrodealkylation process for converting toluene to benzene using hydrogen gas. It discusses the raw materials of toluene and hydrogen, the chemical reaction where toluene and hydrogen produce benzene and methane, properties of benzene, a flow chart of the process, descriptions of process steps including reactor design and hydrogen issues, alternative processes, uses of benzene, and health hazards of benzene exposure.
This document discusses three methods of producing synthetic petrol: polymerization, Fischer–Tropsch process, and Bergius process. Polymerization involves combining smaller hydrocarbon molecules to form heavier molecules resembling gasoline. The Fischer–Tropsch process converts carbon monoxide and hydrogen into liquid hydrocarbons using a catalyst at high pressures and temperatures. The Bergius process directly converts coal to liquids by mixing coal with hydrogen gas and heating it in the presence of a catalyst.
The document discusses the alkylation process. It begins with an overview of the chemistry and components involved. It then describes the typical process which involves reacting olefins like propylene and butylene with iso-paraffins like isobutane in the presence of an acid catalyst to produce a high-octane gasoline blendstock called alkylate. The document concludes by noting that alkylation is an important process for meeting gasoline regulations given alkylate's low emissions profile.
basic building block processes in petrochemical technologyAfzal Zubair
Petrochemical processes involve basic building block processes for manufacturing intermediates and products. Key petrochemical processes include thermal cracking, catalytic cracking, and steam reforming which produce olefins, synthesis gas, and aromatic compounds from petroleum feedstocks like naphtha and gas oil. Thermal cracking uses steam to crack ethane, propane and heavier hydrocarbons to produce ethylene, propylene and other products. Catalytic reforming uses naphtha to produce BTX aromatic compounds. Steam reforming produces a mixture of carbon monoxide and hydrogen from hydrocarbon feeds. Polymerization then links monomer molecules into long chains or networks to form plastics, fibers and other polymer products.
The document discusses various thermal cracking and catalytic cracking processes used in the oil refining industry to break down heavy hydrocarbon molecules into lighter products such as gasoline. It describes processes such as steam cracking, catalytic cracking, hydrocracking, thermal cracking, visbreaking, and coking. It provides details on the operating conditions, reactions, equipment used, and products of each process. The goal of these cracking processes is to produce more valuable and widely used products from heavy oil fractions.
The aniline point test determines the lowest temperature at which equal volumes of aniline and an oil sample fully mix. A lower aniline point indicates a higher aromatic content in the oil sample. The test is suitable for transparent liquid samples with an initial boiling point above room temperature. The aniline point can be used to estimate properties like cetane number, diesel index, and aromatic content, which provide information about the oil sample's combustion quality and suitability for diesel fuel. Extracting the oil sample with furfuraldehyde can lower its aromatic content and thus increase the aniline point.
Thermal conversion processes include thermal cracking, visbreaking, coking, and coke calcination. Thermal cracking involves cracking large hydrocarbon molecules into smaller ones at high temperatures. Visbreaking is a mild thermal cracking process used to reduce the viscosity of residues and produce fuel oil, naphtha, and gas oil. Coking involves heating residues to very high temperatures to produce coke and lighter hydrocarbon products.
Petroleum lab experiment 02 - octane number and cetane numberSafeen Yaseen Ja'far
The document describes an experiment conducted by a group of chemical engineering students to determine the octane number of gasoline samples and the cetane number of diesel fuel samples. It includes the aim of the experiment, theoretical background on octane and cetane numbers, methodology, procedures, calculations, and a discussion section with answers to questions about fuel compositions and effects of adding compounds.
refining of crude oil by Arun kumar ranaBIET Jhansi
This document discusses the refining of crude oil. It begins by describing crude oil as a complex mixture of hydrocarbons found in the Earth's crust. The refining process separates crude oil into fractions using fractional distillation based on differences in boiling points. Major fractions include petroleum gas, naphtha, gasoline, kerosene, diesel, lubricating oil, and fuel oil. Further processing using thermal cracking and catalytic cracking converts heavier fractions into more valuable products like liquefied petroleum gas and gasoline. Refineries are upgraded in response to market demands and clean air regulations.
- The FCC unit uses a catalyst to crack heavy hydrocarbon fractions from the crude oil distillation unit into lighter, more valuable products like gasoline and olefin gases. This catalytic cracking process yields higher octane gasoline and more olefins than thermal cracking.
- The C3 separator separates butanes from the gas fraction, which are then used in isomerization and LPG production. The C2 separator further separates propane and lighter hydrocarbons from the stream.
- These separators allow refineries to separate and recover hydrocarbon fractions at different carbon numbers for downstream refining processes based on differences in density.
CRACKING ppt for chemical engineering studentssmmaker21
Cracking is a process that breaks down complex, heavy hydrocarbons like kerogen and heavy petroleum into lighter, more useful molecules like light hydrocarbons. There are two main types of cracking: thermal cracking uses high temperatures without a catalyst, while catalytic cracking uses lower temperatures with a catalyst. Cracking is necessary to produce important petrochemical feedstocks like ethylene and propylene that are in higher demand than heavier hydrocarbon fractions.
Thermal cracking processes evolved in the early 1900s and were used to produce gasoline from heavier crude oil fractions. These included thermal cracking where crude oil was heated to break larger molecules into gasoline. Visbreaking and coking were also developed, using heat but at lower temperatures to break molecules and reduce viscosity. Modern catalytic cracking, developed in the 1930s, uses a catalyst to produce higher octane gasoline more efficiently than thermal cracking alone. The catalyst directs reactions to produce more desirable products like iso-paraffins and aromatics compared to thermal cracking.
The document provides information on the operation of a crude and vacuum distillation unit. It separates crude oil into different products based on boiling point differences and prepares the feed for secondary processing units. Key features include two kerosene draw-off flexibilities to meet changing specifications and a heavy gas oil draw off to minimize load on the vacuum heater and vacuum column. The crude distillation unit processes various crude oil cases to produce products like fuel gas, LPG, naphtha, kerosene, light gas oil, heavy gas oil, and reduced crude oil.
Fluid catalytic cracking (FCC) converts heavy gas oil into lighter hydrocarbon products like gasoline and gas oils using a catalyst. The process occurs at intermediate to high temperatures under low pressure. Vacuum gas oil is used as feedstock and cracked over a powdered catalyst like alumina and silica particles to form carbonium ions and products. The spent catalyst is regenerated in a regenerator by burning off coke deposits with air to provide heat for the endothermic cracking reactions. Main products include LPG, gasoline, and gas oils that are separated in a fractionator. Typical conditions are a reactor temperature of 470-540°C and regeneration at 590-610°C.
Thermal cracking processes such as visbreaking and delayed coking are used in petroleum refineries to break down heavier hydrocarbon fractions into lighter, more valuable products. Visbreaking involves mildly cracking residual oil at atmospheric pressure to reduce viscosity without significantly affecting boiling points. Delayed coking uses higher temperatures to crack residual oil into coke, gasoline, and other distillates. These thermal cracking processes allow refineries to alter product yields and increase profits.
The document discusses boiler fundamentals, operation, and maintenance. It begins with an outline presenting these topics, then defines a boiler as a closed vessel used to heat water or other fluids. The document covers various boiler types including water tube and fire tube, classifications based on fuel, pressure levels, and circulation. It also addresses considerations for boiler selection and discusses advantages of supercritical boilers, which can achieve higher efficiencies compared to subcritical boilers.
This document provides an overview of parameters and operation of a cement kiln system. It describes key parameters to monitor including back end temperature, material temperature, chain gas temperature, burning zone temperature via shell temperature scanner and kiln drive amps. It explains that kiln stability relies on stable feed, dust return, water injection, chain system, hood pressure, secondary air temperature and production level. The document also outlines priorities for kiln operation and lists potential emergency conditions and problems.
Primary processing in petroleum refineries involves distilling crude oil into basic fractions like gasoline, naphtha, and gas oil. Secondary processing further converts and improves these fractions. It includes physical processes like distillation and chemical processes like catalytic and thermal cracking to break large molecules into smaller, more valuable ones. Thermal cracking processes like visbreaking use heat to reduce the viscosity of heavy residues while delayed coking severely cracks residues into lighter products and a carbon residue of coke. The goal of secondary processing is to upgrade the crude oil fractions and maximize refinery profits.
This document discusses safety interlocks in crude heaters using programmable logic controllers (PLCs) at Bharat Petroleum Corporation's Kochi Refinery. It provides an overview of the refinery's process units including the crude distillation unit (CDU) and describes the various components involved in heating crude oil such as the preheater, desalter, crude heater, burners, and distillation columns. It also discusses the use of intrinsic safety barriers and programmable logic controls to monitor parameters and automatically shut down equipment if safety thresholds are exceeded.
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
The document discusses petroleum refining processes. It begins with an overview of refining which involves separating petroleum into fractions and treating them to produce marketable products. It then discusses four major forces that have influenced the development of refining processes: demand for products, feedstock supply, environmental regulations, and new technology. Next, it provides historical context starting with early refining focused on kerosene production. It then outlines the main categories of modern refining processes: separation, conversion, and finishing. The document dives deeper into specific separation processes like dewatering/desalting, distillation, and vacuum distillation.
Three main methods are used to remove nitrogen from natural gas: cryogenic distillation, adsorption, and membrane separation. Cryogenic distillation involves using low temperatures and pressures to separate gas components. It is most effective at recovering ethane, propane, butane, and natural gasoline. Adsorption uses materials like molecular sieves to attract moisture and other compounds from the gas stream. Membrane separation exploits differences in molecular sizes to selectively permeate some components over others.
The document provides an overview of inplant training at MRPL, including:
- MRPL is a subsidiary of ONGC located in Mangalore, Karnataka.
- The refinery's units include a crude distillation unit, vacuum distillation unit, hydrocracker unit, hydrogen unit, and gas oil hydrodesulfurization unit.
- Each unit is described briefly, outlining its key processes and products. The presentation aims to educate trainees on MRPL's refinery operations and configuration.
The document provides an overview of a fluidized catalytic cracking unit (FCCU) at an Indian oil corporation. It describes the FCCU's feedstocks as heavy vacuum gas oil and once-through hydrogen cracker unit bottom oil. The main products are dry gas, LPG, gasoline, heavy naphtha, light cycle oil, and coke. It outlines the reactor, regenerator, fractionator, and gas concentration sections of the FCCU and discusses key operating parameters like temperatures, pressures, and catalyst/oil ratio.
The document discusses the process of oil refining. Crude oil enters the refinery and is separated into fractions through fractional distillation in distillation towers. It then undergoes additional processes like heating, cooling, and chemical processes. The fractions are treated to remove impurities and blended to produce useful products like gasoline, diesel, kerosene, and others which are then stored for shipping and distribution.
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2008 BUILDING CONSTRUCTION Illustrated - Ching Chapter 02 The Building.pdf
thermalcracking.pptx
1.
2. SECONDARY PROCESSING :
Thermal conversion process
•
•
•
•
T H E R M A L C O N V E R S I O N
P R O C E S S E S
Thermal Cracking
Visbreaking
Coking
Coke Calcination
4. • THERMAL CRACKING
➢The processes is which hydrocarbons are decomposed
at elevated temperatures to from material of lower Mol. wt.
are called thermal conversion process. Any fraction of the
crude from Naphtha to Vac. Residue – can be processed
thermally.
➢The most important types of thermal conversion process
are thermal cracking, visbreaking and coking.
➢Thermal cracking is used for conversion of residues and
higher Mol. wt. hydrocarbons into more useful products by
cracking the large hydrocarbon molecules into smaller ones
at a temp. level of 4500 – 5000C.
➢Cracking activity varies with the type of hydrocarbons
and decrease in the following order:
n–paraffin > Isoparaffins > cycloparaffins > aromatics >
aromatics / naphthenics > polynuclear aromatics.
➢ Olefins crack to smaller olefins and di-olefins
5. ➢ Important variables in thermal cracking are Temp.;
pressure and residence time.
➢Cracking reactions begin to occur at Temp. of 315 – 3700C.
Pressure determines the phase in which the cracking
reactions take place. Thermal cracking conversion increases
with temp. and residence time.
➢Under very severe thermal cracking conditions, there is
tendency for coke formation.
Cracking also generates double bonded hydrocarbons
(olefins). Side reactions like condensation and polymerization
reactions also occur leading to gum formation and tar-like
polymerization products. (To avoid this, gasoline or diesel
blend produced from thermal cracking process are
hydrotreated to make them stable usable product).
Since products of thermal cracking have very poor stability
and require further treatment ; Fluid catalytic cracking FCC
finds more favors with refiners.
6. • Simplified Thermal Cracking Process :
➢Simple Thermal cracking process produces gas,
naphtha, middle distillates and thermal tar from almost
all variety of charge stocks from distillates to the
heaviest crude and residual oils.
➢The feed is heated to cracking temp. 4500 – 5000C
and the cracked products containing gas and Full
Boiling Range distillates enters the fractionators after
passing through an intermediates separator vessel.
8. ➢TYPICAL operating conditions and The Yield Patterns in The
SHELL process for Long Residue (Atmospheric Distillation column
bottoms) and Short Residue (Vacuum Distillation column bottoms)
are :
Cracking temperature, 0C 450 – 500
Furnace outlet pressure, kgf/cm2
4
20
(a) For residue
(b) For heavy residue
Typical Yield Pattern
Products
The yield of fractions in the Shell process for long residue and short
residue
Yield, wt. % on feed
Long residue
(Two furnace operation)
Short residue
(One furnace operation)
2
4
12
C1 – C4
C5 – 1650C
165 – 3500C
4
8.5
23.5
9. • VISBREAKING
➢Visbreaking – an abbreviation for viscosity breaking or
viscosity lowering – is a liquid phase thermal conversion
process to reduce the viscosity of Atmospheric (long
residue) and Vacuum (short residue) to produce
specification fuel oil.
Small quantities of LPG and a fair amount of naphtha are
also produced.
➢Visbreaking is a mild thermal cracking process and
help in reducing the viscosities and pour point of long
and short residues. Refinery production of heavy oils can
be reduced by 30% using visbreaking. Visbreaking also
produces gas, gas oil stock and gasoline which go for
further processing.
10. ➢The principal reaction which occur during The Visbreaking are :
Cracking of the side chains attached to cycloparaffins and
aromatic rings.
Cracking of resins to light hydrocarbons (primarily olefins)
Some cracking of naphthene rings under higher temp.
of operations (5000C)
➢ 2. types of Visbreaking operations :
Conventional Visbreaking (Furnace or coil cracking)
Soaker Visbreaking
➢ Conventional Visbreaking :
Also known as coil cracking, the process uses Furnace
outlet temp. of 475-5000C and reaction time from one to three
minutes. This process produces minimum of Naphtha and a
maximum of fuel oil from long and short residues and other
heavier feed stocks.
Gas, Naphtha and light gas oils are recovered from the top
section of the fractionators. Gas and Naphtha can be further
processed in a gas concentration unit for the recovery of LPG.
13. ➢Typical yield pattern
Gas plus loss 3
Naphtha
Fuel oil (Visbroken
residue)
4
93*
*If diesel production is to be maximized, a second
cracking furnace is added to the stream and the heavy
fraction boiling between 350 – 5000C, obtained by distilling
the visboken residue under vacuum is recycled to second
furnace for further cracking.
➢Run lengths of 3 – 6 minutes are common for coil
visbreakers.
14. ➢ Visbreaking is an effective and cost – effective
way to produce more valuable products from heavy
residues. Earlier, it used to reduce the viscosity and/
or pour point of a fuel oil but now it is employed to
obtain Cat. Cracker feed and to reduce fuel oil
production.
15. • Soaker Visbreaking :
➢In this process a soaker drum is added between the
furnace and the fractionator. This drum provide large
residence time for the feedstock. The cracking reactions
take place in soaking drum. Since higher residence time
allows improved conversion at lower temps. ; Soaker
Visbreaking Technology is more energy efficient and
provides higher run lengths as coking reactions in the
furnace coil are significantly reduced. Run lengths to 6-18
months for Soaker Visbreaker.
➢Other advantages of Soaker Visbreaking are :
Lower capital cost (10/15% lower)
Smaller furnace ; less waste Heat Recovery equipment
Less pressure drop through furnace
▪
▪
▪
▪
▪
Lower fuel consumption (15% less fuel : 0.2% on feed)
Better and more selective yields.
17. ➢ Typical operating condition
Operating parameter
Equipment
Soaker Drum
5 – 15 bar (g)
4400C
Pre.
Temp.
Vapour Cracking
Liquid Cracking
Run length
minimum
Yes
300 days
Yield Pattern
Product
Gas
Naphtha (80-2000C)
Light gas oil (200-3500C)
Heavy gas oil (350-5200C)
Residue (5200C+)
Yield; % of feed
1.7
3.1
13.2
27.0
55.0
18. • COKING
➢Coking is the most widely practiced means of reducing
the C – H ratio of residual oils, Of the 2 main process –
delayed coking and fluid coking – more than 90% capacity is
in delayed coking units.
➢Delayed coking is a thermal cracking process in which a
hydrocarbon feedstock, mainly residue is converted to lighter
and more valuable products and coke.
➢Main advantage of the process is that it can take residual
stocks from a wide variety of process unit in a Refinery
Coking Furnace and the coke drums are the key elements in
the process. Cracking is initiated in the furnace tubes where
short residence time is allowed. Coking of the feed material
is delayed until it reaches large coking drums with larger
retention time; downstream of the coking heater.
➢Three types of coke structures can be produced shot,
sponge or needle coke.
20. ➢ Process Description
•Delayed coking is a semi continuous process in which
the heated charge is transferred to large coking drums
which allow the long residence time needed to allow the
cracking reactions to proceed to completion feed to
these units is normally heavy atmospheric residues,
although heavy catalytic cycle oils and cracked tars may
also be used.
•Feedstock gets pre heated by exchange of heat from
outgoing products and is partially vaporized in a specially
designed coking furnace. Mild cracking takes place in
the furnace where thermal cracking temps; of 4850 to
5050C are reached.
21. • From the furnace, the liquid-vapor mixture goes to the
coking drum (operating in batch-1 coking, the other
decoking). The vapors under-go cracking as they pass
through the coke drum.
•The cracked products go to fractionate where cracked
gas, Naphtha, Kerosene and gas oils are separated. The
petroleum coke is formed in the drum due to high
residence time of cracking in the drum.
• The feed stream is regularly switched between the
operating drum and drum under decoking. Decoking is
done using high pressure water jets. This generally fallows
a 12-16 hr. cycle.
22. ➢ decoking operation
Following procedure is used to remove the coke :
(i) The coke deposit is cooled with water.
(ii)One of the heads of the coking drums is removed
to permit the drilling of a hole through centre of the
deposit.
(iii)A hydraulic cutting device, which uses multiple
high pressure water jets, is inserted into the hole and
the wet coke is removed from the drum.
(iv)After the removal of coke from the coke drum, it is
flushed with water and is readied for reuse.
24. • Fluid Coking
➢Fluid coking is a continuous process that uses the
fluidized solids technique to convert residue including
vacuum pitches to more valuable products.
➢Fluid coking uses 2 vessels – a Reactor and a
Burner. Both the reactor vessel and the burner vessel
contain fluidized beds with coke particles circulating
between the two vessel by fluidized solids technique.
Coke particles are circulated to transfer heat to the
reactor. The residuum is cooled by distributing it as a
thin film of liquid on the outside of the hot-coke
particles.
➢The vapor products pass through cyclones that
remove most of the entrained coke.
25.
26. • COKE CALCINATION PROCESS
➢ Petroleum coke is produced as delayed sponge
coke, delayed needle coke, fluid coke.
➢Calcination of raw petroleum coke (green coke) is
needed to transform it into useable material.
➢Calcined coke is mostly used by the Aluminum
Industry in the manufacture of anodes for Alumina
Reduction, Calcined needle coke is used to
manufacture. Graphite products and prebaked graphite
electrodes for use in electro – metallurgical furnaces.
• Process Description
Calcination of green coke is essentially a high
treatment involving drying,devolatilization
temp.
and
dehydrogenation by which the C/H ratio of the feed is
increased from about 20 to 1000. It may be carried out in a
rotary kiln.
27. To Stock
Steam
Green Coke
Fuel Gas
Rotary Cooler
Calcined
coke
Rotary Kiln
Coke Fines
Incinerator
&
Boiler
Coke calcination process