1.

Overview of the OBE matters

 Course Learning Objectives
 Program Learning Objectives

2. 1st topic

3. Direction of this course

4. Activities

Outline
 CO1- Ability to explain the origin and occurrence of
crude oil and its important properties and composition.
 CO2- Ability to illustrate the overall refinery operations
of crude petroleum in converting raw materials to
valuable major products.
 CO3- Ability to analyze and distinguish specific major
processes in petroleum refining and able to justify the
health and safety issues arises due to process operation
and chemicals used.

Course Learning Outcomes

PLO1: Ability to identify and apply knowledge of
mathematics, basic and applied science, engineering
fundamentals and specialization to solve including
complex engineering problems.
PLO2: Ability to identify, formulate and solve engineering
problems, including complex engineering problems, using
the principles of mathematics, basic and applied science
and engineering fundamentals.
PLO8: Ability to apply the knowledge of safety, health,
and the environment and sustainable development issues
in specific engineering scenarios.

Program Learning Outcomes

 CHAPTER 1: Origin of crude oil
CHAPTER 2: Crude oil distillation
CHAPTER 3: Refinery feedstock and products
CHAPTER 4: Thermal cracking
CHAPTER 5: Hydrotreating
CHAPTER 6: Catalytic cracking
CHAPTER 7: Hydrocracking
CHAPTER 8: Reforming
CHAPTER 9: Alkylation and isomerization
CHAPTER 10: Future trend of crude oil

Topics covered
1) Theory of crude oil formation
2) How crude oil is extracted
3) Crude oil composition
4) Physical properties of crude oil
5) Definition of refinery and its schematic
diagram

Outline of 1st topic

 Mixture of naturally occuring HC,
refined into fuels and petrochemicals.
 Also called CRUDE OIL
 Oily, flammable liquid consist
of chemical compound of organic
matter

What is petroleum?
 Produced in sedimentary rocks together with crude oil.
 Consisting mainly of methane, CH4

 Mixture of: 85% CH4, 10% C2H6, 3% C3H8, C4H10, CO2, H2S, N2 & O2

What is natural gas?

How there are formed?
How do you extract them?
 Differ in viscosity:
1. Field by field
2. The way petroleum
composition was formed

Crude oil can be found either:

- Lighter and sweet  contains higher % of HC is more profitable
as fuel source.
- Denser and sour  less flammable level of HC & high S are
expensive to refine into fuel (suitable for plastic manufacturing)

Classification of crude oil

Crude oil consists of:
- Hydrogen+carbon  hydrocarbons
- Other elements like sulfur, nitrogen and various metals.

Basic of crude oil

 - 3 general categories of
hydrocarbon in crude oil:
1. Paraffins – saturated HCs
2. Naphthenes – cycloparafins
3. Aromatics – contains 1 or more
benzene rings

- Non-hydrocarbon compounds:
 Sulfur compound
 Oxygen compound
 Metallic compound
 Salts

Crude oil composition

Paraffin
 Consistof straight or branched carbon rings saturated with
hydrogen atoms, the simplest of which is methane (CH4) the
main ingredient of natural gas. Other name: Alkane.

Hydrocarbon compound
Naphthenes
 Consistof carbon rings, sometimes with side chains, saturated
with hydrogen atoms.
 Chemically stable, they occur naturally in crude oil and have
properties similar to paraffins. Other name: Cycloalkane.

Hydrocarbon compound
Aromatic
 Contain a ring of six carbon atoms with alternating double
and single bonds and six attached hydrogen atoms.
 The simplest aromatic compound are benzene, toluene and
xylene.
 Important petrochemical intermediates & valuable
component for gasoline

Hydrocarbon compound
 Sulfur Compounds.
 Present in crude oil as hydrogen
sulfide (H2S), mercaptans, sulfides,
disulfides, thiophenes, etc.) or as
elemental sulfur.
 Harmful due to its corrosive
nature.
 Other corrosive substances are
elemental sulfur and the
combustion of petroleum products
containing sulfur compounds
produces undesirables such as
sulfuric acid and sulfur dioxide.

Non-hydrocarbon compound
 Example
picture of
corroded
Heat
Exchanger
Oxygen Compounds

Oxygen compounds such as phenols, ketones, and carboxylic

acids occur in crude oils in varying amounts.

Their presence in petroleum stream is not poisonous to

processing catalyst

Non-hydrocarbon compound
Metallic Compounds
 Metals, including nickel, iron, and vanadium found in crude
oils in small quantities.
 Presence either as inorganic salts (NaCl , Mg2Cl3) or
organometallic cmpds (Ni or V).
 Itis also desirable to remove trace amounts of arsenic,
vanadium, and nickel prior to processing as they can poison
certain catalysts.
 When crude oil is processed, salts can form soap with
carboxylic acid  very corrosive!

Non-hydrocarbon compound
Salt
 Contain inorganic salts such as sodium chloride, magnesium
chloride, and calcium chloride in suspension or dissolved in
entrained water (brine).
 These salts must be removed or neutralized before processing
to prevent catalyst poisoning, equipment corrosion, and
fouling.
 Salt corrosion is caused by:
◦ the hydrolysis of some metal chlorides to hydrogen chloride
(HCl) and
◦ the subsequent formation of hydrochloric acid when crude is
heated.

Non-hydrocarbon compound
Summary of crude oil composition
The important physical properties of petroleum are :
(1) Density is the mass of liquid per unit volume at specific
temperature;
(2) Specific gravity is the ratio of the weight of a given V
to the weight of the same V of water measured at
same T.
(3) Viscosity indicates the ease of (or more correctly the
resistance to) flow.

Physical Properties of Petroleum

Fluids
API gravity is defined as:-
“a measure of the lightness or heaviness of petroleum that is
related to density and specific gravity.”
 Another way to express relative masses of crude oil.
 A low API gravity  heavier crude oil or a petroleum
product
 while a higher API gravity  a lighter crude or product.
 Specific gravities of crude oils roughly range from 0.82 for
lighter crudes to over 1.0 for heavier.

What is API Gravity?

  The observed reading are always corrected for
temperature to 60 °F, by using a prepared table of
standard values:-
141.5
 API   131.5
Sp.Gr. @ 60F

 Sp.Gr. = specific gravity to water at 60°F

 The API gravity of water is 10°
 In the field, the API gravity is readily measured using a
calibrated hydrometer

API Gravity
A Rough Classification of Crude Oil Based on The API Gravity
°API Classification Specific Gravity
10 – 20 Heavy oil 1.0 – 0.93
20 – 30 Medium oil 0.93 – 0.87
> 30 Light oil < 0.87

Conclusion : -
°API Specific Gravity = less valuable petroleum
°API Specific Gravity = more valuable petroleum

API Gravity
Products made from a barrel of crude
oil (gallons)
 Petroleum refinery is an organized and coordinated
arrangement of manufacturing processes designed to
produce physical and chemical changes in crude oil
to convert it into everyday usable finished products
like petrol, diesel, lubricating oil, fuel oil and
bitumen.

What is refinery?
Petroleum Refinery Schematic
 Separation Conversion Finishing
Crude oil Gas sweetening,
Gas
Catalytic isomerization blending

Desalting Light naphtha Light distillate

sweetening,
Heavy naphtha Catalytic reforming hydrotreatment or
Atmospheric blending
distillation Kerosene
Alkylation Polymerization
ADR Middle distillate
Gas oil sweetening,
Light vacuum Fluid catalytic hydrotreatment or
Vacuum gas oil cracking blending
distillation Heavy
VDR vacuum gas oil Hydrocracking
Heavy distillate
Dewaxing sweetening,
Visbreaking hydrotreatment or
Solvent blending
deasphalthing Coking
 CHAPTER 3

Separation Conversion Finishing

Crude oil Gas sweetening,
Gas
Catalytic isomerization blending

Desalting Light naphtha Light distillate

CHAPTER 8 sweetening,
Heavy naphtha Catalytic reforming hydrotreatment or
Atmospheric blending
distillation Kerosene CHAPTER 9
Alkylation
Polymerization Products
ADR Middle distillate
Gas oil sweetening,
Light vacuum CHAPTER 6
Fluid catalytic hydrotreatment or
Vacuum gas oil cracking blending
distillation Heavy
VDR vacuum gas oil Hydrocracking
Heavy distillate
Dewaxing sweetening,
Visbreaking hydrotreatment or
Solvent blending
deasphalthing Coking