P E T R O L E U M R E F I N E RY- P E T R O C H E MI C AL

C O M P L E X I N T E R FA C E

OVERALL VIEW OF PETROCHEMICALS

Carbon
monoxide Methanol
 Girbotol /Amine Treatment Process (Acid Gas Sweetening )

Mono-ethanolamine: 20 %; Di-ethanolamine: 20 to 25 % aq. solution

Methyl-di-ethanolamine:30 to 55% % aq. solution for removal of sour/acid gases

HYDROTREATMENT
OBJECTIVES: (I) To stabilize petroleum products
(II) To remove objectionable elements( S, N, O, halides and trace metals
STABILIZATION:
(I)TO REMOVE LIGHTER FRACTIONS
(II)TO REMOVE OLEFINS, DIOLEFINS LIKE GUM FORMING CONSTITUENTS
feed stocks of hydrotreating ranges from naphtha to reduced crude

DIFFICULTY OF SULFUR REMOVAL : PARAFFIN<NAPHTHENE<AROMATIC

Phenol
PROCESS FLOW DIAGRAM OF
HYDROTREATMENT
Off Gas

Unstabilized
Naphtha

To 2nd
Compressor stage

H2 make up to 2nd stage

PFD OF FIRST STAGE HYDROTREATMENT

PROCESS FLOW DIAGRAM OF

HYDROTREATMENT
Off
Gas

HYDROTREATED
PRODUCT
Recycle compressor

PFD OF SECOND STAGE HYDROTREATMENT

 MEROX PROCESS FOR GAS
EXTRACTION/PURIFICATION

Extraction column Disulfide

Oxidizer separator
Water
wash Treated
section Product

Extraction Spent
Section Air
Caustic

Prewash
section
Disulfide
Feed oil

EXTRACTIVE SULFREX SWEETENING

PROCESS

Sweet LPG cut

 Sulfur recovery process: partial combustion

The first bed is operated at a temperature of 650oF to ensure destruction of the COS and CS2. Subsequent beds
are maintained at 30 degrees above the sulphur dew point to achieve the highest possible conversion. The
overall sulphur recovery increased to 98.0 percent, an approx. 1.9 percent improvement over the two-bed case,
by adding the third catalyst bed

ISOMETRIC VIEW OF A NAPHTHA STEAM-CRACKING FURNACE CELL

SIMPLIFIED FLOW SCHEME OF A COMPLETE NAPHTHA STEAM CRACKING UNIT
SEPARATION & REFRIGERATION SECTIONS OF STEAM
NAPHTHA CRACKING UNIT

Cold separation section of a naphtha steam-cracking unit

Design of Refrigeration Cycles in a Steam Cracker

 NAPHTHA PYROLYSIS:EFFLUENT COMPOSITION VS OPERATION
SEVERITY

Hydrocarbon (% wt.) in effluent

KSF severity Index

The results are obtained with a given feedstock for constant residence time and
partial pressure of HCs. The shaded area shows the normal operating range
of industrial plants.
Ethylene yield (% wt.)

Influence of temperature
& residence time on
ethylene yield

Residence time (s)

Ethylene yield (% wt.)

Influence of partial pressure

of hydrocarbons on ethylene
yield
Partial pressure of hydrocarbons at outlet of pyrolysis tube(10 3 Pa)
Yield (% wt.)

Influence of
steam/naphtha weight
ratio on yield
Steam/Naphtha weight Ratio
 SCHEMATIC SECTION OF RADIANT BURNER

BUTADIENE RECOVERY PROCESS

SOLVENTS
1. Acetonitrile
2. Furfural
3. N-methylpyrrolidone

Butadiene Recovery Process : Extractive Distillation

Butadiene content of C4 fraction is about 20-30wt.% and the net yield of butadiene is about
20.6 wt.% of the thermal cracking feed depending on the nature of the feedstock and the
severity of cracking
In selective extraction process, an aq. Cuprous ammonium acetate solution is used; and butadiene has
the highest solubility in it. At first, all the unsaturated HCs are absorbed in the solution at 27 C & 4 bar.
Next stripping off other unsaturated HC except butadiene. Finally, butadiene is separated in the desorber by
raising the temperature to 80 C and pressure is released to 2 bar. Further fractionation yields 98.5+ %
purity.
 Pyrolysis gasoline hydrogenation

First stage hydrogenation converts mainly di-olefins to saturates under relatively

mild condition (stabilization of pyrolysis gasoline) Second stage hydrogenation
under severe condition at 450-500 C, 10-200 atm, 1.5-8 h-1 space velocity can
eliminate S, N, O bearing impurities (in presence of Co-Mo oxide catalysts.)
 Process Flow Diagram of Formaldehyde Production

Production of Acetic Acid (CH3COOH)

One of the major routes for acetic acid production is the carbonylation of
methanol. Liquid-phase process uses cobalt catalyst at 250 C and a high pressure
70 atm. The vapor-phase process(150 C and atmospheric pressure) uses a rhodium
complex catalyst with CH3I, as promoter achieving 99% selectivity.

Light end columns Drying Column Product Column Finishing Column

Heavy ends to incinerator

 OXO SYNTHESIS (Hydroformylation Technology )
Higher primary alcohols /aldehydes are obtained from olefins and synthesis gas

Step III;

Oxychlorination
 Acetylene-Ethylene Combined
Process for VCM

Acetylene VCM
Reactor II
VCM Purifier
HCl VCM
C2H2+HClCH2CHCl

Ethylene
Cracker
Recycle EDC
Reactor I

Chlorine

Vent

In a typical heterogeneous gas-phase process, acetic acid, oxygen and ethylene

react in presence of Pd/Au heterogeneous catalyst in a fixed-bed tubular
reactor. Moderate conditions : 5.5 BarG and 150 C, high single-pass conversion
about 85 percent. Carbon dioxide, water and other side-products are recovered
and recycled in the purification stage.
ETHANOL AMINE PROCESS FLOW
DIAGRAM
 DIRECT HYDRATION OF ETHYLENE TO ETHANOL

Catalyst: Phosphoric acid on diatomaceous earth. Acid

concentration : ~ 80 %, Residence time: 18-20 s ; Conversion
per pass : ~ 6 %; Byproducts ether and aldehydes (small
amount).
C2 H 4  H 2O  C2 H 5OH

Ethylene

Production of Ethanol through catalytic hydration of ethylene