Downstream Operations

GENERAL OVERVIEW
OF PETROLEUM
DOWNSTREAM STRUCTURE
14 March 2014
Contents
1. Module 2: Refinery Feed Stock Crude Oils
2. Module 3: Refinery Processes & Operations
3. Refining Process Lubes
4. Module 4: Petrochemicals
5. Module 6: Petroleum Products
6. Module 7: Transportation and Storage
7. Module 8: Retail Outlets
8. Module 9: Petroleum Product Economics
2
Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure
OIL RIG UPSTREAM
FLOW STATION
PIPELINE
SHIPMENT
OIL TERMINAL
RETAIL OUTLET
LPG AGO
PMS DPK

Module 2: Refinery Feed Stock
Crude Oils
Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure 7

Refinery Input
CRUDE OILS
PETROLEUM…..PETRA ROCK OLEUM OIL
BROWN OR BLACKISH GELATINOUS
• FREE FLOWING
• SG OF 0.8 TO 1.0
• SULFUR CONTENT OF <1 TO 3%
• BOILING RANGE 37 TO 360oC

Crude Oils
ORIGIN
From decomposed marine organisms (plant & animal)
over hundreds of thousand years
COMPOSITIONS
• Principally Hydrocarbons
• Sulfur
• Oxygen and Nitrogen Derivatives
• Heavy Metals (V.Ni,Na,Fe,Cl, As, Cu,Ag,Hg,Pb)

Crude Oils
HYDROCARBONS
• Paraffins (Normal and Iso)
• Naphthenes (Mono, Bi, and Tricyclo)
• Aromatics (Benzene and Naphthenes)
• Hybrid Molecules with Alkyl Groups to Naphthenes or
Aromatic Ring)
NON HYDROCARBONS
• Sulfur (Organic & Inorganic)
• Nitrogen Compds (Pyrole, Indole, Pyridine)
• Oxygen Compds (Phenols, Naphthenic Acids)
• Metal Precursors (V,Ni,Fe,etc)

Crude Oil Analysis
To Determine Effective Utilization and potential Market Value
• Physical Properties
• SG
• VISCOSITY
• POUR POINT
• Distillation
• ASTM
• TBP
• Chemical Analysis
• Sulfur
• Nitrogen
• Chlorides
• Meta
• Hydrocarbon Group Data
• Individual Saturates C1 – C8
• Parafins C10 –C30 above
• Naphthenes
• Aromatics
Classification
Depends on the relative amount of waxes and asphalt
present
• Using WAX content Crude Oil can be:
• Paraffinic
• Highly Paraffinic
• Naphthenic
• Aromatic
• Using API Gravity
• Light – More valuable Light and Middle distillate
• Heavy – More heavy bottoms (Asphalts)
• Using Sulfur Content
• Sweet
• Sour

Stabilization, Storage & Transportation
• Stabilization
• Dewatering
• Light Hydrocarbon Separation
• Removal of Solids and Metals
• Storage And Transportation
• Tanks
• Transportation By Pipelines to Ocean Liners

Module 3: Refinery Processes &
Operations

Introduction
• Refineries primarily set up to produce transportation

and heating fuels and this has been the force driving
process design and catalyst technology.
• Production of specialty products is secondary.

Refining Processes – Fuels
• Crude is a complex mixture of materials, some in large

amounts and others in small amounts and is of little
practical importance in raw form.
• Has to be processed to obtain over 3000 useful and
saleable products (Fuels, Lubricants and
Petrochemicals)

R and P Plants
• Large sprawling industrial complexes with extensive

network of pipes moving streams of fluids between
processing units and storage facilities.
• The number of processing units and facilities
defines Complexity Index.

Where to Site
• Reasonable distance from residential areas

• Easy access to raw materials and markets
• Easy access to energy and water sources (River and Sea
side/port)
• Abundant space for safety, expansion and co-location
of relevant manufacturing facilities

Environmental Concerns (EIA)
• Substantial Air Pollution
• Industrail noises
• Waste Water disposal
• Risk of accident (Fire and Explosion)
• Therefore Government Agencies involvement
• Hence install equipment needed to comply with EPRA
requirements
• NB: No new refinery built in US since 1976 due to
environmental concerns.

Evolution of Refining Processes
• Distillation (Atmospheric and Vacuum)

• Thermal Cracking
• Hydrogenation
• Reforming
• Solvents Extraction etc.

Development of Refining in Nigeria
• 1965: Old PHC Refinery (NPRC): 35000 BPSD then to

60,000BPSD in 1972.
• 1978: WRPC: 100,000BPSD then to 125,000BPSD in
1986.
• 1980 : KRPC : 100,000BPSD then to 110,000BPSD in
1986
• 1989: New PHRC : 150,000BPSD

The Refinery Complex
• INPUT ---- CRUDE OILS – FEED STOCKS
• OUTPUT
• PETROLEUM FUELS PRODUCTS
• PETROLEUM LUBES PRODUCTS
• PETROCHEMICAL PRODUCT
• PROCESSES
• FACTORS INFLUENCING CHOICE OF PROCESS
SCHEMES

The Fuels Petroleum Refinery
• TOPPING REFINERY
• HYDROSKIMMING REFINERY
• CONVERSION REFINERY

Topping Refinery
• CRUDE DISTILLATION
• GAS PLANT
• LIGHT HYROCARBON RECOVERY

Hydro Skimming Refinery
• TOPPING REFINERY
+
• HYRO TREATING
• CATALYTIC REFORMING

Conversion Refinery
• HYDRO SKIMMING REFINERY

+
• CATALYTIC CRACKING
• HYRO CRACKING
• COKING
• AUXILIARY PROCESS PLANTS

Refining Processes (Operation)
• Physical separation processes
• Chemical conversion
• Finishing & Auxiliary processes preparatory to market.
FACTORS INFLUENCING CHOICE OF PROCESS
SCHEMES
• Crude type
• Product yield: Light vs middle Distillates
• Product Quality

Physical Separation Processes
• DISTILLATION
• ATMOSPHERIC
• VACCUUM
• ABSORBTION – Used to accumulate gases in liquid absorbent
mostly in natural gas processes and Refinery Gas Concentration
Units
• ADSORBTION – Used in adsorbing petroleum gases on solid
materials like molecular sieve, silica gel and alumina
• EXTRACTION – Liquid solvents are used to extract desirable
compounds or mixtures from petroleum streams mostly in lube
oil processes like:
• Propane De asphalting
• Furfural Extraction
• ROSE Process

Conversion Processes
• QUALITY IMPROVEMENT
• QUANTITY IMPROVEMENT OF PREMIUM PRODUCTS

Quality Improvement
• HYDROTREATING
• REFORMING
• ISOMERISATION

Quantity Improvement of Premium
Products
• CRACKING - Production of smaller molecules from
larger ones
• Thermal Cracking
• Catalytic Cracking
• Hydro Cracking
• INCREASING AVERAGE MOLECULAR WEIGHT
• Alkylation
• Dimerisation
• Isomerisation or Condensation

Finishing & Auxiliary Processes
• HYDROGEN PRODUCTION
• SULFUR RECOVERY

Common Process Units in a
Complex Refinery
REFINERY CONFIGURATION= The combination of the
types of processes to produce the desired slate
Modern Refinery Complex will have:
• Atmospheric Distillation Unit
• Distillates (Naphtha, kerosene, gas oils)
• Atmospheric Residue
• Vacuum Distillation Unit
• Vacuum Gas oils
• Vacuum Residue

Complex Refinery
Modern Refinery Cont’d
• Naphtha Hydro treating Unit
• Light Naphtha
• Heavy Naptha
• Catalytic Reforming
• Reformate
• Distillate Hydro treating
• Hydro treated Distillates (kero or Gas oils)

Complex Refinery
• Fluid Catalytic Cracking
• LPG
• Gasoline
• Cycle oils
• Decanted oil
• Hydro Cracking
• LPG
• Gasoline
• Cycle OILS
• Heavy oils
Complex Refinery
• Visbreaker
• LPG
• Gasoline
• Gas Oils
• Pitch
• Coker Unit (Delayed ,Fluid and Flexi)
• Gasoline
• Gas oils
• Petroleum coke

Complex Refinery
• Merox Unit (Gasoline and LPG)
• LPG
• Gasoline
• Kerosene(Jet Fuels)
• Alkylation Unit
• Gasoline
• Dimerisation Unit
• Gasoline
• Gasoline Additves(iso Octane)

Complex Refinery
• Isomerisation Unit
• Gasoline
• Gas Concentration Unit and Gas Treating Unit
• Refinery Fuel Gas
• Hydrogen Sulphide Rich Sour Gas
• Sulfur Recovery Unit
• Elemental Sulfur

Complex Refinery
• Isomerisation Unit
• Gasoline
• Gas Concentration Unit and Gas Treating Unit
• Refinery Fuel Gas
• Hydrogen Sulphide Rich Sour Gas
• Sulfur Recovery Unit
• Elemental Sulfur

Complex Refinery
• Solvent Refining Unit
• Distillates For Lubes Base Oils
• Propane Asphalts
• Solvent Dewaxing Unit
• Dewaxed Base Oils
• Slack waxes
• Solvent Deoiling Units
• Waxes
• Asphalt Blowing Unit
• Asphalts
Schematic Process Flow Diagram of
Fuels Plant

Refining Process Lubes

Lubes Refining
LUBES REFINING PROCESSING SCHEMES
• FEFD STOCK MANUFACTURE
• HIGH VACCUM DISTILLATION UNIT (HVDU)
• PROPANE DEASPHALTING UNIT (PDU)
• VISCOSITY INDEX AND COLOR IMPROVEMENT
• FURFURAL EXTRACTION UNIT (FEU)
• POUR POINT IMPROVEMENT
• MEK/TOLUENE DEWAXING UNIT (MDU

Lubes Refining
• PRODUCTION OF WAXES
• MEK/TOLUENE DEOILING UNIT (MDOU)
• WAX HYDROFINISHING
• GRADES OF WAXES
• PRODUCTION OF ASPHALT
• ASPHALT BLOWING UNIT (ABU)
• GRADES OF ASPHALT : LIQUIDS AND SOLIDS

Lubes Base Oils and Waxes Refining
• INTRODUCTION TO LUBRICATION
• Controls friction and wear.
• Introduces a friction reducing film between moving
surfaces.
• May be a Fluid, Solid or Polymer
• CLASSIFICATION OF LUBRICANTS
• Fluids - Oils an gases
• Solids - Graphite
• Semi Solid - Greases

Greases
Greases are used where liquid lubricants can not provide
required protection.
• Easier to apply.
• Requires little maintenance.
Properties of Greases:
• Stays in place.
• Provides sealing action.
• Provides extra film thickness.
• Components:
• Base Oils.
• Thickners.
• Additives.

Classification of Lube Oils
Classification based on sources:
• Petroleum Lubes.
• Biological: Animal and Plant Lubes.
• Synthetic Lubes.
• Compounded Lubes.
Petro Lubes most extensively used and classified as:
• Industrial Lubes: Spindle, Turbine, Machine, Gear,
Compressor Oils, etc.
• For internal combustion Engines:
• Land – Petrol and Diesel Engine Oils.
• Marine – Cylinder and System Oils.
• Hydraulic Oil – ATF.

Petro Lubes (Cont’d)
• Metal Processing – Cutting, Grinding, Rolling and
Pressing Oils.
• Preservation/Antirust Lubes.
Functions:
• Antifriction.
• Coolant.
• Sealant .
• Stress dispersion (Load carrying capacity).
• Rust prevention.
• Dust prevention.
• Cleaning / Detergency.
• Insulation (Transformer Oil).
Properties: the following properties are required for
proper functioning:
• Viscosity during service should be constant.
• High flash point.
• Low pour point.
• Non-corrosive.
• Oxidation stability.
• Satisfactory and stable colour.
• Low cracking tendency.

Composition:
• Naphthenic:
• Nil or very low wax content.
• Low VI of 25 – 70.
• More oxidation stable.
• Parafinic:
• High wax content.
• High VI of 75 -105.
• Less oxidation stability.

Additives: Materials are usually chemical compounds
added to a base stock to change / improve properties,
characteristics and performance.
• Low temperature detergents.
• High temperature detergents.
• Antioxidants.
• VI improver.
• Pour point depressants.
• Anti-foamers.
• Emulsifiers.
• Load carrying improvers for mild and extreme pressure
conditions.

• Asphalt
Asphalt is used for road pavement and as roofing
materials, it must be inert to most chemicals and
weather conditions.
• Lubricants
Special refining processes produce lubricating oil base
stocks. Additives, such as demulsifiers, antioxidants
and viscosity improvers, are blended into the base
stocks to provide the characteristics required for motor
engine oils, industrial greases and other lubricants.

Schematic Process Flow Diagram of Lubes Plant
Naphtha
Kero FUELS MEK-

PLANT Deoiling
Gas oil
CDU-2 WAX Waxes
Hydro-
Waxy GRADES
Treating
Distillates A,B & C
VDU-2 Base
ATM Residue-2 Oils
100N
150N
150N
Short Residue-
Propane 500N
De-asphalting Bright
Stock
Asphalt Asphalt
2
Blowing GRADES
50/60
60/70
80/100

Lubricating Oil Complex: KRPC
Capacity is 50,000bpsd-Paraffin-Base foreign Crude

Module 4: Petrochemicals

Petrochemicals
• PETROCHEMICALS PROCESSES AND OPERATIONS
• INTRODUCTION
• SOURCES OF RAW MATERIALS
• PRIMARY RAW MATERIALS
• NATURAL GAS
• REFINERY GASES
• REFINERY LIQUIDS

Petrochemicals
• SECONDARY RAW MATERIALS
• EQUIPMENT
• COMMON REACTIONS
• POLYMERS
• CLASSIFICATION
• ELASTOMERS
• PLASTICS
• FIBERS
• PLASTICS
• THERMOPLASTICS
• THERMOSETS

Petrochemical Processes
• LINEAR ALKYL BENZENE ( LAB ) PRODUCTION
• INTRODUCTION
• PROCESS UNITS
• HYDRODESULFURISATION ( HDS ) UINT
• MOLEX UNIT
• PACOL UNIT
• THERMAL HYDRODEALKYLATION ( THDA ) UNIT
• HF ALKYLATION UNIT
• CARBON BLACK PLANT
• POLYMERS
• OL EFINS, POLYETHYLENE AND POLYPROPYLENE

Petrochemical Processes (Operations)
INTRODUCTION
• Petrochemical industry is called “molecular architecture”
• Because products are made from some basic building blocks
called Monomers.
• Over a million ( 1,000,000 ) products known.
• The word Polymer is from Greek words : poly – many and meros –
parts or segments.
• About 6% on Crude is used for production of Petrochemicals
• Process Plants are similar to Refining Plants hence usually located
next to each other and integrated into one large complex.
• Difference lie in high product quality; hence columns are usaully
taller (more trays) but thinner (process less volume)

Petrochemical Processes (Operations)
• Raw Materials
• Synthesis Gas (CO & Hydrogen)
• Olefins
• Aromatics
THEY Can Come From
• Natural Gas: Wet and Dry (Methane to Olefin Derivatives)
• Natural Gas Liquids and Liquified Petroleum Gas
• Natural Gasolines (Isomers for Alkylation iso butanes and iso
pentanes)
• Refinery Gases (Reactive Olefins)
• Refinery Liquids
• Kerosenes (Parafins)
• Reformate (Aromatics ..BTX)
• Decanted Oils and Residual Oils (Poly nuclear Aromatics)

Natural Gas
Dry Natural Gas – No Condensable Hydrocarbons
• Liquids < 0.3 gal7Mcf of gas 85 – 95% CH4
Wet Natural Gas - > 2 gals/Tcf
• More Liquids and less CH4
Typical Composition
Methane 95%
Ethane 0.8%
Propane 0.2%
Carbon Dioxide 3.6%
Nitrogen 0.4%
Contaminants are mainly Acid Gases - H2S and CO2
Some Petrochemicals Schemes
Production of Anionic Surfactants
• Anionic Surfactants are the most important and constitute 60 –
70% of total synthetic surfactant production. Easily biodegradable
• Mostly Soduim or Potassuim salts of Sulfonic acid (less frequently
sulfuric acid) and much better than soaps in many applications.
• Most important Anionic Surfactants are Alkylbenzene sulfonates
made by reacting benzene with Linear alkylbenzenes in the
presence of an acid catalyst (usually HF acid)
• Resulting Alkylbenzene are Sulfonated
• Sulfonic acids are neutralized with sodium hydroxide for solid
detergents or Potassium hydroxide/ Alkanolamines for liquid
detergents.

Schematic Process Flow Diagram of
Lab Plant

Polymer Chemistry
POLYMER used for:
• Plastics
• Fibers
• Elastomers
POLYMER – Macromolecule which contains large number of
building blocks or molecules joined together.
Same Monomer is used or different
Homopolymer monomer joined in a regular
sequence
POLYMER
Copolymer More than one type of monomer by
addition polymerization

Physical Properties of Polymers
Polymers can be characterised by:
I. Average Molecular Weight
II. Number Average Molecular Weight
III. Weight Average Molecular Weight
IV. Crystallinity

POLYETHYLENES
FROM ETHYLENES – KING OF PETROCHEMICALS
KING OF PETROCHEMICALS Resulting from
• Availability Of Monomers
• Ease of Processing
• Relative low operating costs
• Polymer has versatile use
• Resistance to Chemicals
• Has high flexibility
• Strong Market demand
Branched Chains produced by free radical initiated

LDPE polymerization at high pressure. More flexible with
lower crystallinity
PE
Linear Chains produced at low pressure with a metallic
HDPE oxide catalyst of the Ziegler type. More closely packed due
to absence of branches hence molecules are closer and
less permeable to gases

POLYETHYLENES
FROM ETHYLENES – KING OF PETROCHEMICALS

PROPYLENES
CROWN PRINCE OF PETROCHEMICALS
Source
• By Product of Refinery Operations
• Steam Cracking of Ethane in the Production of Ethylene
Uses
• LP Gas
• Alkylate
• Polymer Gasoline Compounds
• Petrochemicals Like
• Acrilo Nitrile
• Propylene Oxides
• Propylene Glycol
• Isopropanol
• Polypropylene

PROPYLENES
PHYSICAL AND CHEMICAL PROPERTIES
• High Crystalline melting point of 170 oC
• Lowest Density of 0.9 – 0.915
• Good electrical and chemical resistance and low water absorbtion
• Good heat resistance and dimensional stability
• High abrasion resistance and very tough
• Lack of toxoicity
• High impact strength
PRODUCTION
• Low Pressure with Ziegler Catayst of TiCl3, TiCl4
• Temp. 50 – 100 oC
• Pres 5 – 30 Bars
USES
• Injection Moulding – 39%
• Fiber and Filaments – 31%
• Films and Sheets – 10%
• Others – 20 %
PROPYLENES

From Hydrocarbons to Petrochemicals

Module 6: Petroleum Products

Fuels Petroleum Products
• MIXED LIQUIFIED PETROLEUM GAS

• PETROL MOTOR SPIRIT – PMS
• DUAL PURPOSE KEROSENE - DPK
• AUTOMOTIVE GAS OIL - AGO
• LOW POUR FUEL OIL - LPFO

Refinery Petroleum Products
BLEND STOCKS
• 100N BASE OIL
• 150N BASE OIL
• 250N BASE OIL
• 500N BASE OIL
• BRIGHT STOCK BASE OIL

Mixed LPG Product Quality
N.N.P.C PRODUCT: MIXED LPG
REFINERY KADUNA
CHEMICAL LABORATORY SPECIFICATION
TEST UNIT TEST METHOD LIMIT

IP ASTM
SPECIFIC GRAVITY 60/60 F Kg/1t __ D To be reported
1657
VAPOUR PRESSURE AT 100 F P sig __ “ 1267 115 max
COPPER STRIP CORROSION ASTMindex __ “ 1838 No 1

max
COMBINED SULPHUR Grains/100 ___ “ 2784 15 max or
cu. Ft. 0.343g/m^3
VOLATILITY 95% EVAPORATED F __ “ 1837 36 max
HYDROGEN SULPHIDE “ 2420 negative
FREE WATER Visual inspection None
COMPOSITION 264 “ 2163
ETHAN AND LIGHTER % moles “ “ “ 0.5 max
PROPANE “ “ “ To be reported
BUTANE “ “ “ “ “ “
PENTANE AND HEAVIER 2 max

Petrol Motor Spirit – PMS
Product Quality
N.N.P.C PRODUCT: SUPER GASOLINE
REFINERY KADUNA SPECIFICATION
CHEMICAL LABORATORY
IP ASTM
SPECIFIC GRAVITY 60/60 F D 1298 To be reported
DISTILLATION D 86
0% EVAPORATED C 70 max
O% “ C 125 max
O% “’ C 180 max 355 F
BP C 205 max
RESIDUE C 2 max
ODOUR Marketable
COLOUR Red
TOTAL SULPHUR % WT D 1266 0.20 max
COPPER CORROSION (3 hr 50 c) “ 130 No 1 strip
max
VAPOUR PRESSURE “ “ PSI “ 323 9.0 max
VAPOUR LIQUID “ ‘
RATIO T36 “ C Calculated 68 min
REXISTENT GUM D 381 4 max

Mg/100ml
OXIDATION STABILITY min D 525 360 min

Remarks
T36 = 98 – 0.812 + 0.00566V^2 – 1.86 WHERE
T 36 = temperature for 33/ vapor / liquid ratio
V =percentage volume evaporated at 70 c
P = Reid vapor pressure (ib. sq . inch)

Dual Purpose Kerosene
Product Quality
N.N.P.C. PRODUCT : KEROSENE
REFINERY KADUNA
CHEMICAL LABORATORY SPECIFICATION

IP ASTM
SPECIFIC GRAVITY AT 60/60 Kg/1 160 D 1298 1. 825
F max
DISTILLATION 123 “ 86
“ RECOVERED AT 200 % VOL “ “ “ 20 min
C
“ E .B .P C “ “ “ 300 max
COLOUR (SAYBOLT) __ _- “ 156 20 min
ODOUR __ __ __ Marketable
FLASH POINT (ABEL) F 170 56 115 min
TOTAL SULPHUR %WT 107 “ 1266 0.15
max
COPPER ORROSION (3hr. AT __ 154 “ 130 No. 1 strip
50 c) ,max
SMOKE POINT Mm 57 __ 22 min
CHART VALUE Mg/kg 10 __ 15
max
Automotive Gas Oil – AGO
Product Quality
N.N.P.C PRODUCT, GASOIL
REFINERY KADUNA SPECIFICATION
CHEMICAL LABORATORY
IP ASTM
SPECIFIC GRAVITY 60/60 F Kg/1 160 D 1298 0.820 min
COLOR ASTM ASTM COLOR __ “ 1500 3 max__
SCALE
DIESEL INDEX __ 21 __ 47 min
DISTILLATION: C 123 “ 86
RECOVERED 357 C %VOL “ “ 90 Min
E. B. P. C 385 max
FLASH POINT P.M F 34 “ 93 150 min
TOTAL SULPHUR %WT __ “ 1552 0.5 min

COPPER CORROSION (3 hr 100 c) 154 “ 130 No . 1 strip
max
KINEMATIC VISCOSITY (100 F) c. s. t 71 “ 445 1.6__5.5
CLOUD POINT F 219 “ 2500 40 max

CARBON RESIDUE (CONRADSON ON10% %WT 13 “ 189 0.15 max
RESIDUE)
STRONG ACID NUMBER Mg/KOHgr 139 “ 974 NIL

Automotive Gas Oil – AGO
Product Quality Cont’d
TOTAL ACID NUMBER Mg/KOHgr 139 “ 974 0.5 max
ASH CONTENT %WT 4 “ 482 0.01 max
WATER BY DISTILLATIONS % VOL 74 “ 95 0.05 max
SEDIMENT BY EXTRACTION %WT 53 “ 473 0.01 max
WATER & SEDIMENT %VOL 53 “ 1796

Module 7: Transportation and
Storage

Petroleum Products Transportation
• PIPELINES
• ROAD
• RAIL
• SEA




Pipelines
PIPELINES Comprises of:
• Pipes
• Carbon Steel
• Alloy Steel
• Wrought Iron
• Brass & Copper
• Valves (Brass, Iron or Steel
• Globe
• Gate
• Check

Fittings
• Flanges
• Elbows
• Tees
• Crosses
• Reducers
• Bushings
• Couplings
• Nipples
• Unions
• Return bends
• Y bends
• Caps & Plugs

Pipelines Design and operations
based on
DIFFERENTIAL PRESSURE BETWEEN THE TWO POINTS
Comprising of
• Head Loss (due to differences in Height) and
• Velocity Loss(due to flow of fluid inside pipe

Pipelines

Pipelines

Storage Tanks
Design Principles
• Physical Properties of Product to be Stored such as
• Boiling Ranges,
• Vapour Pressure,
• Flash Point,
• Congealing Point
• Density or Specific Gravity
• Viscosity
• Capacity
• Filling Rates
• Evacuation Rates

Storage Tanks
Design Principles Cont’d
• Stability & Rigidity to Withstand Weather Conditions
• Wind Load
• Rain
• Snow
• Earth quake

Tankage
TANK TYPES
• Low Pressure : Cone Roof
• High Pressure: Floating Roof
• Spheres
• Spheroids
• Hemispheroids
• Gas Holder
• Safety: Flame Arrestor/Breather Valve

Features Associated With Tanks Operation
• Sizing or Capacity (how long and for what service?)
• Is it hot or very cold service (temperature sensitive) –
lagging required?
• It must have nozzles for inlet and outlet plus side streams
and sensors
• It must breathe – very important for self protection (over
pressure and underpressure can both be experienced)
• It must be accessible
• It must be supported
• Labels
• Drains and Utility Connections

• A total of 166 tanks are available to handle crude,
intermediate and finished products.
• Product evacuation is by Road, Rail and Pipeline.
• Capacity to load 192 trucks of 33,000 litres each daily.

Crude and Product Handling Facilities

Crude and Product Handling Facilities
STORAGE VESSELS – CRUDE OIL TANKS
INTERMEDIATE CRUDE OIL TANK

PRODUCT STORAGE
TANK
Petroleum Product Evacuation
Product Evacuation is by:
• Road
• Rail
• Pipeline
• Sea
Product Loading Facilities Include
• Metering Devices made up of
• Flow Meters
• Instrumentations
• Control valves
• Loading Arms with Automatic Flow Control Shut off
Valves

Petroleum Product Evacuation

Module 8: Retail Outlets
Retail Outlets
Classification and Citing Criteria:
• Urban
• Semi Urban
• Rural
Design & Operations Of Retail Outlets
• Metering
• Safety

Retail Outlets

Module 9: Petroleum Product
Economics
Petroleum Products
• PRODUCTS QUALITY REQUIREMENT

• REFINERY TANKSIDE COSTING
• IMPORT TERMINAL PRICING

POLYMERIZATION REACTION
REACTIONS
 CHAIN Reactions (Addition Polymerization)
 STEP Reactions (Condensation Polymerization)
 COORDINATION Polymerization
 ADDITION Reaction widely used in production of
Thermoplastics which can be: Polyethylenes
Polypropylenes
Polyvinyl Chlorides
Thermosetting Plastics – Teflon
Fibers – Polyacrylonitrile
Elastomers – Poly isoprene
Polybutadiene
Addition Reaction can be by:
 Free Radical Polymerization involving
 Initiation
 Propagation
 Termination
 Ionic Polymerization
 Cationic Polymerization
 Anionic Polymerization
 Coordination Polymerization occur in cases where reactive center in ionic
reaction and the metal are relatively covalent. The reaction takes place in
the presence of Ziegler – Natta catalysts which are complexes of transition
metal halides with organo metallic compounds like Aluminium-titanium
Chloride
PHYSICAL PROPERTIES
 Low Degree of water absorption
 Not attacked by dilute acids and alkalis
 Excellent chemical resistant
 Swell slowly in hydrocarbon and chlorinated hydrocarbon
 Low tensile strength but high impact resistance and excellent electrical resistance
PRODUCTION
Highly exothermic reaction
Heat removal is essential as PE decomposes at high temperature to methane, carbon and
Hydrogen
Reactors can be TUBULAR or AUTOCLAVE
Tubular Reactors have 3 zones
Heating zone
Reaction zone
Cooling zone
LDPE resin grades are branched polyethylenes,
which provide easier processing, higher melt
strength and superior optical properties
compared with linear polyethylenes. The very-
low-haze grades provide excellent optical
properties. The branched structure of LDPE
also makes it ideal to serve as the main resin
component in shrink film structures.
LDPE
Typical Reaction Conditions
Temp: - 100 – 200oC
Pres. - 1,500 – 2000 Bars
Conv. - 95%
• Free Radical Initiator which is O2 or peroxides and chain transfer are fed into the
Reactors with the monomer
• Rate of polymerization is accelerated by increasing the temperature, initiator conc.
And pressure
• Degree of branching and molecular weight distribution depend on pressure and
temperature. Increasing the pres. And decreasing the temp. produce polymer with
a higher density and narrower molecular weight distribution.
• LDPE produced from Tube Reactors are better for film manufacture
• LDPE from Stirred Auto clave reactors are more suitable for coatings
• Later development operate with fluidised bed reactors and at
• Temp. <100 oC
• Pres 100 – 300 Bars
USES
LDPE has the largest volume thermoplastic products which include.
o Building Materials and electrical insulation
o Packing Materials
o Sheets
It is inexpensive and can be
• Moulded into any shape
• Extruded into fibers or filament
• Blown into films or foil
• Films and Sheets and injection moulds
HDPE are used in
• Blow moulded containers
• Pipes for corrosive and abrasive materials
Sponge Bonded PE are used as
Note book covers, wall coverings, tags and labels
Point Bonded PE are used for
Lab Coats, Aprons, Garments and sleeping Bag liners
112
HDPE
 Low Pressure
 Fluidised Bed Reactor
 Catalyst is ziegler type which is a complex between an Aluminium Alkyl
and a transitional metal halide like Titanium tetra chloride or Silica or
alumina impregnated with small amount of Chromium or Molybdenum
Oxide.
 Conversions are very high
 Temp. – 85 – 95 oC and Pres. Below 300 psig
 Polymerization may be in the gas phase or liquid phase.
 Branching is incorporated in the back bone of the polymer by adding
varying amounts of co- monomer like Hexane
 SYNTHESIS GAS
Produced by steam reforming of Natural gas to produce 3 to 1 ratio of H2 to CO
Non Catalytic Process at
Temp. – 1,300 – 1,500 oC
Pres. - 200 – 2,000 psig
USES
 Ammonia from Haber Process – 80% for fertilizers
 Urea – byproduct from Ammonia production ( Carbon dioxide react with ammonia) and utilised as follows
 75% - Fertilizers
 10% - Animal feeds
 15% - Adhesives, plastics and resins
 Nitric Acid produced by oxidising Ammonia with air over Platinum-rhodium wire gauze catalyst at atmos.
Pressure and 900 oC. Used for production of ammonium nitrate, nitrating agent for parraffins and
aromatic compds.
 Hydrazine produced by oxidation of ammonia using sodium hypochlorite to produce chloroamine which
further reacts with ammonia. Uses are as follows:
 Blowing agent – 33%
 Agric. Chemicals – 40%
 Water treatment – 15%
 Others - 12% as oxygen scavengers from steam boilers

Downstream Operations

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Downstream Operations

Uploaded by

Copyright:

Available Formats

GENERAL OVERVIEW

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure 7

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure 14

• Refineries primarily set up to produce transportation

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

• Crude is a complex mixture of materials, some in large

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

• Large sprawling industrial complexes with extensive

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

• Reasonable distance from residential areas

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

• Distillation (Atmospheric and Vacuum)

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

• 1965: Old PHC Refinery (NPRC): 35000 BPSD then to

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

• HYDRO SKIMMING REFINERY

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure 42

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Kero FUELS MEK-

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure 55

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure

Nexus NNPC FSTP 2013 – General Overview of Petroleum Downstream Structure