Petrochemical Technology (CHE1015)

Module 1
Petrochemical & Precursors: Introduction; Petrochemical & its
Precursors

Prof. Samarshi Chakraborty

School of Chemical Engineering
Vellore Institute of Technology, Vellore
Email ID: samarshi.chakraborty@vit.ac.in
Contact : +91-8335002953

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Course Outcomes (CO):
1. Provide a detailed insight of all the chemicals derived from petroleum
2. Explain the different methods for the conversion of monomer to polymers
3. Distinguish different type of polymers for specific application
4. Develop familiarity with major polymerization processes on industrial scale
5. Understand the different process technologies for Elastomers and resins
6. Demonstrate the manufacture of Plastics, Fibres and their applications

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Text and Reference Books
Text Books
1. Mall I.D., Petrochemical Process Technology, 2nd ed., Macmillan Petroleum Chemicals
Ltd, UK, 2011.
2. Chaudhuri U.R., Fundamentals of Petroleum and Petrochemical Engineering, 3rd ed.,
CRC Press, USA, 2011.
Reference Books
1. Richard A. Dawe, Modern petroleum technology, 6th ed., John Wiley & Sons Limited,
USA,2012.
2. Abdulin F., Production of Oil & Gas, 2nd ed., Mir publishers, Russia, 2014.

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Course Syllabus

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Mode of Evaluation
Evaluation Component Time of Total Mark Mark Weightage (%)
Submission/Examination
Quiz 1 After 20 days from start 20 10
CAT 1 To be decided by University To be decided 15
Digital Assignment 1 Any time after CAT 1 20 10
CAT 2 To be decided by University To be decided 15
Quiz 2 Any time after CAT 2 20 10
FAT To be decided by University To be decided 40
Total 100

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 Course Outcome 1:
Provide a detailed insight of all the chemicals derived from petroleum

Module 1: Introduction; Petrochemical & its Precursors

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What is Petroleum/Crude Oil?

• Petroleum occurs in the earth’s crust, in all possible states and varies in colour from light brown to dark
brown to black, exhibiting luminescence in some cases. It is mixture of various hydrocarbons, namely
paraffin, naphthene and aromatics. Petroleum is more homogeneous than coal and occurs mostly in
sedimentary rocks. (Source: Dr. B. K. Bhaskara Rao, Modern Petroleum Refining Processes)
• www.mms.gov/offshore/RenewableEnergy/Definitions.htm :
A mixture of hydrocarbons naturally existing as a liquid in underground reservoirs that remains a liquid at
atmospheric pressure. Crude oil is the raw material which is refined into gasoline, heating oil, jet fuel,
propane, petrochemicals, plastics, pharmaceuticals, and other products.
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What is Petrochemical?
• Petrochemicals are chemicals derived from petroleum or natural gas. They are an essential part
of the chemical industry as the demand for synthetic materials grows continually and plays a
major part in today's economy and society. Petrochemicals are used to manufacture thousands of
different products that people use daily, including plastics, medicines, cosmetics, furniture,
appliances, electronics, solar power panels, and wind turbines.
• It's important to note that the biggest concern about fossil fuel use is from combustion, turning
these hydrocarbons into carbon dioxide and water. So while there are environmental concerns
about petrochemical manufacturing of plastics, it doesn't lead to a significant release of
greenhouse gases that can cause climate change. For example, the plastic manufacturing is
capturing the carbon in an inert form (the plastic) and not releasing it to the atmosphere.
• In terms of production volumes the industry represents approximately 10% of the total
petroleum industry. On the basis of product value, however, the petrochemicals industry
represents a larger share of the total industry, reflecting the higher value of petrochemical
products compared to fuels.
Petrochemical, Jordan Hanania, Kailyn Stenhouse, Luisa Vargas Suarez, Jason Donev

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Why Study Petrochemical Technology?

https://energy.economictimes.indiatimes.com/news/oil-and-gas/why-oil-is-going-to-
remain-indias-most-difficult-conundrum-in-times-to-come/65982168

Revenues (US$ billion)

BASF 79
Sinopec 60
Dow 57
Sabic 44
Royal Dutch Shell 42
ExxonMobil 39
Formosa Plastics 38
LyondellBasell 33
Dupont 31
Ineos 27

https://images.app.goo.gl/NSEFqXbXLX21NAkS6
Table Source: Adapted from Chemical & Engineering News
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Composition of Petroleum/Crude Oil
In general, crude oil or petroleum is made out
of Hydrocarbon and Non-hydrocarbon.
• Hydrocarbons are made out of Carbon,
Hydrogen, Oxygen, Nitrogen, and Sulphur.
• The presence of Oxygen, Nitrogen, and
Sulphur is considered as impurities in Crude
Oil.
• Based on the percentage of sulphur present
crude oil, it can be classified into two types:
• Sweet Crude: Sweet crude is a classification
of petroleum that contains less than 0.42%
sulfur.
• Sour Crude: Sour crude is a type of crude oil
known for its relatively high sulfur content
(greater than 1%). The presence of sulfur
makes oil more difficult and costly to refine,
causing sour crude to be viewed as a less
desirable form of crude oil.
https://www.bing.com/images/search?view=detailV2&ccid=u29wahnp&id

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Composition of Petroleum/Crude Oil (Contd.)
Paraffins (CnH2n+2):
Gas: Methane, Ethane, Propane, Butane (C1-C4)
Liquid: C5-C16
Semi-solid: C16-C30
Solid: >C30
Aromatics: Benzene, Toluene, Xylene
Naphthene: Cyclopentane, Cyclohexane, and
Methylcyclohexane
Olefins: Butylene and Propylene
Sulphur content in most of the crudes are less than 5 wt%. Except, Venezuela, 5.25 wt%, California 5.21%, Iraq 7 wt%
Middle east, Mexican, Russian and Gulf crude oil contains 3-5 wt% sulphur; whereas Indonesian, Indian, United States,
Malaysian, Australian, and Nigerian crude contains less sulphur (less than 0.5 wt%).

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Benchmark Crude Oil
Crude Oil Name API Gravity Specific Gravity Sulphur Content (wt%)

Arabian Light (Middle East) 33.8 0.8560 1.8

Brent Crude 38.1 0.835 0.37

(Scotland and Norway)

Athabasca (Canada) 8 1.0143 4.8

West Texas Intermediate 39.6 0.827 0.24
(USA)
Minas (Sumatran) 35 0.8498 0.08

Bonny Light (Nigeria) 35.4 0.8470 0.14

Tapis Blend 45.9 0.7976 0.03
(Malaysia)

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Crude Oil Characteristics

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Crude Oil Reserves (World & India)

http://www.endofcrudeoil.com/2016/03/the-world-oil-market-march-2016.html https://www.tutorialspoint.com/general_knowledge/general_knowledge
_petroleum_in_india.htm

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Natural Gas Reserves (World & India)

https://ourworldindata.org/grapher/natural-gas-proved-reserves https://twitter.com/gailindia/status/916641265780850690

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Gas Hydrate Reserves

Clathrate hydrates, or gas hydrates, are crystalline water-based solids

https://ktwop.com/2013/03/17/fire-ice-methane-hydrate-success-in-japan-gets-india-all-
excited/
physically resembling ice, in which small non-polar molecules or polar
molecules with large hydrophobic moieties are trapped inside "cages" of
hydrogen bonded, frozen water molecules.
India has long been known to have massive deposits of methane hydrate.
These are tentatively estimated at 1,890 trillion cu.m. An Indo-US scientific
joint venture in 2006 explored four areas: the Kerala-Konkan basin, the
Krishna-Godavari basin, the Mahanadi basin and the seas off the Andaman
Islands. The deposits in the Krishna Godavari basin turned out to be among
the richest and biggest in the world. The Andamans yielded the thickest-
ever deposits 600 metres below the seabed in volcanic ash sediments.
Hydrates were also found in the Mahanadi basin.
https://ktwop.com/2013/03/17/fire-ice-methane-hydrate-success-in-japan-gets-india-
all-excited/

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Why Refine Crude Oil?
1. Removal of unwanted and harmful component from (sulphur, metal, salts) from crude
oil.
2. Convert crude oil into more lighter by products which have a higher value than crude oil.
3. Production of different petroleum products:
1. Liquefied Petroleum Gas (LPG),
2. Naphtha,
3. Gasoline Or Petrol,
4. Jet Fuel,
5. Kerosene,
6. High Speed Diesel,
7. Diesel Oil 
8. Fuel Oils.
9. LOBS
10. Bitumen

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Schematic Diagram of Oil Refinery
• Desalting: Remove water and salt from
crude oil to prevent fouling, corrosion and
catalyst poisoning.
• ADU: Used for separating lighter compounds
from Crude oil such as LPG, Light Naphtha,
Heavy Naphtha, Jet Fuel, Kerosene, Diesel, and
Light gas oil.
• VDU: Used for separating heavier fraction from
Crude oil (Reduced Crude Oil) without
decomposing the crude. vacuum gas oil used as
cracker feed.
• Catalytic Cracking: Produce diesel, gasoline and
LPG from light and heavy vacuum gas oil.
• Reforming Unit: Increase octane number of
heavy naphtha by converting straight chain
paraffin into cyclic-paraffin or naphthenes.
• Isomerization Unit: Increase octane number by
molecular arrangement of gasoline.
• Visbreaking Unit: Produce LPG, VB naphtha,
VBGO from heavy gas oil.

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Role of Distillation in Petroleum Refinery
• A process in which a liquid or
vapour mixture of two or more
substances is separated into its
component fractions of desired
purity, by the application and
removal of heat.
• Crude oil is made up of a mixture of
hydrocarbons, and the distillation
process aims to separate this crude
oil into broad categories of its
component hydrocarbons, or
"fractions." Crude oil is first heated
and then put into a distillation
column, also known as a still, where
different products boil off and are
recovered at different
temperatures.
https://www.eia.gov/todayinenergy/detail.php?id=6970
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Uses of Petroleum products

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Uses of Petroleum products
Fuel oil products include: (IOCL Haldia Refinery)
1. LPG : A portable fuel source, and its production and consumption for both domestic and industrial applications
2. Motor spirit (MS) : Used primarily as a fuel in internal combustion engines.
3. Mineral turpentine oil (MTO) : MTO is Used as an extraction solvent, as a cleaning solvent, as a degreasing solvent and as a solvent Paints, Wood
preservatives, Lacquers, Varnishes.
4. Superior kerosene oil (SKO): used as a degreaser / oil cleaner, fuel oil in heaters, solvent in paint and varnish formulation, antitrust, rust
remover, insecticide and pesticide.
5. Aviation turbine fuel (ATF): use as fuel in aircraft engines.
6. Russian turbine fuel (RTF): use as fuel in fighter aircraft engines (MIG engine) It has a very low freezing point, below −50 °C.
7. High speed diesel (HSD): used as a fuel in medium and high speed compression ignition engines (operating) above 750 rpm) in commercial
vehicles, stationary diesel engines, locomotives and pumps etc.
8. Jute Batching Oil (JBO): a mineral oil fraction used in the processing of jute fibers. to make the jute fibers pliable
9. Naphtha: As solvent. It is used in hydrocarbon cracking, laundry soaps, and cleaning fluids. Naphtha is also used to make varnishes, and
sometimes is used as a fuel for camp stoves and as a solvent (diluent) for paint.
10. Furnace Oil: used primarily for steam boilers in power plants, aboard ships, and in industrial plants. Commercial fuel oils usually are blended
with other petroleum fractions to produce the desired viscosity and flash point.
Lube oil base stocks are:
1. Heavy Vacuum Gas Oil: The primary use of VGO is as feed to cracking units such as the FCC or the hydrocracker. These units upgrade VGO into
more valuable products, namely gasoline and diesel. Lube oil products.
2. Light Vacuum Gas Oil: Hydrocracking unit feed. Gasoline and Middle Distillate

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Uses of Petroleum products
Transportation: Petroleum is a key source of energy for transportation.
Nearly two-thirds of transportation fuels are obtained from petroleum.
The transportation fuels that are derived from petroleum include
gasoline/petrol, diesel, liquefied petroleum gas (LPG), jet fuel, and
marine fuel. While gasoline/petrol is used in cars, motorcycles, light
trucks, and boats, diesel is used as fuel by trucks, buses, trains, boats
and ships. Jet airplanes and some types of helicopters use kerosene, a
byproduct of petroleum refining.
Power generation: Though petroleum is largely used in transportation,
it is also used in electricity generation. A fossil fuel power station uses
petroleum or natural gas to produce electricity. Power generation from
oil still accounts for a significant share in energy mix of many countries,
even though coal is the dominant source for electricity generation.
However, oil-fired power plants cause significant environmental
pollution. Oil-fired power plants also consume huge amounts of water.
According to the Joint Organizations Data Initiative (JODI), Saudi Arabia
is one of the few countries that use crude oil directly for power
generation, due to lack of domestic coal production.
https://www.nsenergybusiness.com/news/newsmajor-uses-of-petroleum-5986242/
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Uses of Petroleum products
Lubricants: Derived from petroleum, lubricants are used in many types of machines in almost all the industries. Lubricants
are used in all kinds of vehicles and industrial machines to reduce friction. Besides, they are used in cooking, bio
applications on humans, ultrasound examination, and medical examinations. Lubricants typically contain 90% of base oil,
usually petroleum fractions.
Pharmaceuticals: Petroleum byproducts such as mineral oil and petrolatum are used in the manufacture of creams and
topical pharmaceuticals. Though most of the pharmaceuticals consist of complex organic molecules, the basis, however, is
linked to simple organic molecules, which are mostly petroleum byproducts.
Agriculture: Petroleum is used in the production of ammonia, which is used as a source of nitrogen in agricultural
fertilizers. To achieve high crop yields, pesticides are widely in agricultural sector. Most of the pesticides are produced from
petroleum. Besides, machinery for agricultural tasks also consume petroleum. In this way, agriculture is one of the major
users of petroleum.
Chemical industry: Petroleum by-products are used by many chemical companies as raw materials. They are used in the
manufacture of chemical fertilizer, synthetic fiber, synthetic rubber, nylon, plastics, pesti­cides and insecticides, perfumes,
and dyes, paints, among others. Refining of crude oil results in the production of several by-products, which are used in
making different products for household and industrial purposes. Major by-products of petroleum include plastic,
detergents, naphtha, grease, Vaseline, wax, and butadiene, among others.
Domestic uses: Many household products such as detergents, Vaseline, wax, and others are derived from petroleum.
Kerosene, a byproduct of petroleum, still used in many countries for cooking, lighting and other domestic purposes.  
https://www.nsenergybusiness.com/news/newsmajor-uses-of-petroleum-5986242/
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Brief Overview of Petrochemical Plants
Petrochemicals are derived from hydrocarbons
such as propane, ethane, butane, or other
components separated from crude oil and
natural gas liquids. Naphtha - a mixture of
flammable liquid hydrocarbons - is also
important in the production of products made
from petrochemicals. After being separated in
some sort of distillation process, separated
hydrocarbons can be fed to a manufacturing
facility known as a cracker. This cracker works
to break chemical bonds in hydrocarbon
materials which allows them to be converted
into more useful chemicals for production. One
major petrochemical is ethylene, used to
create polyethylene - one of the most
important plastics in manufacturing.
Petrochemical, Jordan Hanania, Kailyn Stenhouse, Luisa Vargas Suarez, Jason Donev https://images.app.goo.gl/nnGuZR2k3PMjRViV9

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Petrochemicals for daily uses
99% of all plastics are created from oil and
natural gas, with most being manufactured
using naphtha feedstock. Naphtha is created
during the distillation process, and is heavier
than gasoline. It is one of the most important
of all the petrochemicals simply because it is
used in the production of plastics. Other
important petrochemicals include:
Ethylene: Used in paper, consumer electronics,
detergents, footwear, and adhesives
Propylene: Used in paints, furniture, textiles,
pharmaceuticals, and food packaging
Benzene: Creates pharmaceuticals, furniture,
electronics, and food packaging
Methanol: Used in thermal insulation and
building construction
Toluene: Creates inks and sports equipment
most important plastics in manufacturing .

Petrochemical, Jordan Hanania, Kailyn Stenhouse, Luisa Vargas Suarez, Jason Donev https://images.app.goo.gl/3fXRAB1DQW2YK2E26

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Relation between Petroleum and Petrochem Industry

https://images.app.goo.gl/bU8VDKZ6rkeuUT5a9

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Petrochemical Industry Value Chain

https://images.app.goo.gl/m9cc4AsVHaapMsCu9

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Petrochemical Industry: Raw Material to Product

https://images.app.goo.gl/xn429pSFZGiYehec7

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Petrochemical Products in a nutshell

https://images.app.goo.gl/xtHPjQjLbK3q99E17

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