Transcript Refinery Basics

Refinery Basics
John Kulluk Ph.D.
Torrance Fire Department
&
Robert Distaso PE – 714/573-6253
Orange County Fire Authority
Refining Means. . .
1. To reduce to a pure state, to remove
impurities
2. To improve or perfect
Refinery Process Flow Chart
Sulfur
Gas Plant
Fuel Gas
Isom
Splitter
Gasoline
Distilling
Reformer
Jet Fuel
Hydrotreating
Hydrotreating
Distillate Fuel
Alky
CCU
Flasher
Visbreaker
Leffler, 1985
Residual
Fuel
Other Refinery Units
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Steam Generation
Wastewater Treatment
Hydrogen Generation
Power Generation (e.g., cogen)
Air Separation Plant
Loading/Unloading - Railcar, Trucks, etc.
Storage (high pressure hydrocarbon, crude oil, intermediates)
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Floating-Roof Tanks - 150‘ diameter is common
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Spherical Tanks - 50‘ are common
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Horton Spheroid (refrigerated)
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Steam-Heated Tanks for “Heavier” Products
Self-Contained Firewater Supply
Firewater Pumps
What is Crude Oil?
• Mixture of organic
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carbon chain
molecules
Impurities include
sulfur and nitrogen
compounds
Some metals and
salts too
Components such as . . .
• Straight-Chain
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Hydrocarbons
Olefins
Cyclic H/C
Aromatics
(Benzene, toluene,
xylenes)
• Mercaptans
• Hydrogen Sulfide
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(H2S)
Greases
Propane
LPG
Other Hazardous Materials
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Sulfur
Hydrofluoric Acid (HF)
Sulfuric Acid (H2SO4)
Ammonia (NH3)
Sodium Hypochlorite
Radioactive Materials
Chlorine
Amines
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MEK
Sulfur Dioxide (SO2)
Heavy Metal Catalysts
Sour Water
Caustic (fresh/spent)
Alcohol
Asbestos
What’s All this Stuff?
What Goes on at a Refinery. . .?
• Separation of components by distillation, e.g.:
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Atmospheric
Vacuum
Hydrotreating (uses excess hydrogen)
• Breaking apart molecules to make smaller ones, e.g.:
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catalytic cracking
hydrocracking
• Joining molecules to make bigger ones, e.g.:
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Reforming - alkylation that lengthens the hydrocarbon
chain
Reforming - cyclic that generates hydrogen
Physical Hazards
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High Pressure/Temperature Steam
Oil/Gas-Fired Furnaces
Acoustic
High Voltage (4160V, 480V, 13.2 kV)
Falling Hazards
Confined Space Hazards
Cranes/Lifting Hazards
Hot Work Hazards
Acid Exposure
Toxic Vapors
Radiation
Flammability Hazards
Common PPE Requirements
• Hardhat
• Hardsoled / Hardtoe Shoes
• Safety Glasses with Side
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Protection
Safety Goggles or Faceshield
Fire-Resistant Clothing
Process Hazards
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Emergency Flare
Atmospheric Pressure Relief
High Temperature (up to 2000oF)
Low Temperature (e.g., Brittle Fracture)
High Pressure (up to 3000 psig)
Low Pressure (e.g., vacuum)
QUESTIONS ?