Transcript www.eng.umd.edu

Crude Oil Distillation
04/03/1
4
Matthew Allsop, Mallory Clites,
Chris Nunes, Charles Onyenemezu
Outline
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Introduction
o Description of Petroleum (composition, sources, etc.)
o Petroleum Products (products made from refining petroleum)
o Fractional Distillation, Pseudocomponents
Project Description: Fractional Distillation of Crude Oil
o Objectives: Obtaining 6 product streams, Production
targets,Constraints: cost, utility costs
o General Steps (Rough process flow diagram)
o Feed Composition (propane, butane & pseudocomponents)
o Process and Environmental Safety
o Prices and Profitability
Petroleum-Sources
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Obtained by drilling into a
formation
Remains of organisms under
high heat and pressure
Oil well may be on land or
offshore
>50% of known reserves are
located in Middle East
Kaes, Gerald L. Refinery Process Modeling: A Practical
Guide to Steady State Modeling of Petroleum Processes
(using Commercial Simulators). Athens, GA: Athens Print.,
2000. Print.
“Petroleum." E-News. Pennsylvania State University, n.d.
Web. 02 Apr. 2014.
“Oil Seeping into Louisiana, But Not From Where You'd Think." : April 2011. The Power
Generation Blog, n.d. Web. 02 Apr. 2014.
Petroleum-Composition
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Yellow/black liquid composed of thousands of hydrocarbons
The hydrocarbons can be classified as: paraffin,
cycloalkane, aromatic, or asphalt
Paraffin-simplest example: methane
Cycloalkane- contains saturated ring- simplest
example: cyclopentane
Aromatics- contains at least one unsaturated ringsimplest example: benzene
Some components have a ring, but a long side chain
(in between classes)
Refinery may process crude from various sources
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Kaes, Gerald L. Refinery Process Modeling: A Practical Guide to Steady State Modeling
of Petroleum Processes (using Commercial Simulators). Athens, GA: Athens Print.,
2000. Print.
http://www.corbisimages.com/images/CorbisLK006275.jpg?size=67&uid=ab7f3995-94ed-46ad-9042-6de3f439aaa7
Petroleum Derived
Products
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Gasoline
Diesel fuel
Grease
Motor Oil
Epoxy
Rubbing Alcohol
Many products made out of plastic: boots, cups, trash bags, etc.
Kaes, Gerald L. Refinery Process Modeling: A Practical Guide to Steady State Modeling of Petroleum Processes (using Commercial Simulators). Athens,
GA: Athens Print., 2000. Print.
http://www.ranken-energy.com/Products%20from%20Petroleum.htm
Pseudo-components
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Because petroleum contain thousands of species, individual analysis is not practical or cost
effective
Instead, pseudo-component are defined to represent a boiling point range of feed using data
from distillation tests
o Data in the form of percent distilled (weight or volume basis) in increments of 10% versus
temperature
o During distillation, cracking may occur above 344°C at 760 mmHg, so pressure may be
reduced to 10 mmHg when gathering data
Use of pseudo-components is an oversimplification, but a practical and necessary assumption
Physical properties of each pseudo-component must be estimated
Kaes, Gerald L. Refinery Process Modeling: A Practical Guide to Steady State Modeling of Petroleum Processes (using Commercial Simulators). Athens,
GA: Athens Print., 2000. Print.
Setting Pseudo-component
cutoffs
Kaes, Gerald L. Refinery Process Modeling: A Practical Guide to
Steady State Modeling of Petroleum Processes (using Commercial
Simulators). Athens, GA: Athens Print., 2000. Print.
Crude Oil Distillation
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Fractional Distillation (multiple side streams)
used when components have close boiling
points
Intermediate reflux provided by pumparound
cooling circuit
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In various ways they improve heating
efficiency, and decrease size of column
Smaller stripping units to remove light
hydrocarbons from side stream outputs, purify
fuels
Potentially add vacuum distillation column to
decompose residue
Kaes, Gerald L. Refinery Process Modeling: A Practical Guide to Steady
State Modeling of Petroleum Processes (using Commercial Simulators).
Athens, GA: Athens Print., 2000. Print.
Fractional Distillation. Digital image. BBC, n.d. Web.
Project Specification
Objective
Design a crude oil distillation process that produces six marketable side streams and makes a profit.
Inlet flow rate
300,000 barrels of oil per day (“stdL BPSD” = “Barrels per stream day”)
at 25 C and 1 atm
Composition taken from crude assay
Production Target
About 8,408 lbmol/h for each stream
Goal
Less than 10 billion dollars in fixed costs.
Advanced Processing
“Froth treatment-Froth treatment is an oil refining technique which converts bitumen recovered from oil sands
into diluted bitumen, a marketable product, which can be shipped through an oil pipeline to a oil refinery or oil
terminal. The process removes heavier hydrocarbon compounds producing dilbit which can flow through a
pipeline.”
“An upgrader is a facility that upgrades bitumen (extra heavy oil) into synthetic crude oil.”
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Kaes, Gerald L. Refinery Process Modeling: A Practical Guide to Steady State Modeling of Petroleum Processes (using Commercial Simulators).
Athens, GA: Athens Print., 2000. Print.
Crude Assay of Kearl Oil Sands Project
Kearl Oil Sands Project - Currently in early phases of operation
● Location: Alberta, Canada near Kearl Lake
● Open-pit mining to extract bitumen from clay and rock
● First project investment of $12.9 billion (Canadian)
● Partners: ExxonMobil, Imperial Oil
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Produces 110,000-to 300,000 barrels-per-day
“Kearl is a heavy, high sulfur diluted bitumen that is ideal for
refineries with heavy crude capabilities. Kearl has an API
gravity of 22.6, and contains 3.4 wt% sulfur and 8.9 wt%
Conradson carbon, making it an attractive coking crude.”
Kearl Oil Sands with Assay. Digital image. ExxonMobil, n.d. Web. 2 Apr. 2014.
"First Nations Walk Targets Alberta Tar Sands Development." The Buffalo Post RSS. The Buffalo Post, n.d. Web. 02 Apr. 2014.
Block Flow Diagram
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35 Stages
Inlet: Crude Oil; Outlet:
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Petroleum gas:
stage 1
Gasoline:
stage 6
Kerosene:
stage 12
Heating/Diesel Oil: stage 18
Lubrication/Fuel Oil: stage 23
Residue
stage 35
http://elmhcx9.elmhurst.edu/~chm/onlcourse/chm110/outlines/distill.html
Process Safety
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Corrosion
o equipment failure; facility shutdown
o petroleum refining in US lost $3.7 billion in 1996
 maintenance expenses: $1.8 billion
 vessel purchases: $1.4 billion
 fouling: $0.5 billion
Carbon steel replaced by low alloy steels or stainless steel
On-line corrosion monitoring techniques
o Linear Polarization Resistance
 determines corrosiveness from electrodes in process
 applied potential yields current; provides resistance/conductivity
"Corrosion Costs 
and Preventative
Strategies in the
United States." NACE
International(n.d.):
n. pag.
Web. 1 Apr. 2014.
high electrical
conductivity
indicates
high
corrosiveness
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Environmental Safety
Concerns
Pollution to ecosystem (oil spills)
o 1985:
 6,169 incidences
 8,436,248 gallons
o 2010:
 3007 incidences
 1,132,593 gallons
Greenhouse gas emissions
o Differs based on the mix of fuels
o Predictions are often exceeded
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"Table 4-54: Petroleum Oil Spills Impacting Navigable U.S. Waterways |
Bureau of Transportation Statistics." Bureau of Transportation Statistics.
United States Department of Transportation, n.d. Web. 01 Apr. 2014.
Indiana Refinery spilled as much as 1600 barrels into
Lake Michigan--(03-24-14)
Jackson, Angie. "Lake Michigan Oil Spill Estimate Doubles in Size, Possibly
up to 1,600 Gallons, BP Reports." MLive.com. N.p., 27 Mar. 2014. Web. 30
Mar. 2014.
Process Economics
Overall economics of an oil refinery depends on:
1. The choice of crude oil used
➢ Lighter vs. Heavier
2. The complexity of the refining equipment
➢ Plant type and functionality
3. The desired type and quality of products
➢ Efficiency of refining complex
"Refinery Economics." Natural Resources Canada. N.p., n.d. Web. 02 Apr. 2014.1
Crude Oil Pricing
Two major crude oil suppliers
Brent Crude Oil (Europe) → $101.67/barrel
West Texas Intermediate Crude Oil (Midwest and Gulf Regions of U.S.) →
$108.07/barrel
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Crude Assay of Kearl Oil
Canadian Crude Oil: 675.60 Cdn $/m3 → 97.43 USD $/barrel
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"Summary of Par Crude Postings at Edmonton March 2014." Natural Resources Canada. N.p., n.d. Web. 02 Apr. 2014.
"Crude Oil Price, Oil, Energy, Petroleum, Oil Price, WTI & Brent Oil, Oil Price Charts and Oil Price Forecast." OilPricenet RSS. N.p.,
n.d. Web. 31 Mar. 2014.
Refinement Product Prices
Refinement Products
Sale Price ($/gallon)
Propane
1.322
Motor Gasoline
2.759
Kerosene
3.847
No. 2 Diesel Fuel
3.055
No. 2 Fuel Oil
3.576
Residual Fuel Oil
2.458
Petroleum gas:
stage 1
Gasoline:
stage 6
Kerosene:
stage 12
Heating/Diesel Oil: stage 18
Lubrication/Fuel Oil: stage 23
Residual:
stage 35
U.S. Refiner Petroleum Product Prices." U.S. Refiner Petroleum Product Prices. N.p., n.d. Web. 02 Apr. 2014.
Utilities- Costing
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Cooling water
o needed for condenser
in distillate overhead
Steam
o strips lightest crude
products from feed
o also used to purify side
streams with strippers
Intermediate streams can
save heating costs
“Study Updates Refinery Investment Cost Curves." Login to Access the Oil & Gas Journal Subscriber Premium Features. N.p., n.d. Web. 02 Apr. 2014.
Profitability
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Typically, refineries are profitable when they process at least 50,000 barrels per
day
Profits have increased in recent years because of a surge in hydrofracking, since
natural gas is used to power most refineries (reduced daily cost by as much as
$665,000 a day)
Profits can be increased by building refineries near current shale gas drilling sites
Exxon earned $1.77 billion dollars in the last quarter of 2012 from refineries alone
Profits based on feed costs alone: $6 million/day
Krauss, Clifford. "Oil Refining’s Fortunes Rise." The New York Times. The New York Times, 24 Oct. 2012. Web. 02 Apr. 2014.
Carroll, Joe. "Exxon Profit Rises as Cheap U.S. Oil Lifts Refining." Bloomberg.com. Bloomberg, 1 Feb. 2013. Web. 02 Apr. 2014.
Questions?