1

Kuwait University

College of Engineering & Petroleum

Chemical Engineering Department

ChE 472/572

Petroleum Refining Engineering

Supplementary Class Notes Fall 2015/2016

Dr. Tareq A. Albahri

Copyrights © 2001 – 2015

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Table of contents

Front Matter – Tables, conversion factors and abbreviations

Part 1

Chapter 1 - Introduction

Chapter 2 - Composition of Petroleum

Chapter 3 - Significance of lab tests in petroleum refining

Chapter 4 - Characterization & properties estimation of crude oil and petroleum products

Chapter 5 - Refinery Feeds and Products

Chapter 6 - Modern Refinery Layout

Part 2

Chapter 7 - Separation Processes (CDU, VRU)

Chapter 8 - Desulfurization Processes (HTU, ARDS, Isomax, Merox)

Chapter 9 - Conversion Processes (FCC, HCR)

Chapter 10 - Heavy Oil Processing / Residue Upgrading (Coker, H-Oil)

Chapter 11 - Finishing Processes (Reforming, Alkylation)

Chapter 12 - Supporting Processes (H2 Production, H2 Recovery, Sulfur)

Chapter 13 - Product Blending

Part 3

Chapter 14 - Optimization

Chapter 15 - Economics

Chapter 16 - Environmental

Chapter 17 – Combustion

Chapter 18 – Safety

Chapter 19 – Future

Chapter 20 - Catalysis

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Appendix A

Common Abbreviations Used in Petroleum Refining

API American Petroleum Institute

ARD or ARDS Atmospheric Residue Desulfurization.

ASTM American Standards for Testing and Materials

ATK Aviation Turbine Kerosene.

Atm. Resid. Atmospheric Residue

BPA Bottom pump-around

BPSD Barrels per stream day

BS&W Bottom sediment and water

C3 Propane

C3= Propene

CABP Cubic Average Boiling Point

Cat Cracker Catalytic Cracker

CCR Central Control Room.

CCR Central Control Room.

CDU Crude Distillation Unit.

CN Cetane Number

D Diesel

DHTU Diesel Hydrotreating Unit.

DPK Dual Purpose Kerosene (Illumination + Aviation)

EGO Export Gas oil

EOR End of run

FBP Final Boiling Point

FUP Future Upgrade Project

GO Gas oil

GPH Gallons per hour

GPM Gallons per minute

GPSA Gas Processors Sellers Association

HFO Heavy fuel Oil

H-Oil unit Heavy Oil Unit

HP High Pressure

HP Diesel

HRI

High Pour Point Diesel

Hydrocarbon Research, Inc. (HRI

HSD High speed diesel

HSR Hydrogen Sulfide Removal

IBP Initial Boiling Point

IFP Institute Francais du Pétrole

IK Illuminating Kerosene

JGC Japan Gas Corporation

K Kerosene

KDC Kuwait Drilling Company

KHTU Kerosene Hydrotreating Unit.

KNG Kuwait Natural Gasoline

KOC Kuwait Oil Company

KPC Kuwait Petroleum Corporation

LCR Local Control Room.

LCR Local Control Room.

LFO Light Fuel Oil

LGO Light Gas Oil

LNG Liquefied Natural gas

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LP Low Pressure

LPG Liquefied petroleum gas

LSFO Low Sulfur Fuel Oil

Lub Oil Lubricating oil.

MAA Mina Al-Ahmadi Refinery.

MAB Mina Abdulla Refinery.

MABP Molal average boiling point

MDO Marine Diesel Oil

MeABP Mean average boiling point

MOGAS Motor Gasoline

MON Motor Octane Number

MOR Middle of run

MPA Middle pump-around

MTBE Methyl Tertiary Butyl Ether

N Naphtha

NGPSA National Gas Processors Sellers Association

NHTU Naphtha Hydrotreating Unit.

NPSH Net positive suction head

O/H Overhead

PBD Barrels per day

PCN Petrochemical Naphtha

PON Posted Octane number

PSA Pressure Swing Adsorption Unit.

RMP Refinery Modernization Project

RON research octane number

SCFH Standard cubic foot per hour

SHU Shuaiba Refinery.

SOR Start of run

SR Straight Run

SRU Sulfur Recovery Unit

SRU Sulfur Recovery Unit.

SW Sour Water

SWT Sour Water Treating Unit

TBP True Boiling Point

TEL Tetra Ethyl Lead

TGT Tail Gas Treating Unit

TPA Top pump-around

UOP Universal Oil Company

VABP Volumetric average boiling point

VRU Vaccum Rerun Unit.

WABP Weight average boiling point

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Appendix B

Conversion Factors

Length

1 in. = 25.4 mm

1 ft = 12 in.

= 304.8 mm

1 mi = 5280 ft

= 1.6093 km

Volume

1 ft³ = 1728 cu in.

= 7.4805 gal

= 28.317 liters

= 62.30 1b H2O@60ºF in air

= 62.38 1b H2O@60ºF in vacuum

1 gal = 231 in.³

= 3785.41 milliliters

= 8.328 1b H2O @ 60ºF in air

= 8.338 1b H2O @ 60˚F in vacuum

1bbl = 42 US Gal

= 5.6146 cu ft

= 349.8 lb H2O @60ºF in air

Weight

1 lb = 453.59 gm

Pressure

1 atm = 14.696 1b/in.²

= 760 mmHg @ 0ºC

= 33.93 ft H2O @ 60ºF

1 kg/cm2 = 14.223343 psi (lb/in2)

1 lb/in.² = 51.71 mm Hg @ 0ºC

= 27.70 in. H2O @ 60ºF

= 2.309 ft H2O @ 60ºF

= 0.13456 Kg/cm³

= 1 psi

1 Kg/m³ = 7.432 psi

1 ft H2O @ 60ºF = 0.4332 lb/in.²

Flow rate

1 bbl/day (BPD) = 1.75 gal/hr (GPH)

= 0.2339 ft³/hr

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= 0.02917 gal/min

1 GPM = BPD / 34.3

1 m³/hr = 150.95 bbl/day

1 ft³/sec = 448.8 gal/min (GPM)

1 lb mol/hr = 9108 ft³/day @ 60ºF, 1atm

1 gal H2O/min @ 60ºF = 499.7 lb/hr in air

(14.59) sp.gr.

lb/hr BPD ,

(500) sp.gr.

lb/hr GPM ,

(8.33) sp.gr.

lb/hr GPH

Energy

1 Btu = 778.2 ft. 1bf

1 Kwh = 3412 Btu

1 hp = 550 ft.1bf/sec

= 2544 Btu/hr

= 745.7 watts

Viscosity

1 cp = 0.000672 lbm/sec.ft

= 0.00002089 lbf.sec./ft²

= 2.419 1bm/hr.ft

1 dyne/cm = 28,570 lbm/hr²

Standard gravity

g = 32.174 ft/sec²

= 4.17X10 8 ft/hr²

Temperature

ºR = ºF + 459.67

K = ºC + 273.134

ºR = 1.8 K

ºF = 1.8 ºC + 32

multiply ºC with 2 , remove 10% , then add 32

Ideal gas volume

V = 379.49 ft³/lb mol @ 60ºF, 1atm (14.696 psia)

= 22.414 liters @ 32ºF, 1atm (14.696 psia)

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Gas constant

R = 1.986 Btu/lbmol.ºR

= 10.73 psi.ft³/lbmol.ºR

= 555 mm Hg.ft³/lbmol.ºR

Density

1 sp.gr.60/60ºF = 1 gm/cm3

= 8.34 lb/gal

= 62.3 lb/ft3

= 350 lb/bbl

= 1000 Kg/m3

Density of water @60ºF = 8.3372 lb/gal (weight in vacuum)

= 0.99902 g/cc (weight in vacuum)

Density of water @60ºF (g/cc) = 0.999015 (sp.gr.)@60/60ºF

5.131(sp.gr.)

141.5 API

FF/60@60

H2 flow 1 Nm3 ₌ 35.31467 SCF

H2 flow 1 lb/hr ₌ 4554 SCFD

H2 flow 1 lb/hr ₌ 192 SCFH

1 kcal = 3.9657 Btu

1 ton water = 269 gal

1 ton = 2000 lb

1 metric ton = 2204.62 lb

1 long ton = 2240 lb

1 short ton = 2000 lb

1 m3/hr = 6333.3 GPD

1 kg/hr = 52.92 lb/d

1kJ = 0.94781712267 Btu

1 Kilograms = 0.26417 Gallons [US]

1 lb = 0.1198 US gal

1 m3 = 264.172 US gal

1 m3 = 6.29 bbl

1 L = 0.264172 US Gal

1 W = 3.412141633 Btu/hr

1 mole ideal gas = 379.482 SCF

1 BHP = 0.745699872 KW

1 gal MEA = 8.34 lb

BHP = 0.7457 KW

bbl/6.29 = kL

1 bbl oil = 159 liter

Oxygen: 1 m3 = 1141 kg = 1.141 tonns

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APPENDIX - C

Useful Properties

Table 3.4: Properties of Hydrocarbons and common gases1

Compound

MW

Heating Value

60ºF, 1 atm (Btu/scf)

Net Gross

Methane

Ethane

Propane

i-Butane

n-Butane

i-Pentane

n-Pentane

n-Hexane

n-Heptane

n-Octane

n-Decane

Hydrogen sulfide

Nitrogen

Oxygen

Carbon Dioxide

Water

Air

16.043

30.070

44.097

58.123

58.123

72.150

72.150

86.177

100.204

114.231

142.285

34.080

28.013

31.999

44.010

18.0153

28.9625

909.4

1618.7

2314.9

3000.4

3010.8

3699.0

3706.9

4403.8

5100.8

5796.1

7189.6

586.8

-

-

-

-

-

1010.0

1769.6

2516.1

3251.9

3262.3

4000.9

4008.9

4755.9

5502.5

6248.9

7742.9

637.1

-

-

-

-

- 1 Source GPSA Engineering Data Book, 10th ed., 1987.

Atomic weights; C = 12.011 H = 1.008 N = 14.0067 O = 15.9994 S = 32.06

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Appendix - D

Table A6-1 Properties of Hydrocarbons and Common Gases. Source: GPSA Engineering Data Book, 10th Ed., 1987

Boiling Point Vapor Press Critical Liquid Volume

Compound Formula Mol Wt oF (1 atm) @ 100 F

Psia

Press

Psia

Temp.

Degr F

Spec.

Grav.

60/60 F

Ratio

Scf gas/

gal liq.

Methane

Ethane

Propane

Iso- Butane

Normal Butane

Iso- Pentane

Normal Pentane

n- Hexane

n- Heptane

n- Octane

n- Decane

Nitrogen

Oxygen

Carbon Dioxide

Hydrogen Sulfide

Water

Air

CH4

C2H6

C3H8

C4H10

C4H10

C5H12

C5H12

C6H14

C7H16

C8H18

C10H22

N2

O2

CO2

H2S

H2O

Mixture

16.043

30.070

44.097

58.123

58.123

72.150

72.150

86.177

100.204

114.231

142.285

28.013

31.999

44.010

34.08

18.0153

28.9625

-258.73

-127.49

-43.75

10.78

31.08

82.12

96.92

155.72

209.16

258.21

345.48

-320.45

-297.33

-109.26b

-76.50

212.00

-317.8

(5000)a

(800)a

188.64

72.581

51.706

20.445

15.574

4.960

1.620

0.537

0.061

-

-

-

394.59

0.950

-

666.4

706.5

616.0

527.9

550.6

490.4

488.6

436.9

396.8

360.7

305.2

493.1

731.4

1071

1300

3198.8

546.9

-116.67

89.92

206.06

274.46

305.62

369.10

385.8

453.6

512.7

564.2

652.0

-232.51

-181.43

87.91

212.45

705.16

-221.31

(0.3)a

0.35619c

0.50699c

0.56287c

0.58401c

0.62470

0.63112

0.66383

0.68820

0.70696

0.73421

0.80940d

1.1421d

0.81802c

0.80144c

1.00000d

0.87476d

(59.135)a

37.476c

36.375c

30.639c

31.790c

27.393

27.674

24.371

21.729

19.580

16.326

91.413c

112.93c

58.807c

74.401c

175.62c

95.557c

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Table A6-1 continued

Compound

Acentric Factor,

Flammability Limits,

vol% in Air Mixt.

Lower Upper

Heating Value

60oF, 1 atm (Btu/ scf)

Net Gross

Freezing Point @ 1 atm

Degr F

Heat of Vap’n @ 1 atm

Btu/lb

Methane

Ethane

Propane

Iso- Butane

Normal Butane

Iso- Pentane

Normal Pentane

n- Hexane

n- Heptane

n- Octane

n- Decane

Nitrogen

Oxygen

Carbon Dioxide

Hydrogen

Sulfide

Water

Air

0.0104

0.0979

0.1522

0.1852

0.1995

0.2280

0.2514

0.2994

0.3494

0.3977

0.4898

0.0372

0.0216

0.2667

0.0948

0.3443

-

5.0

2.9

2.0

1.8

1.5

1.3

1.4

1.1

1.0

0.8

0.7

-

-

-

4.3

-

-

15.0

13.0

9.5

8.5

9.0

8.0

8.3

7.7

7.0

6.5

5.4

-

-

-

45.5

-

-

909.4

1618.7

2314.9

3000.4

3010.8

3699.0

3706.9

4403.8

5100.8

5796.1

7189.6

-

-

-

586.8

-

-

1010.0

1769.6

2516.1

3251.9

3262.3

4000.9

4008.9

4755.9

5502.5

6248.9

7742.9

-

-

-

637.1

-

-

-296.44f

-297.04f

-305.73f

-255.28

-217.05

-255.82

-217.05

-139.58

-131.05

-70.18

-21.36

-346.00f

-361.82f

-69.83

-121.88f

32.00

-

219.45

211.14

183.01

157.23

165.93

147.12

153.57

143.94

136.00

129.52

119.65

85.59

91.59

246.47

235.63

970.18

88.20

a. Above critical point, extrapolated or estimated.

b. Sublimation point.

c. At saturation pressure, 60oF.

d. At normal boiling point.

e. Gas at 60oF, liquid at normal boiling point.

f. At the triple point pressure.

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Appendix - E

Properties of Hydrocarbons

Name Formul

a MW

Tb

(ºF)

Tc

(ºR)

Pc

(psia)

ppg

(lb/gal)

as

liquid

ºAPI

as

liquid

BPD/

(mol/hr)

as liquid

P @

100 ºF

(psia) Kw

Water H2O 18.02 212 1165 3206 8.334 10 1.235

Oxygen O2 32 -297 278 731 2.92

Nitrogen N2 28.02 -320 227 478 2.92

Air Air 28.98 -318 239 547

Carbon

monoxide CO 28.01 -313 242 514 2.92

Carbon dioxide CO2 44.01 -109 548 1072 3.71

Hydrogen sulfide H2S 34.08 -77 672 1306 2.91

Hydrogen H2 2.016 -423 60(7

4)

188(3

06 105 1.1

Methane C1 16.04 -259 343 673 2.19 407 4.19 -4120 21

ethene = C2 28.05 -155 510 742 3.44 211 4.66 -1090 18.1

ethane C2 30.07 -128 550 708 3.42 213 5.03 -720 18.62

propene = C3 42.08 -54 657 667 4.352 140 5.525 224 14.18

propane C3 44.09 -44 666 617 4.233 147 5.953 189 14.7

1-butene = nC4-1 56.1 21 755 583 5.013 104 6.395 62.4 13.03

2-butene = nC4-2 56.1 36 771 600 5.229 97 6.131 48 12.64

i-butene = iC4 56.1 20 752 580 5.004 104 6.407 63.7 13.04

i-butane iC4 58.12 11 735 529 4.695 120 7.074 71.9 13.81

n-butane nC4 58.12 31 765 551 4.872 111 6.817 51.5 13.5

pentene? = C5 70.13 86 854 586 5.384 87.6 7.443 19.1 12.65

i-pentane iC5 72.15 82 830 483 5.209 95 7.914 20.4 13.05

n-pentane nC5 72.15 97 846 490 5.262 92.7 7.835 15.6 13.03

cyclopentane CP 70.13 121 922 655 6.257 57.1 6.405 9.91 11.11

i-hexane iC6 86.17 140 897 440 5.485 83.6 8.977 6.77 12.82

n-hexane nC6 86.17 156 914 440 5.536 81.6 8.895 4.96 12.81

cyclohexane CH 84.16 177 996 590 6.532 49.1 7.362 3.26 10.98

benzene B 78.11 176 1013 714 7.375 28.5 6.052 3.22 9.73

toluene T 92.13 231 1070 590 7.269 30.8 7.243 1.03 10.14

o-xylene o-X 106.16 292 1138 530 7.377 28.4 8.223 0.26 10.28

m-xylene m-X 106.16 282 1115 510 7.243 31.4 8.375 0.33 10.42

p-xylene p-X 106.16 281 1113 500 7.218 32 8.404 0.34 10.45

ethylbenzene EB 106.16 277 1116 540 7.268 30.8 8.347 0.37 10.36

n-heptane nC7 100.2 209 973 397 5.738 74.1 9.978 1.62 12.71

n-octane nC8 114.22 258 1025 362 5.893 68.7 11.076 0.54 12.67

n-nonane nC9 128.25 303 1071 331 6.017 64.6 12.18 0.18 12.66

PD462