1.

Overview of the OBE matters

Course Learning Objectives
Program Learning Objectives
2. 1st topic
3. Direction of this course
4. Activities

Outline

CO1- Ability to explain the origin and occurrence of

crude oil and its important properties and composition.

CO2- Ability to illustrate the overall refinery operations

of crude petroleum in converting raw materials to
valuable major products.

CO3- Ability to analyze and distinguish specific major

processes in petroleum refining and able to justify the
health and safety issues arises due to process operation
and chemicals used.

Course Learning Outcomes

PLO1: Ability to identify and apply knowledge of

mathematics, basic and applied science, engineering
fundamentals and specialization to solve including
complex engineering problems.
PLO2: Ability to identify, formulate and solve engineering
problems, including complex engineering problems, using
the principles of mathematics, basic and applied science
and engineering fundamentals.
PLO8: Ability to apply the knowledge of safety, health,
and the environment and sustainable development issues
in specific engineering scenarios.

Program Learning Outcomes

CHAPTER 1: Origin of crude oil

CHAPTER 2: Crude oil distillation
CHAPTER 3: Refinery feedstock and products
CHAPTER 4: Thermal cracking
CHAPTER 5: Hydrotreating
CHAPTER 6: Catalytic cracking
CHAPTER 7: Hydrocracking
CHAPTER 8: Reforming
CHAPTER 9: Alkylation and isomerization
CHAPTER 10: Future trend of crude oil

Topics covered

1)
2)
3)
4)
5)

Theory of crude oil formation

How crude oil is extracted
Crude oil composition
Physical properties of crude oil
Definition of refinery and its schematic
diagram

Outline of 1st topic

 Mixture of naturally occuring HC,

refined into fuels and petrochemicals.
Also called CRUDE OIL
Oily, flammable liquid consist
of chemical compound of organic
matter
.

What is petroleum?

 Produced in sedimentary rocks together with crude oil.

Consisting mainly of methane, CH4
Mixture of: 85% CH4, 10% C2H6, 3% C3H8, C4H10, CO2, H2S, N2 & O2

What is natural gas?

How there are formed?

How do you extract them?

Differ in viscosity:
1. Field by field
2. The way petroleum
composition was formed

Crude oil can be found either:

- Lighter and sweet contains higher % of HC is more profitable
as fuel source.
- Denser and sour less flammable level of HC & high S are
expensive to refine into fuel (suitable for plastic manufacturing)

Classification of crude oil

Crude oil consists of:

- Hydrogen+carbon hydrocarbons
- Other elements like sulfur, nitrogen and various metals.

Basic of crude oil

- 3 general categories of
hydrocarbon in crude oil:
1. Paraffins saturated HCs
2. Naphthenes cycloparafins
3. Aromatics contains 1 or more
benzene rings

Non-hydrocarbon compounds:
Sulfur compound
Oxygen compound
Metallic compound
Salts

Crude oil composition

Paraffin
Consist

of straight or branched carbon rings saturated with

hydrogen atoms, the simplest of which is methane (CH4) the
main ingredient of natural gas. Other name: Alkane.

Hydrocarbon compound

Naphthenes
Consist

of carbon rings, sometimes with side chains, saturated

with hydrogen atoms.
Chemically stable, they occur naturally in crude oil and have
properties similar to paraffins. Other name: Cycloalkane.

Hydrocarbon compound

Aromatic
Contain a ring of six carbon atoms with alternating double
and single bonds and six attached hydrogen atoms.
The simplest aromatic compound are benzene, toluene and
xylene.
Important petrochemical intermediates & valuable
component for gasoline

Hydrocarbon compound

Sulfur Compounds.

Present in crude oil as hydrogen

sulfide (H2S), mercaptans, sulfides,
disulfides, thiophenes, etc.) or as
elemental sulfur.
Harmful due to its corrosive
nature.
Other corrosive substances are
elemental
sulfur
and
the
combustion of petroleum products
containing
sulfur
compounds
produces undesirables such as
sulfuric acid and sulfur dioxide.

Non-hydrocarbon compound

Example
picture of
corroded
Heat
Exchanger

Oxygen Compounds
Oxygen compounds such as phenols, ketones, and carboxylic
acids occur in crude oils in varying amounts.
Their presence in petroleum stream is not poisonous to
processing catalyst

Non-hydrocarbon compound

Metallic Compounds
Metals, including nickel, iron, and vanadium found in crude
oils in small quantities.
Presence either as inorganic salts (NaCl , Mg2Cl3) or
organometallic cmpds (Ni or V).
It

is also desirable to remove trace amounts of arsenic,

vanadium, and nickel prior to processing as they can poison
certain catalysts.
When crude oil is processed, salts can form soap with
carboxylic acid very corrosive!

Non-hydrocarbon compound

Salt
Contain inorganic salts such as sodium chloride, magnesium
chloride, and calcium chloride in suspension or dissolved in
entrained water (brine).
These salts must be removed or neutralized before processing
to prevent catalyst poisoning, equipment corrosion, and
fouling.
Salt corrosion is caused by:
the hydrolysis of some metal chlorides to hydrogen chloride
(HCl) and
the subsequent formation of hydrochloric acid when crude is
heated.

Non-hydrocarbon compound

Summary of crude oil composition

The important physical properties of petroleum are :

(1)
(2)

(3)

Density is the mass of liquid per unit volume at specific

temperature;
Specific gravity is the ratio of the weight of a given V
to the weight of the same V of water measured at
same T.
Viscosity indicates the ease of (or more correctly the
resistance to) flow.

Physical Properties of Petroleum

Fluids

API gravity is defined as:a measure of the lightness or heaviness of petroleum that is
related to density and specific gravity.

Another way to express relative masses of crude oil.

A low API gravity heavier crude oil or a petroleum
product

while a higher API gravity a lighter crude or product.

Specific gravities of crude oils roughly range from 0.82 for
lighter crudes to over 1.0 for heavier.

What is API Gravity?

The observed reading are always corrected for

temperature to 60 F, by using a prepared table of
standard values:-

141.5
API
131.5
Sp.Gr. @ 60F

Sp.Gr. = specific gravity to water at 60F

The API gravity of water is 10
In the field, the API gravity is readily measured using a
calibrated hydrometer

API Gravity

A Rough Classification of Crude Oil Based on The API Gravity

API

Classification

Specific Gravity

10 20
20 30
> 30

Heavy oil
Medium oil
Light oil

1.0 0.93
0.93 0.87
< 0.87

Conclusion : API Specific Gravity

API Specific Gravity

API Gravity

= less valuable petroleum

= more valuable petroleum

Products made from a barrel of crude

oil (gallons)

Petroleum refinery is an organized and coordinated

arrangement of manufacturing processes designed to
produce physical and chemical changes in crude oil
to convert it into everyday usable finished products
like petrol, diesel, lubricating oil, fuel oil and
bitumen.

What is refinery?

Petroleum Refinery Schematic

Separation
Crude oil

Gas

Desalting
Atmospheric
distillation
ADR

Conversion
Catalytic isomerization

Light naphtha
Heavy naphtha
Kerosene

Catalytic reforming
Alkylation

Polymerization

Gas oil

Vacuum
distillation
VDR

Light vacuum
gas oil

Fluid catalytic
cracking

Heavy
vacuum gas oil

Hydrocracking

Dewaxing
Solvent
deasphalthing

Visbreaking

Coking

Finishing
Gas sweetening,
blending

Light distillate
sweetening,
hydrotreatment or
blending
Middle distillate
sweetening,
hydrotreatment or
blending

Heavy distillate
sweetening,
hydrotreatment or
blending

CHAPTER 3

Separation
Crude oil

Gas

Desalting
Atmospheric
distillation
ADR

Conversion

Light naphtha
Heavy naphtha
Kerosene
Gas oil

Vacuum
distillation
VDR

Catalytic isomerization

Light vacuum
gas oil
Heavy
vacuum gas oil

Dewaxing
Solvent
deasphalthing

CHAPTER 8
Catalytic reforming
CHAPTER
9
Polymerization

Alkylation

CHAPTER
6
Fluid catalytic
cracking

Finishing
Gas sweetening,
blending

Light distillate
sweetening,
hydrotreatment or
blending
Middle distillate
sweetening,
hydrotreatment or
blending

Hydrocracking
Visbreaking

Coking

Heavy distillate
sweetening,
hydrotreatment or
blending

Products