Introduction To Refining Part 1

KLM Technology Group
Practical Solutions
Practical Engineering Guidelines

for Processing Plant Solutions
Standards, Solutions, Software

KLM Technology Group Practical Engineering Solutions
Based in USA since 1995,

KLM is a technical consultancy
group, providing specialized
services and equipment to
improve process plant operational
efficiency, profitability and safety.
Training Practical Engineering Solutions
Today we are discussing - Introduction To Petroleum Refining
We also offer training classes in;

1. Advanced Petroleum Refining for Technical Professionals
2. Advanced Crude Unit Troubleshooting
3. Refining for Operations
4. Troubleshooting for Operations
5. Refinery Catalytic Processes
6. Refining for Non Technical Professionals
As well as other process units and equipment groups. Most of the

courses are 3 to 5 days. The course descriptions may be found on the
website.
www.klmtechgroup.com/training
Kolmetz Handbook of Process Equipment Design
In 2007 we began writing the Kolmetz Handbook of

Process Equipment Design. There are multiple chapters
for Petroleum Refining design in the Handbook. We
have over 50 individual chapters on a wide range of
subjects.
Each chapter is 70 to 160 pages including design and

sizing guidelines.
The handbook may be found here;

www.klmtechgroup.com/Engineering_Design_Guildelines.htm
Some of the Refining Chapters include;
1. General Distillation Tower Design – 93 Pages

2. Refinery Desalter Unit – 67 pages
3. Refinery Crude Tower – 164 Pages
4. Refinery Vacuum Tower – 136 Pages
5. Refinery FCC Units – 98 Pages
6. Hydrotreater Units – 70 Pages
7. Refinery Catalytic Reformer – 90 Pages
8. BTX Extraction Units – 75 Pages
9. Refinery Furnace – 185 Pages
10. Other Chapters – Reboilers, Flares, Tanks, Waste Treatment
Introduction to Refining Practical Engineering Solutions
We are going to cover Introduction to Refining in

Two Parts
Part One we will cover;
1. Crude Unit Properties

2. Atmospheric Crude Towers
3. Vacuum Towers
4. DAO Towers
5. Coker Units
Introduction to Refining Practical Engineering Solutions
We are going to cover Introduction to Refining in

Two Parts
Part Two we will cover;
1. Hydro De Sulphurization Units

2. Refinery Catalytic Reformers
3. Refinery FCC Units
4. Refinery Alkylation Units
5. Refinery Isomeration Units
Origins of the Petroleum Industry Practical Engineering Solutions
• Bitumen seeping to the surface used as

building material, lining water cannels,
sealing joints in boats and lighting in the
middle East as far back as 3,000 BC.
• Petroleum encountered when digging salt

wells in China 200 BC and used for lighting
and fuel.
• Petroleum industry developed in Eastern

Europe in early 19th century – shafts dug by
hand
• Primitive oil industry in Pennsylvania in mid

19th century gathering surface oil.
• Processes developed for the production of

lighting fluid termed “kerosene in 1854.
• First scientific investigation into the

properties of petroleum carried out by the
American Chemist Benjamin Sillman Jr in
1855.
Origins of the Petroleum Industry KLM Technology Group
Practical Engineering Solutions
• Around 1830 the Chinese method of salt

boring or drilling imported into Europe and
United States.
• Salt-boring technique adapted to drill the first

oil well by Edwin Drake in Titusville,
Pennsylvania in 1859.
• Oil transported in barrels with volume

standardized to 42 gallons in 1866 (after the
size of barrels used for herrings in England) –
still used as standard.
In the earliest days of the oil industry they

distilled oil to get kerosene for lamps
Crude Oil Pot Still 19th Century Lamps
The lighter and heavier fractions were thrown away –

typically in a waterway
Later, when automobiles created a market for

gasoline, the lighter fractions became more
valuable
lights waste
Crude gasoline cars
Oil kerosene lamps
fuel oil ship fuel
• Over the years 1920 – 1960, processes were

developed to convert low value fractions into high
value products
• Processes were also invented to improve the

product properties
• Petrochemicals (chemicals from petroleum) grew

rapidly from mid 20th century
• The refinery therefore evolved from a simple boiling

operation into the complex plant we see today
Refinery Products Practical Engineering Solutions
Fuel gas Fuel or chemical feedstock

Liquified gases
Gasoline Motor transportation
Naphtha Chemical feedstock
Jet fuel Aviation fuel
Diesel fuels Motor, railroad and marine transportation
Fuel oils Industrial fuel
Lubricating oils Machine lubrication
White Oils Electrical insulation, lubrication and
pharmaceuticals
Waxes Coatings, polishes, candles and
pharmaceuticals
Bitumen (asphalt) Road making and waterproofing
Petroleum coke Fuel, electrodes, or for metal manufacture
Different types of refineries have evolved KLM Technology Group
For different range of products:
Fuels Coke Lubricants Petrochemicals

And for different feed types KLM Technology Group
light
low sulphur
oil
heavy
high sulphur
oil
Refinery Overview Practical Solutions
• Refining is the second largest chemical

industry only superseded by ammonia
production. Refining contains almost every
unit operation and is a challenging, yet
rewarding occupation.
• A refinery is an organized and coordinated

arrangement of unit operations designed to
provide physical and chemical changes to
petroleum crude oils.
Refinery Overview KLM Technology Group
Practical Solutions
PLANT GAS
LIGHT ENDS
LSR
NAPHTHA CAT C5 RAF AROMATICS

HDS REFORMER
CMS
HDS
CRUDE ATMOS KEROSINE
TOWER SALES
HDS
DIESEL OIL #2
HDS
AGO
ALKYL GASOLINE
BLENDING
LVGO
VACUUM
TOWER HVGO HDS FCC
HDS
LCO
HDS
FUEL OIL
DAO DAO
#6
TOWER
COKE
COKER
ASPHALT/
FUEL OIL
Practical Solutions
PLANT GAS
LIGHT ENDS (C1-C4)
LSR
(C5-C10)
NAPHTHA C5 RAF
HDS CAT AROMATICS
REFORMER
CMS
HDS
TOWER HDS SALES
DIESEL OIL #2
HDS
AGO (C9-C17)
ALKYL GASOLINE
(C13-C18)
BLENDING
LVGO
VACUUM
TOWER HVGO HDS FCC
HDS
(C16-C22+)
LCO
HDS
FUEL OIL
DAO DAO
#6
TOWER (C16-C22+)
COKE
COKER
ASPHALT/
FUEL OIL
Petroleum Practical Solutions
• Petroleum is not an element or even a compound,

but is a complex mixture of a number of related
chemical compounds generally called
hydrocarbons.
• In its natural state, it varies in appearance from

whitish clear liquid of very light consistency through
brownish or greenish color all the way to a black,
heavy asphaltic, almost solid material.
• Hydrocarbons are the basic and most important

family of the organic class of compounds.
Crude Oil Types KLM Technology Group
Practical Solutions
• Thousand of different hydrocarbon and other

chemicals from very light components to
compounds as heavy as C80.
• May be found singularly or associated with

natural gas.
• It will be noted that as the number of carbon

atoms increases, the material becomes heavier
and boiling point and specific gravity increases.
• Above 17 carbon atoms, the compounds are solid

at room temperature and atmospheric pressure.
Refinery Overview Practical Solutions
(0) PLANT GAS

LIGHT ENDS (0)
LSR
(0.5 wt%) CAT (0.1 ppm)
NAPHTHA C5 RAF
HDS REFORMER AROMATICS
CMS (50 - 100 ppm)
HDS
ATMOS
CRUDE KEROSINE
TOWER HDS SALES
(0.5 wt%)
DIESEL OIL #2
HDS
AGO (1.2 wt%)
ALKYL GASOLINE
(1 – 2 wt%)
BLENDING
LVGO
VACUUM
TOWER HVGO HDS FCC
HDS
(3 – 4 wt%)
LCO
HDS
(5 – 10 wt%)
(0.5 wt%)
FUEL OIL #6
DAO DAO
TOWER
(2.9 wt%) COKE

COKER
ASPHALT/
(1.9 wt%) FUEL OIL
Practical Solutions
Sulfur Content
• High sulfur crudes are more difficult to

refine and may require special equipment.
• Sweet Crude < 0.5 wt% sulfur
• Sour Crude > 2.5 wt% sulfur

Houston Refinery KLM Technology Group
Practical Solutions
Practical Solutions
Density
• May be know as light, intermediate or heavy

depending on the actual mixture of hydrocarbons.
One of the best know crudes is West Texas
Intermediate (WTI).
• Light crudes are easier to process into high value

products.
• Heavy crudes are more difficult to process and
make less high value products
Practical Solutions
West Texas Intermediate Crude Yields
LPG 1.5%
Naphtha 25.5%
Kerosene 10.5%
Gas Oil 21.0%
Fuel Oil 41.5%
Basic Petrochemical Flow Scheme Practical Solutions
Reformer
BTX
Diesel
Crude Refinery
Oil Benzene
Fuel Oil
Toluene
BTX
Gas Oil Extraction
Xylene
Naphtha
Py-Gas
Ethane Steam
Cracker Ethylene
Gas Propane
Natural
Separation Propylene
Gas
Unit
LPG
Butadiene/
Condensate Butylenes
Methane Methanol
Practical Solutions
PLANT GAS
LIGHT ENDS
LSR

HDS REFORMER
CMS
HDS
TOWER SALES
HDS
DIESEL OIL #2
HDS
AGO
ALKYL GASOLINE
BLENDING
LVGO
VACUUM
TOWER HVGO HDS FCC
HDS
LCO
HDS
FUEL OIL
DAO DAO
#6
TOWER
COKE
COKER
ASPHALT/
FUEL OIL
Crude Tower KLM Technology Group
Practical Solutions
The function of a atmospheric / crude tower is to distill

(separated with heat) the lighter and more valuable
portions of the crude.
The crude should be processed safely, economically,

environmentally and reliably. This is a very difficult
task. Reliably means to be able to run and process
more than four years and you really want five years.
Practical Solutions
If you go research there are over many people who

list themselves as crude unit designers. But there
is only a very small group that I actually trust.
The first question you might want to ask a “crude

unit expert” is how many running towers have you
designed and commissioned. A good answer might
be ten to twenty. Many of this group have only one,
and it most likely did not function well.
Practical Solutions
The second question might be to ask for a list of

people, (more than one) that would recommend them.
All at once the list of “crude unit designers” gets very

small. We would be happy to recommend a qualified
“crude unit designer” to review your project.
If you have a small project, a P&ID and Distillation

Equipment review would be wise. If you have a large
project you should bring them in early in the project.
Practical Solutions
Crude Tower Practical Solutions
Light Ends
Water
Light Naphtha
SR Heavy Naphtha
SR kerosene
SR Diesel
Fumace
Desalter Steam
Atmospheric
Heat Heat Steam
Recovery Recovery Gas Oil
Residue
Practical Solutions
Practical Solutions
Practical Solutions
In middle is
the crude
tower, on the
right is the
vacuum tower
Practical Solutions
Practical Solutions
Practical Solutions
PLANT GAS
LIGHT ENDS
LSR

HDS REFORMER
CMS
HDS
TOWER SALES
HDS
DIESEL OIL #2
HDS
AGO
ALKYL GASOLINE
BLENDING
LVGO
VACUUM
TOWER HVGO HDS FCC
HDS
LCO
HDS
FUEL OIL
DAO DAO
#6
TOWER
COKE
COKER
ASPHALT/
FUEL OIL
Vacuum Tower KLM Technology Group
Practical Solutions
The function of a vacuum tower is to distill

(separated with heat) at low pressure some of the
remaining more valuable portions of the crude. The
crude tower does not remove 100% of the valuable
portions so we then process in the Vacuum Tower
The crude again should be processed safely,

economically, environmentally and reliably. This is a
very difficult task. Reliably means to be able to run
and process more than four years and you really
want five years.
The vacuum tower has one of the highest failure

rates in distillation
Practical Solutions
Practical Solutions
Picture of the Houston

Refinery where I worked
for 16 years
On the right – crude

tower, middle vacuum
tower.
Vacuum Tower Practical Solutions
Noncondensible
Steam Ejection
CW Gas Oil
CW
Light Vacuum
Gas Oil
Heavy Vacuum
Gas Oil
Steam
Steam 390° to 450° Vacuum Residue

(Asphalt)
Practical Solutions
Ejector
steam
Off gas
CW CW CW
150 oF, 10
mmHgA
Hot Well
Flash
distillate
LVGO
Sour
water
Combined Gas Oil

HVGO
to Hydrotrating
Furnace and Catalytic
Cracking Unit
Wash Section
Atmospheric To Vacuum
Maximum 780-
650 Resid 800 oF Overflash
Resid or
Feed Furnace inlet
Transfer Line
pressure drop
100-200 mmHg
750-770 oF,
20 mmHg
(abs)
1050 Vacuum
Resid
Practical Solutions
Practical Solutions
PLANT GAS
LIGHT ENDS
LSR

HDS REFORMER
CMS
HDS
TOWER SALES
HDS
DIESEL OIL #2
HDS
AGO
ALKYL GASOLINE
BLENDING
LVGO
VACUUM
TOWER HVGO HDS FCC
HDS
LCO
HDS
FUEL OIL
DAO DAO
#6
TOWER
COKE
COKER
ASPHALT/
FUEL OIL
DAO Unit KLM Technology Group
Practical Solutions
The function of a DAO unit is to remove the

remaining higher value products from the asphalt.
The feed is combined with a solvent, and the De

Asphaltene Oil is removed by the solvent.
The solvent is the recovered and recycled. The

asphalt is then routed to storage.
Solvent De Asphalting Practical Solutions
• Further separation of vacuum residue by distillation without

decomposition is difficult
• Solvent extraction can be used instead of distillation
• De Asphalted Oil (DAO)
Solvent
Cs Soluble Recovery
Solvent
Deasphalted Oil
Residue
Mixer
Cs Insoluble (Asphalt)
Solvent De Asphalting Practical Solutions
Practical Solutions
PLANT GAS
LIGHT ENDS
LSR

HDS REFORMER
CMS
HDS
TOWER SALES
HDS
DIESEL OIL #2
HDS
AGO
ALKYL GASOLINE
BLENDING
LVGO
VACUUM
TOWER HVGO HDS FCC
HDS
LCO
HDS
FUEL OIL
DAO DAO
#6
TOWER
COKE
COKER
ASPHALT/
FUEL OIL
Coker Unit KLM Technology Group
Practical Solutions
The function of a coker unit is to crack with heat the

asphalt into higher value products
The feed is kept at high temperature for a longer

period in a coking drum, producing cracked products
and coke.
It has multiple coke drums where the feed is cracked

and then taken off line and the coke is removed.
Practical Solutions
Practical Solutions
Practical Solutions
Practical Solutions
PLANT GAS
LIGHT ENDS
LSR

HDS REFORMER
CMS
HDS
TOWER SALES
HDS
DIESEL OIL #2
HDS
AGO
ALKYL GASOLINE
BLENDING
LVGO
VACUUM
TOWER HVGO HDS FCC
HDS
LCO
HDS
FUEL OIL
DAO DAO
#6
TOWER
COKE
COKER
ASPHALT/
FUEL OIL
Introduction to Refining Practical Solutions
For this presentation we discussed;
1. Crude Unit Properties

2. Atmospheric Crude Towers
3. Vacuum Towers
4. DAO Towers
5. Coker Units
Introduction to Refining Practical Solutions
Part Two we will cover;
1. Hydro De Sulphurization Units

2. Refinery Catalytic Reformers
3. Refinery FCC Units
4. Refinery Alkylation Units
5. Refinery Isomeration Units
An Engineering Corporation KLM Technology Group
Practical Solutions
Thank You

Introduction To Refining Part 1

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KLM Technology Group

KLM Technology Group

Practical Engineering Guidelines

Standards, Solutions, Software

Based in USA since 1995,

Today we are discussing - Introduction To Petroleum Refining

We also offer training classes in;

As well as other process units and equipment groups. Most of the

Kolmetz Handbook of Process Equipment Design

In 2007 we began writing the Kolmetz Handbook of

Each chapter is 70 to 160 pages including design and

The handbook may be found here;

Some of the Refining Chapters include;

1. General Distillation Tower Design – 93 Pages

We are going to cover Introduction to Refining in

Part One we will cover;

1. Crude Unit Properties

We are going to cover Introduction to Refining in

Part Two we will cover;

1. Hydro De Sulphurization Units

• Bitumen seeping to the surface used as

• Petroleum encountered when digging salt

• Petroleum industry developed in Eastern

• Primitive oil industry in Pennsylvania in mid

• Processes developed for the production of

• First scientific investigation into the

• Around 1830 the Chinese method of salt

• Salt-boring technique adapted to drill the first

• Oil transported in barrels with volume

In the earliest days of the oil industry they

Crude Oil Pot Still 19th Century Lamps

The lighter and heavier fractions were thrown away –

Later, when automobiles created a market for

• Over the years 1920 – 1960, processes were

• Processes were also invented to improve the

• Petrochemicals (chemicals from petroleum) grew

• The refinery therefore evolved from a simple boiling

Fuel gas Fuel or chemical feedstock

For different range of products:

Fuels Coke Lubricants Petrochemicals

• Refining is the second largest chemical

• A refinery is an organized and coordinated

NAPHTHA CAT C5 RAF AROMATICS

• Petroleum is not an element or even a compound,

• In its natural state, it varies in appearance from

• Hydrocarbons are the basic and most important

• Thousand of different hydrocarbon and other

• May be found singularly or associated with

• It will be noted that as the number of carbon

• Above 17 carbon atoms, the compounds are solid

(0) PLANT GAS

(2.9 wt%) COKE

• High sulfur crudes are more difficult to

• Sweet Crude < 0.5 wt% sulfur

• Sour Crude > 2.5 wt% sulfur

• May be know as light, intermediate or heavy

• Light crudes are easier to process into high value

West Texas Intermediate Crude Yields

NAPHTHA CAT C5 RAF AROMATICS

The function of a atmospheric / crude tower is to distill

The crude should be processed safely, economically,

If you go research there are over many people who

The first question you might want to ask a “crude