Petroleum Refining Design and Applications Handbook, Volume 1
Inbunden, Engelska, 2018
Av A. Kayode Coker, UK) Coker, A. Kayode, PhD. (University of Wolverhampton, A Kayode Coker
4 799 kr
Produktinformation
- Utgivningsdatum2018-09-25
- Mått10 x 10 x 10 mm
- Vikt454 g
- FormatInbunden
- SpråkEngelska
- Antal sidor654
- FörlagJohn Wiley & Sons Inc
- ISBN9781118233696
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Kayode Coker PhD, is Engineering Consultant for AKC Technology, an Honorary Research Fellow at the University of Wolverhampton, U.K., a former Engineering Coordinator at Saudi Aramco Shell Refinery Company and Chairman of the department of Chemical Engineering Technology at Jubail Industrial College, Saudi Arabia. He has been a chartered chemical engineer for more than 30 years. He is a Fellow of the Institution of Chemical Engineers, U.K. and a senior member of the American Institute of Chemical Engineers. He holds a B.Sc. honors degree in Chemical Engineering, a Master of Science degree in Process Analysis and Development and Ph.D. in Chemical Engineering, all from Aston University, Birmingham, U.K. and a Teacher's Certificate in Education at the University of London, U.K. He has directed and conducted short courses extensively throughout the world and has been a lecturer at the university level. His articles have been published in several international journals. He is an author of five books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design. Vol 61. He was named as one of the International Biographical Centre's Leading Engineers of the World for 2008. Also, he is a member of International Who's Who of ProfessionalsTM and Madison Who's Who in the U.S.
- Preface xixAcknowledgments xxiAbout the Author xxiii1 Introduction 1References 62 Composition of Crude Oils and Petroleum Products 7 2.1 Hydrocarbons 82.1.1 Alkynes Series 122.2 Aromatic Hydrocarbons 142.3 Heteroatomic Organic Compounds 152.3.1 Non-Hydrocarbons 152.3.2 Sulfur Compounds 182.4 Thiols 182.5 Oxygen Compounds 202.6 Nitrogen Compounds 222.7 Resins and Asphaltenes 232.8 Salts 242.9 Carbon Dioxide 242.10 Metallic Compounds 242.11 Products Composition 252.11.1 Liquefied Petroleum Gas (LPG) (C3 and C4) 262.11.2 Gasoline (C5 to C11) 262.11.3 Condensate (C4, C5 and C6 >) 272.11.4 Gas Fuel Oils (C12 to C19) 272.11.5 Kerosene 272.11.6 Diesel Fuel 282.11.7 Fuel Oils # 4, 5, and 6 282.11.8 Residual Fuel Oil 282.11.9 Natural Gas 29References 303 Characterization of Petroleum and Petroleum Fractions 313.1 Introduction 313.1.1 Crude Oil Properties 323.1.2 Gravity, API 323.1.3 Boiling Point Range 333.1.4 Characterization Factor 333.1.5 The Universal Oil Product Characterization factor, KUOP 343.1.6 Carbon Residue, wt% 343.1.7 Nitrogen Content, wt% 363.1.8 Sulfur Content, wt% 363.1.9 Total Acid Number (TAN) 363.1.10 Salt Content, pounds/1000 barrels 363.1.11 Metals, parts/million (ppm) by weight 363.1.12 Pour Point (oF or °C) 363.2 Crude Oil Assay Data 373.2.1 Whole crude oil average properties 373.2.2 Fractional properties 373.3 Crude Cutting Analysis 373.4 Crude Oil Blending 373.5 Laboratory Testing of Crude Oils 463.5.1 True Boiling Point (TBP) Curve 463.5.2 ASTM D86 Distillation 463.5.3 Boiling Points 473.5.4 Conversion Between ASTM and TBP Distillation 493.5.5 Petroleum Pseudo-Components 543.5.6 Pseudo-Component Normal Boiling Points 553.5.7 ASTM D1160 Distillation 553.5.8 Determination of ASTM IBP, 10%, 20–90% Points of Blend 553.5.9 ASTM 10–90% Points 563.5.10 Initial Boiling Point Determination 563.5.11 ASTM End Point of Blend 563.5.12 Flash Point 563.5.13 Flash Point, °F, as a Function of Average Boiling Point 573.5.14 Smoke Point of Kerosenes 573.5.15 Luminometer Number 573.5.16 Reid Vapor Pressure (RVP) 573.5.17 Vapor Pressure of Narrow Hydrocarbon Cuts 583.6 Octanes 583.7 Cetanes 583.7.1 Cetane Index 593.8 Diesel Index 593.9 Determination of the Lower Heating Value of Petroleum Fractions 593.10 Aniline Point Blending 603.11 Correlation Index (CI) 603.12 Chromatographically Simulated Distillations 61References 62 4 Thermodynamic Properties of Petroleum and Petroleum Fractions 634.1 K-Factor Hydrocarbon Equilibrium Charts 644.2 Non-Ideal Systems 724.3 Vapor Pressure 744.3.1 Vapor Pressure Determination using the Clausius-Clapeyron and the Antoine Equations 754.4 Viscosity 804.4.1 Conversion to Saybolt Universal Viscosity 804.4.2 Conversion to Saybolt Furol Viscosity 824.4.3 Equivalents of Kinematic (cSt), Saybolt Universal (SUS), and Dynamic viscosity 824.4.4 Viscosity of Liquid Hydrocarbons 834.4.5 Gas Viscosity 844.5 Refractive Index 874.6 Liquid Density 894.6.1 Gas Density 894.7 Molecular Weight 904.8 Molecular Type Composition 904.9 Critical Temperature, Tc 964.10 Critical Pressure, Pc 974.11 Pseudo-Critical Constants and Acentric Factors 984.12 Enthalpy of Petroleum Fractions 994.13 Compressibility Z Factor of Natural Gases 1004.14 Simulation Thermodynamic Software Programs 105References 1105 Process Descriptions of Refinery Processes 1115.1 Introduction 1115.2 Refinery and Distillation Processes 1155.3 Process Description of the Crude Distillation Unit 1205.3.1 Crude Oil Desalting 1215.3.2 Types of Salts in Crude Oil 1225.3.3 Desalting Process 1225.3.4 Pumparound Heat Removal 1275.3.5 Tower Pressure Drop and Flooding 1305.3.6 Carbon Steel Trays 1305.3.7 Rectifying Section of the Main Column 1305.3.8 Side Stripping Columns 1305.3.9 Crude Column Overhead 1305.3.10 General Properties of Petroleum Fractions 1305.4 Process Variables in the Design of Crude Distillation Column 1325.4.1 Process Design of a Crude Distillation Column 1335.5 Process Simulation 1345.5.1 Overall Check of Simulation 1355.5.2 Other Aspects of Design 1365.5.3 Relationship between Actual Trays and Theoretical Trays 1375.6 Process Description of Light Arabian Crude Using UniSim® Simulation Software [12] 1385.6.1 Column Conventions 1415.6.2 Performance Specifications Definition 1425.6.3 Cut Points 1425.6.4 Degree of Separation 1425.6.5 Overflash 1425.6.6 Column Pressure 1435.6.7 Overhead Temperature 1435.6.8 Bottom Stripping 1445.6.9 Side Stream Stripper 1445.6.10 Reflux 1445.7 Troubleshooting Actual Columns 1445.8 Health, Safety and Environment Considerations 145References 1486 Thermal Cracking Processes 1496.1 Process Description 1526.2 Steam Jet Ejector 1526.3 Pressure Survey in a Vacuum Column 1546.4 Simulation of Vacuum Distillation Unit 1566.5 Coking 1576.5.1 Delayed Coking 1576.5.2 Delayed Coker Yield Prediction 1616.5.3 Coke Formation 1626.5.4 Thermodynamics of Coking of Light Hydrocarbons 1626.5.5 Gas Composition 1636.6 Fluid Coking 1646.6.1 Flexi-Coking 1656.6.2 Contact Coking 1676.6.3 Coke Drums 1686.6.4 Heavy Coker Gas Oil (HCGO) Production 1706.6.5 Light Coker Gas Oil (LCGO) Production 1706.7 Fractionator Overhead System 1706.8 Coke Drum Operations 1726.9 Hydraulic Jet Decoking 1736.10 Uses of Petroleum Coke 1746.11 Use of Gasification 1746.12 Sponge Coke 1756.13 Safety and Environmental Considerations 1756.14 Simulation/Calculations 1766.15 Visbreaking 1776.15.1 Visbreaking Reactions 1806.15.2 Visbreaking Severity 1806.15.3 Operation and Control 1806.15.4 Typical Visbreaker Unit 1816.15.5 Typical Visbreaker Unit with Vacuum Flasher 1826.15.6 Typical Combination Visbreaker and Thermal Cracker 1836.15.7 Product Yield 1836.16 Process Simulation 1846.17 Health, Safety and Environment Considerations 185References 186 7 Hydroprocessing 1877.1 Catalytic Conversion Processes 1877.1.1 Hydrocracking Chemistry 1887.1.2 Hydrocracking Reactions 1907.1.3 Typical Hydrocracking Reactions 1917.2 Feed Specifications 1947.2.1 Space Velocity 1957.2.2 Reactor Temperature 1957.2.3 Reactor Pressure 1957.2.4 Hydrogen Recycle Rate 1957.2.5 Oil Recycle Ratio 1957.2.6 Heavy Polynuclear Aromatics 1967.3 Feed Boiling Range 1967.4 Catalyst 1967.4.1 Catalyst Performance 1977.4.2 Loss of Catalyst Performance 1977.4.3 Poisoning by Impurities in Feeds or Catalysts 1987.4.4 The Apparent Catalyst Activity 2007.5 Poor Gas Distribution 2007.6 Poor Mixing of Reactants 2007.7 The Mechanism of Hydrocracking 2007.8 Thermodynamics and Kinetics of Hydrocracking 2017.9 Process Design, Rating and Performance 2047.9.1 Operating Temperature and Pressure 2057.9.2 Optimum Catalyst Size and Shape 2057.9.3 Pressure Drop (ΔP) in Tubular/Fixed-Bed Reactors 2057.9.4 Catalyst Particle Size 2077.9.5 Vessel Dimensions 2087.10 Increased ΔP 2107.11 Factors Affecting Reaction Rate 2147.12 Measurement of Performance 2157.13 Catalyst-Bed Temperature Profiles 2167.14 Factors Affecting Hydrocracking Process Operation 2177.15 Hydrocracking Correlations 2177.15.1 Maximum Aviation Turbine Kerosene (ATK) Correlations 2197.15.2 Process Description 2207.15.3 Fresh Feed and Recycle Liquid System 2247.15.4 Liquid and Vapor Separators 2257.15.5 Recycle Gas Compression and Distribution 2267.15.6 Hydrogen Distribution 2267.15.7 Control of the Hydrogen System 2267.15.8 Reactor Design 2277.16 Hydrocracker Fractionating Unit 2287.16.1 Mild Vacuum Column 2307.16.2 Steam Generation 2307.17 Operating Variables 2317.18 Hydrotreating Process 2347.18.1 Process Description 2377.18.2 Process Variables 2377.18.3 Hydrotreating Catalysts 2407.19 Thermodynamics of Hydrotreating 2407.20 Reaction Kinetics 2437.21 Naphtha Hydrotreating 2457.21.1 Hydrotreating Correlations 2457.21.2 Middle Distillates Hydrotreating 2487.21.3 Middle Distillate Hydrotreating Correlations 2487.22 Atmospheric Residue Desulfurization 2507.22.1 High-Pressure Separator 2527.22.2 Low-Pressure Separator 2527.22.3 Hydrogen Sulfide Removal 2527.22.4 Recycled Gas Compressor 2527.22.5 Process Water 2527.22.6 Fractionation Column 2537.22.7 Operating Conditions of Hydrotreating Processes 2537.23 Health, Safety and Environment Considerations 258References 2588 Catalytic Cracking 259 8.1 Introduction 2598.2 Fluidized Bed Catalytic Cracking 2628.2.1 Process Description 2628.3 Modes of Fluidization 2698.4 Cracking Reactions 2708.4.1 Secondary Reactions 2728.5 Thermodynamics of FCC 2738.5.1 Transport Phenomena, Reaction Patterns and Kinetic models 2738.5.2 Three- and Four-Lump kinetic models 2768.6 Process Design Variables 2788.6.1 Process Variables 2798.6.2 Process Operational Variables 2808.7 Material and Energy Balances 2818.7.1 Material Balance 2818.7.2 Energy Balance 2828.8 Heat Recovery 2838.9 FCC Yield Correlations 2848.10 Estimating Potential Yields of FCC Feed 2868.11 Pollution Control 2908.12 New Technology 2928.12.1 Deep Catalytic Cracking 2938.12.2 Shell’s Fluid Catalytic Cracking 2948.12.3 Fluid Catalytic Cracking High Severity 2958.12.4 Fluid Catalytic Cracking for Maximum Olefins 2958.13 Refining/Petrochemical Integration 2968.14 Metallurgy 2968.15 Troubleshooting for Fluidized Catalyst Cracking Units 2978.16 Health, Safety and Environment Considerations 2988.17 Licensors’ Correlations 2998.18 Simulation and Modeling Strategy 300References 3049 Catalytic Reforming and Isomerization 3059.1 Introduction 3059.2 Catalytic Reforming 3069.3 Feed Characterization 3069.4 Catalytic Reforming Processes 3089.4.1 Role of Reformer in the Refinery 3099.4.2 UOP Continuous Catalytic Regeneration (CCR) Reforming Process 3109.5 Operations of the Reformer Process 3129.5.1 Effect of Major Variables in Catalytic Reforming 3149.6 Catalytic Reformer Reactors 3169.7 Material Balance in Reforming 3179.8 Reactions 3209.8.1 Naphthene Dehydrogenation to Cyclohexanes 3209.8.2 Dehydrocyclization of Paraffins to Aromatics 3219.8.3 Dehydroisomerization of Alkylcyclopentanes to Aromatics 3219.8.4 Isomerization of n-Paraffins 3219.9 Hydrocracking Reactions 3229.10 Reforming Catalyst 3229.11 Coke Deposition 3249.12 Thermodynamics 3269.13 Kinetic Models 3269.14 The Reactor Model 3269.15 Modeling of Naphtha Catalytic Reforming Process 3299.16 Isomerization 3299.16.1 Thermodynamics 3309.16.2 Isomerization Reactions 3319.17 Sulfolane Extraction Process 3319.17.1 Sulfolane Extraction Unit (SEU) Corrosion Problems 3329.17.2 Other Solvents for the Extraction Unit 3339.18 Aromatic Complex 3339.18.1 Aromatic Separation 3359.19 Hydrodealkylation Process 3369.19.1 Separation of the Reactor Effluents 337References 337 10 Alkylation and Polymerization Processes 339 10.1 Introduction 33910.2 Chemistry of Alkylation 34010.3 Catalysts 34210.4 Process Variables 34310.5 Alkylation Feedstocks 34510.6 Alkylation Products 34610.7 Sulfuric Acid Alkylation Process 34610.8 HF Alkylation 34710.9 Kinetics and Thermodynamics of Alkylation 35110.10 Polymerization 35410.11 HF and H2SO4 Mitigating Releases 35410.12 Corrosion Problems 35610.13 A New Technology of Alkylation Process Using Ionic Liquid 35610.14 Chevron – Honeywell UOP Ionic liquid Alkylation 35710.15 Chemical Release and Flash Fire: A Case Study of the Alkylation Unit at the Delaware City Refining Company (DCRC) Involving Equipment Maintenance Incident 358References 36211 Hydrogen Production and Purification 365 11.1 Hydrogen Requirements in a Refinery 36511.2 Process Chemistry 36611.3 High-Temperature Shift Conversion 36811.4 Low-Temperature Shift Conversion 36811.5 Gas Purification 36811.6 Purification of Hydrogen Product 36911.7 Hydrogen Distribution System 37011.8 Off-Gas Hydrogen Recovery 37111.9 Pressure Swing Adsorption (PSA) Unit 37111.10 Refinery Hydrogen Management 37511.11 Hydrogen Pinch Studies 377References 37912 Gas Processing and Acid Gas Removal 381 12.1 Introduction 38112.2 Diesel Hydrodesulfurization (DHDS) 38312.3 Hydrotreating Reactions 38312.4 Gas Processing 38812.4.1 Natural Gas 38812.4.2 Gas Processing Methods 38912.4.3 Reaction Gas Processes 39012.4.4 Sweetening Process 39012.4.5 MEROX Process 39012.5 Sulfur Management 39112.5.1 Sulfur Recovery Processes 39312.5.2 Tail Gas Clean Up 40112.6 Physical Solvent Gas Processes 40112.6.1 Physical and Chemical Processes 40212.6.2 Advantages and Disadvantages of the Sulfinol® Process 40212.7 Carbonate Process 40212.8 Solution Batch Process 40312.9 Process Description of Gas Processing using UniSim® Simulation 40512.10 Gas Dryer (Dehydration) Design 41012.10.1 The Equations 41212.10.2 Pressure Drop (ΔP) 41312.10.3 Fouled Bed 41312.11 Kremser-Brown-Sherwood Method-No Heat of Absorption 41512.11.1 Absorption: Determine Component Absorption in Fixed Tray Tower (Adapted in part from Ref. 12) 41512.11.2 Absorption: Determine the Number of Trays for Specified Product Absorption 41712.11.3 Stripping: Determine the Number of Theoretical Trays and Stripping Steam or Gas Rate for a Component Recovery 41812.11.4 Stripping: Determine Stripping-Medium Rate for a Fixed Recovery 42012.12 Absorption: Edmister Method 42112.12.1 Absorption and Stripping Efficiency 42712.13 Gas Treating Troubleshooting 43212.13.1 High Exit Gas Dew Point 43212.13.2 High Glycol Losses 43212.13.3 Glycol Contamination 43212.13.4 Poor Glycol Reconcentration 43312.13.5 Low Glycol Circulation – Glycol Pump 43312.13.6 High Pressure Drop Across Contactor 43312.13.7 High Stripping Still Temperature 43312.13.8 High Reboiler Pressure 43312.13.9 Firetube Fouling/Hot Spots/Burn Out 43312.13.10 High Gas Dew Points 43312.13.11 Cause – Inadequate Glycol Circulation Rate 43312.13.12 Low Reboiler Temperature 43312.13.13 Flash Separator Failure 43412.13.14 Cause – Insufficient Reconcentration of Glycol 43412.13.15 Cause – Operating Conditions Different from Design 43412.13.16 Cause – Low Gas Flow Rates 43412.13.17 High Glycol Loss 43412.14 Cause – Loss of Glycol Out of Still Column 43412.15 The ADIP Process 43512.16 Sour Water Stripping Process 435References 438Glossary of Petroleum and Technical Terminology 441Appendix A Equilibrium K values 533Appendix B Analytical Techniques 547Appendix C Physical and Chemical Characteristics of Major Hydrocarbons 557Appendix D A List of Engineering Process Flow Diagrams and Process Data Sheets 573Index 623