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Refinery Basic
Refineries process crude oil through distillation and other separation processes to produce fuels and other products. Crude oil is separated into components like gasoline, jet fuel, diesel, and residual fuel through units like atmospheric distillers, vacuum distillers, reformers, crackers, and hydrotreaters. Refineries also have utilities like hydrogen plants, sulfur recovery units, wastewater treatment, and power generation. Hazards in refineries include fires and explosions from flammable liquids and gases, exposure to toxic chemicals, and physical hazards from high pressures and temperatures.
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Refinery Basic
- 1. Refinery Basics John KullukPh.D. Torrance Fire Department & Robert Distaso PE – 714/573-6253 Orange County Fire Authority
- 2. Refining Means. .. 1. To reduce to a pure state, to remove impurities 2. To improve or perfect
- 3. Refinery Process FlowChart Sulfur Gas Plant Fuel Gas Isom Splitter Gasoline Distilling Reformer Jet Fuel Hydrotreating Hydrotreating Distillate Fuel Alky CCU Flasher Visbreaker Leffler, 1985 Residual Fuel
- 5. Other Refinery Units • • • • • • • SteamGeneration Wastewater Treatment Hydrogen Generation Power Generation (e.g., cogen) Air Separation Plant Loading/Unloading - Railcar, Trucks, etc. Storage (high pressure hydrocarbon, crude oil, intermediates) Floating-Roof Tanks - 150‘ diameter is common Spherical Tanks - 50‘ are common Horton Spheroid (refrigerated) Steam-Heated Tanks for “Heavier” Products Self-Contained Firewater Supply Firewater Pumps • •
- 8. What is CrudeOil? • Mixture of organic • • carbon chain molecules Impurities include sulfur and nitrogen compounds Some metals and salts too
- 10. Components such as. . . • Straight-Chain • • • Hydrocarbons Olefins Cyclic H/C Aromatics (Benzene, toluene, xylenes) • Mercaptans • Hydrogen Sulfide (H2S) • Greases • Propane • LPG
- 11. Other Hazardous Materials • • • • • • • • Sulfur HydrofluoricAcid (HF) Sulfuric Acid (H2SO4) Ammonia (NH3) Sodium Hypochlorite Radioactive Materials Chlorine Amines • • • • • • • MEK Sulfur Dioxide (SO2) Heavy Metal Catalysts Sour Water Caustic (fresh/spent) Alcohol Asbestos
- 13. What’s All thisStuff?
- 14. What Goes onat a Refinery. . .? • Separation of components by distillation, e.g.: Atmospheric Vacuum Hydrotreating (uses excess hydrogen) • Breaking apart molecules to make smaller ones, e.g.: catalytic cracking hydrocracking • Joining molecules to make bigger ones, e.g.: Reforming - alkylation that lengthens the hydrocarbon chain Reforming - cyclic that generates hydrogen
- 15. Physical Hazards • • • • • • • • • • • • High Pressure/TemperatureSteam Oil/Gas-Fired Furnaces Acoustic High Voltage (4160V, 480V, 13.2 kV) Falling Hazards Confined Space Hazards Cranes/Lifting Hazards Hot Work Hazards Acid Exposure Toxic Vapors Radiation Flammability Hazards
- 17. Common PPE Requirements •Hardhat • Hardsoled / Hardtoe Shoes • Safety Glasses with Side • • Protection Safety Goggles or Faceshield Fire-Resistant Clothing
- 18. Process Hazards • • • • Emergency Flare AtmosphericPressure Relief High Temperature (up to 2000oF) Low Temperature (e.g., Brittle Fracture) • High Pressure (up to 3000 psig) • Low Pressure (e.g., vacuum)
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