2. OVERVIEW OF CHEMICAL PROCESS
INDUSTRIES (CPI)
Defn;
An organization that transforms raw materials into useful products
involving chemical change (including physicochemical changes e.g
separation and purification)
Examples of CPI; SONARA, Brasseries, Dangote cement.
Chemical Plant;
An industrial process plant that manufactures (or processes) chemicals
usually on a large scale involving a chemical or biological
transformation.
3. OVERVIEW OF CPI CONT…..
Process Flow Diagram, PFD;
It is an authorized process blueprint. It gives the basic processing scheme, the
basic control concept, and the process information from equipment can be
specified and designed.
It is used to:
• Define and refine a process
• Document a process
• Construct a process
• Operate a process
4. OVERVIEW OF CPI CONT……
Block Diagram;
It’s the simplest but least descriptive of the schematic diagrams. It consists of neat rectangular blocks
which usually represent a single unit operation in a plant or an entire section of a plant. The blocks
are connected by arrows indicating the direction of flow. Block diagram is extremely useful in the
early stages of a process.
Graphic Flow Diagram;
It is used most frequently in advertising, company financial reports, and technical reports in which
certain features of the flow diagram require extra emphasis.
5. OVERVIEW OF CPI CONT…..
Process and Instrumentation Diagram (P&ID);
It provides the basis for detailed design, offers a precise description of
piping, instrumentation and equipment. This key drawing defines the
plant system, describes equipment, and shows all instrumentation,
piping and valving.
It is used to train personnel and aids in trouble-shooting during start-up
and operation. The P&ID assigns item numbers to all equipment (e.g.,
towers, reactors, and tanks), gives dimensions of equipment. And vessel
elevations, and shows all piping, including line numbers, sizes, and
specifications and all valves.
6.
7.
8. INTRODUCTION TO PETROLEUM
Millions of years ago, algae and plants lived in shallow seas. After
dying and sinking to the seafloor, the organic material mixed with
other sediments and was buried.
Over millions of years under high pressure and high temperature, the
remains of these organisms transformed into what we know today as
fossil fuels.
Brent, Kole, Mbome, Bonny light
9. IMPORTANCE OF CRUDE OIL IN THE
WORLD ECONOMY
Crude oil is mainly used as a fuel and combustible, but is also
indispensable as a chemical raw material. It is the foundation of
modern life and in virtually every product around us – from
smartphones and vehicle parts to wind turbines.
10. INSTABILITY OF CRUDE OIL PRICES
Crude oil prices are determined by global supply and demand.
Economic growth is one of the biggest factors affecting petroleum
product—and therefore crude oil—demand. Growing economies
increase demand for energy in general and especially for transporting
goods and materials from producers to consumers.
Discover how OPEC (Organization of the Petroleum Exporting
Countries is an organization enabling the co-operation of leading oil-
producing countries, in order to collectively influence the global
market and maximize profit), natural disasters, production costs, and
political instability are some of the major causes in oil price
fluctuation.
11.
12. CHEMISTRY OF CRUDE OIL
Crude oils is a mixture of chemicals called hydrocarbons. These are
chemicals that contain hydrogen and carbon only. It made from
ancient biomass, mainly plankton.
Crude oil straight out of the ground is not much use, as there are too
many substances in it, all with different boiling points
Main HC components in crude oil:
• Paraffin; straight chain single bond
• Olefin; straight chain double bond
• Naphthene; ring chain single bond
• Aromatics; ring double
14. CRUDE OIL REFINING PROCESS
CRUDE OIL STORAGE TANK:
Storage of crude oil for 72hrs for optimal decantation
Purge the tank to separate water and HC
Also to eliminate mud, Heavy metals, salts.
HEAT EXCHANGER (HX):
Exchange of energy between two products – a hot (heating) and cold (heated)
products.
16. CRUDE OIL REFINING CONT…
DESALTER:
The two most typical methods of crude-oil desalting, chemical and
electrostatic separation, use hot water as the extraction agent.
19. ATMOSPHERIC DISTILLATION COLUMN
REFLUX: It is a technique use to
ameliorate the quality of product
during distillation involving the
condensation of the vapor and
returning the condensate back into
the system.
There also internal reflux whereby
vapor inside the column looses its
energy and condenses and the
condensate later gains energy and
vaporizes.
Reboiler: an equipment usually a
heat exchanger that supplies heat
to the bottom product enabling
further separation of lighter HC
from the bottom heavy HC.
20. SECTIONS IN A DISTILLATION COLUMN
• Rectifying (enriching) section:
the more volatile component is
removed through contacting the
rising vapor with the down
flowing liquid.
• Stripping section: the down-
flowing liquid is stripped of the
more volatile component by a
rising vapor.
• Flash section: point of feed
injection where initial separation
occurs.
21. TRAYS IN A DISTILLATION COLUMN
Valve tray
Bubble cap tray
Sieve tray
22. HYDROTREATMENT OF NAPHTHA
It is the process whereby hydrogen is used to remove Sulphur,
Nitrogen, Oxygen and some heavy metals in the naphtha which have
adverse effects to the catalyst in catalytic reforming process. The
catalyst used in this process is either nickel-molybdenum or cobalt-
molybdenum at a pressure between 30bar – 40bar and temperature of
2900C – 3500C.
29. OTHER REFINING PROCESSES
CRACKING:
It is the process of converting lower value products into high valued
products. For instance Distillate into gasoline, gasoil. The following are
types of cracking processes
1. Fluid Catalytic Cracking (FCC);
A chemical process that uses a catalyst (crystalline zeolite) to
create new, smaller (simple) molecules from larger (complex)
molecules to make gasoline and distillate fuels.
30.
31. Hydrocracking:
Process whereby heavier HC with high boiling points is cracked into
lighter HC in the presence of hydrogen and a catalyst (zeolite catalyst).
32. Thermal cracking / Visbreaking:
A process in which hydrocarbons present in crude oil are subject to
high heat and temperature to break the molecular bonds and breaking
down long-chained, higher-boiling hydrocarbons into shorter-chained,
lower-boiling hydrocarbons.
34. CHEMICAL TREATEMNT
• Ferric chloride (FeCl3) It offers versatility in the water treatment
industry, by working as a flocculant and coagulant, as well as a
reactant. It promotes faster sedimentation in general and specifically,
better sedimentation in cold water, making it an ideal choice for the
industry.
• Polymers Common flocculants used in wastewater treatment include
polyacrylamide and other polymers. Together, coagulants and
flocculants work to improve the efficiency of wastewater treatment
by creating larger flocs that are easier to remove from the water.
35. BIOLOGICAL TREATMENT
• There are two types of biological treatment process; aerobic and
anaerobic. Biological wastewater treatment is an extremely cost
effective and energy efficient system for the removal of BOD
(Biological Oxygen Demand), since only micro-organisms are used.
• The goal of biological wastewater treatment is to remove organic
matter from the wastewater that is present in soluble and colloidal
form, as well as nutrients such as nitrogen and phosphorus
• It comprises of activated and clarification tanks.
• Activated sludge tank is where nitrification and denitrification
processes occur.
36. Activated Sludge Tank – Phosphate elimination
A
• A biological phosphorus removal – tank (BPR-
tank) is used for phosphate removal.
• Exclusion of free and dissolved oxygen
• Multiplication of anaerobic bacteria and
elimination of phosphate.
• Other micro-organisms at this stage are inactive.
B
• Exclusion of free and dissolved oxygen
• Multiplication of anoxic bacteria and conversion
of nitrate and nitrite into nitrogen.
C
• Wastewater is enriched with oxygen
• Multiplication of aerobic bacteria with oxygen
and conversion of nitrate/nitrite into ammonia
• Aerobic bacteria metabolize all carbon
compounds and produce carbon dioxide.
Phosphate
elimination
(A)
Phosphate
Anaerobic
bacteria
Nitrate/nitrite
Denitrification
tank (B)
Nitrogen
Oxygen
Nitrification
tank (C)
37. Biological Oxygen Demand (BOD) and Chemical
Oxygen Demand (COD)
COD and BOD indicate the degree contamination, how long the
waste water will need to remain in the biological treatment stage,
and if it has been treated sufficiently.
BOD refers to the amount that would be consumed during 5 days
of incubation at 200C if all the organics in 1L of water were
oxidized by bacteria.
COD dictates the amount of oxygen which consumes the entire
cast for the oxidation in water contained organic substances.
38. Clarification Tank
• Heavy substances sink to the floor, lighter substances accumulate on
the surface.
• A removal device moves heavy substances to the middle, where they
can be evacuated.
• A rake skims off lighter substances
• Removal sludge is returned to the activated sludge tank or pumped to
a sludge lagoon.
