Hydrocarbon Processing and Refining Principles and Practices

This book covers petroleum refining and gas purification processes, including refinery configurations comprising of relevant units with special emphasis on processing of heavy crudes with high acid number. It includes a short review of distillation principles, distillation column auxiliaries, critical column pressure control strategies, critical issues of crude and vacuum distillation units particularly for heavy crude processing. Different corrosion mechanisms and their prevention with regards to heavy high TAN crude processing are also included. Fundamentals are explained with support of steady-state simulation and presented with simulation flowsheets and outputs, supported by examples of calculations and troubleshooting case studies. Features: • Deals with principles and practices in the hydrocarbon industry and petroleum refinery with emphasis on heavy crude processing • Focuses on operation and practices of the major process units with simulation examples and aimed at the professional engineer • Covers acid gas treatment in view of increased emphasis on carbon capture and storage, and introduction of residue gasification processes • Elucidates methodologies for safety relief load computation for distillation columns • Explains real-life problems in reboilers, column internals, column pressure controls and corrosion in crude, and vacuum distillation and secondary units with several case studies This book is aimed at professionals in petroleum engineering and graduate students in chemical engineering.

1.0 Overview of refining and distillation1.1Overview of refinery1.2Distillation – an overview 1.3Column pressure control strategies and reboilers 1.4Processing of heavy crudes 1.5Corrosion in crude- vacuum distillation units with heavy crudes1.6Processing of high TAN crudes1.7Processing of crude oils with high calcium1.8Case studies in distillation units 2.0Fluidized catalytic cracking unit (FCCU) 2.1Process description2.2Reactor regenerator heat balance2.3Combustion modes of regenerators2.4Definition of Delta coke 2.5Power recovery from regenerator flue gas2.6Operating variables2.7Fluidization and related equipment in FCCU2.8Physical properties of catalysts related to fluidization2.9Guidelines for design of cyclones2.10Problems related to cyclones2.11Riser separation system and positive / negative pressure cyclones2.12Estimation of transport disengaging height in regenerators2.13Design guidelines for cyclone dip legs2.14Design and operating guidelines for FCCU catalyst standpipes2.15Reactions in FCCU and catalysts features and additives 2.16Corrosion in FCCU its prevention and mitigation 3.0Delayed Coking unit (DCU)3.1Introduction3.2Process description 3.3Operating variables3.4Activities in decoking operation3.5Effect of feed stock on coking3.6Coker furnace and factor affecting fast furnace coking and decoking operation3.7Coke drum and drum deformities3.8Coke morphology and effect on operation3.9Safety in Coke storage and handling3.10Case studies 4.0Hydrotreaters and Hydrocrackers4.1Introduction of the process and basic functions4.2Catalysts and reasons for deactivation4.3Process variables4.4Operating concerns in Naphtha hydrotreater units 4.5Diesel hydrotreaters and common operating problems4.6Heavy distillate hydrotreaters and common operating problems 4.7Overview of residue hydrotreater4.8Hydrocrackers and various configurations4.9Metallurgy of hydrotreaters and hydrocrackers4.10Case studies4.11Improvement of recycle gas purity 5.0Acid gas treatment 5.1Introduction5.2Options for acid gas removal5.3Common physical solvents for acid gas removal5.4Physical chemical solvents5.5Chemical solvents and processes5.6Recent trends and advances5.7Different types of membranes and processes5.8Experiences of amine unit performance in Industry5.9Case studies 5.10Carbon capture 6.0Hydrogen generation units6.1Introduction6.2Description of steam reformer6.3Common process problems 6.4Mechanism for deactivation of catalysts 6.5Case studies6.6Hydrogen recovery6.7Capacity augmentation 7.0Sulfur recovery unit7.1Introduction7.2Process description and reaction mechanism7.3Enhanced sulfur recovery7.4Common problems in SRUs7.5Capacity augmentation 8.0Plant safety8.1Introduction8.2Methodologies for relief load computation for columns8.3Relief load calculation of a crude distillation column8.4Relief load calculation of a Vacuum distillation column8.5Summary of contingencies8.6Safety measures in high pressure and low-pressure interconnections8.10 Location and special features of installation of safety valve8.11Relation between design pressure and test pressure of equipment 9.0Technical challenges in refining9.1 Lower crude and product differential9.2 Stricter product specifications9.3 Stricter emission norms9.4 Limited sales of Coke and heavy oils 10.0 Renewable energy 10.1 Introduction10.2 Types of renewable energy10.3 Types of biomass10.4 conversion of biomass to energy and byproducts10.5 Forms of bio fuels and benefits of biofuels10.6 Bio refinery10.7 Renewable hydrogen fuel

Ashis Nag is a professional Chemical Engineer with 40 + years of rich experience in various fields of Petroleum refining and related downstream process technologies. He has worked in different refineries of Indian oil corporation and in Essar oil refinery, Jamnagar. He served as Head of special central process engineering and design cell of Indian Oil Corporation Limited (IOCL) as Executive Director. Presently, he is working as a process consultant. Internationally traveled and author ofseveral papers for international journals and forums, he has also authored a book titled Distillation and Hydrocarbon Processing Practices. He has received a couple of awards for innovative designs, and obtained a B.CH.E degree in chemical engineering from Jadavpur university, Kolkata, India, in 1976.