This book presents the thermal and catalytic processes in refining. The differences between each type of process and the types of feedstock that can be used for the processes are presented. Relevant process data is provided, and process operations are fully described. This accessible guide is written for managers, professionals, and technicians as well as graduate students transitioning into the refining industry.
Key Features:
- Describes feedstock evaluation and the effects of elemental, chemical, and fractional composition.
- Details reactor types and bed types.
- Explores the process options and parameters involved.
- Assesses coke formation and additives.
- Considers next generation processes and developments.
Author(s): James G. Speight
Series: Petroleum Refining Technology Series
Publisher: CRC Press
Year: 2023
Language: English
Pages: 350
City: Boca Raton
Cover
Half Title
Series Page
Title Page
Copyright Page
Table of Contents
Preface
Author
Chapter 1 Overview of Refining Processes
1.1 Introduction
1.2 Thermal Cracking Processes
1.2.1 Visbreaking
1.2.2 Thermal Cracking
1.2.3 Coking
1.2.3.1 Delayed Coking
1.2.3.2 Fluid Coking
1.2.3.3 Flexicoking
1.3 Catalytic Processes
1.3.1 Catalytic Cracking
1.3.2 Bed Types
1.3.3 Catalysts
1.4 Additional Refinery Processes
1.4.1 Hydroprocesses
1.4.1.1 Hydrotreating
1.4.1.2 Hydrocracking
1.4.2 Reforming Processes
1.4.2.1 Thermal Reforming
1.4.2.2 Catalytic Reforming
1.4.3 Isomerization Processes
1.4.4 Alkylation Processes
1.4.5 Polymerization Processes
1.4.6 Solvent Processes
1.4.6.1 Deasphalting and Solvent Extraction
1.4.6.2 Dewaxing and Wax Deoiling
1.4.7 Treating Processes
1.4.7.1 Acid Treatment
1.4.7.2 Alkali Treatment
1.4.7.3 Clay Treatment
References
Chapter 2 Feedstocks and Feedstock Composition
2.1 Introduction
2.2 Non-Viscous Feedstocks
2.2.1 Naphtha
2.2.1.1 Manufacture
2.2.1.2 Composition
2.2.1.3 Properties and Uses
2.2.2 Middle Distillates
2.2.2.1 Manufacture
2.2.2.2 Composition
2.2.2.3 Properties and Uses
2.2.3 Gas Oil
2.2.3.1 Manufacture
2.2.3.2 Composition
2.2.3.3 Properties and Uses
2.2.4 Wax
2.2.4.1 Manufacture
2.2.4.2 Composition
2.2.4.3 Properties and Uses
2.2.5 Biomass and Bio-Oil
2.2.5.1 Manufacture
2.2.5.2 Composition
2.2.5.3 Properties and Uses
2.3 Viscous Feedstocks
2.3.1 Heavy Crude Oil
2.3.2 Extra Heavy Crude Oil
2.3.3 Tar Sand Bitumen
2.3.4 Residuum
2.4 Feedstock Composition
2.5 Elemental Composition
2.6 Chemical Composition
2.6.1 Hydrocarbon Constituents
2.6.1.1 Paraffin Derivatives
2.6.1.2 Cycloparaffin Derivatives
2.6.1.3 Aromatic Derivatives
2.6.1.4 Unsaturated Hydrocarbon Derivatives
2.6.2 Non-Hydrocarbon Constituents
2.6.2.1 Sulfur Compounds
2.6.2.2 Nitrogen Compounds
2.6.2.3 Oxygen Compounds
2.6.2.4 Metal-Containing Constituents
2.6.2.5 Porphyrin Derivatives
2.7 Fractional Composition
2.7.1 Solvent Methods
2.7.2 Adsorption Methods
2.7.3 Chemical Methods
2.8 Use of the Data
References
Chapter 3 Feedstock Evaluation
3.1 Introduction
3.2 Feedstock Evaluation
3.2.1 Physical Properties
3.2.1.1 Acid Number
3.2.1.2 Elemental Analysis
3.2.1.3 Density and Specific Gravity
3.2.1.4 Metals Content
3.2.1.5 Viscosity
3.2.2 Thermal Properties
3.2.2.1 Carbon Residue
3.2.2.2 Critical Properties
3.2.2.3 Heat of Combustion
3.2.2.4 Liquefaction and Solidification
3.2.2.5 Pressure-Volume-Temperature Relationships
3.2.2.6 Volatility
3.2.3 Chromatographic Properties
3.2.3.1 Adsorption Chromatography
3.2.3.2 Gas Chromatography
3.2.3.3 Gel Permeation Chromatography
3.2.3.4 High-Performance Liquid Chromatography
3.2.3.5 Ion-Exchange Chromatography
3.2.3.6 Simulated Distillation
3.2.3.7 Supercritical Fluid Chromatography
3.2.4 Spectroscopic Properties
3.2.4.1 Infrared Spectroscopy
3.2.4.2 Mass Spectrometry
3.2.4.3 Nuclear Magnetic Resonance Spectroscopy
3.2.5 Molecular Weight
3.3 Biomass Feedstocks
3.3.1 Properties
3.3.1.1 Proximate Analysis
3.3.1.2 Ultimate Analysis
3.3.1.3 Heat of Combustion
3.3.1.4 Ash Analysis
3.3.1.5 Bulk Density
3.3.2 Pretreatment
3.4 Use of the Data
References
Chapter 4 Thermal Cracking Processes
4.1 Introduction
4.2 Thermal Cracking
4.3 History
4.4 Distillate Cracking
4.5 Visbreaking
4.5.1 Coil Visbreaking
4.5.2 Soaker Visbreaking
4.5.3 Other Variants
4.6 Coking
4.6.1 Delayed Coking
4.6.2 Fluid Coking
4.6.3 Flexicoking
4.7 Thermal Cracking Chemistry
4.7.1 General Chemistry
4.7.2 Asphaltene Chemistry
4.7.3 Biomass Chemistry
4.8 Process Parameters
4.8.1 The Reactor
4.8.2 Temperature
4.8.3 Coke Formation
4.9 Options for Viscous Feedstocks
4.9.1 Aquaconversion Process
4.9.2 Asphalt Coking Technology Process
4.9.3 Cherry-P Process
4.9.4 Continuous Coking Process
4.9.5 Decarbonizing Process
4.9.6 Deep Thermal Conversion Process
4.9.7 ET-II Process
4.9.8 Eureka Process
4.9.9 Fluid Thermal Cracking Process
4.9.10 High-Conversion Soaker Cracking Process
4.9.11 Mixed-Phase Cracking Process
4.9.12 Selective Thermal Cracking Process
4.9.13 Tervahl-T Process
4.9.14 Other Options
References
Chapter 5 Catalytic Cracking Processes
5.1 Introduction
5.2 Process Types
5.2.1 Fixed-Bed Processes
5.2.2 Moving-Bed Processes
5.2.3 Fluid-Bed Processes
5.3 Coke Formation and Additives
5.3.1 Coke Formation
5.3.2 Additives
5.4 Process Parameters
5.4.1 Catalyst Activity
5.4.2 Catalyst/Feedstock Ratio
5.4.3 Feedstock Conversion
5.4.4 Feedstock Preheating
5.4.5 Feedstock Pressure
5.4.6 Feedstock Quality
5.4.7 Process Design
5.4.7.1 Commercial Technology Changes
5.4.7.2 Modifications for Existing Units
5.4.7.3 New Directions
5.4.8 Reactor Temperature
5.4.9 Recycle Rate
5.4.10 Regenerator Air Rate
5.4.11 Regenerator Temperature
5.4.12 Residence Time
5.4.13 Space Velocity
5.5 Catalysts
5.5.1 Catalyst Types
5.5.2 Catalyst Manufacture
5.5.3 Catalyst Selectivity
5.5.4 Catalyst Deactivation
5.5.5 Catalyst Stripping
5.5.6 Catalyst Treatment
5.5.6.1 Demet Process
5.5.6.2 Met-X Process
5.5.7 Recent Advances
5.5.7.1 Matrix, Binder, Zeolite
5.5.7.2 Additives
5.5.7.3 Metal Traps
5.5.7.4 Low Rare Earths
5.5.7.5 Catalysts for Olefin Production
5.5.7.6 Catalysts for Jet and Diesel Production
5.5.7.7 New Directions
5.6 Options for Viscous Feedstocks
5.6.1 Asphalt Residual Treating (ART) Process
5.6.2 Heavy Oil Treating Process
5.6.3 Reduced Crude Oil Conversion Process
5.6.4 Residue FCC Process
5.6.5 R2R Process
5.6.6 Shell FCC Process
5.6.7 S&W FCC Process
5.6.8 Other Options
5.7 Chemistry
References
Chapter 6 Fouling during Thermal and Catalytic Processes
6.1 Introduction
6.2 The Concept of Fouling
6.2.1 Types of Fouling
6.2.2 Parameters Affecting Fouling
6.2.2.1 Fluid Flow Velocity
6.2.2.2 Surface Temperature
6.2.2.3 Surface Material
6.2.2.4 Surface Roughness
6.2.2.5 Fluid Properties
6.2.3 Asphaltene Deposition
6.2.4 Wax Deposition
6.2.4.1 Deposition
6.2.4.2 Factors Leading to Wax Deposition
6.2.4.3 Mechanism
6.3 Fouling during Thermal Cracking
6.3.1 Fouling during Visbreaking
6.3.1.1 Types of Foulants
6.3.1.2 Impact of Foulants
6.3.2 Fouling during Coking
6.3.2.1 Types of Foulants
6.3.2.2 Impact of Foulants
6.4 Fouling During Catalytic Cracking
6.4.1 Types of Foulants
6.4.1.1 Organic Foulants
6.4.1.2 Inorganic Foulants
6.4.2 Impact of Fouling
6.4.2.1 Heat Exchanger Fouling
6.4.2.2 Fractionator Fouling
6.4.2.3 Catalyst Fouling
6.5 Management and Mitigation
References
Chapter 7 Importance in the Refinery
7.1 Introduction
7.2 Thermal Processes and Catalytic Processes
7.3 The Need for Thermal and Catalytic Processes
7.3.1 Visbreaking, Thermal Cracking, and Coking
7.3.2 Catalytic Cracking
7.4 Refinery of the Future
7.4.1 The Biorefinery
7.5 Epilog
References
Glossary
Conversion Factors
Index
