IntroductiontoPetrochemical engineering.pptx

IntroductiontoPetrochemical engineering.pptx

1. Petrochemical Engineering (CHL4350) Unit-1: Introduction Instructor: Dr. Krunal Gangawane

2. Objective Provide background information about the petrochemical engineering including definition, petrochemical products and processes Learning Outcome Gain a holistic view of Petrochemical Engineering and learn about the importance of petrochemical products and processes Textbooks 1. Chaudhuri U. R. (2011) Fundamentals of Petroleum and Petrochemical Engineering, CRC Press 2. Ram Prasad (1998), Petroleum Refining Technology, Khanna Publishers 3. Hatch, Lewis Frederic, and Sami Matar (1981) From hydrocarbons to petrochemicals, Gulf Publishing Company, Book Division. Reference Books 1. Meyers, Robert, and Robert Allen Meyers, eds. (2005) Handbook of petrochemicals production processes. McGraw-Hill. Petrochemical Engineering (CHL4350) 2

3. Syllabus Unit Topic I Introductory Concepts for Crude Petroleum and Petrochemicals: Motivation, Formation of oil and gas, oil exploration, production of crude oil and natural gas, crude of chemistry and composition, classification of crude oil II Transportation and quality control of crude oil: Pipeline transportation, Methods for pipeline transportation, Pump characteristics for crude oil, classification of lab tests, carbon residue, etc. III Petrochemical Intermediates from Petroleum Products: Manufacturing processes for carbon black from methane/ natural gas, polyethylene production from ethane, Terephthalic acid and PET from from Xylene, Naphtha for olefins, sulfuric acid from sulfur, cosmetics and food grade coating wax from wax, naphtha cracking IV Petrochemical Finished Products from Intermediates: Manufacturing of paint, fiber, plastics, rubber, Nylons, fibers, processing of plastic, rubber and fibers V Layout and Unit Operations in Petrochemical Plants: Petrochemical complex, Reactors processing units, offsite facilities, power and steam generating plants, cooling tower Petrochemical Engineering (CHL4350) 3

4. Evaluation pattern Evaluation type Allocated marks Exam Minor-1 Minor-2 Major 60 15 15 30 Continuous Assessment Test Research assignment 40 20 20 Total 100 Petrochemical Engineering (CHL4350) 4

5. UNIT -1 Introductory Concepts for Crude Petroleum and Petrochemicals Petrochemical Engineering (CHL4350) 5

6. Introduction Energy is known to play a vital and important role in the industrial and economic development. Petroleum provide relatively cheap and convenient source of energy as compared to other fuels (coal and electricity). 5 th Largest consumer of petroleum products worldwide 25 th in rank worldwide for crude oil production Petrochemical Engineering (CHL4350) 6

7. The occurrence of crude oil without gas is rare . On the contrary, large deposits of gas occur without oil in many places, as Po (Italy), Siberia (Russia) and (Sind) Pakistan. Oil is generally associated with gas in a ratio- oil/gas ratio. The oil/gas ratio depends on the chemical nature and physical conditions of its occurrence. Such as trap (natural barrier that prevents further flow of oil), depth and temperature. Petrochemical Engineering (CHL4350) 7

8. History Historically, petroleum and its derivatives have been known and used for millennia. Scientifically, petroleum is a carbon-based resource and is an extremely complex mixture of hydrocarbon compounds, usually with minor amounts of nitrogen-, oxygen-, and sulfur-containing compounds , as well as trace amounts of metal-containing compounds. Heavy oil is a subcategory of petroleum that contains a greater proportion of the higher-boiling constituents and heteroatom compounds ( any atom that is not carbon or hydrogen ) . Petrochemical Engineering (CHL4350) 8

9. In the crude state, petroleum, heavy oil, and bitumen have minimal value . However, when refined, they provide high-value liquid fuels, solvents, lubricants, and many other products. The fuels derived from petroleum contribute approximately one-third to one-half of the total world energy supply and are used not only for transportation fuels (i.e., gasoline, diesel fuel, and aviation fuel, among others) but also to heat buildings . Petroleum products have a wide variety of uses that vary from gaseous and liquid fuels to near-solid machinery lubricants. Petrochemical Engineering (CHL4350) 9

10. Formation of oil and gas Two theories of the genesis of petroleum Organic theory Petroleum is of organic origin Formed from remains of the plant and animals died millions of years ago & accumulated on ocean floors. Tiny marine animals & plants used to float on the surface of sea, and were abundant during Mesozoic era (225 millions years ago) & Cainozoic era (65 millions years ago). On contrary, the rock surface and land were continuously eroded. Broken pieces of materials, like sand, clay, limestone are carried away by rain, and deposited on the beds of ocean. Over millions of years, sediments pile up to a great height, resulting in increased temperature and pressure over the rocks of ocean floors. Some complex chemical transformation took place. Resulting in fats, amino acids, lipids and finally oil and gas. Temperature range: 100-200 o C -- Oil Temperature range: greater than 180 o C -- Gas As per theory: India is oil-poor country. Non-organic theory Petroleum is of non-organic origin Oil was formed by action of water and metallic carbides or by atmospheric radioactivity or cosmic radiation. Minor occurrence of oil in meteorites, igneous dykes, in Petrozoic rocks weighs in favor of theory. As per theory: India is oil rich. Petrochemical Engineering (CHL4350) 10

11. Drilling for oil and gas recovery Derrick : A tall huge tower which is anchored to the ground, engines, mud pumps, water tanks, draw-works, etc. Crown block : A large pully at the top of the derrick. Travelling block : Suspended from the crown block. Swivel : Attached by large hook to the travelling block. It can rotate freely and Kelly is fitted onto it. Kelly : A long square or hexagonal steel bar with a hole drilled through the middle for a fluid path. Rotary table : A mechanical device on a drilling rig that provides clockwise (as viewed from above) rotational force to the drill string to facilitate the process of drilling a borehole. Petrochemical Engineering (CHL4350) 11

12. Oil and gas exploration Deciding where to drill may be as much of an art as it is a science. The primary search for hydrocarbons frequently begins with observation of surface terrain. Location of faults at the surface are very important because they indicated where potential structural traps may lie beneath the surface in reservoir rocks. The observation of anticlines, another type of structural trap, also indicate potential traps at depth. Naturally existing crude oil seeps blacken the ground and spread rainbow films on streams. Such direct evidence is useful, but most such places have long ago been identified and explored. Petrochemical Engineering (CHL4350) 12

13. Methodologies used for hydrocarbons in the subsurface GEOPHYSICAL SURVEYS REMOTE SENSING WILDCAT Petrochemical Engineering (CHL4350) 13

14. GEOPHYSICAL SURVEYS Geophysical techniques used for petroleum exploration utilize equipment to measure such things as: Electrical currents Gravitational and magnetic anomalies Heat flow Geochemical relationships Density variations from deep within the earth Each technique records a different set of characteristics which can be used to locate hydrocarbons beneath the surface of the earth. Petrochemical Engineering (CHL4350) 14

15. Seismic surveys use vibration ( induced by an explosive charge or sound generating equipment ) to provide a picture of subterranean rock formations at depth, often as deep as 30,000 feet below ground level (BGL). This is accomplished by generating sound waves downward into the earth's crust which reflect off various boundaries between different rock strata. On the land, the sound waves are generated by small explosive charges embedded in the ground or by vibrator trucks , sometimes referred to as thumpers which shake the ground with hydraulically driven metal pads. The human ear can barely hear the thump , but the frequency generated penetrates the earth's crust. The echoes are detected by electronic devices called geophones which receive the reflected sound waves. The data are recorded on magnetic tape which is printed to produce a two-dimensional graphic illustrating the subsurface geology. Petrochemical Engineering (CHL4350) 15

16. Offshore surveys are conducted in a slightly different manner. Boats tow cables containing hydrophones in the water, which is similar to geophones on land. Sound waves use to be created by dynamite, but this method killed a variety of sea life. The most acceptable method today is to generate sound waves using pulses of compressed air which creates large bubbles that burst beneath the water surface creating sound. The sound waves travel down to the sea floor, penetrate the rocks beneath, and return to the surface where they are intercepted by the hydrophones. Petrochemical Engineering (CHL4350) 16

17. In this type of survey, sound waves are sent into the earth where they are reflected by the different layers of rock. The time taken for them to return to the surface is measured as a function of time. This measurement reveals how deep the reflecting layers are; the greater the time interval, the deeper the rock layer. Moreover, this technique also can determine what type of rock is present because different rocks transmit sound waves differently. Petrochemical Engineering (CHL4350) 17

18. OTHER GEOPHYSICAL TECHNIQUES Magnetometers and gravimeters : A device that is pulled behind an airplane on a long cable that detects variations in the earth's magnetic field. Sedimentary rocks generally have low magnetic properties compared to other rock types. A gravimeter measures minute differences in the pull of gravity at the earth's surface. Mapping these differences reveals large masses of dense subsurface rock which allows geologists to have a better idea of the structures below ground. Geochemical prospecting (a relatively new technique) : It uses sensitive instruments to detect minute quantities of gases that seep upward from petroleum deposits. This is a relatively new technique, but is one that is gaining wider acceptance. Petrochemical Engineering (CHL4350) 18

19. REMOTE SENSING Remote Sensing (RS) is the use of aerial photographs to locate and map surface features. Increasing use of satellite imagery is being made because it shows large areas on the surface of the earth. Even though the photographs are taken form several hundred miles up in space, they are able to show features only a few feet in size. And satellite imagery not only indicates what the human eye can see. But they can also reveal subtle variations in soil moisture, mineral and vegetation distribution, and soil type, all of which are import pieces to the exploration puzzle. Petrochemical Engineering (CHL4350) 19

20. Once an area is selected and the satellite imagery obtained, the exploration geologist utilizes mapping techniques to produce a geologic map (a map that indicates geological structures by using conventional symbols) for the area. The series of lines and arrows indicate the type of structure that exists at the surface. These mountains are comprised of folded and faulted Paleozoic strata which are buried beneath younger sediments toward the south. These mountains are made of a combination of structures called anticlines, synclines, and faults, all of which form various types of hydrocarbon traps. REMOTE SENSING Petrochemical Engineering (CHL4350) 20

21. WILD CAT Wildcat drilling is a form of exploratory drilling in the oil & gas exploration and production process that seeks to exploit unproven or high-risk areas. A wildcat driller may alternatively seek to return to existing or older wells that are no longer profitable or useful for larger oil companies. Wildcatting often involves smaller firms and can involve both high risk and high reward for stakeholders. Petrochemical Engineering (CHL4350) 21

22. Steps in Production of Crude oil and Natural gas Crude petroleum is found in the void spaces of porous rock along with gas and water. Oil is trapped under immense pressure beneath the impermeable rock formations. When trapped formation is pierced, the fluid flows out of the trap into well bore. The fluid in the bore-well is lifted naturally (due to release of gas) or with mechanical pump to maintain influx into the well bore. However, the withdrawal of fluid from reservoir lowers the pressure therein and in turn reflux rate into the bore-well decreases. This rate decreases to a value, insufficient to pay for the cost of lifting fluid to the surface. The recovered oil accounts: 15-20% of original oil. Petrochemical Engineering (CHL4350) 22

23. This is called as primary oil recovery ( maximum 20% recovery ). The method of increasing the oil recovery is called as Enhanced oil recovery ( EOR ). In EOR, Two stages: i ) Secondary recovery, and ii) tertiary recovery Secondary recovery Water is injected into series of wells in order to displace the oil to adjoining producing wells. Water, due to its high density, efficient displacement characteristics, and incompressible nature can raise the reservoir pressure quickly. Steps in Production of Crude oil and Natural gas Petrochemical Engineering (CHL4350) 23

24. Disadvantages of using water It does not flush/flood all of the oil from the pores as it moves through reservoir rock. About 30-70% oil is left behind in the form of small droplets within the pores of reservoir. Advancing water front bypasses significant portions of the reservoir due to difficult well placement & unexpected geological configurations. Petrochemical Engineering (CHL4350) 24 Steps in Production of Crude oil and Natural gas Recovery of remaining oil is called as Enhanced Oil Recovery (EOR) . EOR Techniques Miscible/immiscible displacement process Thermal recovery process Chemical flooding process

25. EOR techniques Petrochemical Engineering (CHL4350) 25 Miscible/immiscible displacement process Thermal recovery process Chemical flooding process Miscible hydrogen displacement (LPG enriched gas & lean gas) CO 2 injection Inert gas injection Steam simulation Stream flooding (including hot water) In-situ combustion Surfactant flooding Polymer injection Alkaline flooding Selection of suitable EOR technique requires careful analysis of reservoir configuration & oil properties.

26. EOR techniques Trapping and release of fluids from porous media is complex phenomenon. For a specific system, trapping behavior is controlled by, Fluid rock properties (wettability: the attraction of a liquid phase to solid surface) Pore geometry of rock matrix Fluid-fluid interactions, including viscosity, rock density difference, interfacial tension, and partition coefficient . Petrochemical Engineering (CHL4350) 26

27. Petrochemicals Petrochemical Engineering (CHL4350) 27

28. Petrochemical Engineering (CHL4350) 28 Petrochemicals are chemical compounds recovered partially/entirely from petroleum or natural gas hydrocarbons. Petrochemical industry produces different kinds of chemical products such as, polymers, fibers, or rubber, from raw materials like petroleum, LPG, natural gas, etc. What are Petrochemicals? About 5% of oil and natural gas consumed each year is required to make all petrochemical products. Petrochemical products play a significant role in our food, clothing, shelter, etc.

29. Petrochemical Engineering (CHL4350) 29 Classification of Petrochemicals? Classification of Petrochemicals Light petrochemicals Medium petrochemicals Heavy petrochemicals Mainly used as a bottled fuel and raw materials for other organic chemicals. Lightest- methane, ethane and ethylene (gaseous at room temperature). Next light fractions compromise petroleum ether and light naptha with boiling points in range 27-88 o C. Hydrocarbons with 6-12 carbon atoms (called as gasoline) are mainly used as fuel in automobiles. Octane (eight carbon atoms) – good automobile fuel. Kerosene has 12-15 carbon atoms & used as solvents for heating and lighting. Diesel oil Heating and lubricating oil Contain 15-18 carbon atoms with boiling points between 300-400 o C. The heaviest fraction of all are called bitumen and are used to surface roads.

30. Petroleum refining, operation and optimization Petrochemical Engineering (CHL4350) 30

31. Petroleum refining Crude oil in its raw form has got very limited use. By adopting various refining processes in the refineries, crude oils are separated into a number of fractions. The fractionation of crude oil yields the following streams in the order of rising boiling point ranges. Methane, ethane, propane mixtures Liquified petroleum gases Kerosene High speed diesel oil (HSD) and light diesel oil (LDO) Reduced crude oil Petrochemical Engineering (CHL4350) 31

32. Selection of processes for optimization Petrochemical Engineering (CHL4350) 32

33. Selection of processes for optimization Optimization : Method of determining best refining process subjected to constraints. The important factors that influences the optimization of refining process are given below. Type of crudes Product slate Product specification Investment and operating costs Petrochemical Engineering (CHL4350) 33

34. Type of crude Type of crude to be processed in the refinery will have significant impact on process scheme. For example, crude containing high Sulphur requires installation of desulfurization process. Some crudes are not suitable for making lubricating oils. Some crudes are not suitable for making bitumen. Petrochemical Engineering (CHL4350) 34

35. Product slate The capacity of the refinery, the type and size of the secondary processing units is largely governed slate, which is turn decided by demand of petroleum products. The process scheme to be adopted is based on the product slate. INDIA: Maximization of middle distillates is main criteria. If objective is to maximize the high-speed diesel oil (HSD) in refinery processing high Sulfur crudes, it is advantageous to use FCC unit. Petrochemical Engineering (CHL4350) 35

36. Crude oil classification & characterization UNIT 2 Petrochemical Engineering (CHL4350) 36

37. Classification of crude The hydrocarbons found in petroleum are classified into the following types: Paraffins(C n H 2n+2 ): Saturated hydrocarbons with straight or branched chains, but without any ring structure. Carbon atoms connected by single bond Other bonds saturated with hydrogen 2. Cycloparaffins (C n H 2n )( naphthenes ): Saturated hydrocarbons containing one or more rings, each of which may have one or more paraffin side-chains(also known as alicyclic hydrocarbons). Ringed Paraffins (Cycloparaffins) All bonds saturated with hydrogen Petrochemical Engineering (CHL4350) 37