Petroleum and Gas Processing - Semester TKK-2136
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Petroleum and Gas
Processing(TKK-2136)
16/17 Semester
Instructor: Rama Oktavian
Email:
Oktavian.rama2@gmail.com
Office Hr.: M.10-15, Tu. 08-12, W. 13-15, Th. 13-15, F. 09-11
Outlines
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Catalytic reforming
Hydroconversion
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Hydroconversion is a term used to describe all different
processes in which hydrocarbon reacts with hydrogen.
To describe the process of the removal of sulphur,
nitrogen and metal impurities in the feedstock by
hydrogen in the presence of a catalyst.
Hydrotreating
The process of catalytic cracking of feedstock to
products with lower boiling points by reacting
them with hydrogen.
Hydrocracking
Hydrogenation
aromatics are saturated by hydrogen to the
corresponding naphthenes.
Hydrotreating
Objectives of Hydrotreating
1.
Removing impurities
, such as sulphur, nitrogen and
oxygen for the control of a final product
specification or for the preparation of feed for
further processing.
2.
Removal of metals
, usually in a separate guard
catalytic reactor when the organo-metallic
compounds are hydrogenated and decomposed,
resulting in metal deposition on the catalyst pores.
3.
Saturation
of olefins and their unstable compounds.
Hydrotreating
Role of hydrotreating (HT) in the refinery
HT are located before
the reformer,
hydrocracker and FCC
They are also
needed to adjust the
final product
specification for
various streams,
such as light naphtha,
kerosene and low
sulphur fuel oils
(LSFOs).
Hydrotreating
Main role of hydrotreating
1. Meeting finished product specification.
Kerosene, gas oil and lube oil desulphurization.
Olefin saturation for stability improvement.
Nitrogen removal.
De-aromatization for kerosene to improve cetane
number.
Cetane number
is the percentage of pure cetane in a
blend of cetane and alpha-methyl-naphthalene. The latter
matches the ignition quality of
kerosene sample.
Hydrotreating
Main role of hydrotreating
2. Feed preparation for downstream units
:
Naphtha is hydrotreated for removal of metal and
sulphur.
Sulphur, metal, polyaromatics and Conradson carbon
removal from vacuum gas oil (VGO) to be used as FCC
feed.
Pretreatment of hydrocracking feed to reduce sulphur,
nitrogen and
aromatics.
Hydrotreating
1.
The liquid feed
is mixed
with hydrogen and fed into a
heater and then
fed into a fixed bed catalytic reactor
.
2.
The effluent is cooled and hydrogen-rich gas is
separated
using a high pressure separator
.
The main elements
of a hydrotreating
process
Hydrotreating
3. Before the hydrogen is recycled, hydrogen sulphide can
be removed using an amine scrubber.
4. Some of the recycle gas is also purged
- To prevent the accumulation of light hydrocarbons
(C1–C4)
- To control hydrogen partial pressure.
Hydrotreating
5. The liquid effluent for the reactor is introduced to a
fractionator for product separation.
Hydrotreating
Operating Conditions
The operating conditions of the hydrotreating
processes
pressure
temperature
catalyst loading
feed flow rate
hydrogen partial pressure
Hydrotreating
Operating Conditions
Increasing hydrogen partial pressure
improves the
removal of sulphur and nitrogen compounds and
reduces coke formation.
Higher temperatures
will increase the reaction rate
constant and improve the kinetics. However, excessive
temperatures will lead to thermal cracking and coke
formation.
The space velocity is the reverse of reactor residence
time (y).
High space velocity
results in low
conversion, low hydrogen consumption and low coke
formation.
Hydrotreating
Operating Conditions
Hydrocracking
Hydrocracking is a catalytic hydrogenation process in
which
high molecular weight feedstocks
are converted and
hydrogenated to
lower molecular weight products
.
The catalyst used in hydrocracking is a
bifunctional one
. It
is composed of a metallic part, which promotes
hydrogenation, and an acid part, which promotes cracking.
Hydrogenation removes impurities in the feed such as
sulphur, nitrogen and metals.
Cracking will break bonds, and the resulting unsaturated
products are consequently
hydrogenated into stable
compounds.
Hydrocracking
•
It is mainly used to produce
middle distillates of low
sulphur content such as
kerosene and diesel.
•
If mild hydrocracking is used,
a LSFO can be produced.
•
It has been used to remove
wax by catalytic dewaxing and
for aromatic removal by
hydrogen saturation.
•
This has been applied to the
lube oil plants and is gradually
replacing the old solvent
dewaxing and aromatic solvent
extraction.
Hydrocracking
Feeds and Products
•
VGO is the main feed for hydrocrakers
Hydrocracking
Hydrocracking Catalysts
The cracking function is provided by an acidic support,
whereas the hydrogenation–dehydrogenation function is
provided by active metals.
Hydrocracking
Hydrocracking Process
The following factors can affect operation (product quality),
yield (quantity), and the total economics of the process:
1. Process configuration: one stage (once-through or recycle) or
two stages
2. Catalyst type
3. Operating condition (depends on process objective)
- Conversion level
- Maximization of certain product
- Product quality
- Catalyst cycle
- Partial hydrogen pressure
- Liquid hourly space velocity
- Feed/hydrogen recycle ratio
Hydrocracking
Process Configuration
Simplified flow
diagram of one-stage
hydrocracking
process with and
without recycle
In commercial hydrocrackers, a conversion of 40–80% of the feed can
be achieved.
However if high conversion is required the product from the bottom of
the distillation tower is recycled back to the reactor for complete
conversion.
This configuration can be used to maximize a diesel product, and it
employs an amorphous catalyst.
Hydrocracking
Process Configuration
Conventional two-
stage hydrocracker
The effluent from the first stage reactor is sent to a separator and fractionator.
The fractionator bottoms are sent to the second reactor.
The catalyst in the
first
stage
has a
high
hydrogenation/acidity
ratio
, causing sulphur
and nitrogen removal
In the
second reactor
, the
catalyst used is of a
low
hydrogenation/acidity
ratio
in which naphtha
production is maximized
Product blending
The main purpose of product blending is to find the best
way of mixing different intermediate products available
from the refinery and some additives in order to adjust the
product specifications.
octane number, Reid vapour pressure (RVP) and
volatility
Gasoline
diesel index, flash point, pour point and
viscosity
Diesel oil
Product blending
The desired property P
Blend
where P
i
is the value of the property of component i and q
i
is the mass,
volume or molar flow rate of component i contributing to the total amount
of the finished product.
Product blending
Product blending
Reid Vapor Pressure
the vapour pressure at 100 F of a product determined in a
volume of air four times the liquid volume.
RVP blending index
Product blending
Product blending
Product blending
Product blending
Gasoline octane number blending
Octane number is a measure of a fuel’s tendency to knock in a
test engine compared to other fuels.
Octane number blend
Product blending
Oxygenated compound to increase octane number
Product blending
This course, taught by Instructor Rama Oktavian, focuses on the processing of petroleum and gas. Covering key aspects such as refining techniques, exploration methods, and industry standards, students will gain a comprehensive understanding of the field. With a mix of theory and practical applications, learners will be equipped to pursue careers in the petroleum and gas industry.
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Presentation Transcript
16/17 Semester Petroleum and Gas Processing(TKK-2136) Instructor: Rama Oktavian Email: Oktavian.rama2@gmail.com Office Hr.: M.10-15, Tu. 08-12, W. 13-15, Th. 13-15, F. 09-11
Outlines 1. Hydroconversion 2. Hydrotreating 3. Hydrocracking
Hydroconversion Introduction Introduction Hydroconversion is a term used to describe all different processes in which hydrocarbon reacts with hydrogen. To describe the process of the removal of sulphur, nitrogen and metal impurities in the feedstock by hydrogen in the presence of a catalyst. Hydrotreating The process of catalytic cracking of feedstock to products with lower boiling points by reacting them with hydrogen. Hydrocracking aromatics are saturated by hydrogen to the corresponding naphthenes. Hydrogenation
Hydrotreating Objectives of Hydrotreating 1. Removing impurities, such as sulphur, nitrogen and oxygen for the control of a final product specification or for the preparation of feed for further processing. 2. Removal of metals, usually in a separate guard catalytic reactor when the organo-metallic compounds are hydrogenated and decomposed, resulting in metal deposition on the catalyst pores. 3. Saturation of olefins and their unstable compounds.
Hydrotreating HT are located before the reformer, hydrocracker and FCC They are also needed to adjust the final product specification for various streams, such as light naphtha, kerosene and low sulphur fuel oils (LSFOs). Role of hydrotreating (HT) in the refinery
Hydrotreating Main role of hydrotreating 1. Meeting finished product specification. Kerosene, gas oil and lube oil desulphurization. Olefin saturation for stability improvement. Nitrogen removal. De-aromatization for kerosene to improve cetane number. Cetane number is the percentage of pure cetane in a blend of cetane and alpha-methyl-naphthalene. The latter matches the ignition quality of kerosene sample.
Hydrotreating Main role of hydrotreating 2. Feed preparation for downstream units: Naphtha is hydrotreated for removal of metal and sulphur. Sulphur, metal, polyaromatics and Conradson carbon removal from vacuum gas oil (VGO) to be used as FCC feed. Pretreatment of hydrocracking feed to reduce sulphur, nitrogen and aromatics.
Hydrotreating The main elements of a hydrotreating process 1. The liquid feed is mixed with hydrogen and fed into a heater and then fed into a fixed bed catalytic reactor. 2. The effluent is cooled and hydrogen-rich gas is separated using a high pressure separator.
Hydrotreating 3. Before the hydrogen is recycled, hydrogen sulphide can be removed using an amine scrubber. 4. Some of the recycle gas is also purged - To prevent the accumulation of light hydrocarbons (C1 C4) - To control hydrogen partial pressure.
Hydrotreating 5. The liquid effluent for the reactor is introduced to a fractionator for product separation.
Hydrotreating Operating Conditions The operating conditions of the hydrotreating processes pressure temperature catalyst loading feed flow rate hydrogen partial pressure
Hydrotreating Operating Conditions Increasing hydrogen partial pressure improves the removal of sulphur and nitrogen compounds and reduces coke formation. Higher temperatures will increase the reaction rate constant and improve the kinetics. However, excessive temperatures will lead to thermal cracking and coke formation. The space velocity is the reverse of reactor residence time (y). High space velocity results in low conversion, low hydrogen consumption and low coke formation.
Hydrotreating Operating Conditions
Hydrocracking Hydrocracking is a catalytic hydrogenation process in which high molecular weight feedstocks are converted and hydrogenated to lower molecular weight products. The catalyst used in hydrocracking is a bifunctional one. It is composed of a metallic part, which promotes hydrogenation, and an acid part, which promotes cracking. Hydrogenation removes impurities in the feed such as sulphur, nitrogen and metals. Cracking will break bonds, and the resulting unsaturated products are consequently hydrogenated into stable compounds.
Hydrocracking It is mainly used to produce middle distillates of low sulphur content such as kerosene and diesel. If mild hydrocracking is used, a LSFO can be produced. It has been used to remove wax by catalytic dewaxing and for aromatic removal by hydrogen saturation. This has been applied to the lube oil plants and is gradually replacing the old solvent dewaxing and aromatic solvent extraction.
Hydrocracking Feeds and Products VGO is the main feed for hydrocrakers
Hydrocracking Hydrocracking Catalysts The cracking function is provided by an acidic support, whereas the hydrogenation dehydrogenation function is provided by active metals.
Hydrocracking Hydrocracking Process yield (quantity), and the total economics of the process: 1. Process configuration: one stage (once-through or recycle) or two stages 2. Catalyst type 3. Operating condition (depends on process objective) - Conversion level - Maximization of certain product - Product quality - Catalyst cycle - Partial hydrogen pressure - Liquid hourly space velocity - Feed/hydrogen recycle ratio The following factors can affect operation (product quality),
Process Configuration Hydrocracking Simplified flow diagram of one-stage hydrocracking process with and without recycle In commercial hydrocrackers, a conversion of 40 80% of the feed can be achieved. However if high conversion is required the product from the bottom of the distillation tower is recycled back to the reactor for complete conversion. This configuration can be used to maximize a diesel product, and it employs an amorphous catalyst.
Hydrocracking The catalyst in the first stage has a high hydrogenation/acidity ratio, causing sulphur and nitrogen removal Process Configuration In the second reactor, the catalyst used is of a low hydrogenation/acidity ratio in which naphtha production is maximized Conventional two- stage hydrocracker The effluent from the first stage reactor is sent to a separator and fractionator. The fractionator bottoms are sent to the second reactor.
Product blending The main purpose of product blending is to find the best way of mixing different intermediate products available from the refinery and some additives in order to adjust the product specifications. octane number, Reid vapour pressure (RVP) and volatility Gasoline diesel index, flash point, pour point and viscosity Diesel oil
Product blending The desired property PBlend where Pi is the value of the property of component i and qi is the mass, volume or molar flow rate of component i contributing to the total amount of the finished product.
Product blending Reid Vapor Pressure the vapour pressure at 100 F of a product determined in a volume of air four times the liquid volume. RVP blending index
Product blending Gasoline octane number blending Octane number is a measure of a fuel s tendency to knock in a test engine compared to other fuels. Octane number blend
Product blending Oxygenated compound to increase octane number
