P & PCI Perto Chemical

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Prof. K. S. K.

Rao Patnaik
Chemical Engineering Programme
SOMCME, ASTU

Petroleum and Petro-Chemical


Industries
• Ranks highest of all the Chemical
Industries
• Major Source of Energy
• Natural Product
• Basic raw material for Synthetic
Organic Chemical Industries

Petroleum and Petro-Chemical


Industries
• Petroleum formed several million
years ago from organic matter of
marine deposits in a deficiency of
oxygen.
• Selective bacteria attack destroyed
proteins and carbohydrates, leaving
fats to accumulate as oils reserves,
hence the name fossil fuel.

Occurrence
• Kerosene from Shale oil-lighting
• Industrial Production in 1958,PA
• Automobile Industry,1912

History
• 532 MT to 1700 MT WORLD
• The refineries are producing excess
naphtha which is being converted to
synthesis gas for Fertilizer industry
and Petro-Chemical industries.

Consumption
• P exploration and development of
crude oil production facilities to
provide P for the refineries.

Production of crude Petroleum


• Kuwait 22 Middle East 60
• S Arabia 17
• Iran 12
• Iraq 09
• USA 11
• USSR 10
• Venezula 06
• Canada 05,Indonesia 03,India 0.5

Distribution of Present P
Reserves (approx)
• Surface Geological
Methods • Geophysical Methods
• 1.Extensive
• 1.Sensitive GC
• Sesmic surve measures
• 2.Microbiological • Air surveys
flora
• 2.Intensive
• 3.Radioactive • Sonic and ultrasonic
isotopic exchange probing
of carbon • Neutron reflecting
measurents

Exploration Methods
• Yields-
• Drilling-off
reservoir
shore
hydrocarbons

Methods of Production
Chemical composition Refinery crude P
• a.Open chain or • a.Paraffin base
aliphatic • b.Naphthene
compounds base
• b.Ring or cyclic • c.Intermediate
compounds base
• c.Asphalts

Classification of crude P
P Refinery product
classification
• 1.Gas fraction
• Natural gas, light gas,off gas
• 2.Light ends
• Petrol, solvent naphtha & kerosene,light
heating oils
• 3.Intermediate Distillates
• Heavy fuel oils, Diesel oils, gas oils
• 4.Heavy distillates
• Mineral oil,flotation and frothing
oil,waxes, lubricating oil
• 5.Residues
• Lubricants,fuel oil,greases, P,
Asphalt,Road oils,P coke
• 6.By- products
• Detergents, ammonia, sulpur &
derivatives
Chemical changes or
Physical changes or UO conversions UP

• Extraction • Pyrolysis & Cracking


• Adsorption • Reforming
• Crystillization • Polymerization
• Distillation • Alkylation
• Heat Transfer • Hydrodealkylation
• Fluid flow • Isomerization
• Hydrogenation
• Other UO
• Sulfur removal
• Absorption
Refinery processes
• Pyrolysis is defined as the treatment of
hydrocarbons at high temp to change their
molecular weights.The principal purpose is
to crack larger molecules to smaller
ones,yet higher mol.wt compounds are
produced simultaneously,particularly in
thermal,non-catalytic pyrolysis.
• Catalysts were developed to permit lower
temp and pr and obtain a higher selectivity
of cracking with side reactions.

Pyrolysis and Cracking


• Catalytic Reforming is used to convert
hydrocarbons to aromatics which have
high octane rating.
• Polymerization is defined as in the P
Industry as the combining of two or more
olefinec molecules to yeild larger
molecules.Thus C3 and C4 olefins from
Catalytic Cracking can be converted to
liquid hydrocarbons of the dimer and
trimer type.

Reforming and Polymerization


• All the gases contain impurities namely :
• 1.Water vapour
• 2.Mechanical-suspended impurities
• 3.Chemical impurities
• 4.Other than above impurities

Purification of Gases
• 1.absorption-desorption
• 2.compression-liquefation
• 3.low-temp fractionation
• 4.adsorption
• 5 separation techniques:
• 6.special techniques

Separation of gases
Economics Feed stocks
• 2.Light liquids: Natural
• More complex gas liquids,
• Both public and naphathas,wild gasolines,
kerosene,gas oils
private
reformates,coker
fractions,FCC lights.etc
• 3.Heavy liquids: Vaccum
gas oils,hevy crudes
• 1.Gases: Lean gases,
LPG,natural gases
• 4.Solids: waxes

Petro-Chemical Industries
Over View of Petro-chemicals
• 1. Natural Gas (largely methane)
• 2.Liquified Petroleum Gas (LPG)
• 3.Refinery Off –Gases
• 4.Hydroforming of P Stocks
(BTX)
• 5.Naphatha and Fuel oil
• 6.P Coke (Al industry )

Principal Raw Materials


• 1. C1 group-Methane,CO-H2 Synthesis gas
• 2. C2 group-Ethane,ethylene,acetylene
3. C 3 group-Propane,propylene
• These raw materials contain one or several predominant
hydrocarbons which can be separated so that
compounds are synthesized from each of the following
types:
• 4. C4 C5 group- Butane, butene,pentane,pentene
• 5. Aromatic group-Benzene,Tolune,Xylene,Naphthalene

Basis for Study


• Mol.wt 32.04 • Formaldehyde
• Methods of • Exports
Production: • Propulsion systems
• 1.catalytic • End uses:
hydrogenation of CO • Methyl methacrylate
• 2.Oxidation of LPG • Antifrreezes
• 3.catalytic • Solvens
hydrogenation of CO2 • chloromethanes

Chemicals from C1 : Methane


Petro-chemicals from Methane
• Mol.wt. 28.03
• End uses :
• Methods of
Production • Polyethylene
• Steam pyrolysis of P • Styrene
from LPG and • Vinyl chloride
naphtha • Glycol
• Thermal pyrolysis of • Ethyl chloride
ethanol • Ethylene dichloride
• Dehydration of • Ethanol
ethanol

Chemicals from C2: Ethane


Petro-chemicals from Ethane
• Propane:
• Mol.wt.
• Methods of
Production: • End uses:
• 1.Direct catalytic • Acetone
hydration of • Solvents
propylene
• Chemicals
• 2.Hydration of
• Drugs
polymers via sulfation
and hydrolysis

Chemicals from C3 :
• Mol.wt.54.09
• Methods of
Production
• Butanes and • End uses:
Butenes:
• 1.Hehydration of
butane2
• 2.Steam Cracking

Chemicals from C4 :
• B-
Styrene,BHC,Phenol
• T-Solvents,benzoic
• BTXN acid,
• X-o-xylene,m- xylene
• End uses:
• N-Phthalic anhydride

Chemicals from Aromatics


Petro-chemicals from Benzene
Petro-chemicals from Xylene
Petrochemicals from Propylene
Petro-chemicals at a Glance
Principal Reactions of Methane
Methanol Production
Formaldehyde from Methanol
Ethylene chemicals
Ethanol production from Ethylene
Chemicals from Propylene
Isoproponol Production
Production of Glycerine
Fluid Bed Reactor
Production of Accetic Acid
Natural Gas-Steam Reforming
Naphtha Steam Reforming
Production from Naphtha
Synthesis Gas via partial oxidation
Catalytic Reforming
Separation of BTX
Benzene by dealkylation of Toluene
Production of Caprolactum
Adama Science and Technology University
Week #1 Petroleum Industries:
Occurrence,Classification, Production of Crude
Petroleum and Exploration Methods.

Week #2 Petroleum Refinery Product Classification,


Characteristics of Refineries,Unit Operations and
Conversions of Refinery Processes.

Week #3 Pyrolysis, Cracking and Reforming

Week #4 Purification of Gases, Separation of Gases,


Kerosene, Purification of End -products

Week #5 Petro-Chemical Industries: Feed stocks, Overview


of Petro–Chemicals, Basis for study
Week #6 Chemicals from C1 hydrocarbons:
Methane

Week #7 Chemicals from C2 hydrocarbons : Ethylene

Week #8 Chemicals from C3 hydrocarbons : Propane

Week #9 Chemicals from C4 hydrocarbons : Butane


Week #10 Chemicals from Aromatics : Production of
Benzene
Week #11
Production of Tolune
Week #12
Production of Xylene

Week #13
Petro-Chemicals at glance, Important
Derivatives and End Products.
Week #14
Exploration and Development of Gas
& Oil fields with special reference to
Nile River Basin, Ethiopia

Week #15
Course review and Evaluation.
Pre-requisites Fundamentals of Chemical Engineering

Semester Year 4, Semester -1


Status of Course Major Elective
Teaching & Learning Classroom Contact/Lecture,Test,Quizzes and Assignment (group and individual work ( independent learning))
Methods

Assessment/Evaluation Continuous Assessment.................... …………… 60%


Continuous  Assignments....................20 %
 Quizzes...........................20 %
 Tests …… . …………20 %
Final exam................................................................40%
Course policy Attendance: As per the harmonizedacademic policy
Assessments: Students are supposed to handle all the assessmentson time.
Cheating/ Plagiarism:
 It is strictly forbidden and any misconductis accountable as per the students’ code of conduct.
 Please do not chew gum, eat, listen to recorders or CD players, wear sunglasses, or talk about personal problems.
 Please be sure to switch off cell phones before class and exam sessions

Literature References:
1.Advanced Petrochemicals, G.N.Sarkar,Khanna Publishers,New Delhi,2002
2.Outlines of Chemical Technology,C.E.Dryden,East-Westpress,New Delhi,1966
3.Petroleum Refining Engineering,W.L.Nelson, McGraw-Hill,New York,1987
4.Petroleum Processing Handbook,William F Bland & Robert L.Davidson,2015
Production of Caprolactum

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