Refinery Basics
John Kulluk Ph.D.Torrance Fire Department
&
Robert Distaso PE – 714/573-6253
Orange County Fire Authority
Refining Means. . .
1. To reduce to a pure state, to remove impurities
2. To improve or perfect
Refinery Process Flow Chart
Distillin
g
Flasher
Visbreaker
CCU
Alky
Sp
litter
Hydrotreating
Hydrotreating
Isom
Reformer
Gas Plant
Sulfur
Fuel Gas
Gasoline
Jet Fuel
Distillate Fuel
ResidualFuel
Leffler, 1985
Other Refinery Units
• Steam Generation• Wastewater Treatment• Hydrogen Generation• Power Generation (e.g., cogen)• Air Separation Plant• Loading/Unloading - Railcar, Trucks, etc.• Storage (high pressure hydrocarbon, crude oil, intermediates)
Floating-Roof Tanks - 150‘ diameter is common Spherical Tanks - 50‘ are common Horton Spheroid (refrigerated) Steam-Heated Tanks for “Heavier” Products
• Self-Contained Firewater Supply• Firewater Pumps
What is Crude Oil?
• Mixture of organic carbon chain molecules
• Impurities include sulfur and nitrogen compounds
• Some metals and salts too
Components such as . . .
• Straight-Chain Hydrocarbons
• Olefins
• Cyclic H/C
• Aromatics (Benzene, toluene, xylenes)
• Mercaptans
• Hydrogen Sulfide (H2S)
• Greases
• Propane
• LPG
Other Hazardous Materials
• Sulfur
• Hydrofluoric Acid (HF)
• Sulfuric Acid (H2SO4)
• Ammonia (NH3)
• Sodium Hypochlorite
• Radioactive Materials
• Chlorine
• Amines
• MEK
• Sulfur Dioxide (SO2)
• Heavy Metal Catalysts
• Sour Water
• Caustic (fresh/spent)
• Alcohol
• Asbestos
What’s All this Stuff?
What Goes on at a Refinery. . .?
• Separation of components by distillation, e.g.: Atmospheric Vacuum Hydrotreating (uses excess hydrogen)
• Breaking apart molecules to make smaller ones, e.g.: catalytic cracking hydrocracking
• Joining molecules to make bigger ones, e.g.: Reforming - alkylation that lengthens the hydrocarbon
chain Reforming - cyclic that generates hydrogen
Physical Hazards
• High Pressure/Temperature Steam• Oil/Gas-Fired Furnaces• Acoustic• High Voltage (4160V, 480V, 13.2 kV)• Falling Hazards• Confined Space Hazards• Cranes/Lifting Hazards• Hot Work Hazards• Acid Exposure• Toxic Vapors• Radiation• Flammability Hazards
Common PPE Requirements
• Hardhat
• Hardsoled / Hardtoe Shoes
• Safety Glasses with Side Protection
• Safety Goggles or Faceshield
• Fire-Resistant Clothing
Process Hazards
• Emergency Flare
• Atmospheric Pressure Relief
• High Temperature (up to 2000oF)
• Low Temperature (e.g., Brittle Fracture)
• High Pressure (up to 3000 psig)
• Low Pressure (e.g., vacuum)
QUESTIONS ?