Petroleum Refinery Unit

Bill Liang, Eric Severini, Leonora Kuzmenko, Nick Kurtz

1

Chemical Engineering and Materials Science

University of California, Irvine

Outline

●Introduction & Objectives

●Process Overview○ Process Flow Diagram○Heat & Material Balance○ Pump Calculations○ Equipment Sizing

●Economic Analysis○ Equipment Pricing○ Plant Cost Estimation

●Other Considerations○Health, Environment, etc.

2

Introduction & Objectives

• Separate crude oil into “cuts” based on boiling point range

• Can be done at atmospheric and vacuum pressure

• First step in overall refinery process

3

Process Flow Diagram

Crude Distillation Process

4

Crude: 165,000 bpsd

Product: 164,834 bpsd

5

Heat Integration

● Used in estimating number of heat exchanger shells

● Large approach temp is cheaper, less efficient

● Additional cooling provided by air (>130F) and water (<130F) cooling

Pump Calculations

6

● Used for pump sizing and cost estimation

● Centrifugal pumps:○ Most commonly used○ low cost○ easy to maintain/operate○ many diff sizes

● Pump Horsepower:

PH= (Q x

h)/3960

Equipment SizingHeat Exchanger sizing:

Column & Vessel sizing: Sauder’s and Brown Correlation:

7

8

Equipment Pricing Tools

Scaling Factor: Cost Index:

*Chemical Engineering Plant Cost Index

“Equipment Cost” Link from Plant Design and Economics for Chemical Engineers Text<<http://www.mhhe.com/engcs/chemical/peters/data/ce.html>>

9

Pre-Design Cost Estimate

10

Capital Estimation Tools

Fixed Capital Investment = Direct Cost + Indirect Cost

Direct cost = 75% of Fixed Capital Investment

Total Capital Investment = Fixed Capital Investment + Working Capital

Working Capital = 15% of Total Capital Investment

11

Economic Analysis of Process Design

Economic Effects of Assumptions and Uncertainties

● Heat exchangers and vessels are carbon steel

● Centrifugal pumps are cast steel

● Investment data calculated from equipment cost○ Omit data such as insurance and contingency costs○ Six-tenths rule to scaling equipment size

12

Engineering Code of Ethics

The Fundamental Principles of the NSPE Code of Ethics states that:

1. Engineers shall hold paramount the safety, health, and welfare of the public.

2. Engineers shall avoid deceptive acts.

3. Engineers shall perform services only in their area of competence.

13

Environmental Regulations

Gas Emissions

14

Environmental Regulations

Wastewater

15

Environmental RegulationsNoise Pollution

16

Site Safety● Implement a good training program

● Check equipment and maintain process units on a daily or weekly basis

● Encourage personnel to report problems

● Make sure supervisors and operators are adequately trained

● Make sure there is adequate communication

● Make sure all employees are using adequate Personal Protective Equipment (PPE)

17

18

Thank you