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 ?