Conversion type refinery

Figure 2 shows a simplified flow plan for a typical conversion type refinery. The atmospheric P/S residuum can be fed to a vacuum pipestill. The vacuum tower enables the refiner to cut deeper into the crude, at the same time avoiding high temperatures (above about 750 °F) which cause thermal cracking with resultant deposition of coke and tarry residues in the equipment. 

Figure 3. Flowsheet for a maximum conversion type refinery.

From the inspection of the gasoline pool of a conversion type refinery, it is clear that major contributions with respect to octane optimization, may be expected from the fluid catalytic cracker and the downstream upgrading of its products. The development of zeolites contributes very substantially to these goals, both by their introduction into FCC catalysts and their use in the upgrading of some of the side streams. 

Also in a conversion type refinery, there are several streams containing substantial amounts of olefins which are not upgraded for instance, the propylene splitter bottom. 

There is a wide range of conversion levels. The term maximum conversion type has no precise definition but is often used to describe a level of conversion, where there is no net fuel oil manufactured. A fuel products refinery with specialities may manufacture lubricating oils, asphalts, greases, solvents, waxes and chemical feed stocks in addition to the primary fuel products. The number and diversity of products will naturally vary from one refinery to another. Refineries produce chemical feed stocks for sale to the chemical affiliates and do not have responsibility for the manufacture of chemical products directly. Both operations may be carried out at the same physical location but the corporate product responsibilities are usually separate. 

An old variation of the conversion type is a catalytic combination unit. Development of this scheme was necessitated by the rising cost of refinery construction after World War II and by the great demand for capital for postwar expansion. The scheme reduced the investment and operating costs for refining equipment. The basic feature of the combination unit lies in the integration of the fractionation facilities of the reduced crude distillation and catalytic cracking sections. 

We cite isomerization of Cs-Ce paraffinic cuts, aliphatic alkylation making isoparaffinic gasoline from C3-C5 olefins and isobutane, and etherification of C4-C5 olefins with the C1-C2 alcohols. This type of refinery can need more hydrogen than is available from naphtha reforming. Flexibility is greatly improved over the simple conventional refinery. Nonetheless some products are not eliminated, for example, the heavy fuel of marginal quality, and the conversion product qualities may not be adequate, even after severe treatment, to meet certain specifications such as the gasoline octane number, diesel cetane number, and allowable levels of certain components. 

The valorization of by-products in biomass conversion is a key factor for introducing a biomass based energy and chemistry. There is the need to develop new (catalytic) solutions for the utilization of plant and biomass fractions that are residual after the production of bioethanol and other biofuels or production chains. Valorization, retreatment or disposal of co-products and wastes from a biorefinery is also an important consideration in the overall bioreftnery system, because, for example, the production of waste water will be much larger than in oil-based refineries. A typical oil-based refinery treats about 25 000 t d-1 and produces about 15 000 t d 1 of waste water. The relative amount of waste water may increase by a factor 10 or more, depending on the type of feed and production, in a biorefinery. Evidently, new solutions are needed, including improved catalytic methods to eliminate some of the toxic chemicals present in the waste water (e.g., phenols). 

In its 1977 survey, the U.S. Environmental Protection Agency (USEPA) identified over 150 separate processes being used in refineries [5]. A refinery may employ any number or a combination of these processes, depending upon the type of cmde processed, the type of product being produced, and the characteristics of the particular refinery. The refining processes can generally be classified as separation, conversion, and chemical treatment processes [1]. 

The physical processes by which natural gas liquids are recovered include phase separation, cooling, compression, absorption, adsorption, refrigeration, and any combination of these. Obviously the definition already stated excludes refinery light volatiles produced by the destructive decomposition of heavy petroleum fractions and it also excludes liquids that may be produced synthetically from natural gas. These distinctions are of economic importance in considering our basic energy reserves. Both the refinery volatiles and the synthetic liquids represent conversion products from other hydrocarbons and the conversion is usually attended by a considerable loss. Thus it has been stated that only about 47% (17) of the energy of natural gas is realized in the liquid hydrocarbon products of the Fischer-Tropsch type of synthesis. 

A conceptual material balance of a refinery producing 100,000 bbl/ day of fuel oil from coal was calculated (Table IV) based on the bench-scale data obtained by the authors and the published data available. In this projection, a coal containing 7.5% moisture, 10% ash, and 2.5% total sulfur is used as the feed. The hydrogenation can be performed in any type of reactor system in the ranges of 500°-550°C and 2000-3000 psi. The process conditions will be optimized for a coal conversion of about 80%. The hydrocarbon gases produced in the process will be used... 

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