Fundamentals of Petroleum and Petrochemical Engineering (Chemical Industries)

The supply of petroleum continues to dwindle at an alarming rate, yet it is the source of a range of products - from gasoline and diesel to plastic, rubber, and synthetic fiber. Critical to the future of this commodity is that we learn to use it more judiciously and efficiently. Fundamentals of Petroleum and Petrochemical Engineering provides a holistic understanding of petroleum and petrochemical products manufacturing, presented in a step-by-step sequence of the entire supply chain. Filled with crucial information relevant to a range of applications, the book covers topics such as: The essential preliminaries for the exploration and production of crude petroleum oil and gas; Analysis of crude oil and its petroleum products; The processing of petroleum in refineries; The fundamentals of lubricating oil and grease; Petrochemicals - their raw materials and end products, and manufacturing principles of industrially important products; Theories and problems of unit operations and the processes involved in refineries and petrochemical plants; Automatic operations in plants; Start up, shutdown, maintenance, fire, and safety operations; Commercial and managerial activities necessary for the ultimate success of a refining or manufacturing business. Due to the advancement of technology, new petrochemicals are being invented and will continue to be relevant to the petroleum industry in the near future. Those entering the industry need a firm grasp of the basics as the field continues to open up new avenues of possibility, while at the same time being cognizant of the challenges that exist through the heightened focus on sustainable energy -- Publisher's description Fundamentals Of Petroleum And Petrochemical Engineering......Page 2 Chemical Industriesa Series Of Reference Books And Textbooks......Page 3 Fundamentals Of Petroleum And Petrochemical Engineering......Page 8 Dedication......Page 10 Contents......Page 12 Preface......Page 22 Author......Page 24 Introduction......Page 26 1.1.1 HYDROCARBON GROUPS......Page 27 1.1.1.1 Complex Hydrocarbons......Page 29 1.1.1.2 Non-Hydrocarbons or Hetero-Atomic Compounds......Page 30 1.2 PHYSICAL PROPERTIES OF CRUDE OIL......Page 32 1.3 ORIGIN OF HYDROCARBONS......Page 33 1.4.1 GRAVIMETRIC METHOD......Page 35 1.4.4 REMOTE SENSING METHOD......Page 36 1.5 RESOURCE ESTIMATION......Page 37 1.5.1 EFFECT OF PRESSURE......Page 38 1.5.4 EFFECT OF VISCOSITY......Page 39 1.6 OIL FIELD DEVELOPMENT......Page 40 1.8 OIL PRODUCTION PROCESSES......Page 42 1.9 CRUDE CONDITIONING AND STORAGE......Page 45 1.10 TRANSPORTATION AND METERING OF CRUDE OIL......Page 46 1.11 GAS HYDRATES......Page 47 1.12 COAL BED METHANE......Page 48 QUESTIONS......Page 49 2.1 CRUDE OIL ANALYSIS......Page 51 2.1.2 CHARACTERISATION FACTOR......Page 53 2.2.1 LIQUIFIED PETROLEUM GAS......Page 54 2.2.2.1 Smoke Point......Page 56 2.2.2.3 Char Point and Bloom......Page 57 2.3.1 MOTOR SPIRIT......Page 58 2.3.1.1 American Standard for Testing Material Distillation......Page 59 2.3.1.2 Octane Number......Page 60 2.3.1.3 Corrosion......Page 61 2.3.2 HIGH SPEED DIESEL......Page 62 2.3.2.2 Diesel Index......Page 63 2.3.2.8 Viscosity......Page 64 2.5.1 GASEOUS FUELS......Page 65 2.6 LUBRICATING OILS......Page 66 2.6.3 REDWOOD METHOD......Page 67 2.6.5 VISCOSITY INDEX......Page 68 2.6.7 POUR POINT......Page 69 2.7.2 MINERAL TURPENTINE OIL......Page 70 2.7.4 BITUMEN......Page 72 2.7.5 PETROLEUM COKE......Page 73 QUESTIONS......Page 74 3.2 DESALTING OF CRUDE OIL......Page 75 3.3 DISTILLATION AND STRIPPING......Page 77 3.3.1 ATMOSPHERIC DISTILLATION......Page 78 3.4 STABILISATION......Page 80 3.6 DE- ETHANISER......Page 81 3.7 MEROXING AND CAUSTIC WASH......Page 82 3.9 NAPHTHA REDISTILLATION......Page 84 3.10 NAPHTHA PRETREATMENT......Page 85 3.11 NAPHTHA PLATINUM REFORMING ( PLATFORMING)......Page 86 3.12 KEROSENE HYDRODESULFURISATION......Page 88 3.13 DIESEL HYDRODESULFURISATION......Page 89 3.14 VACUUM DISTILLATION......Page 90 3.15 SOLVENT EXTRACTION......Page 92 3.17 SOLVENT DEWAXING......Page 93 3.18 HYDROFINISHING......Page 95 3.19 CATALYTIC PROCESSES FOR LUBE OIL BASE STOCK MANUFACTURE......Page 96 3.20 HYDROCRACKING......Page 97 3.21 MILD HYDROCRACKING......Page 99 3.22.2 PRIMARY REFORMING......Page 100 3.22.4 SHIFT REACTORS......Page 101 3.23 FLUID CATALYTIC CRACKING......Page 102 3.25 VIS- BREAKING......Page 105 3.26 COKING......Page 106 QUESTIONS......Page 107 4.1 COMPONENTS OF FINISHED LUBRICATING OILS......Page 109 4.2 AUTOMOTIVE OILS......Page 110 4.3.1 BEARING LUBRICANTS......Page 111 4.3.4 PUMP LUBRICANTS......Page 112 4.4 AVIATION LUBRICANTS......Page 113 4.6 GREASES......Page 114 4.7 LUBE BLENDING AND GREASE MANUFACTURE......Page 115 4.8 ENVIRONMENTAL IMPACT OF LUBRICANTS......Page 116 4.9 RECLAMATION OF USED LUBRICANTS......Page 118 4.10 POWER CONSUMPTION IN A BLENDING TANK......Page 120 QUESTIONS......Page 124 5.1.2 INTERMEDIATES......Page 127 5.1.3 FINISHED PRODUCTS......Page 128 5.2 NAPHTHA CRACKING......Page 129 5.2.2 HYDROGEN SEPARATOR......Page 131 5.3.1 POLYETHYLENE......Page 133 5.3.1.1 Low Density Polyethylene......Page 134 5.3.1.2 High Density Polyethylene......Page 135 5.3.1.3 LINEAR LOW DENSITY POLYETHYLENE......Page 136 5.3.3 POLYETHYLENE TEREPHTHALATE......Page 137 5.3.5 POLYSTYRENE......Page 141 5.3.8 STYRENE– BUTADIENE RUBBER......Page 142 5.3.11 NYLONS......Page 143 5.3.14 MELAMINE FORMALDEHYDE......Page 146 5.3.15.1 Toluene Diisocyanate......Page 147 5.4.2 PETROCHEMICALS' HUB......Page 148 5.5 PROCESSING OF PLASTIC, RUBBER, AND FIBRE......Page 149 5.5.2 EXTRUSION MOULDING......Page 150 5.5.6 INJECTION MOULDING......Page 152 5.5.7 RUBBER COMPOUNDING......Page 153 QUESTIONS......Page 154 6.2 PROCESSING UNITS......Page 157 6.3.1 FLOATING ROOF TANK......Page 160 6.3.2 FIXED ROOF TANK......Page 161 6.3.5 ACCESSORIES......Page 162 6.3.8 PIPELINE TRANSPORT......Page 165 6.3.9 EFFLUENT WATER TREATMENT......Page 166 6.3.10 OFF GAS TREATMENT......Page 167 6.4 POWER AND STEAM GENERATING PLANT......Page 170 6.6 WATER CONDITIONING PLANT......Page 173 QUESTIONS......Page 176 7.1.1 TANK DIPPING......Page 177 7.1.3 DENSITY CORRECTION......Page 179 7.3 MATERIAL BALANCE IN A PLANT......Page 184 7.3.1 FLOW METER READINGS......Page 186 7.3.4 OVERALL MATERIAL BALANCE......Page 187 7.4.2 ENERGY BALANCE IN A HEAT EXCHANGER......Page 190 7.4.3 ENERGY BALANCE IN A FURNACE......Page 191 7.4.4 ENERGY BALANCE IN A DISTILLATION COLUMN......Page 192 7.4.5 OVERALL ENERGY BALANCE......Page 194 QUESTIONS......Page 196 8.2 THEORY OF HEAT EXCHANGE......Page 197 8.2.1 HEAT BALANCE......Page 199 8.2.2 RATE......Page 200 8.3 FOULING......Page 203 8.6 SCRAPED SURFACE EXCHANGER......Page 211 8.7 HEAT EXCHANGER TRAIN......Page 212 8.8 PIPE- STILL FURNACE......Page 214 8.9.1 HEATER PIPES......Page 216 8.9.3 BURNERS......Page 217 8.9.5 RADIANT SECTION......Page 218 8.10 OPERATION OF A FURNACE......Page 219 8.12 FURNACE DESIGN BY THE WILSON, LOBO AND HOTTEL METHOD......Page 220 8.12.1 FURNACE DESIGN......Page 231 QUESTIONS......Page 232 9.2 BATCH DISTILLATION......Page 233 9.4 THEORY OF DISTILLATION......Page 234 9.5 CONTINUOUS DISTILLATION......Page 236 9.5.1 TOP REFLUX DRUM......Page 237 9.5.2.2 Streams Entering the Envelope under Study......Page 238 9.5.2.4 Stripping Section......Page 239 9.5.2.5 Feed Plate or Flash Zone......Page 240 9.5.2.6 Evaluation of Fraction Vaporised (f) from the Quality of the Feed......Page 241 9.6 MCCABE– THIELE METHOD......Page 243 9.6.2 OPERATING LINE......Page 244 9.7.1 REFLUX DRUM......Page 245 9.7.2 TOP PLATE......Page 246 9.7.3 REBOILER......Page 247 9.7.4 NUMERICAL SOLUTION......Page 249 9.7.5 TYPES......Page 255 9.8 GAP AND OVERLAP......Page 256 9.9 PACKIE'S CORRELATION......Page 257 QUESTION......Page 260 10.1 EXTRACTION PRINCIPLE......Page 261 10.3.1 PARTITION COEFFICIENT......Page 262 10.3.6 SELECTIVITY......Page 263 10.4 PHASE EQUILIBRIUM IN THE EXTRACTION PROCESS......Page 264 10.5 BATCH EXTRACTION......Page 265 10.6.1 COMPUTATION OF NUMBER OF PLATES......Page 266 QUESTIONS......Page 274 11.2 REACTION STOICHIOMETRY, MECHANISM, AND PATHWAYS......Page 275 11.3 RATE OF REACTION AND KINETIC EQUATIONS......Page 276 11.4 BATCH, CONTINUOUS STIRRED TANK REACTOR, AND PLUG FLOW REACTOR CONCEPTS......Page 278 11.5 NAPHTHA REFORMER CALCULATIONS......Page 295 11.6 CALCULATIONS FOR A FLUIDISED CATALYTIC CRACKING REACTOR......Page 297 12.2 FITTINGS AND SUPPORTS......Page 301 12.2.1 CORROSION PROTECTION......Page 302 12.3.1 DESIGN STEPS FOR CRUDE PIPES......Page 303 12.4 PRODUCT TRANSFER LINES......Page 305 12.5 GAS TRANSFER LINES......Page 306 12.6.1 CENTRIFUGAL PUMPS......Page 307 12.6.2 POSITIVE DISPLACEMENT PUMPS......Page 313 12.6.3 ROTARY PUMPS......Page 314 12.6.4 COMPRESSORS......Page 315 12.7 POWER CALCULATIONS FOR PUMPING AND COMPRESSION......Page 316 13.1.1 HARDWARE......Page 323 13.1.2 CABLES......Page 324 13.2 CONTROL LOOPS......Page 325 13.4 CONTROL SOFTWARE......Page 327 13.5 DISTRIBUTED CONTROL SYSTEM......Page 330 13.7 CRUDE THROUGHPUT CONTROL......Page 331 13.8 DESALTER CONTROL......Page 332 13.9.2 REFLUX DRUM LEVEL CONTROL......Page 334 13.9.4 DRAW PLATE TEMPERATURE......Page 336 13.10 VACUUM DISTILLATION CONTROL......Page 338 13.12 FLUID CATALYTIC CRACKING UNIT CONTROL......Page 340 13.12.1 REACTOR OUTLET TEMPERATURE CONTROL......Page 342 13.13.1 NORMAL RUNNING CONDITIONS......Page 345 13.13.2 DURING PLANNED SHUTDOWN......Page 347 13.13.3 DURING ACCIDENTS OR EMERGENCY SHUTDOWN......Page 348 13.14 STANDARD SIGNALS IN PROCESS CONTROL......Page 349 14.1.1 POWER PLANT STARTUP......Page 351 14.1.2 STARTUP A CRUDE DISTILLATION UNIT......Page 352 14.1.3 STARTING A NAPHTHA PRETREATMENT PLANT......Page 353 14.1.5 STARTING A FLUID CATALYTIC CRACKING PLANT......Page 354 14.2 SHUTDOWN......Page 355 14.2.3 REGENERATION OF THE CATALYST......Page 356 14.2.5 REGENERATION OF REFORMING CATALYST......Page 357 14.3 MAINTENANCE OF PLANT AND EQUIPMENTS......Page 358 14.4 FIRE AND EXPLOSION......Page 359 14.4.1 PYROPHORIC IRON......Page 360 14.5 FACTORIES ACT......Page 361 14.6 SAFETY ANALYSIS......Page 363 15.1.1 CAPACITY RATIO METHOD......Page 369 15.4 PRODUCT COST......Page 370 15.7 BREAKEVEN POINT, PAYOUT PERIOD, AND RATE OF RETURN......Page 371 15.7.2 RATE OF RETURN......Page 372 15.8 LINEAR PROGRAMMING......Page 375 15.9.1 CATEGORY OF MATERIALS......Page 378 15.9.2.3 Tank Dip Memos......Page 379 15.9.2.6 Daily Operation Record......Page 381 15.9.3 MATERIAL AUDIT OF CAPITAL GOODS......Page 392 15.10.1 ELECTRICITY AUDIT......Page 393 15.10.3 STEAM BALANCE......Page 394 Appendix......Page 401 "A complete delineation of the basics of crude oil, petrochemicals, refineries, and hydrocarbon processing plants, this book begins with coverage of crude exploration and production and concludes with start up and shut down. Each chapter contains with exercises and questions at the end and solved problems have been provided throughout the book. The book includes topics such as products from crude oil and their testing, refinery operations, lubricants and petrochemical manufacture, plastic and rubber processing, offsites, utilities, and chemicals, plant and equipment calculations, instrumentation and control, and management."-- Provided by publisher A complete delineation of the basics of crude oil, refineries, petrochemicals, and hydrocarbon processing plants, this book begins with coverage of crude exploration and production and concludes with start up and shut down. Each chapter contains exercises at the end and solved problems have been provided throughout the book