Catalytic gasification of oil sludge with calcined dolomite

Abstract

Gasification of carbon-based residues for synthesis gas production is one of the most important strategies for clean energy production and environmental management. Currently, China is the world's largest net oil importer which is a result of China's added refinery capacity. In this article, a simulation model of oil sludge gasification with a combination of air and steam was developed using Aspen Plus software. Effect of dolomite as an active catalyst on gas composition was studied at various operating conditions. Results showed that H₂ and CO increased with reaction temperature, while CH₄ decreased from 9.1 to 4.71?vol% because of increased steam reforming of CH₄. By adding steam to the gasifier, H₂ content increased significantly, while CO content showed an opposite trend.     

Influence of Ice on the Infiltration of Petroleum into Frozen Coarse-grained Soil

Abstract

Knowledge of how contaminants spread through frozen ground is required to better protect water quality and environmental health. This study investigates the effect of pore ice on vertical and lateral movement of a petroleum product in coarse-grained soils. Time lapse photography is used to track diesel product migrating through two-dimensional flumes packed with wetted soil frozen to ?5°C. Results from these flow studies indicate that the presence of pore ice blocks pore space, causing increased lateral movement of petroleum, creates preferential pathways resulting in increased petroleum penetration depths, and can restrict infiltration of petroleum into soils with high ice saturations.     

采用焦化加工路线的炼油厂增效措施分析与应用

某炼油厂为提高经济效益,通过分析焦化加工路线的特点,发现焦化加工路线具有加工原油品种选择范围宽,装置建设投资成本低和运行操作费用低的效益优势,同时具有产品结构差和产品性质差的效益劣势。该炼油厂充分发挥焦化加工路线的效益优势,采取优化原油采购、减产石油焦、增产汽油和喷气燃料以及节能降耗、保持CFB锅炉长周期运行等措施,大幅降低了原油采购成本,优化了产品结构,降低了操作费用,与设计方案相比,按2015年实际产品结构计算,经济效益提高10.33亿元/a。     

基于炼油过程仿真的优化生产计划系统的开发与应用

为改进炼油厂制定生产计划的决策过程，提高炼油厂的科学管理水平，研究并开发了基于炼油过程仿真的优化生产计划系统，使计划编制和炼油工艺过程及油品市场需求紧密结合起来，提高生产计划系统的实用性，并给出基于炼油过程仿真优化生产计划系统的框架结构、优化原理和应用实例。制定的生产计划能真正指导炼油厂的实际生产，改变以前生产计划与生产装置相脱节的问题，提高企业经济效益。     

Analysis of petroleum coke from low grade oily sludge of refinery

Petroleum coke is often shortened as pet coke. Petroleum coke or pet coke is a product obtained from oil of all kinds during the oil refining process. Petroleum coke is a carbon-rich solid originating from petroleum refining and is obtained by cracking process. Petroleum coke is a byproduct of the coking unit, a residual fuel upgrader. The coke quality depends on the crude oil processed in refinery. The mixture of oil, solids and water deposited at the bottom of the storage deposit is known as waste oil sludge. Oil sludge is one of the solid wastes produced in petroleum refinery and it is a complex emulsion composed of various petroleum hydrocarbons, heavy metals, solid particles, and water. As a result of the refining process of crude oil, the contaminated sludge is biodegraded and converted into waste products that damage the environment and human health. In the coke processing, the assessment of oil sludge fraction is based on the principle of heating to high temperatures and the removal of light fractions from the breakdown. If the oil sludge initially contains low levels of sulfur and metal, the resulting petroleum coke is then calcined before use. The high quality needle type coke produced on convenient conditions in the coking unit.     

先进控制技术在常减压装置上的应用

对先进控制技术在大庆石化分公司炼油厂一套常减压装置的应用情况进行了论述.常减压装置应用先进控制技术后,控制效果得到了改善;实现了稳定操作;提高了高附加值产品收率.先进控制技术作为一种优化控制手段,可以在炼油厂的其它装置上推广应用.     

UPGRADING OF PETROLEUM RESIDUES BY VACUUM PYROLYSIS

ABSTRACT

Vacuum pyrolysis of petroleum residues which are classified as hazardous materials was performed in a batch reactor and enabled us to separate an upgraded oil from water and residual solids. Conversion of petroleum wastes to reusable oils reached 85% on an organic basis.

The pyrolysis oils and solid products were analysed for maltene, asphaltene and sulfur content. We found a significant increase in the pyrolysis oil maltene content. Much less sulfur was detected in the pyrolysis oil compared with the original organic waste material. The resin content of the pyrolysis oil decreased and the aliphatic, alicyclic and monoaromatic hydrocarbon content increased. The heavy portion of the pyrolysis oil contained approximately 5% of undesirable n-alkenes ranging from n-C₁₄ to n-C₃₈. Only trace amounts of organic and inorganic contamination was found in the solid phase leachate. The aqueous phase contained a small quantity of soluble organics which will be easily removed in a standard refinery water treatment plant. Results showed the merits of vacuum pyrolysis for upgrading petroleum residues.     

Novel Impact of Wet Dosages of NMP in Extraction for Production of High BMCI Carbon Black Feedstocks

Abstract

In separation sciences, “Solvent Extraction” is one of the most important unit operations, a very widely used process, next only to distillation. In the petroleum refining industry, solvent extraction is commonly widely applied to produce a number of specialty products such as BTX, lube base oils, waxes, etc. There are many solvents used in various separation processes, like sulfolane, phenol, furfural, ketones, and N-methyl pyrollidone (NMP). NMP in particular is an environmentally benign, new generation solvent, which can be tailored for specific separations by using it in conjunction with small doses of water. In recent years, researchers are re-looking at the separation processes and their modifications to exploit these for producing high-value industrial products from low-value refinery streams. The present study deals with the production of high-quality carbon black feedstocks (CBFS) from clarified oils. The study shows the beneficial effect of using NMP in combination with different dosages of water as extraction solvent to extract low-value clarified oil, a cracked material from the FCC unit of an operating Indian refinery. In the present study, water ranging from 0.3 wt% to 10 wt% was used with NMP to produce aromatic extract of BMCI (Bureau of Mines Correlation Index) up to 146 through liquid-liquid equilibrium and mass transfer studies on clarified oil (CLO). The effect of solvent-to-feed ratio at constant temperature on solvent extraction was also studied. The addition of water in NMP alters the “selectivity” of solvent, which can be exploited for producing aromatic extracts of a wide range of BMCI for different end-use applications. The major users of such high BMCI extracts are carbon black and electrode pitch manufacturers. Regression analysis was also done to develop correlations between water percentage in NMP and targeted BMCI of aromatic extract. Presently, CLO is blended with fuel oil and sold as a very low value product in refinery. Since the demand of CBFS is increasing continuously and current short-fall in India is met through imports from China, Korea, and Japan, it is desirable that such studies are undertaken and will lead to production of high-value CBFS from low-value refinery streams through separation processes.     

Soil Microbial Degradation of Vacuum Residue

Abstract

The effect of microbial consortia on the alteration of petroleum residual structure and portions was studied, which can propose an alternative or complementary method for stringent upgrading heavy crude oil methods, which consist of heavy and complex hydrocarbons. Biological processing of petroleum heavy fractions and residua may provide an alternative or complementary process in refining heavy crudes—the dominant refinery feed in the future—with less severe process conditions and higher selectivity to upgrade heavy fractions of crude oil. The primary objective was to observe the ability of an indigenous bacterial consortium taken from a soil bellow the vacuum column contaminated with vacuum residue (VR) for several decades from the Tehran refinery distillation unit, in degradation of residua components. Enrichment with VR, as sole source of carbon and energy, is the selected biosurfactant-producing microbial consortium. The biodegradation of net VR using indigenous consortia from this specific ecosystem was studied. The considered period of biodegradation of these heavy hydrocarbons was remarkably shorter than usual studies. Bacterial growth and VR biodegradation ability of this consortium analyzed with SARA test in 20 days. Studying the inoculum size and aeration effect revealed the significance of oxygen for this consortia activity and the similarity of 7% and 5% inoculation on alteration percentage of alkane, aromatic, and asphaltene and resin in VR. Results study revealed a 30.4%, 6.9%, and 9.4% decrease in the asphaltene, aromatics, and saturated aliphatic contents of VR, respectively, in only 20 days in 30°C at 150 rpm.     

COPROCESSING OF COAL WITH HEAVY PETROLEUM CRUDES AND RESIDUA

ABSTRACT

This work investigates the coprocessing of coal in six different heavy petroleum crudes and residua. Coprocessing reactions of coal and the petroleum solvents are performed under three sets of constant reaction conditions, yielding informative comparative data for processing applications. Definitive comparisons of coal reactivity and solvolysis in the petroleum solvents have been obtained using solvent fractionation which provides a measure of the degree of upgrading achieved by the liquefied coal. Regressive reactions and low coal conversions are observed in coprocessing reactions in N₂ at 400^°C. Higher conversions and a reduction in regressive reactions are observed in H₂ at 400^°C. Catalytic hydrotreatment and higher temperature, 425^°C, result in increased coal conversion and a net production of pentane soluble materials. The amount of product fractions obtained from the upgrading of the coal alone is calculated. The effect of reaction temperature using different solvents and reaction conditions on the product slate is also examined.     

炼油企业提高制氢装置产氢量的技术措施

为满足油品质量升级的要求,某炼油厂相继建设了汽油脱硫装置和柴油脱硫装置。而制氢装置的能力没有变化,因此炼油厂在油品升级后存在氢气缺口,为能够使制氢装置多产氢气,文中从装置实际生产出发通过指标控制、原料选择、设备优化等方面进行调整,提高了装置的氢气产量。     

STUDIES ON FLUID CATALYTIC CRACKING OF HYDROPROCESSED FEEDSTOCKS

ABSTRACT

Worldwide public concern about environment and increased demand for better quality fuels by automobile industries has necessiated developed countries like USA, UK and Japan to stipulate stringent specifications for petroleum fuel products. Fluid catalytic cracking (FCC) is a major secondary process for fuel products and quality of products coming from FCC unit depends largely on the feedstock used. FCC naphtha makes up for 30–40% gasoline in a typical refinery pool. This FCC naphtha contributes to around 90% of the gasoline pool sulphur. Hence, sulfur and nitrogen reduction have become essential for meeting the quality requirements of fuel products resulting in the growing importance for pretreatment of FCC feedstock. In the present work, studies were carried out in pilot plant on hydrotreatment of feedstock for FCC unit. The results indicate better quality products for treated feedstock vis-a-vis untreated heavy vacuum gas oils from Persian Gulf (PG) crudes. Hydroprocessing of FCC feed has helped refiners in meeting the fuel products quality especially with feedstocks, which are characterized as heavy and refractory in nature.     

Refinery Cost Functions in the U.S. Gulf Coast

Abstract

Construction cost functions for the main process units that comprise a refinery are developed. The cost estimates pertain exclusively to grassroots construction; are limited to equipment inside the battery limits; and include materials and labor, design, engineering, contractor's fees, overhead, and expense allowance. The methodological framework, data sources, and normalization procedures used for cost estimation is presented, followed by a discussion of the limitations of analysis. This material updates and extends the investment cost curves presented by Gary and Handwerk in a previous publication.     

Viscosity Model for Petroleum Gases

Abstract

The production processes for petroleum gases employ a broad range of simulation packages to reduce capital, time, and cost associated with actual recovery and pipeline transportation. Viscosity model is an important component of these packages. In this work, we have presented an empirical model for predicting the viscosity of petroleum gases, developed from the three-parameter Yaws equation. New constants were derived for various petroleum gases, as well as for gaseous carbon dioxide. Results obtained with the new model were compared with the viscosity predictions from the Yaws model, and the Miadonye and Clyburn correlation. For four petroleum gases and carbon dioxide at temperatures of 110 K to 1,500 K, the model gave an excellent viscosity prediction with overall average absolute deviations of 0.34% and 0.98%, respectively. The model is simple to incorporate into design and simulation packages, and more accurate than any correlation currently used in petroleum industry for predicting the viscosities of petroleum gases.     

Superstructure Optimization for Oil Refinery Design

Abstract

In this work, the optimal petroleum refinery topology is formulated as a conceptual process synthesis problem using the superstructure optimization approach. We begin with the development of a state–task network (STN)-based superstructure representation that is sufficiently rich to encompass all possible topology alternatives of a conventional oil refinery. Subsequently, a biobjective mixed-integer linear program (MILP) of maximization of profit and minimization of environmental impacts is formulated according to the constructed superstructure. Then, based on a given set of fixed amounts of desired products with available crude oil, the model is solved to generate an optimal topology. The proposed optimization framework also incorporates principles from life cycle analysis (LCA) to account for potential environmental impacts. A numerical example is illustrated to implement the modeling approach.     

炼油厂能量综合优化与挖潜增效

对炼油厂挖潜增效两种途径的各自影响因素及其变化进行了分析,阐明炼油企业中系统技术的重大意义。分析了炼油厂总流程规划中能量综合优化.总流程规划优化及老厂改造等问题。并指出如何从管理中挖掘更大的能量综合优化效益潜力。     

Simulation analysis of steam gasification of petroleum coke with CaO

Abstract

The work deals with the effect of calcium oxide adsorption on the production of hydrogen and methane in steam gasification of petroleum coke using Aspen Plus process simulator. The prediction accuracy of the proposed model is verified by comparing with the existing experimental results. The effects of water vapor flux, the mass ratio of calcium oxide to petroleum coke, pressure, temperature on hydrogen or methane gasification from petroleum coke steam are studied. The production of hydrogen from petroleum coke gasification requires a low temperature and low pressure environment, while increasing the flow of water vapor is beneficial to the production of hydrogen. Maximum H₂ volume fraction of 87.3% is obtained at a temperature of 600?°C, a pressure of 0.1?MPa, the mass of steam to petroleum coke is 1, and the mass of CaO to petroleum coke is 3. The H₂ and CO₂ volume fractions are found to be increased and decreased by 20% and 27.8% respectively, when compared with the corresponding non-CaO case. The production of methane from petroleum coke gasification requires a low temperature and high pressure environment, while decreasing the flow of water vapor is beneficial to the production of methane. Maximum CH₄ volume fraction of 63% is obtained at a temperature of 600?°C, a pressure of 1?MPa, the mass of steam to petroleum coke is 1, and the mass of CaO to petroleum coke is 1. The CH₄ and CO₂ volume fractions are found to be increased and decreased by 14.4% and 21% respectively, when compared with the corresponding non-CaO case.     

Nanotechnology Prospects in the Petroleum Industry

Abstract

Fulfilling worldwide energy demand in the 21st century is the most challenging problem. Current technologies simply cannot meet these demands. Therefore, we need new discoveries in underlying core science and engineering to find answers to this problem. Nanotechnology offers the prospect of opening an entirely new frontier for energy exploration, the ability to stretch the limits of our current energy sources and to go beyond these sources into new and uncharted territories. Nanotechnology is poised to impact dramatically on all sectors of the energy industry. There is great potential in nanotechnology research to revolutionize the petroleum industry and for the industry to capitalize on nanotechnology's immense benefits. Nanotechnology may someday boost the average global recovery factor of oil and gas. Research in nanotechnology in the petroleum industry is advancing rapidly and an explosion in the application of nanotechnology in this area is to be expected in the next 5 years. This article will specifically address the need for nanotechnology in the petroleum industry that can aid in the development of cheaper, more efficient, and environmentally appealing energy supplies. It also covers the promises of alternative energy sources using nanotechnology.     

21世纪的炼油技术和炼油厂(2)

综　述4　面向 2 1世纪的创新炼油技术4.1　绿色炼油技术面向 2 1世纪的绿色炼油技术有以下几种。( 1 )固体酸烷基化技术。目前已进行中试的固体酸烷基化技术有 4种 ,但均不是理想的替代技术 ,主要是均未彻底解决环保问题 ,而且技术尚未成熟。硫酸化氧化锆 (ＳＯ42 - /ＺｒＯ2 )超强酸催化剂 ,有可能成为固体酸烷基化技术工业应用的一个新亮点[1 8] 。 ( 2 )拟烷基化技术。为解决ＭＴＢＥ替代组分问题 ,出现了利用经过改造的ＭＴＢＥ装置和异丁烯原料通过二聚 加氢生产异辛烷的拟烷基化技术。目前已经工业应用或即将工业应用的有ＵＯＰ公司…     

Selection Separation Method for Hydrogen and Light Hydrocarbons Gases from Waste-Gas Streams of a Petroleum Refinery

Abstract

The four main processes for hydrogen upgrading in refineries include pressure swing adsorption, selective permeation using polymer membranes, cryogenic separation, and dephlegmation. Each of these processes is based on a different separation principle and, consequently, the process characteristics differ significantly. Selection of an appropriate hydrogen and light gas separation process depends not only on economics but on other project considerations such as process flexibility, reliability, and ease of future expansion. A review of the separation process characteristics and equipment is provided in this article, followed by discussions of other project considerations. General and application-specific selection guidelines are then presented, along with process integrations that take advantage of the complementary characteristics of the four processes. Due to the worldwide depletion of petroleum reservoirs and the growing use of hydrotreating in petroleum refineries, much attention has been given to light hydrocarbons and hydrogen recovery from refinery waste streams.