Refinery Basics

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Refinery Basics

• John Kulluk Ph.D.
• Torrance Fire Department
• Robert Distaso PE 714/573-6253
• Orange County Fire Authority

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Refining Means. . .

• 1. To reduce to a pure state, to remove
  impurities
• 2. To improve or perfect

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Refinery Process Flow Chart
Sulfur
Gas Plant
Fuel Gas
Isom
Distilling
Splitter
Gasoline
Reformer
Jet Fuel
Hydrotreating
Distillate Fuel
Hydrotreating
Alky
CCU
Flasher
ResidualFuel
Visbreaker
Leffler, 1985
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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

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What is Crude Oil?

• Mixture of organic carbon chain molecules
• Impurities include sulfur and nitrogen compounds
• Some metals and salts too

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Components such as . . .

• Straight-Chain Hydrocarbons
• Olefins
• Cyclic H/C
• Aromatics (Benzene, toluene, xylenes)

• Mercaptans
• Hydrogen Sulfide (H2S)
• Greases
• Propane
• LPG

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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

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Whats All this Stuff?
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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

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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

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Common PPE Requirements

• Hardhat
• Hardsoled / Hardtoe Shoes
• Safety Glasses with Side Protection
• Safety Goggles or Faceshield
• Fire-Resistant Clothing

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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)

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QUESTIONS ?