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Crude Oil Refining Processes

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Isomerization

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Rearranges the linear structure of hydrocarbons into branched forms to increase octane rating without altering the carbon number. It creates high-quality gasoline blending components.

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Coking

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Heats heavy oil residues to high temperatures to crack them into lighter products and a solid carbon byproduct (coke). Outputs include gasoline and diesel.

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Lubrication Oil Refining

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Involves multiple processes such as distillation, solvent extraction, and hydrofinishing to produce lubricating oils of various grades.

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Bitumen Upgrading

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Processes heavy crude bitumen into lighter, higher-value synthetic crude oil, making it suitable for further refining into various petroleum products.

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Power Recovery

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Captures the kinetic and thermal energy from various refining processes and converts it into electrical power, reducing energy consumption.

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Atmospheric Distillation

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This process separates crude oil into fractions based on boiling point. The output includes naphtha, kerosene, diesel, and heavy gas oil.

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Amine Gas Treating

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Uses aqueous solutions of amines to remove hydrogen sulfide and carbon dioxide from gas streams, usually as a precursor to sulfur recovery processes.

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Thermal Cracking

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A process that uses heat to break down heavy hydrocarbon molecules into lighter compounds. It was used historically before catalytic cracking became more popular.

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Light-Ends Recovery

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Separates the lightest components of crude oil, such as methane, ethane, propane, and butane, which can be used as feedstock for other processes or sold as individual products.

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Gas to Liquid (GTL) Process

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Converts natural gas into liquid synthetic fuels such as diesel or jet fuel through processes like the Fischer-Tropsch synthesis.

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Vacuum Distillation

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Performed at pressures below atmospheric level to separate heavier fractions without thermal cracking. Outputs vacuum gas oils used for further processing.

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Steam Reforming

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Converts hydrocarbons into hydrogen and carbon monoxide by reacting them with steam over a nickel catalyst.

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Solvent Deasphalting

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Separates asphalt from crude oil using solvents like propane, which precipitates the asphalt and allows for the recovery of deasphalted oil.

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Gas Sweetening

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A process that removes acidic gases such as hydrogen sulfide and carbon dioxide from natural gas to prevent corrosion and meet pipeline specifications.

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Alkylation

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Combines light hydrocarbon molecules such as propylene and butylene with isobutane to create high-octane alkylate for gasoline blending.

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Hydrotreating

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Removes sulfur, nitrogen, and metals from petroleum fractions by reacting them with hydrogen at high pressure. Improves the quality of the product, producing cleaner fuels.

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Sulfur Recovery

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Treats acid gas streams to recover sulfur, typically using the Claus process, converting hydrogen sulfide into elemental sulfur while minimizing emissions.

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Hydrodesulfurization

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A hydrotreating process focused on removing sulfur from fractions like diesel. Protects the environment by reducing sulfur content in fuels.

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Fluid Catalytic Cracking (FCC)

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Uses a fluidized catalytic process to convert heavy hydrocarbons into lighter ones like gasoline and propylene in a more efficient manner than regular catalytic cracking.

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Solvent Extraction

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Uses solvents to dissolve and remove undesired components, like aromatics and sulfur compounds, improving the quality of lube oil fractions.

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Hydrocracking

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Similar to catalytic cracking but hydrogen is added to prevent formation of unsaturated hydrocarbons. Outputs include jet fuel, diesel, and naphtha.

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Delayed Coking

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A severe form of thermal cracking that involves delayed coker units to convert residual oils into more valuable lighter products, and solid coke which is used as a fuel or carbon source.

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Catalytic Cracking

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This process breaks down larger hydrocarbons into smaller ones using a catalyst. The main output is high-octane gasoline and lighter hydrocarbon products.

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Merox Process

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Treats LPG, jet fuel, or kerosene to convert mercaptans to disulfides, thus removing sulfur and sweetening the product. It stands for Mercaptan Oxidation.

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Hydrodearomatization

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Similar to hydrotreating, it specifically targets the removal of aromatic hydrocarbons to improve the smoke point and combustion properties of kerosene and jet fuels.

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Octane Boosting

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Enhances the octane rating of gasoline through the blending of ethanol, MTBE, or the use of certain refining processes like catalytic reforming.

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Catalytic Reforming

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Converts naphtha into high-octane reformate (a gasoline blendstock), hydrogen, and other products by altering molecular structures.

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Naphtha Hydrotreating

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A hydrotreating process that removes impurities such as sulfur, nitrogen, and metals from naphtha to improve its quality for further processing.

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Visbreaking

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Mild thermal cracking which reduces the viscosity of heavy oil residues, making them easier to process. Generates small amounts of lighter products.

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