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Crude Oil Refining Processes
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Isomerization
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.
Coking
Heats heavy oil residues to high temperatures to crack them into lighter products and a solid carbon byproduct (coke). Outputs include gasoline and diesel.
Lubrication Oil Refining
Involves multiple processes such as distillation, solvent extraction, and hydrofinishing to produce lubricating oils of various grades.
Bitumen Upgrading
Processes heavy crude bitumen into lighter, higher-value synthetic crude oil, making it suitable for further refining into various petroleum products.
Power Recovery
Captures the kinetic and thermal energy from various refining processes and converts it into electrical power, reducing energy consumption.
Atmospheric Distillation
This process separates crude oil into fractions based on boiling point. The output includes naphtha, kerosene, diesel, and heavy gas oil.
Amine Gas Treating
Uses aqueous solutions of amines to remove hydrogen sulfide and carbon dioxide from gas streams, usually as a precursor to sulfur recovery processes.
Thermal Cracking
A process that uses heat to break down heavy hydrocarbon molecules into lighter compounds. It was used historically before catalytic cracking became more popular.
Light-Ends Recovery
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.
Gas to Liquid (GTL) Process
Converts natural gas into liquid synthetic fuels such as diesel or jet fuel through processes like the Fischer-Tropsch synthesis.
Vacuum Distillation
Performed at pressures below atmospheric level to separate heavier fractions without thermal cracking. Outputs vacuum gas oils used for further processing.
Steam Reforming
Converts hydrocarbons into hydrogen and carbon monoxide by reacting them with steam over a nickel catalyst.
Solvent Deasphalting
Separates asphalt from crude oil using solvents like propane, which precipitates the asphalt and allows for the recovery of deasphalted oil.
Gas Sweetening
A process that removes acidic gases such as hydrogen sulfide and carbon dioxide from natural gas to prevent corrosion and meet pipeline specifications.
Alkylation
Combines light hydrocarbon molecules such as propylene and butylene with isobutane to create high-octane alkylate for gasoline blending.
Hydrotreating
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.
Sulfur Recovery
Treats acid gas streams to recover sulfur, typically using the Claus process, converting hydrogen sulfide into elemental sulfur while minimizing emissions.
Hydrodesulfurization
A hydrotreating process focused on removing sulfur from fractions like diesel. Protects the environment by reducing sulfur content in fuels.
Fluid Catalytic Cracking (FCC)
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.
Solvent Extraction
Uses solvents to dissolve and remove undesired components, like aromatics and sulfur compounds, improving the quality of lube oil fractions.
Hydrocracking
Similar to catalytic cracking but hydrogen is added to prevent formation of unsaturated hydrocarbons. Outputs include jet fuel, diesel, and naphtha.
Delayed Coking
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.
Catalytic Cracking
This process breaks down larger hydrocarbons into smaller ones using a catalyst. The main output is high-octane gasoline and lighter hydrocarbon products.
Merox Process
Treats LPG, jet fuel, or kerosene to convert mercaptans to disulfides, thus removing sulfur and sweetening the product. It stands for Mercaptan Oxidation.
Hydrodearomatization
Similar to hydrotreating, it specifically targets the removal of aromatic hydrocarbons to improve the smoke point and combustion properties of kerosene and jet fuels.
Octane Boosting
Enhances the octane rating of gasoline through the blending of ethanol, MTBE, or the use of certain refining processes like catalytic reforming.
Catalytic Reforming
Converts naphtha into high-octane reformate (a gasoline blendstock), hydrogen, and other products by altering molecular structures.
Naphtha Hydrotreating
A hydrotreating process that removes impurities such as sulfur, nitrogen, and metals from naphtha to improve its quality for further processing.
Visbreaking
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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