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Introduction to Refining Processes
Petrochemical intermediates are generally produced by chemical conversion of primary petrochemicals to form more complicated derivative products. Petrochemical derivative products can be
made in a variety of ways: directly from primary petrochemicals; through intermediate products
which still contain only carbon and hydrogen; and, through intermediates which incorporate chlorine, nitrogen, or oxygen in the finished derivative. In some cases, they are finished products; in
others, more steps are needed to arrive at the desired composition.
Of all the processes used, one of the most important is polymerization. It is used in the production of plastics, fibers, and synthetic rubber, the main finished petrochemical derivatives. Some
typical petrochemical intermediates are vinyl acetate for paint, paper, and textile coatings; vinyl
chloride for polyvinyl chloride (PVC); resin manufacture; ethylene glycol for polyester textile fibers;
and styrene that is important in rubber and plastic manufacturing. The end products number in the
thousands, some going on as inputs into the chemical industry for further processing. The more
common products made from petrochemicals include adhesives, plastics, soaps, detergents, solvents, paints, drugs, fertilizer, pesticides, insecticides, explosives, synthetic fibers, synthetic rubber,
and flooring and insulating materials.
15.16 FUTURE OF REFINING
In spite of claims to the contrary based on the concept of peak oil (Hubbert, 1962), the world is not
about to run out of petroleum, heavy oil, or tar sand bitumen. However, cheap petroleum may be
difficult to obtain as recent price fluctuations have indicated—the causes may vary from petroleum
being difficult to obtain from underground formations to petro-politics (Speight, 2011a).
However, as feedstocks to refineries change, there must be an accompanying change in refinery
technology. This means a movement from conventional means of refining heavy feedstocks using
(typically) coking technologies to more innovative processes (including hydrogen management) that
will produce the ultimate amounts liquid fuels from the feedstock and maintain emissions within
environmental compliance (Penning, 2001; Lerner, 2002; Davis and Patel, 2004; Hsu and Robinson,
2006; Gary et al., 2007; Speight, 2008).
During the next 20–30 years, the evolution future of petroleum refining and the current refinery
layout will be primarily on process modification with some new innovations coming on-stream
(Speight, 2011b). The industry will move predictably on to (1) deep conversion of heavy feedstocks,
(2) higher hydrocracking and hydrotreating capacity, and (3) more efficient processes.
High conversion refineries will move to gasification of feedstocks for the development of alternative fuels and to enhance equipment usage. A major trend in the refining industry market demand
for refined products will be in synthesizing fuels from simple basic reactants (e.g., synthesis gas)
when it becomes uneconomical to produce super clean transportation fuels through conventional
refining processes. Fischer–Tropsch plants together with IGCC systems will be integrated with or
even into refineries, which will offer the advantage of high-quality products (Stanislaus et al., 2000).
15.16.1 FeedstoCks
As the average quality of crude oil has deteriorated in recent decades and will continue to do so as
more heavy oil and tar sand bitumen are being sent to refineries (Speight, 2008, 2011a), the nature of
crude oil refining will change. In addition, the general trend throughout refining has been to produce
more products from each barrel of petroleum and to process those products in different ways to meet
the product specifications for use in modern engines. Overall, the demand for gasoline has rapidly
expanded and demand has also developed for gas oils and fuels for domestic central heating, and
fuel oil for power generation, as well as for light distillates and other inputs, derived from crude oil,
for the petrochemical industries.
Refineries will need to be adapted and upgraded to remain viable and responsive to ever-changing
patterns of crude supply and product market demands. As a result, refineries have been introducing
Introduction to Refining Processes
Petrochemical intermediates are generally produced by chemical conversion of primary petrochemicals to form more complicated derivative products. Petrochemical derivative products can be
made in a variety of ways: directly from primary petrochemicals; through intermediate products
which still contain only carbon and hydrogen; and, through intermediates which incorporate chlorine, nitrogen, or oxygen in the finished derivative. In some cases, they are finished products; in
others, more steps are needed to arrive at the desired composition.
Of all the processes used, one of the most important is polymerization. It is used in the production of plastics, fibers, and synthetic rubber, the main finished petrochemical derivatives. Some
typical petrochemical intermediates are vinyl acetate for paint, paper, and textile coatings; vinyl
chloride for polyvinyl chloride (PVC); resin manufacture; ethylene glycol for polyester textile fibers;
and styrene that is important in rubber and plastic manufacturing. The end products number in the
thousands, some going on as inputs into the chemical industry for further processing. The more
common products made from petrochemicals include adhesives, plastics, soaps, detergents, solvents, paints, drugs, fertilizer, pesticides, insecticides, explosives, synthetic fibers, synthetic rubber,
and flooring and insulating materials.
15.16 FUTURE OF REFINING
In spite of claims to the contrary based on the concept of peak oil (Hubbert, 1962), the world is not
about to run out of petroleum, heavy oil, or tar sand bitumen. However, cheap petroleum may be
difficult to obtain as recent price fluctuations have indicated—the causes may vary from petroleum
being difficult to obtain from underground formations to petro-politics (Speight, 2011a).
However, as feedstocks to refineries change, there must be an accompanying change in refinery
technology. This means a movement from conventional means of refining heavy feedstocks using
(typically) coking technologies to more innovative processes (including hydrogen management) that
will produce the ultimate amounts liquid fuels from the feedstock and maintain emissions within
environmental compliance (Penning, 2001; Lerner, 2002; Davis and Patel, 2004; Hsu and Robinson,
2006; Gary et al., 2007; Speight, 2008).
During the next 20–30 years, the evolution future of petroleum refining and the current refinery
layout will be primarily on process modification with some new innovations coming on-stream
(Speight, 2011b). The industry will move predictably on to (1) deep conversion of heavy feedstocks,
(2) higher hydrocracking and hydrotreating capacity, and (3) more efficient processes.
High conversion refineries will move to gasification of feedstocks for the development of alternative fuels and to enhance equipment usage. A major trend in the refining industry market demand
for refined products will be in synthesizing fuels from simple basic reactants (e.g., synthesis gas)
when it becomes uneconomical to produce super clean transportation fuels through conventional
refining processes. Fischer–Tropsch plants together with IGCC systems will be integrated with or
even into refineries, which will offer the advantage of high-quality products (Stanislaus et al., 2000).
15.16.1 FeedstoCks
As the average quality of crude oil has deteriorated in recent decades and will continue to do so as
more heavy oil and tar sand bitumen are being sent to refineries (Speight, 2008, 2011a), the nature of
crude oil refining will change. In addition, the general trend throughout refining has been to produce
more products from each barrel of petroleum and to process those products in different ways to meet
the product specifications for use in modern engines. Overall, the demand for gasoline has rapidly
expanded and demand has also developed for gas oils and fuels for domestic central heating, and
fuel oil for power generation, as well as for light distillates and other inputs, derived from crude oil,
for the petrochemical industries.
Refineries will need to be adapted and upgraded to remain viable and responsive to ever-changing
patterns of crude supply and product market demands. As a result, refineries have been introducing