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ITP Petroleum Refining

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ITP Petroleum Refining 1 Acknowledgements This report was written by Joan Pellegrino, Sabine Brueske, Tracy Carole, and Howard Andres of Energetics, Incorporated under the direction of Scott Richlen and Brian Valentine of the U.S. Department of Energy, Industrial Technologies Program. 2 Table of Contents Acknowledgements.................................................................................................................... 2 Table of Contents....................................................................................................................... 3 1 Overview................................................................................................................................5 1.1 Petroleum Refining: An Essential and Volatile Industry.......................................... 5 1.2 Market Trends and Economic Statistics..................................................................... 9 1.3 Energy and Materials Consumption......................................................................... 19 1.4 Environmental Overview ......................................................................................... 22 2 The Integrated Petroleum Refinery...................................................................................... 39 2.1 Overview.................................................................................................................. 39 2.2 Energy Overview ..................................................................................................... 42 2.3 Environmental Overview ......................................................................................... 43 3 Separations: Atmospheric and Vacuum Distillation........................................................... 48 3.1 Distillation Process Overview.................................................................................. 48 3.2 Energy Requirements............................................................................................... 53 3.3 Air Emissions........................................................................................................... 54 3.4 Effluents ................................................................................................................... 54 3.5 Waste, Residuals and By-products........................................................................... 56 4 Cracking and Coking Processes........................................................................................... 57 4.1 Cracking and Coking Process Overview ................................................................. 57 4.2 Energy Requirements............................................................................................... 67 4.3 Air Emissions........................................................................................................... 70 4.4 Effluents ................................................................................................................... 71 4.5 Waste, Residuals and By-products........................................................................... 73 5 Catalytic Reforming............................................................................................................. 74 5.1 Catalytic Reforming Process Overview................................................................... 74 5.2 Energy Requirements............................................................................................... 76 5.3 Air Emissions........................................................................................................... 77 5.4 Effluents ................................................................................................................... 78 5.5 Waste, Residuals and By-products........................................................................... 78 6 Alkylation........................................................................................................................... 117 6.1 Alkylation Overview.............................................................................................. 117 6.2 Energy Requirements............................................................................................. 121 6.3 Air Emissions......................................................................................................... 122 6.4 Effluents ................................................................................................................. 123 6.5 Waste, Residuals and By-products......................................................................... 123 7 Hydrotreatment .................................................................................................................. 117 7.1 Hydrotreatment Overview...................................................................................... 117 7.2 Energy Requirements............................................................................................. 119 7.3 Air Emissions......................................................................................................... 120 7.4 Effluents ................................................................................................................. 120 7.5 Waste, Residuals and By-products......................................................................... 121 8 Additives & Blending Components ................................................................................... 117 8.1 Additives and Blending Components Overview.................................................... 117 8.2 Energy Requirements............................................................................................. 123 8.3 Air Emissions......................................................................................................... 126 3 8.4 Effluents ................................................................................................................. 127 8.5 Hazardous and Toxic Residuals............................................................................. 127 9 Lubricating Oil Manufacture.............................................................................................. 117 9.1 Lubricating Oil Manufacture Process Overview.................................................... 117 9.2 Energy Requirements............................................................................................. 126 9.3 Air Emissions......................................................................................................... 127 9.4 Effluents ................................................................................................................. 127 10 Supporting Processes: Sulfur Management, Chemical Treatment, Water Treatment, & Process Heating...................................................................................................................... 128 10.1 Overview of Auxiliary Processes........................................................................... 128 10.2 Energy Requirements............................................................................................. 137 10.3 Air Emissions......................................................................................................... 137 10.4 Effluents ................................................................................................................. 139 10.5 Waste, Residuals and By-products......................................................................... 139 BIBLIOGRAPHY.................................................................................................................. 141 4 1 Overview 1.1 Petroleum Refining: An Essential and Volatile Industry Petroleum is the single largest source of energy for the United States. When measured in British thermal units (Btu), the Nation relies on petroleum two times more than either coal or natural gas, and four times more than nuclear power, hydroelectricity, and other renewable energy sources. On average, every U.S. citizen consumes about 20 pounds of petroleum per day. This primary dependence on petroleum for energy has been a reality for decades, and despite the influx of potential alternative fuels, is predicted to continue well into the future [DOE 2006c]. Before petroleum can be used it must be “refined” into products with the desired properties. This occurs in Petroleum Refining petroleum refineries, where various physical and chemical methods are used to convert crude oil into a large The U.S. Petroleum Refining Industry array of useful petroleum products. Petroleum refineries • Produces fuels to power land, air and sea are considered to be part of the U.S. manufacturing sector transport and heat homes and businesses and are an essential component of the economy. In • Provides petrochemical building blocks for addition to the millions of Americans who depend on plastics and other consumer products petroleum fuels to enable them to get to work and have a • Manufactures products for use in decent quality of life, there are also nearly 2 million jobs buildings and infrastructure, such as associated with the infrastructure for production, refining, asphalt and roofing materials and distribution of petroleum fuels [Vision 2020]. Over the last three decades, petroleum and refined petroleum products have become one of the most traded commodities in the world. The petroleum industry in general has a volatile history, and trading of crude oil continues to be a subject of controversy and uncertainty in global markets. The results of uncertainty are
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